Flexible Drive Torque Monitoring With Feedback Control
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Solution Overview
Problem
Existing conveyor systems with flexible drives lack effective torque monitoring, leading to inefficient load distribution and potential damage from torque spikes, and require manual troubleshooting for maintenance issues.
Innovation Solution
A self-monitoring flexible drive system with torque sensors and controllers that continuously measure and adjust torque, providing real-time alerts and proactive maintenance, ensuring balanced load distribution and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If torque monitoring is added to flexible drive systems, then system reliability and preventive maintenance capability are improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical torque measurement systems with electronic sensors and digital signal processing. Torque sensors convert mechanical torque into electrical signals that are processed by controllers, eliminating the need for complex mechanical linkages and manual measurement devices while improving reliability and enabling predictive maintenance.
Solution Approach 2:
The patent introduces torque sensors as intermediary devices between the drive motor and the flexible drive means. These sensors act as mediators that convert mechanical parameters into electrical signals, allowing the controller to monitor and analyze torque without directly interfering with the mechanical drive system, thus adding monitoring capability while maintaining system simplicity.
2Loss of time
If manual troubleshooting is used for maintenance issues, then device complexity is kept low, but loss of time increases due to inability to detect torque anomalies early
Solution Approach 1:
The patent implements continuous torque monitoring with feedback to the controller, which analyzes torque signals to detect anomalies, imbalances, and abnormal conditions. This automated feedback loop enables early detection of problems before they cause failures, significantly reducing downtime compared to manual troubleshooting while maintaining reasonable automation levels through programmable logic controllers.
3Productivity
If torque sensors and controllers are added to enable real-time torque measurement and adjustment, then load balance and system efficiency are improved, but device complexity and initial cost increase
Solution Approach 1:
The patent enables the flexible drive system to self-monitor and self-adjust through automated torque analysis. The controller automatically detects torque imbalances and abnormal conditions, and can adjust drive parameters or alert operators without requiring constant manual intervention. This self-service capability improves system efficiency by optimizing performance while the automation manages the increased complexity.
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
Enables early detection of torque anomalies, improves load balance, and facilitates predictive maintenance, reducing downtime and enhancing system efficiency.
Implementation Method 1
the torque sensor being loaded through a torque arm fixedly secured with respect to a housing of the drive motor, and a load measuring support arm supporting a distal portion of the torque arm against a stationary support structure
Data Source
AI summary
A self-monitoring flexible drive system including a drive motor having an output member coupled to a flexible drive means configured to move one or more work pieces by loading the flexible drive means in tension. The drive motor is supported by a mount that fixes a position of the drive motor while allowing free rotation. A torque sensor measures torque applied to the flexible drive means by the drive motor. The torque sensor is provided by a torque arm fixedly secured with respect to a housing of the drive motor, and a load measuring support arm supporting a distal portion of the torque arm against a stationary support. A controller receives a variable non-binary output signal from the torque sensor that indicates a value of the measured torque. The controller is programmed to output a signal configured to modify an input drive signal controlling the output of the drive motor.