Recuperation system for the recovery of electrical energy for machines, systems and equipment (MAE) along the travel axes

Abstract

The inductive coil system with its application-specific configured and dimensioned electrically conductive coils, its mutually polarized permanent magnet, which is installed along the travel axes of machines, systems and technical equipment, especially in machine tools and conveyor systems, and has a sufficiently large distance from the coil system to optimally absorb the magnetically induced voltage and transmit it to the electromechanical transformation and storage modules

Description

[0001] The invention relates to a recuperation system for recovering electrical energy for machines, systems, and equipment (MSE) along the travel axes. The recuperation system operates according to the method of contactless energy transfer by electromagnetic induction. The energy transfer takes place via the air interface by means of electromagnetism.

[0002] In near-field magnetic induction, an electrical conductor is pulled through a directed magnetic field, for example a permanent magnet, which leads to a potential shift of the electrons in the conductor and generates an electrical voltage. Alternatively, an electrical voltage is generated when a permanent magnet is inserted into a non-current-carrying coil.

[0003] The principle of magnetic induction corresponds to the current state of the art, for example for charging batteries in smartphones or the charging principle in electric vehicles.

[0004] The invention described here relates to new application possibilities, especially in machines, systems and equipment that predominantly perform linear, preferably terministic, kinematic processes.

[0005] Potential application areas include machine tools such as CNC machining centers, milling machines, laser cutting machines, 3D printing machines, punching machines, etc.

[0006] Furthermore, preferred application areas include continuous conveyors, for example circulating conveyors, steel belt conveyors, belt conveyors, drag chain conveyors, scraper conveyors, link belt conveyors, hinge belt conveyors, plate belt conveyors, etc.

[0007] Depending on the application, the individual components must be selected and dimensioned accordingly. In principle, it is essential to ensure that the mechanical properties of the technical device are not impaired, for example, by vibrations caused by the system, changes in acceleration or acceleration and braking distances, positioning accuracy, heat generation, air resistance, magnetic influences in the application environment, etc.

[0008] It should be noted that the components in the area of ​​the drive axles are made of non-magnetic materials. The recuperation system described here should not be confused with conventional energy recovery systems in electric motors or thermal recuperation systems in braking devices.

[0009] The mechanical design of the recuperation system in machine tools involves installing the coil(s) on the movable carriage or on non-load-bearing parts of the machine, system, or equipment. In particularly cost-effective designs, the permanent magnet(s) with alternating polarity, used to generate a contactless alternating voltage in the coil, is attached to the guide rail or to the load-bearing components of the machine, system, or equipment as a rigid feedthrough, for example, as a round bar. The magnet(s) with alternating polarity can be mounted as pressed parts, fully or partially integrated with homogeneous spacing within the feedthrough structure. The magnetic field can then be transmitted to a receiver coil via the air interface.

[0010] The mechanical design of the recuperation system for continuous conveyors involves installing the coil(s) on the load-bearing components of the conveyor system. The permanent magnet(s) with alternating polarity are attached as an integrated component to the circulating or moving chains, belts, conveyors, rollers, or carriers. For example, differently polarized magnetic strips could be integrated into the conveyor belts. Magnetic induction occurs at the side edges, above, or below the conveyor belts, etc. The coil system is integrated into a dirt-resistant housing, such as a U-shaped jaw profile or individual mounting profiles. These are attached to the sides, below, or above the moving conveyor units. Decoupling the coil system from the conveyor system body is recommended, for example, by means of a separate stand or buffering.Attachment to the body of the system via adhesive or screw mounting is possible in cases of low vibration.

[0011] The electrical voltage induced in the coil is transformed into direct current (DC) by an intelligent rectifier and stored in a capacitor. The charging management system aims for energy storage with minimal loss. After charging, a discharge process follows, dependent on consumption. Power storage can be decentralized at the device itself or centralized. The current is delivered to a battery either as alternating current (AC) or direct current (DC).

[0012] The physical principle is described by the law of induction. The law of induction describes the relationship between an induced electrical voltage Uind as a function of the number of turns of a closed conductor coil N and the rate of change of the magnetic flux φ (Phi). Uind=−N⋅dϕdt

[0013] The formula describes the voltage through the time-dependent change of the magnetic flux. The magnetic flux Φ is described as a vector of the flux density. B→ as a measure of the effective magnetic strength emanating from an area A. ϕ=∫AB→⋅cosα⋅dA

[0014] The induced voltage depends on the magnetic force of the magnet. Therefore, the magnetic force (F_mag) corresponds to the total force of all charge carriers (N) in the investigated conductor section. The constant velocity (v_L) of the charge carriers can be used for the quotient of conductor length and time difference (Δl / Δt). Reaction losses of the magnetic field and those of the charge carriers in the coil must be taken into account. The duration of magnetic polarization is until the effect of the opposite polarization occurs. This is because the following generally applies: v = s [m] / t [s] Fmag=B→n⋅N⋅e⋅vL

[0015] Due to their high complexity, the calculation principles for the design and dimensioning of the system components are not described in detail here. 2. Components

[0016] The recuperation system ( Fig. 1-3) consists of the following sub-components: a permanent magnet b Electrically conductive coil c Inverter d Electronic filters e Volatile energy storage device (capacitor(s)) f Printed circuit board with electrical control g Electrical conductors (cables) h Accumulator(s) (energy storage) i Technical protective device(s) j control cabinet module / s 3. Requirements • One particularly cost-effective option involves using copper for the electrically conductive coil. • Another variant proposes that the electrically conductive coil be made of aluminum. • Another variant proposes that the electrically conductive coil be made of silver. • Other versions of the coil can be made from alternative materials • One particularly cost-effective variant involves the electrically conductive coil not containing a core. • Another variant involves the electrically conductive coil containing a ferrite core. • Another variant provides that the electrically conductive coil contains an aronite core. • Another variant involves the electrically conductive coil containing a ferron core. • Another variant provides that the electrically conductive coil contains a zero-ohm coil core (NOS). • Other variants of the coil cores can be made from alternative materials • One particularly advantageous variant provides for the coil winding to have a minimal winding spacing. • One particularly advantageous variant provides that the coil winding has a maximum winding height. • Other coil winding variants may have alternative spacings • One particularly cost-effective option involves a round coil winding. • Another variant provides for a rectangular coil winding. • Another variant involves winding the coil transversely to the driving axis. • Other coil winding variants may have alternative winding types. • One particularly cost-effective option is to have the coil at its maximum length • Another variant stipulates that the coil has the minimum length • Other variants may have alternative lengths • One particularly cost-effective option involves using a permanent magnet made of neodymium. • Another variant involves the neodymium magnet being a super magnet with or without an additional coating. • Another variant involves the permanent magnet containing iron. • Another variant proposes that the permanent magnet contains boron • Another variant involves the permanent magnet containing samarium and cobalt (SmCo magnet) • Another variant involves the permanent magnet containing aluminum, nickel and cobalt (AlNiCo magnet) • Other versions may feature magnets made of alternative materials • One particularly cost-effective option involves using a permanent magnet in the form of a round rod. • Another variant involves the permanent magnet being designed as a hollow rod. • Another variant involves the permanent magnet being designed as a square profile. • Another variant proposes that the permanent magnet be U-shaped. • Another variant involves the permanent magnet being designed as a disc magnet. • Another variant involves the permanent magnet being designed as a cuboid magnet. • Another variant involves the permanent magnet being designed as a ring magnet. • Another variant involves the permanent magnet being designed as a flexible strip. • Another variant involves the permanent magnet being designed as a cube magnet. • Other variants may feature magnets with alternative designs. • One particularly cost-effective option involves attaching the permanent magnet as a pressed component to the feedthrough profile. • Another variant involves permanently integrating the permanent magnet into the feedthrough profile. • Another option involves screwing the permanent magnet onto the feedthrough profile. • Another variant involves gluing the permanent magnet to the feedthrough profile. • Another option involves integrating the permanent magnet into the conveyor belt. • Another variant involves sewing on the permanent magnet. • Another variant involves welding the permanent magnet in place. • Other versions may feature magnets with alternative fastening methods. • One particularly cost-effective option involves rectifying the alternating voltage using an inverter (direct current). • Another option involves storing the energy in a capacitor. • Another option involves storing the energy in a capacitor. • Another option involves charging and discharging the energy through intelligent charging management or circuit board control. • Another option involves smoothing the electrical currents through additional filters and transforming them with minimal energy loss. • Another option involves transmitting the electrical energy using cable ladders suitable for drag chains. • Another option involves transmitting electrical energy using oil-resistant cable conductors. • Another option involves transmitting electrical energy using oil-resistant cable conductors. • Another option involves storing the electrical energy in a decentralized battery. • Another option involves storing the electrical energy in a central accumulator. • Other variants may have additional electrical components 6. Reference symbols. See point 5. Drawings

[0017] Fig. 1: Recuperation system using machine tools as an example 1 permanent magnet with alternating polarization 2 Movable sleds 3 Electrical coil(s)

[0018] Fig. 2: Recuperation system using conveyor belts as an example 4 permanent magnetic tape (circumferential) with alternating polarization

[0019] Fig. 3: Recuperation system using conveyor belts as an example 5 electrical coils enclosed in a dirt-repellent housing including electronics 6 spacers / mounting plates 7 Cable feedthrough

Claims

[1] The inductive coil system with its application-specific configured and dimensioned electrically conductive coils, its mutually polarized permanent magnet, which is installed along the travel axes of machines, systems and technical equipment, especially in machine tools and conveyor systems, and has a sufficiently large distance to the coil system to optimally absorb the magnetically induced voltage and transmit it to the electromechanical transformation and storage modules [2] An intelligent storage management system which transforms the induced alternating voltage at different feed rates into a uniform electrical voltage, filters overvoltages at 85% of the signal strength, resulting in lower transmission resistances, and with downstream filters additionally smooths the currents in order to store the energy centrally or decentrally with minimal losses

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