Industrial Truck Eddy Current Brake Regenerative Torque Control
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Solution Overview
Problem
Industrial trucks with electric travel drives face insufficient braking torque during regenerative operation, especially at high speeds and high payloads, leading to inadequate stopping distances and potential battery overvoltage.
Innovation Solution
The integration of an eddy current brake controlled by a sophisticated control system that regulates and supplements the regenerative braking torque, ensuring a constant and sufficient braking torque by adjusting the eddy current brake's setpoint based on rpm, load, and battery voltage to prevent excessive regenerative current and overvoltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the electric travel drive is operated exclusively as a motor without regenerative braking, then the drive system is simpler and more reliable, but energy efficiency deteriorates and operating costs increase
Solution Approach 1:
The electric travel drive serves dual functions: as a motor during acceleration and as a generator during braking. The system recovers kinetic energy during deceleration and feeds it back to recharge the battery, making the system self-sufficient and improving overall energy efficiency without requiring an external power source for braking energy recovery
Solution Approach 2:
The electric travel drive is designed to perform multiple functions: it operates as a motor for propelling the industrial truck and as a generator for regenerative braking. This multi-functionality allows the same component to serve different purposes, reducing the need for separate braking systems and improving energy efficiency
2Force
If regenerative braking is implemented without an eddy current brake, then the system is simpler, but braking torque becomes insufficient at high speeds and high payloads
Solution Approach 1:
The regenerative braking system and eddy current brake are merged into a coordinated braking system. The electric travel drive provides regenerative braking by generating electrical current during deceleration, while the eddy current brake provides supplemental electromagnetic braking force. Both systems work together to ensure sufficient braking torque across all operating conditions
Solution Approach 2:
The control system acts as an intermediary that coordinates between the regenerative braking system and the eddy current brake. It manages the interaction between these two braking mechanisms, ensuring they work together harmoniously to provide the required braking torque while optimizing energy recovery and preventing system conflicts
3Reliability
If regenerative braking is used without control regulation, then the system is simpler, but battery overvoltage occurs and braking performance becomes unreliable
Solution Approach 1:
The control system continuously monitors braking conditions, battery charge state, and system parameters, using this feedback to dynamically adjust the regenerative braking torque and eddy current brake activation. This closed-loop control ensures reliable braking performance while preventing battery overvoltage by regulating the amount of electrical current generated during regenerative braking
Solution Approach 2:
The braking system dynamically adjusts its characteristics based on real-time operating conditions. The control system varies the regenerative braking torque and eddy current brake activation according to factors such as vehicle speed, load, and battery charge state, ensuring optimal braking performance and preventing battery overvoltage across all operating conditions
4Force
If the eddy current brake is activated at low speeds, then braking torque is maintained, but the brake may lock and cause damage
Solution Approach 1:
The control system continuously monitors vehicle speed and braking conditions, using this feedback to dynamically adjust the eddy current brake activation. As the vehicle approaches low speeds, the control system reduces or deactivates the eddy current brake to prevent wheel lockup, while maintaining sufficient braking torque through regenerative braking alone
Solution Approach 2:
The eddy current brake activation is dynamically adjusted based on vehicle speed. The control system varies the braking torque in real-time, reducing activation at low speeds to prevent lockup while maintaining adequate braking force through the combination of regenerative braking and controlled eddy current brake application
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 provides reliable braking performance across various conditions, maintaining consistent braking torque and preventing battery overvoltage, ensuring safe operation on ramps and with high payloads by complementing regenerative braking with eddy current braking.
Implementation Method 1
an eddy current brake (48) that is controlled or regulated by the controls (20) to brake the industrial truck (1) during regenerative operation of the travel drive (14)
Implementation Method 2
the travel drive (14) is used as a generator, the generated current of which is supplied to a battery (32)
Data Source
AI summary
Industrial truck with an electric travel drive and controls that can switch the electric travel drive to regenerative operation to brake the industrial truck, wherein an eddy current brake is provided that can be controlled or regulated by the controls during regenerative operation to brake the industrial truck, wherein the controls control or regulate the eddy current brake depending on the rpm of the electric travel drive, and wherein the controls control or regulate the eddy current brake in a manner such that the braking torque of the travel drive is supplemented at high rpms by the braking torque generated by the eddy current brake.