Direct Drive Roller Mill Torque Motors
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Solution Overview
Problem
Existing roller mills with belt and pulley drive systems are noisy, prone to wear, energy inefficient, require frequent maintenance, occupy excessive space, and have limited torque range and speed control, leading to suboptimal processing of cereals and grain products.
Innovation Solution
A roller mill with direct drive magnetic motors, where torque motors with permanent magnets are mounted on each cylinder shaft, and a control circuit manages the energy supplied to coils to control rotation speed and torque, allowing for variable speed settings and energy recovery between cylinders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If belt and pulley drive units are used to transmit motion between cylinders, then speed synchronization between cylinders is achieved, but the drive units produce noise, wear, and require frequent maintenance
Solution Approach 1:
The patent replaces the mechanical belt and pulley drive system with an electronic control system. Each cylinder is equipped with its own asynchronous motor and speed sensor, and a microprocessor-controlled electronic system coordinates the rotation speeds of both cylinders. This substitution eliminates mechanical wear, noise, and maintenance issues associated with belts and pulleys while achieving precise speed synchronization through electronic feedback control.
2Speed
If belt drive units are used to transmit motion, then space for mechanical coupling is provided, but the drive units occupy excessive space and require additional infrastructure
Solution Approach 1:
The patent eliminates the need for belt drive units and mechanical coupling components by using direct-drive asynchronous motors on each cylinder. The electronic control system replaces the physical space previously occupied by belts, pulleys, and tensioning mechanisms, significantly reducing the overall footprint and infrastructure requirements of the rolling mill.
3Power
If asynchronous motors are used with belt drive units, then rotation is transmitted to cylinders, but energy losses occur due to low efficiency of the drive unit
Solution Approach 1:
The patent eliminates the intermediate belt drive system that caused energy losses through friction, slippage, and mechanical inefficiency. By using direct-drive asynchronous motors with electronic speed control, the system achieves superior energy efficiency by transmitting power directly from the motor to the cylinder without mechanical intermediaries, reducing energy losses while maintaining precise rotation control.
4Productivity
If pulleys with different pitch diameters are used to obtain different rotation speeds, then optimal treatment of cereals is achieved, but the system requires stopping and reinstallation to change speed ratios
Solution Approach 1:
The patent implements dynamic speed control using electronic feedback systems with speed sensors on each cylinder and microprocessor-based controllers. This allows the rotation speeds of both cylinders to be independently adjusted and optimized for different cereal processing requirements without any physical changes to the system. The electronic control system can instantly modify speed ratios to adapt to various processing needs, eliminating the need to stop and reconfigure mechanical components.
5Area of stationary object
If the same motor is used to operate both cylinders, then space is saved, but the torque developed is insufficient at lower speeds required for optimal processing
Solution Approach 1:
The patent divides the drive system into two independent units, with each cylinder having its own asynchronous motor. This segmentation allows each motor to be optimized for its specific cylinder's speed and torque requirements, particularly providing sufficient torque at lower speeds for optimal cereal processing. While this increases the number of motors, the electronic control system coordinates them efficiently, and the improved processing capability compensates for the additional component count.
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 solution reduces maintenance, increases torque availability across a wide range of speeds, optimizes processing, and recovers energy, while minimizing mechanical parts and space requirements, enabling better control over grinding operations.
Implementation Method 1
a torque motor with magnetic drive is mounted or assembled on at least one end of each shaft
Implementation Method 2
torque motors with permanent magnets are mounted on each cylinder shaft
Implementation Method 3
a control circuit manages the energy supplied to coils to control rotation speed and torque
Implementation Method 4
roller mill with direct drive motors where torque motors with permanent magnets are mounted on each cylinder shaft
Data Source
Figure 1
AI summary
The invention is a mill or rolling mill having at least one pair of parallel cylinders (C', C") positioned side by side, wherein each cylinder (C', C") of each pair of cylinders is provided with its own torque motor mounted directly on its own shaft, and wherein at least one control circuit (Z) is suited to supervise the rotation parameters of said cylinders (C', C") of each pair.