Hoist Energy Flow Control Using Regenerative Storage Feedback
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Solution Overview
Problem
Existing lifting devices face inefficiencies in energy management, leading to excess energy surplus or deficit, which affects system performance and energy consumption.
Innovation Solution
A method and device that control energy flow by utilizing an energy storage device to store secondary energy during lifting and lowering operations, optimizing energy usage based on load mass, height, and storage capacity, minimizing reliance on external power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If energy storage device is used to store secondary energy during lifting and lowering operations, then energy efficiency is improved and primary energy draw is reduced, but device complexity increases due to additional control systems and sensors
Solution Approach 1:
The control unit continuously monitors the state of charge of the energy storage device, lifting height via sensors, and load mass to dynamically regulate energy flow. This feedback mechanism optimizes energy utilization by adjusting the charging/discharging rates based on real-time system conditions, resolving the contradiction between improved energy efficiency and increased control complexity through intelligent automation.
Solution Approach 2:
The system dynamically adjusts energy flow parameters based on varying operating conditions such as lifting speed, load mass, and energy storage capacity. The control unit modulates the energy transfer rates to match actual demand, enabling optimal energy efficiency while managing complexity through adaptive control rather than fixed configurations.
2Reliability
If brake chopper is used to absorb and dissipate excess secondary energy, then energy surplus is prevented, but energy efficiency deteriorates due to energy loss as heat
Solution Approach 1:
The energy storage device serves itself by automatically absorbing and storing excess secondary energy during lowering operations, eliminating the need for external brake choppers. The system uses its own stored energy capacity to manage energy surpluses, converting what would be wasted heat dissipation into useful stored energy, thereby improving overall energy efficiency while maintaining reliable control.
Solution Approach 2:
Instead of dissipating excess secondary energy as harmful heat through brake choppers, the system converts this energy into beneficial stored energy in the energy storage device. The energy that would otherwise be wasted is now captured and stored for later use, transforming an energy loss problem into an energy storage opportunity.
3Productivity
If lifting and lowering speeds are increased to improve productivity, then work cycle time is reduced, but energy demand increases and energy efficiency deteriorates
Solution Approach 1:
The system maintains continuous energy exchange between the electric motor and energy storage device throughout the lifting and lowering cycles. By keeping the energy storage device actively charging during lowering and discharging during lifting, the system sustains useful energy action without interruption, enabling high productivity while minimizing energy losses through continuous regenerative capture.
Solution Approach 2:
The energy storage device is pre-charged during lowering operations before the next lifting operation begins. This preliminary energy storage action ensures that energy is available when needed, allowing the system to maintain high speeds without energy constraints, thereby improving productivity while managing energy consumption through advance energy preparation.
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
Enhances energy efficiency by optimizing energy utilization, reducing primary energy draw, and eliminating the need for brake choppers, while ensuring reliable operation and smaller component dimensions.
Implementation Method 1
converting kinetic energy into electrical energy during regenerative braking of the electric motor-driven crane drives, for example, during the lowering process of a load via the lifting drive
Implementation Method 2
the brake chopper is connected to a braking resistor, through which the excess secondary energy is converted into heat
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for controlling or regulating the energy and energy flow or power in a lifting device, in particular a manually operated one, with a cable pull (1), the lifting drive of which has a generator-operated electric motor (2) for recuperation during the lowering process of a load (L), wherein the electric motor (2) is electrically connected to an energy storage device (5a) via a power drive system in order to provide or store secondary energy, which is drawn from or fed back by the electric motor (2) during operation, in particular during the lifting and/or lowering process, wherein within a work cycle for an upcoming lifting or lowering process the energy flow as secondary energy via the energy storage device (5a) to and/or from the electric motor (2) of the lifting drive takes place, insofar as the latter has the required charge or capacity for this purpose and only in the case that the charge of the energy storage device is insufficient,A supplementary energy flow as primary energy is supplied to the electric motor (2) of the lifting drive via a connection (5b) to an external electrical energy source, wherein the energy flow is controlled or regulated by a controller (7) depending on the mass of the load (L), the lifting height (h) of the load (L) determined by a lifting height sensor (9), and depending on the state of charge of the energy storage device (5a). The invention further relates to a lifting device for carrying out this method.