Electromechanical Actuator Nailing Machine Energy Savings

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Solution Overview

Problem

Hydraulic systems used in wood-processing machines for nailing wooden parts are inefficient, noisy, energy-consuming, and environmentally unfriendly due to the need for constant engine operation and frequent oil replacement.

Innovation Solution

The use of electromechanical actuators, specifically servo engines, to power the pressing ram, which are more energy-efficient, quieter, and eco-friendly, with the actuators only running during the pressing ram's movement, reducing energy consumption by 60% compared to hydraulic systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hydraulic systems are used to power the pressing ram, then high force and reliability are achieved, but energy consumption increases and environmental friendliness decreases

Engineering Contradiction:

ImprovereliabilityVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces the hydraulic system with an electromechanical actuator system. The electromechanical actuator directly converts electrical energy to mechanical motion, eliminating the need for hydraulic fluid and pumps. This substitution maintains the pressing force capability while significantly reducing energy consumption and eliminating the need for continuous engine operation, as the electric motor only runs during the pressing cycle.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Force

If hydraulic systems are used to power the pressing ram, then high force is achieved, but noise levels increase

Engineering Contradiction:

Improvepressing forceVSAvoidnoise

Core Design Contradiction:

ForceVSObject-generated harmful factors

Solution Approach 1:

The electromechanical actuator replaces the noisy hydraulic system components (pumps, valves, fluid flow). Electric motors operate much quieter than hydraulic systems, eliminating the noise generated by hydraulic fluid circulation, pressure regulation, and component operation while maintaining the required pressing force through direct electromagnetic force generation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Duration of action of stationary object

If hydraulic systems are used to power the pressing ram, then continuous operation capability is achieved, but environmental friendliness decreases

Engineering Contradiction:

Improvecontinuous operation capabilityVSAvoidenvironmental friendliness

Core Design Contradiction:

Duration of action of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The electromechanical actuator eliminates environmental harm by replacing hydraulic oil (which requires periodic replacement and can leak) with an electric motor system. The electric system produces no fluid leaks, no oil contamination risks, and no hydraulic fluid disposal issues. The motor can operate continuously or intermittently without environmental impact, and the system requires no hydraulic fluid maintenance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Use of energy by moving object

If electromechanical actuators are used to power the pressing ram, then energy efficiency and eco-friendliness improve, but purchase price increases

Engineering Contradiction:

Improveenergy efficiencyVSAvoidpurchase price

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent changes the power source parameter from hydraulic (continuous engine operation) to electromechanical (intermittent electric motor operation). This parameter change enables energy efficiency improvements of up to 60% because the electric motor only operates during the actual pressing cycle rather than running continuously. The higher initial purchase price is offset by significantly lower operating costs and energy consumption over the system's lifetime.

Inventive Principle:

Principle #35Parameter changes

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 electromechanical actuator solution provides precise control, reduced noise, and significant energy savings while maintaining high efficiency and accuracy in the nailing process, making it a more cost-effective option in the long run.

Implementation Method 1

The motion of the actuators is based on servo engines, preferably with 4kW of power

Methodology Applied

Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Implementation Method 2

the actuators exerting the force on pressing ram. Further, the pressing ram pushes the sliding bars mounted to the hammers and presses the nails into wood parts

Methodology Applied

Scientific EffectMechanical force transmission: Mechanical Force

Data Source

PatentEP2563557B1Nailing machine

Publication Date: 2020.01.08 STORI MANTEL

Figure 1
Figure 2

AI summary

Nailing machine (2) for nailing wooden parts, such as palettes, wooden boxes and indented beams, where the pressing ram (3) is movable in vertical axis, the machine (2) comprises electromechanical actuators (1) for exerting mechanic pressure on the pressing ram (3). Further, the pressing ram (3) pushes the sliding bars of the hammers (4), thereby pressing the nails into wooden parts (6). The electromechanical actuator comprises a sliding rod (7), a solid part (8) with flanges for mounting to the machine (2) frame and for mounting to a spacer (9) of the drive unit (10).