Electronic Braking System for Irrigation Machine Coasting
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Solution Overview
Problem
Modern irrigation machines experience coasting issues on uneven terrain, leading to inconsistent application of water and chemicals, as existing solutions like high gear ratios and mechanical brakes result in excessive wear, heat, and maintenance costs.
Innovation Solution
An electronic braking system using a drive controller and a 3-phase induction motor that applies DC current to the motor windings when motive power is removed, creating static friction to prevent movement and eliminate coasting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high gear ratio worm drive gear boxes are used to prevent coasting, then coasting is reduced, but dynamic friction increases causing excessive wear and heat
Solution Approach 1:
The patent replaces the mechanical friction-based braking system with an electromagnetic braking system. The electromagnetic brake uses magnetic fields to create holding force on the drive shaft, eliminating the need for high gear ratios and mechanical friction. This substitution resolves the contradiction by providing coasting prevention without the excessive wear and heat generation associated with mechanical friction systems.
Solution Approach 2:
The patent changes the operating parameters of the drive system by introducing electromagnetic braking force as a controllable parameter. Instead of relying on fixed mechanical friction from high gear ratios, the system dynamically adjusts electromagnetic brake engagement to provide precise coasting control. This parameter change allows effective coasting prevention with minimal energy loss and no excessive wear.
2Reliability
If mechanical brakes are used to prevent coasting, then movement is prevented during off period, but corrosion and wear increase leading to high maintenance costs
Solution Approach 1:
The patent replaces mechanical brakes with an electromagnetic braking system. The electromagnetic brake uses magnetic fields to hold the drive shaft stationary during the off period, eliminating contact-based mechanical braking. This substitution resolves the contradiction by providing reliable coasting prevention without the corrosion and wear problems that plague mechanical brake systems in wet irrigation environments, thereby reducing maintenance costs.
3Reliability
If high ratio worm center drive gear boxes are used to minimize spin-down, then coasting is reduced, but energy consumption increases
Solution Approach 1:
The patent replaces high ratio worm drive gear boxes with an electromagnetic braking system that directly controls the drive shaft. This substitution eliminates the need for excessive mechanical friction and high gear ratios, providing effective coasting control with significantly reduced energy consumption. The electromagnetic brake engages only when needed to prevent coasting, rather than continuously resisting motion through mechanical friction.
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
Effectively reduces coasting on uneven surfaces by momentarily freezing the motor's rotor, switching from dynamic to static friction, thereby preventing further movement and ensuring precise application of irrigation fluids and chemicals.
Implementation Method 1
an electromagnetic brake which includes a brake controller that signals an ON condition when motive power is removed from a motor and an OFF condition when motive power is applied to the motor; and an electromagnetic brake that applies a magnetic force to a drive shaft when the brake controller signals the ON condition
Data Source
AI summary
The present invention provides an electronic braking system for an irrigation machine. According to an exemplary preferred embodiment, the present invention includes a drive controller which includes a power supplying circuit which signals an ON condition when a motive power request is input into the drive controller and an OFF condition when motive power is not input into the system. According to a further preferred embodiment, the present invention further includes a 3-phase induction motor connected to apply torque to a drive shaft which is connected to a least one drive wheel. According to a further preferred embodiment, the power supplying circuit supplies 480V AC of motive power to the drive motor when the drive controller signals the ON condition and 10-80V DC of non-motive power to at least one phase of the motor when the drive controller signals the OFF condition. According to a further preferred embodiment, the application of the DC current is applied immediately after the motive power is removed from the drive motor and the application of non-motive power brakes and prevents the drive shaft from turning until the DC current is removed.