Packaging Material Feed Motors Without Brushes or Contact Wear
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Solution Overview
Problem
Existing packaging material provision apparatuses using electric motors face issues such as reduced service life due to wear, increased risk of overheating and fire, especially when processing recycled paper, and higher development costs and times for new apparatuses designed for specific materials and shapes.
Innovation Solution
The apparatus employs a brushless DC motor or stepper motor with a stationary stator and a rotor mounted movably, devoid of electrical contact coupling, and equipped with a position detector for precise rotor position sensing, allowing for efficient operation and reduced wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electric motors are used to drive packaging material provision apparatus, then productivity and production capacity are improved, but reliability deteriorates due to wear and increased risk of failure
Solution Approach 1:
The patent removes the electrical contact coupling (brushes and commutator) from the electric motor, extracting the wear-prone components while retaining the motor's driving function. This is achieved by using a brushless DC motor or stepper motor where the rotor and stator are separated by an air gap, eliminating direct electrical contact and thus wear.
Solution Approach 2:
The patent replaces the mechanical electrical contact system (brushes sliding on commutator) with a non-contact electromagnetic field system. The electrical energy is transmitted through the air gap via electromagnetic induction, substituting mechanical contact with field-based energy transfer, thereby eliminating wear.
2Productivity
If electric motors are used in packaging material provision apparatus, then productivity is improved, but object-generated harmful factors worsen due to overheating and fire risk
Solution Approach 1:
The patent extracts the electrical contact coupling from the motor system, removing the source of friction and resistive heating that leads to overheating. By using non-contact electromagnetic energy transfer, the system eliminates the primary heat generation mechanism in traditional motors.
Solution Approach 2:
The patent converts the potential harm of electrical contact (friction and heat) into a beneficial non-contact system. The air gap between rotor and stator, which could be seen as a limitation, becomes an advantage by eliminating wear and heat generation, allowing the motor to operate cooler and safer.
3Productivity
If electric motors with contact coupling are used, then productivity is improved, but device complexity increases due to additional components requiring maintenance
Solution Approach 1:
The patent removes the electrical contact coupling components (brushes, commutator, and associated wiring) from the motor system. This extraction simplifies the overall device structure by eliminating parts that require maintenance and replacement, reducing the total component count.
Solution Approach 2:
The patent employs a standardized brushless DC motor or stepper motor design that can be universally applied across different packaging material provision apparatus configurations. This universal motor type reduces the need for custom-designed components and simplifies the overall system architecture.
4Productivity
If traditional electric motors are used, then productivity is improved, but loss of time increases due to motor replacement after service life
Solution Approach 1:
The patent extracts the wear-prone electrical contact components from the motor system, eliminating the primary source of degradation. Without brushes and commutators that wear down over time, the motor maintains its operational capability indefinitely, removing the need for scheduled replacements and associated downtime.
Solution Approach 2:
The patent inverts the traditional approach by creating a motor that is not disposable but rather long-lasting. By eliminating the wear components, the motor becomes a permanent installation that does not require periodic replacement, effectively making the service life infinite compared to traditional motors.
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 configuration extends the service life of electric motors, reduces the risk of overheating and fire, and decreases development times and costs for packaging material provision apparatuses by standardizing the higher-level controller and using electric motor-own sub-controllers.
Implementation Method 1
a coil arrangement of the rotor or of the stator to which an excitation current is applied
Data Source
AI summary
An apparatus for providing packaging material (e.g. a corrugated board web section or a paper cushioning material strand) by manipulating (e.g. deforming, conveying and/or separating) a fiber starting material (e.g. a single or multi-ply paper web or a corrugated board web) may include at least one working device to be driven mechanically by at least one electric motor having a stationary stator and a rotor mounted movably thereto. An excitation current may be applied to a coil arrangement of the rotor or of the stator. The motor may be free of an electrical contact coupling for transmitting the excitation current between the stator and the rotor, and may include a detector to detect the position of the rotor. The working device may be a deformation device (e.g. a pair of deformation wheels), a conveyor (e.g. a pair of conveyor wheels), or a separating device (e.g. a rotary or translational cutter).