Conveyor Power Supply Segmentation for Energy Reduction
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Solution Overview
Problem
Conveyor systems face challenges in reducing the dimensioning of power supply apparatuses while optimizing drive quality and energy consumption, particularly due to the need for large frequency converters and cooling systems that result in increased energy consumption and space requirements, and synchronization issues during load changes.
Innovation Solution
Implementing a method that uses two adjustable supply devices, a soft starter and an inverter, to adjust power supply based on conveyor power requirements, with the soft starter handling higher currents at lower switching frequencies during heavy loading and the inverter handling lower currents at higher frequencies during idle periods, minimizing power losses and reducing overexcitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a frequency converter is used to supply power to the drive machinery, then the running speed and energy consumption can be adjusted, but the power-handling capacity must be dimensioned for full load which increases the size of the frequency converter and cooling apparatus
Solution Approach 1:
The power supply system is segmented into two separate supply devices: a first supply device (frequency converter) for low power requirements and a second supply device (direct network connection) for high power requirements. This segmentation allows each device to be dimensioned for its specific operating range, reducing the overall size and cost of the power supply system while maintaining energy efficiency across all operating conditions.
Solution Approach 2:
The system dynamically switches between two power supply configurations based on the actual power requirements of the conveyor. The control unit monitors the power demand and automatically connects or disconnects the second supply device to the drive machinery, optimizing the balance between energy consumption and equipment size in real-time.
2Volume of stationary object
If the power supply is switched from frequency converter to direct network connection during heavy loading, then the frequency converter size can be reduced, but synchronization errors cause nudge or impact detected by users
Solution Approach 1:
Before switching from the first supply device to the second supply device, the control unit performs preliminary synchronization of the voltage amplitude and frequency of the frequency converter output with the network voltage. This preliminary action ensures that when the switch occurs, there is no voltage mismatch, preventing nudge or impact sensations for users while still allowing the frequency converter to be downsized.
Solution Approach 2:
The control unit continuously monitors the operating conditions and power requirements of the conveyor, providing feedback to determine the optimal moment for switching between power supply devices. This feedback mechanism ensures smooth transitions by switching only when conditions are favorable, maintaining operational smoothness while enabling equipment size reduction.
Data Source
AI summary
A conveyor system and a method for driving a conveyor are disclosed. In the method, electric power is supplied to the drive machinery of a conveyor depending on the power requirement with a supply device to be selected from at least two different adjustable supply devices, and the supply device supplying power to the drive machinery is changed on the basis of the power requirement of the conveyor.