Escalator Drive Motor Load Control and Role Switching
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Solution Overview
Problem
Related-art escalators consume unnecessary power as all drive units operate regardless of load, and existing control methods lead to uneven device lifetimes and increased replacement frequencies due to inconsistent load handling.
Innovation Solution
A man conveyor apparatus with multiple drive motors and a load detection system that adjusts the number of active motors based on load, dynamically switching the main motor to optimize energy usage and reduce replacement frequency disparities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If all drive motors are operated continuously regardless of load, then the man conveyor apparatus can handle maximum load capacity, but power consumption increases unnecessarily
Solution Approach 1:
The system dynamically adjusts the number of operating drive motors based on real-time load detection. The controller monitors load conditions and activates or deactivates drive motors accordingly, transitioning the system from a static all-or-nothing operation mode to a dynamic adaptive mode that matches power output to actual demand.
Solution Approach 2:
The controller changes the operational parameters of the drive motor system by adjusting the number of active motors based on load detection values. When load decreases below certain thresholds, the controller reduces the number of operating motors from all motors to fewer motors, thereby changing the system's power consumption parameter to match actual requirements.
2Use of energy by moving object
If one drive motor is always selected as main motor in light-load state, then energy saving is achieved, but device lifetime varies significantly and replacement frequency increases
Solution Approach 1:
The controller implements periodic switching of the main drive motor role among multiple drive motors. Instead of designating one motor as the permanent main motor, the system cycles through different motors in the main motor role over time, ensuring that each motor experiences similar operational stress patterns and wear, thereby equalizing their lifetimes.
Solution Approach 2:
The controller proactively manages the operational distribution among drive motors by pre-planning the switching sequence of main motor roles. This preliminary action prevents any single motor from bearing excessive cumulative stress, thereby extending and equalizing the service life of all motors in the system.
Data Source
AI summary
Provided is a man conveyor apparatus (1), including: steps (17) connected in an endless manner; two or more drive motors (4a and 4b), each being configured to circulate the steps (17); a load detection device (10) configured to detect a load of the drive motors (4a and 4b); and a controller (11) configured to control an operation and stop of each of the drive motors (4a and 4b), wherein the controller (11) increases or decreases the number of the drive motors to be driven in accordance with a value of the load detected by the load detection device (10) and changes a drive motor to be driven as a main motor each time the number of drive motors to be driven is decreased.