Electromagnetic Switch Coils for Sliding Shoe Sorter Heat Reduction
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Solution Overview
Problem
Conveyor systems, particularly sliding shoe sorter conveyor systems, face inefficiencies and reliability issues due to the high electrical power requirements and heat generation of electromagnetic switches, especially at higher conveyor speeds, which can lead to reduced reliability.
Innovation Solution
The use of multiple electromagnetic coils operated in sequence, combined with a downstream permanent magnet, to divert shoes by generating magnetic fields that urge the shoes towards a diverting path, optimizing energy usage and reducing heat generation through dynamic current control and energy recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electromagnetic coils are used to generate strong magnetic fields for diverting shoes at high conveyor speeds, then the diverting reliability is improved, but heat generation increases and coil lifespan decreases
Solution Approach 1:
The patent applies periodic action by using pulsed electromagnetic fields instead of continuous fields. The controller activates electromagnetic coils in sequential pulses as different portions of the shoe pass through the switch, generating strong magnetic fields only when needed. This pulsed operation reduces average power consumption and heat generation while maintaining sufficient magnetic field strength for reliable diverting at high conveyor speeds
Solution Approach 2:
The patent changes the temporal parameters of electromagnetic coil activation by adjusting pulse duration, pulse timing, and pulse intensity based on shoe speed and position. The controller dynamically modifies these parameters to optimize the magnetic field generation, ensuring reliable diverting while minimizing heat generation and energy consumption
2Reliability
If electromagnetic coils operate continuously to maintain strong magnetic fields, then diverting effectiveness is improved, but energy consumption increases
Solution Approach 1:
The system uses periodic pulsed activation of electromagnetic coils rather than continuous operation. The controller timing the pulses to coincide with shoe passage through the switch, maintaining strong magnetic fields only when needed for diverting. This reduces average electrical power consumption while preserving diverting effectiveness
Solution Approach 2:
The controller anticipates shoe arrival and pre-activates electromagnetic coils in a sequential pattern as different portions of the shoe approach and pass through the switch. This preliminary and staged activation ensures the magnetic field is ready when needed while avoiding unnecessary energy consumption from continuous operation
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 enhances the reliability and efficiency of the electromagnetic switch by reducing power consumption and heat generation, ensuring effective diversion of shoes even at higher conveyor speeds, thereby improving the overall performance of sliding shoe sorter conveyor systems.
Implementation Method 1
energizing a first electromagnetic coil of the electromagnetic switch while the shoe is adjacent the first electromagnetic coil to generate a first magnetic field urging the shoe towards the diverting path
Implementation Method 2
energizing a first electromagnetic coil of the electromagnetic switch while the shoe is adjacent the first electromagnetic coil to generate a first magnetic field
Implementation Method 3
a third magnetic field generated by the permanent magnet further urges the shoe towards the diverting path
Data Source
AI summary
A method, electromagnetic switch, controller and program product utilize multiple electromagnetic coils that, whenever it is desirable to divert a shoe, are operated in sequence to urge the shoe into a diverting path downstream of the electromagnetic switch. The multiple electromagnetic coils may also be used in combination with a downstream permanent magnet such that energization of the electromagnetic coils appropriately positions the shoe adjacent the permanent magnet such that the permanent magnet can further urge the shoe towards the diverting path.