Brushless Motor Drive for Dust-Prone Packaging Material Feed
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Solution Overview
Problem
Existing packaging material supply devices using electric motors face issues with increased failure risks due to overheating, clogging, and higher development costs, especially when handling recycled paper, which has shorter fibers leading to dust and shreds, and pose a fire hazard.
Innovation Solution
A packaging material supply device utilizing a mechanically driven working unit with a brushless DC motor or stepper motor, equipped with a rotor position detection system and control subunits, eliminating electrical contact couplings and incorporating a communication link for data exchange, to enhance reliability and reduce development time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electric motors are used to drive packaging material supply devices, then productivity and automation are improved, but reliability deteriorates due to overheating, clogging, and fire hazards
Solution Approach 1:
The patent removes the electrical contact coupling (brushes and commutator) from the motor system by implementing a brushless DC motor design. The electrical contacts are extracted and replaced with electronic commutation using Hall sensors and transistors, eliminating the wear and fire hazards associated with traditional contact-based systems while maintaining the motor's ability to drive the packaging material supply device
Solution Approach 2:
The patent replaces the mechanical contact-based electrical system (brushes and commutator) with an electronic field-based system. The mechanical wear and thermal contact issues are substituted with electronic commutation through Hall effect sensors and transistor switching, reducing reliability issues while maintaining productivity
2Device complexity
If electric motors with contact couplings are used, then power transmission is simplified, but service life deteriorates due to wear and tear
Solution Approach 1:
The brushes and commutator are extracted from the motor design, removing the wear-prone components while maintaining the essential function of electrical-to-mechanical energy conversion through electronic commutation
Solution Approach 2:
The mechanical contact system is replaced with an electronic field system using Hall sensors for position detection and transistor-based electronic commutation, eliminating mechanical wear while preserving the motor's rotational drive capability
3Adaptability or versatility
If recycled paper with shorter fibers is processed, then sustainability is improved, but device reliability worsens due to increased clogging from dust and shreds
Solution Approach 1:
The mechanical contact system that generated sparks and heat is replaced with electronic commutation, reducing the fire hazard when processing dust-prone recycled paper materials. The electronic field-based system eliminates the thermal contact issues that could ignite paper dust
Solution Approach 2:
The electrical contact coupling is removed, eliminating the source of overheating and fire risk that would be particularly problematic when processing recycled paper materials that generate dust and shreds
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution increases the service life of the electric motor, reduces failure risks, and decreases development efforts by standardizing control units, ensuring efficient and safe operation with recycled paper materials.
Implementation Method 1
an electric motor driving the working unit, with a stationary stator, a rotor movably mounted thereto, and a coil arrangement of the rotor or the stator supplied with an excitation current
Data Source
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AI summary
The invention relates to an apparatus for providing packaging material, such as a corrugated board web section or a paper cushion material strand, by manipulation, in particular forming, conveying and/or separating a fiber starting material, such as a single or multi-layer paper web or a corrugated board web, comprising at least one working device to be mechanically driven, such as a deformation device, in particular a deformation wheel pair; a conveying device, in particular a cutting device, in particular a rotation cutter or a translation cutter; at least one electric motor, which drives the working device and has a stationary stator, a rotor, which is movably mounted relative thereto; and a coil arrangement of the rotor or stator to which an excitation current is applied, wherein the electric motor is free of an electrical contact coupling for transferring the excitation current between the stator and the rotor and comprises a device for detecting the position of the rotor.