Integrated Motor Controller for Roller Conveyor Wiring Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The increasing complexity and size of unit handling roller conveyor systems lead to excessive cabling, increasing installation time and cost, as separate conductors are required for signal communication between zones, and within each zone for motor and sensor connections.
Innovation Solution
Integration of a motor controller directly onto the motor housing with a circuit board and terminal block, allowing for reduced wiring by connecting it during assembly and eliminating the need for external controller lead assembly, with the controller being mounted below the rollers and between frame members, and using flexible drive members to connect the motor to rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate conductors are provided to carry individual signals between zones and within zones, then communication and control between zones and components is achieved, but the amount of wiring increases, adding time and cost to installations
Solution Approach 1:
The patent combines the motor controller with the motor housing, integrating multiple control functions into a single unit. This merging eliminates the need for separate external controller wiring, reducing the overall wiring complexity while maintaining reliable communication through integrated circuit boards and terminal blocks within the housing.
2Ease of operation
If separate conductors are provided for each signal between the controller and motors/sensors in the zone, then precise control of individual components is achieved, but the amount of wiring within the zone increases
Solution Approach 1:
The controller is pre-integrated into the motor housing during manufacturing, with circuit boards and terminal blocks预先 configured. This preliminary integration means that during installation, workers only need to connect power and signal cables to the terminal blocks without performing complex internal wiring, significantly reducing installation time while maintaining precise control capabilities.
3Adaptability or versatility
If an external controller is used separate from the motor, then control functions can be independently optimized, but additional cabling and lead assembly are required
Solution Approach 1:
The controller is integrated directly into the motor housing, combining what were previously separate components into a unified assembly. This integration maintains control adaptability through programmable logic and multiple terminal block connections while dramatically simplifying installation by eliminating the need for separate controller mounting and extensive lead assembly.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A drive unit (40) for a roller conveyor assembly having a motor (50) and an integrated motor controller (100). The controller (100) is mounted on a circuit board and connected to the rear of the motor housing (52). A cover (102) for the controller substantially encloses the controller (100). An opening (104) in the cover allows access to a terminal block (106) from the controller (100). The terminal block (106) receives wiring to external devices and to other zone controllers. Wiring between the circuit board for the controller (100) and the motor (50) is performed as a step in the assembly of the integrated motor (50) and controller (100). The motor (50) and controller (100) are configured to be mounted below the rollers and between the side frames of a conveyor assembly. An output shaft (60) from the motor is coupled to the rollers to power the conveyor assembly.