Integrated Roller Drive with Inductive Power Transfer
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Solution Overview
Problem
Existing roller drive systems are inefficient in load conveyance and energy consumption, as they lack intelligent control and optimal integration of sensors and motors, leading to suboptimal energy usage and logistical performance.
Innovation Solution
A compact roller drive system where an electric motor is integrated with sensors, allowing for inductive energy and data transmission without contact, enabling intelligent control and efficient energy management by detecting load arrival and properties, and optimizing motor operation based on load characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If an electric motor drives the roller in a conventional manner, then the roller can convey loads, but energy consumption is high and control is inefficient
Solution Approach 1:
The patent combines the electric motor, sensors, electronic circuits, and roller into a single integrated unit. The motor is at least partially surrounded by the roller to form a housing, creating a compact modular assembly where all components work together efficiently. This merging eliminates the need for separate control systems and reduces energy losses through optimized component interaction.
Solution Approach 2:
Sensors are integrated into the roller drive to detect load arrival, load properties, and system state. This feedback is processed by electronic circuits within the integrated unit, enabling intelligent control that adjusts motor operation to actual needs. The system can detect when a load is present and optimize energy consumption accordingly, improving both energy efficiency and logistical performance.
2Device complexity
If sensors and electronic circuits are integrated into the roller, then the unit becomes compact and intelligent, but the roller structure becomes more complex
Solution Approach 1:
The patent integrates sensors, electronic circuits, and the electric motor into a single unified roller drive unit. The roller itself forms part of the housing structure, enclosing these components. This merging creates a compact modular unit that is easier to install and maintain despite the increased internal complexity, as the entire assembly functions as one integrated system.
Solution Approach 2:
The integrated roller drive unit performs multiple functions: the motor provides drive power, sensors detect load presence and properties, electronic circuits process information and control motor operation, and the roller structure itself serves as both the conveying element and part of the housing. This multi-functionality reduces the need for separate components and simplifies the overall system architecture.
3Reliability
If energy is transmitted inductively without contact, then safety is improved through galvanic isolation, but the energy transmission efficiency may be reduced
Solution Approach 1:
The patent uses inductive coupling with primary and secondary windings as an intermediary mechanism to transfer energy and data without direct electrical contact. The primary winding is connected to the power source, and the secondary winding is connected to the motor and sensors on the roller. This inductive intermediary provides galvanic isolation for safety while maintaining efficient energy and data transmission through magnetic coupling.
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
The system achieves efficient load conveyance and reduced energy costs by integrating sensors and motors, allowing for intelligent control and optimal energy usage, with enhanced safety through galvanic isolation and high interference immunity.
Implementation Method 1
an electric motor driving the roller is at least partially surrounded by the roller to form a housing
Implementation Method 2
energy and/or data can be transmitted inductively, a secondary winding being arranged such that it can rotate with the roller, which is arranged inductively coupled to a primary winding provided in the roller carrier
Data Source
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AI summary
The invention relates to a roller drive and a method for controlling a system comprising a roller that is rotatably mounted on a roller support. An electric motor that drives the roller is at least partly surrounded by the roller such that a housing is formed. At least one sensor lies on the roller drive, and energy and/or data can be contactlessly transmitted between the roller drive and the roller or a part that can be rotated with the roller.