Clipping Machine Regenerative Braking for Unstable Power Grids
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Solution Overview
Problem
Clipping machines for producing sausage-shaped products face challenges in reliable operation due to unstable power grids, leading to potential power interruptions, voltage peaks, and equipment damage, particularly in areas requiring specific power precautions.
Innovation Solution
A clipping machine with a motor driver unit that recovers electric braking energy, stores it in a storage device, and prioritizes its use for the control unit and other components, reducing reliance on the power grid and preventing grid overload.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If electric motors are used to drive components of the clipping machine, then the machine can operate with precise control and automation, but power interruptions and voltage peaks in unstable power grids can cause equipment damage and operational failures
Solution Approach 1:
The system performs preliminary action by recovering and storing braking energy during normal operation in advance. The capacitor bank accumulates energy during regenerative braking phases so that this stored energy can be immediately utilized during power interruptions or high-demand moments, preventing operational failures before they occur.
Solution Approach 2:
The capacitor bank acts as an energy buffer that cushions the system against power grid instabilities. By storing energy during low-demand periods and releasing it during high-demand or power-failure conditions, the system is protected from voltage peaks and power interruptions, maintaining operational reliability.
2Speed
If multiple electric motors start simultaneously, then the clipping machine can be quickly prepared for operation, but voltage or current peaks occur that may collapse the power grid
Solution Approach 1:
The system performs preliminary energy recovery during deceleration and braking phases before startup demands occur. The capacitor bank accumulates this energy in advance, creating a local power reservoir that can immediately supply startup currents without drawing excessive power from the external grid, thus avoiding voltage peaks.
Solution Approach 2:
The system converts the harmful effect of braking (energy loss) into a beneficial resource (stored energy in capacitor bank). The regenerative braking energy that would normally be wasted is captured and stored, then reused during startup phases, transforming a potential power demand problem into an energy solution.
3Device complexity
If braking energy is dissipated as heat during motor deceleration, then the system is simple to implement, but energy is wasted and power consumption increases
Solution Approach 1:
The system converts the harmful waste heat from braking into a useful resource. The regenerative braking mechanism captures kinetic energy during motor deceleration and transforms it into electrical energy that is stored in the capacitor bank, turning energy loss into energy recovery.
Solution Approach 2:
Instead of discarding braking energy as waste heat, the system recovers it through regenerative braking. The capacitor bank captures and stores this recovered energy for later use, preventing energy waste and reducing overall power consumption.
4Duration of action of stationary object
If a large capacitor bank is used to store recovered energy, then more energy can be stored for extended operation during power interruptions, but the device complexity and space requirements increase
Solution Approach 1:
The system implements partial energy storage by using a capacitor bank sized for typical operational needs rather than maximum possible storage. This provides sufficient energy for most power interruptions without the excessive complexity and cost of a fully sized storage system for all possible scenarios.
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
Ensures reliable and safe operation by minimizing power demands, preventing equipment damage, and maintaining functionality during power interruptions, while optimizing energy use and reducing peak loads.
Implementation Method 1
a motor driver unit adapted to operate the electric motor in an accelerating mode for increasing the speed of the electric motor, in a driving mode for maintaining the speed of the electric motor, and in an electric braking mode for decreasing the speed of the electric motor
Implementation Method 2
at least one storage device for storing the recovered electric braking energy and providing the recovered electric energy at a time point independent from the time point of the energy recovering process
Data Source
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AI summary
The present invention relates to a clipping machine (CM) for producing sausage-shaped products (S), like sausages, by filling a flowable filling material into a tubular or bag-shaped packaging casing (M) and closing said tubular or bag-shaped packaging casing (TM) by a closure means (C), like a closure clip, and a method for controlling the clipping machine (CM). The clipping machine (CM) comprises a filling tube (10) for feeding the filling material into the tubular or bag-shaped packaging casing (TM) stored on the filling tube (10) and being closed at its first end, a casing brake assembly (16) for applying a braking force to the tubular or bag-shaped packaging casing (M) while being pulled-off from the filling tube (10), gathering means (30) for gathering the filled tubular or bag-shaped packaging casing (M) and for forming a plait-like portion (P) thereto, the gathering means (30) including a first displacer unit (32) and a second displacer unit (34), a clipping device (20) having a first and a second closing tool (22, 24) being reversibly movable between an opened position and a closed position, for applying at least one closure means (C) to the plait-like portion (P) and closing said closure means (C) when the closing tools (22, 24) are in their closed position, and at least one drive device (DD) for driving at least one component of the clipping machine (CM), including at least one electric motor (EM). The clipping machine (CM) further comprises a motor driver unit (MU) adapted to operate the electric motor (EM) in an accelerating mode for increasing the speed of the electric motor (EM), in a driving mode for maintaining the speed of the electric motor (EM), and in an electric braking mode for decreasing the speed of the electric motor (EM), and a control unit (CU) adapted to control the at least one motor driver unit (MU) such that during the braking mode electric braking energy is recovered.