Conveyor Drive Motor Torque Control for Load Stability
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Solution Overview
Problem
Current transport goods conveyor control systems face challenges in accurately controlling the position and stopping distance of conveyed goods, particularly due to variations in operating temperature and weight, leading to inconsistent stopping distances and potential tipping or deformation of loads.
Innovation Solution
A control device with a processor that generates control signals for drive motors using phase control, adjusting torque based on detected process data including operating temperature and weight, to implement a gradual start-up and stop-down process, reducing the risk of tipping or deformation by managing torque levels according to a customizable stopping function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the drive motor is controlled with constant torque during stopping, then the stopping distance can be kept short, but the transport goods may tip over or deform due to sudden torque changes
Solution Approach 1:
The stopping function dynamically adjusts the torque profile during the stopping process. The processor controls the drive motor to reduce torque gradually according to a predefined stopping function, transitioning from full torque to zero torque over a specified stopping period. This dynamic torque adjustment prevents sudden changes that would cause goods to tip or deform, while still achieving adequate stopping distance.
Solution Approach 2:
The system changes the torque parameter over time during the stopping process. The stopping function defines how torque decreases from its initial value to zero, with the stopping period being adjustable as a parameter. This parameter-based control allows optimization between stopping distance and goods stability by adjusting the torque decay profile.
2Object-affected harmful factors
If the stopping period is extended to reduce torque gradually, then the risk of tipping or deformation decreases, but the stopping distance increases
Solution Approach 1:
The system uses a dynamic stopping function that can be adjusted in real-time based on operating conditions. The processor selects appropriate stopping functions from a set of predefined functions, each with different characteristics. This allows the system to adapt the torque reduction profile to minimize both stopping distance and goods deformation risk under varying conditions.
Solution Approach 2:
The system incorporates feedback from process data including operating temperature and weight of transport goods. The processor uses this feedback to select and adjust the stopping function parameters, optimizing the balance between stopping distance and goods stability for each specific operating condition.
3Manufacturing precision
If the stopping function is adjusted based on operating temperature and weight, then the precision of position control improves, but the device complexity increases
Solution Approach 1:
The system adjusts stopping function parameters based on detected process data such as operating temperature and weight. The processor selects from predefined stopping functions or modifies parameters of existing functions based on these inputs. This parameter-based adaptation improves position control precision without requiring a completely new control architecture.
Solution Approach 2:
The control system automatically adapts the stopping function based on sensor inputs from the environment and load conditions. The processor performs the selection and adjustment of stopping parameters autonomously using the detected process data, eliminating the need for manual configuration and reducing operational complexity.
4Object-affected harmful factors
If phase control is used to reduce starting torque, then the risk of tipping or deformation during start-up decreases, but the start-up time increases
Solution Approach 1:
The phase control mechanism applies torque in a controlled periodic manner during start-up. By gradually increasing the phase angle, the system creates a smooth torque build-up profile that avoids sudden jumps. This periodic adjustment of phase angles reduces mechanical shocks to goods while maintaining relatively efficient start-up performance.
Solution Approach 2:
The start-up process uses dynamic phase control to adjust torque delivery in real-time. The processor controls the phase angle progression to optimize the balance between start-up speed and goods stability, creating a dynamic torque profile that adapts to the load conditions and minimizes both deformation risk and start-up time.
Data Source
Figure 1~2A
Figure 2B~2D
Figure 3A~3B
AI summary
The invention relates to a control device (1) for a goods transport conveyor (100), which device has a processor (10) which generates control signals for at least one drive motor (350) of a transport section (110; 120; 130) of the goods transport conveyor (100), said motor operating in stop-and-go mode, wherein the processor (10) is configured in order to control the drive motor (350) by means of a forward phase and/or reverse phase, when the transport section (110; 120; 130) of the goods transport conveyor (100) stops, such that the torque (M(t)) produced by the drive motor (350) is reduced according to an adjustable stopping function. The processor (10) sets the stopping function in dependence of detected process data of the transport section (110; 120; 130).