Canopy Motor Control with Ratcheting Synchronization and Current Monitoring
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Solution Overview
Problem
Existing cargo canopy deployment systems face challenges such as complex and costly hydraulic or air-driven motor controls, potential motor burnout due to uneven power consumption, and erratic operation from misalignment and synchronization issues, with conventional circuit breakers failing to adequately protect motors from overload and overheating.
Innovation Solution
A novel canopy deployment and retraction system using inexpensive electrical motors with a protective device that measures energy drawn by the motor in terms of current and time, featuring a programmable circuit breaker that interrupts power when a preset energy limit is reached, and a ratcheting gear mechanism for precise alignment and synchronization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional circuit breakers are used to protect motors, then device complexity is reduced, but motor reliability deteriorates due to inadequate protection from overload and overheating
Solution Approach 1:
The system performs preliminary measurement of current and time parameters before motor damage occurs. The microprocessor continuously monitors current draw and accumulates time data to calculate energy consumption, enabling preventive protection before overload or overheating damages the motor windings.
Solution Approach 2:
The system implements feedback by continuously measuring motor current, calculating energy consumption, and comparing it against predetermined thresholds. When the accumulated energy exceeds the threshold, the circuit breaker trips to interrupt power, creating a closed-loop protection system that adapts to actual motor operating conditions.
2Reliability
If more rugged electric motors with wider performance characteristics are used, then motor reliability improves under varying conditions, but device complexity and cost increase
Solution Approach 1:
The system changes the operational parameters dynamically by monitoring current and time to calculate actual energy consumption. This allows the use of standard motors with predictable performance characteristics while achieving reliable operation under varying conditions through intelligent control rather than selecting overly rugged motors for all conditions.
Solution Approach 2:
The protection system serves itself by using the motor's own current draw characteristics to determine when protection is needed. The microprocessor calculates energy consumption based on actual motor operation, allowing the system to adapt to different operating conditions without requiring pre-configured conservative motor selections.
3Productivity
If higher DC currents are used to overcome resistance, then productivity improves by clearing obstacles, but motor reliability deteriorates due to increased heat generation and burnout risk
Solution Approach 1:
The system uses periodic monitoring of current and accumulated time to detect when energy consumption thresholds are exceeded. This allows the motor to operate at high currents when necessary to clear obstacles while providing periodic checks to prevent sustained overload conditions that would cause burnout, enabling productive operation with reliability protection.
Data Source
AI summary
In the coupling of bi-directional, non-freewheeling-type DC motors (24,25) to the pulling spool (23) of a canopy (11) deployment strap (21,22) and to a take-up roller (15), ratchet gears (26,27) assure automatic alignment and synchronization of the deployment and retraction mechanisms. The reverse direction rotation of the unwinding motor can be uninhibited through the slipping of its ratchet gear when the winding motor is slow to take up the pulling strap or the tarp (11) being wound thereon. The slipping provides sufficient slack to accommodate changes of spool and roller diameters as more material is successively wound thereon. A friction brake acting against a flange of die spool keeps it from spinning freely when not engaged by the motor. Winding motors can be protected against excessive power use by measuring the level of drawn current with a digital ammeter. If the current exceeds a threshold level of operation, a timer is started. As soon as a given absolute safe period of operation is surpassed, a breaker switch is tripped interrupting the motor power supply. A plural number of trip points can be programmed into the device.