Direct-Drive Reel Winding for High Torque at Low Speed
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Solution Overview
Problem
Existing winding devices face challenges in providing high torque at low speeds while maintaining modularity and efficiency, particularly in applications with varying installation heights, displacement speeds, and accelerations.
Innovation Solution
A winding device utilizing a permanent magnet synchronous direct drive motor with a rotor and stator configuration, featuring trapezoidal-shaped permanent magnets and three-phase windings, coupled with an electronic speed variator for torque control, eliminates the need for gearboxes and allows for modular adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a motor with magnetic coupler and gearbox is used, then modularity is improved, but mechanical wear and reliability worsen
Solution Approach 1:
The patent extracts and eliminates the gearbox and magnetic coupler from the drive system, using a direct-drive motor that connects the motor shaft directly to the reel. This removal of intermediate mechanical components eliminates the associated wear and failure points while maintaining the ability to adapt to different applications through motor selection rather than mechanical reconfiguration.
Solution Approach 2:
The patent replaces the mechanical transmission system (gearbox and magnetic coupler) with an electrical control system. The variable frequency motor with electronic control unit provides the necessary speed and torque control without mechanical intermediaries, substituting mechanical complexity with electrical control sophistication.
2Reliability
If a variable frequency motor with electronic control is used, then reliability is improved, but modularity worsens
Solution Approach 1:
The patent employs a variable frequency motor with electronic control unit that dynamically adjusts motor parameters (speed, torque) based on real-time application requirements. This dynamic control capability provides adaptability to different installation heights, speeds, and accelerations without requiring physical reconfiguration, maintaining modularity through software/control flexibility rather than mechanical adaptability.
3Force
If traditional motor-gearbox system is used, then torque delivery is improved, but device complexity and mechanical wear worsen
Solution Approach 1:
The patent removes the gearbox from the system, using a direct-drive motor configuration where the motor shaft is directly coupled to the reel. This eliminates the complex mechanical transmission train while delivering substantial torque directly at low speeds, reducing device complexity and eliminating mechanical wear associated with gear meshes and couplings.
4Reliability
If direct drive motor is used, then mechanical wear is reduced, but torque at low speed must be optimized
Solution Approach 1:
The patent uses a variable frequency motor that can change its operating parameters (frequency, voltage, current) to optimize torque delivery at low speeds. The electronic control unit adjusts motor parameters in real-time to maintain high torque output at the low rotation speeds required by the reel, compensating for the absence of mechanical advantage from a gearbox.
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 provides high torque at low speeds, enhances reliability, reduces mechanical wear, and enables rapid torque adjustments, overcoming gearbox limitations and improving emergency braking performance.
Implementation Method 1
at least one permanent magnet synchronous direct drive motor, comprising a stator carrying windings adapted to be electrically three-phase powered and a rotor carrying the permanent magnets facing windings of the stator
Implementation Method 2
a rotor carrying the permanent magnets facing windings of the stator
Data Source
AI summary
The invention relates to a device for winding/unwinding a link adapted to transporter a fluid or transmit energy and/or signals, comprising:a reel (2) adapted to receive said link in wound form,a hollow through shaft (3) adapted to the passage of said link or fluid between a rotating joint and the reel, said hollow shaft (3) being integral with the reel (2) in order to drive said reel in rotation about a longitudinal axis (X) of said shaft,at least one permanent magnet synchronous direct drive motor, comprising a stator carrying windings (10) adapted to be electrically three-phase powered and a rotor carrying the permanent magnets (11) facing windings (10) of the stator.