Conditioning Roller Electric Drive With Regenerative Braking
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Solution Overview
Problem
Existing drive systems for conditioning rollers in forage harvesters do not account for operating conditions where one roller needs to be braked to maintain desired speed, leading to inefficient energy conversion and potential impairment of the conditioning action.
Innovation Solution
Incorporating an electric motor/generator in the drive system that can operate as a generator to brake the conditioning roller, allowing the generated energy to be returned to the drive system, thereby improving efficiency and maintaining desired speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the electric motor runs at adjustable speed in harvesting mode, then the speed of the conditioning roller can be varied, but the motor always requires a certain drive power which is wasted when braking is needed
Solution Approach 1:
The patent converts the harmful effect of excessive roller speed into beneficial braking energy. When the roller rotates faster than desired, the electric motor operates as a generator, converting the kinetic energy of the roller into electrical energy that can be returned to the drive system, thus eliminating energy waste while maintaining speed control.
Solution Approach 2:
The patent implements dynamic operation mode switching for the electric motor. The motor can operate in motor mode to accelerate the roller or in generator mode to brake the roller, allowing the system to adapt its energy flow direction based on real-time operating conditions and optimize energy utilization.
2Speed
If the conditioning roller is simply pulled along and rotates more rapidly than desired, then the roller speed increases, but the desired conditioning action is impaired
Solution Approach 1:
The patent implements a feedback control mechanism where the actual speed of the conditioning roller is continuously monitored and compared with the desired speed. When the roller exceeds the target speed, the system automatically activates the electric motor as a generator to provide braking force, ensuring the roller speed remains within the optimal range for conditioning action.
3Speed
If the braking energy is converted into heat in a resistor, then the roller speed is controlled, but the overall efficiency of the electrical drive train is reduced
Solution Approach 1:
The patent recovers the braking energy that would otherwise be discarded as heat. By operating the electric motor as a generator during braking, the system converts the kinetic energy of the rolling roller into electrical energy that is returned to the drive system, transforming energy loss into energy recovery and improving overall system efficiency.
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
This solution enables the drive system to efficiently manage operating conditions where braking is necessary, improving overall efficiency by directly returning braking energy into the drive system, rather than converting it to heat.
Implementation Method 1
an electric motor/generator (80) for driving the conditioning roller (40), said electric motor/generator (80) being able to be operated as a generator for braking the conditioning roller (40)
Implementation Method 2
The generated electrical energy is able to be returned into the drive system of the forage harvester
Data Source
AI summary
A drive arrangement of a conditioning apparatus of a forage harvester having two conditioning rollers, with at least one of the conditioning rollers able to be driven at variable speed via an electrical drive train, includes an electric motor/generator for driving the conditioning roller. The electric motor/generator is able to be operated as a generator for braking the conditioning roller and to return the generated electrical energy into a drive system of the forage harvester.