Electromagnetic Vibratory Conveyor Amplitude Control
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Solution Overview
Problem
Existing vibratory conveyor systems for filling machines face challenges in amplitude control, speed, precision, cost, wear, and unwanted vibration, particularly in applications like pharmaceutical packaging, where precise item conveyance and counting are critical.
Innovation Solution
A vibratory conveyor system utilizing an electromagnetic linear actuator with a movable drive train, including parallel spring elements and closed-loop sensor feedback control, to adjust and maintain precise movement of a titanium or titanium-adhesive feed tray, minimizing unwanted vibrations and optimizing amplitude and speed control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a rotary motor with eccentric mass is used for vibration, then frequency control is good, but amplitude control is difficult and excess vibration is created on the machine frame
Solution Approach 1:
The patent replaces the traditional rotary motor with eccentric mass mechanical system with an electromagnetic linear actuator system. This substitution allows for precise control of both frequency and amplitude through electrical signals, eliminating the mechanical limitations of the rotary system while reducing unwanted vibrations on the machine frame.
Solution Approach 2:
The patent enables independent control of vibration parameters by using an electromagnetic linear actuator that can separately adjust frequency and amplitude through electrical parameters. This allows optimization of both frequency control (inherited from rotary systems) and amplitude control (new capability) without the trade-offs of mechanical systems.
2Manufacturing precision
If hydraulic vibratory conveyors are used, then directional control and precision are high, but speed is limited and an independent hydraulic control system is required
Solution Approach 1:
The patent replaces the hydraulic drive system with an electromagnetic linear actuator system. This substitution eliminates the need for complex hydraulic control infrastructure while enabling higher speeds through direct electromagnetic force application, maintaining precise directional control through the linear actuator's controlled motion.
Solution Approach 2:
The patent extracts and eliminates the independent hydraulic control system from the conveyor design by using an electromagnetic linear actuator that integrates control functions directly into the drive mechanism, simplifying the overall system while maintaining precision and increasing speed.
3Speed
If pneumatic vibratory conveyors are used, then speed is higher than hydraulic conveyors, but precise control of distance and amplitude is lacking
Solution Approach 1:
The patent replaces the pneumatic drive system with an electromagnetic linear actuator system that provides both high speed capability and precise distance/amplitude control through electrical parameter adjustment, eliminating the precision limitations of pneumatic systems while maintaining high-speed performance.
Solution Approach 2:
The patent implements a closed-loop control system with sensors that detect the position and motion of the feed tray, providing feedback to the controller. This feedback mechanism enables precise control of distance and amplitude while maintaining high speed operation, as the system can make real-time adjustments based on actual performance.
4Manufacturing precision
If electric rotary vibratory conveyors with servo-motor and crankshaft are used, then precision is good based on servo-motor speed control, but amplitude adjustment is difficult due to mechanical limits, and the system is expensive with high wear requiring oil bath
Solution Approach 1:
The patent replaces the complex mechanical system of servo-motor coupled with crankshaft and piston with a direct electromagnetic linear actuator system. This eliminates the mechanical limits that restrict amplitude adjustment while maintaining precision control, reduces wear by eliminating contact mechanics, and removes the need for oil bath maintenance.
Solution Approach 2:
The patent makes the system dynamically adjustable by using an electromagnetic linear actuator that can vary its output characteristics (force, speed, amplitude) through electrical control without being constrained by fixed mechanical parameters. This enables easy amplitude adjustment while maintaining precision and reducing mechanical wear.
5Manufacturing precision
If electromagnetic linear actuator with movable drive train is used, then precise amplitude and speed control is achieved, but device complexity increases
Solution Approach 1:
The patent implements a closed-loop feedback control system where sensors detect the actual position and motion of the feed tray, and the controller adjusts the electromagnetic linear actuator accordingly. This feedback mechanism simplifies the control logic by using actual system state information, making the system easier to control despite the added sensor components.
Solution Approach 2:
The patent enables the system to self-regulate its operation through the feedback control loop, which automatically adjusts parameters to maintain desired performance. This self-service capability reduces the need for complex external control systems and manual intervention, simplifying overall system operation despite the presence of additional control components.
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 system achieves precise control over vibration amplitude and speed, reducing wear and cost while minimizing unwanted vibrations, thereby enhancing the accuracy and efficiency of item conveyance and counting in filling machines.
Implementation Method 1
an electromagnetic linear actuator with a movable drive train, including parallel spring elements and closed-loop sensor feedback control
Implementation Method 2
The movable drive train includes at least one parallel spring element therealong
Implementation Method 3
A sensor assembly is positioned to detect movement of the electromagnetic linear actuator
Data Source
AI summary
A vibratory conveyor includes a feed tray, an electromagnetic linear actuator and a movable drive train interconnecting the feed tray and the electromagnetic linear actuator such that the electromagnetic linear actuator will move the feed tray during energization of the electromagnetic linear actuator. A sensor assembly is positioned to detect movement of the electromagnetic linear actuator. A controller connected to receive an output of the sensor assembly and connected to control energization of electromagnetic linear actuator, wherein the controller is configured to adjust energization of the electromagnetic linear actuator based upon the output of the sensor assembly. A vibratory conveyor in which the movable drive train includes at least one parallel spring element therealong is also disclosed.