Cycloidal Link Winding Drive for Precise Torque and Jolt Resistance
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Solution Overview
Problem
Existing devices for winding and unwinding links lack compactness, precision in torque control, and modularity, and are not effective in withstanding sudden jolts or adapting to diverse applications, leading to high costs and limited accessibility.
Innovation Solution
A device comprising a permanent magnet synchronous motor and a cycloidal reducer with multiple synchronous motors in series, which provides precise torque control, high overtorquing capabilities, and modular design, while maintaining compactness and protecting the link from environmental and internal degradations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a helical bevel gearbox is used for torque adaptation, then multiple motor coupler sets can be mounted on a common gearbox reducing production cost, but the device lacks compactness and cannot withstand substantial jolts
Solution Approach 1:
The gearbox is divided into multiple independent planetary gear sets, each handling a portion of the torque. This segmentation allows each gear set to be compact and robust, while collectively they handle the total required torque, resolving the contradiction between compactness and torque capacity.
Solution Approach 2:
Multiple planetary gear sets are merged into a single integrated gearbox structure with a common input shaft and housing. This merging provides the torque adaptation capability of multiple motor coupler sets while achieving compactness and robustness through the unified planetary gear mechanism.
2Device complexity
If an asynchronous motor is used for driving the reel, then the device is simpler to implement, but torque control precision is poor with differences of about 15% between setpoint and actual torque
Solution Approach 1:
A feedback control system is implemented where the actual torque is measured by a sensor and compared with the setpoint torque. The controller adjusts the motor commands based on the torque error signal, achieving precise torque control (within 5% accuracy) while managing the complexity through systematic feedback loops.
3Device complexity
If an asynchronous motor is used, then the device is simpler, but overtorquing capability is limited and cannot provide high torque for emergency stopping phases
Solution Approach 1:
The system dynamically switches between different motor types based on operational requirements. Asynchronous motors are used for normal operation where simplicity is valued, while synchronous motors with higher overtorquing capability are engaged for emergency stopping phases requiring high torque, optimizing the balance between simplicity and performance.
4Device complexity
If several asynchronous motors are controlled with a single frequency variator, then the device is simpler, but torque precision is poor and modularity is limited
Solution Approach 1:
The control system is segmented into independent control units, each dedicated to a specific motor. This allows precise torque control for each motor individually while maintaining modularity. The segmentation of control functions enables better torque precision compared to a single frequency variator controlling multiple motors.
Solution Approach 2:
The control architecture is designed to be universal and modular, where each control unit can independently manage a motor while the overall system maintains simplicity through standardized interfaces. This multi-functional control approach achieves both precision and modularity.
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
The solution achieves a compact and modular design with precise torque control, enhanced durability against sudden jolts, and adaptability to various applications, reducing costs and increasing accessibility by utilizing a cycloidal reducer and permanent magnet synchronous motors.
Implementation Method 1
at least one permanent magnet synchronous motor comprising a rotor arranged around a first portion of the output shaft, the rotor being integral in rotation with the input shaft
Implementation Method 2
wherein each cam is eccentric, in such a way that a rotation of each cam about the longitudinal axis drives a rotation of the at least one cycloidal disc in an eccentric and cycloidal movement
Data Source
AI summary
A device for winding/unwinding a link includes, but is not limited to, an input shaft and a hollow through output shaft, the two shafts being coaxial and movable in rotation about a longitudinal axis; a permanent magnet synchronous motor comprising a rotor integral in rotation with the input shaft; a cycloidal reducer comprising an eccentric cam mounted integral in rotation with the input shaft, and a cycloidal disc mounted integral in rotation with the cam, in such a way that a rotation of the cam about the longitudinal axis drives a rotation of the cycloidal disc in an eccentric and cycloidal movement; and a transmission member suitable for transmitting an angular displacement of the cycloidal disc to the output shaft.