Linear Motor Hammer Control for Smooth Reversal
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Solution Overview
Problem
Existing hammer operating technologies fail to effectively control and regulate linear motors during the impact and rebound phases, leading to potential damage and inefficient energy use, particularly in preventing abrupt reversals and managing sticky or strong rebounds.
Innovation Solution
A method where the linear motor's power is controlled by a control unit based on time, speed, and position, with the field inversion occurring before impact to manage hysteresis cycles, and additional devices for braking and acceleration are used to optimize the hammer's operation, allowing for early intervention and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the linear motor is switched off before the hammer reaches the lower reversal point, then energy consumption is reduced, but the hammer may experience abrupt reversal causing damage to the linear motor components
Solution Approach 1:
The control unit inverts the polarity of the linear motor's magnetic field in advance, before the hammer reaches the lower reversal point. This preliminary field inversion ensures that when the motor is switched off, the hammer experiences a smooth deceleration and reversal rather than an abrupt stop, preventing mechanical damage while still allowing the motor to be de-energized early for energy savings
Solution Approach 2:
The system dynamically adjusts the linear motor's operational state based on real-time position and velocity feedback. The motor transitions from powered operation to field-inverted coasting to complete stop, with the control unit continuously monitoring hammer position and adjusting the field inversion timing to optimize both energy consumption and mechanical protection
2Reliability
If the field of the linear motor is inverted early to provide a time window for hysteresis cycle, then the reversal of movement is controlled cleanly, but the time window for control intervention is extended
Solution Approach 1:
The magnetic field inversion is performed in advance of the actual reversal point, creating a controlled transition period. During this pre-inversion phase, the hammer continues moving downward while the reversed field begins to decelerate it, providing a smooth and controlled reversal that prevents mechanical shock while the control system has adequate time to manage the transition
3Reliability
If additional braking and acceleration devices are controlled based on linear motor performance, then operational reliability is increased, but device complexity increases
Solution Approach 1:
The control unit serves as an intelligent intermediary that coordinates between the linear motor and the auxiliary braking/acceleration devices. It monitors the linear motor's performance in real-time and activates the auxiliary devices only when necessary, such as providing additional braking force during strong rebounds or supplementary acceleration when needed, thereby increasing reliability without requiring constant operation of complex auxiliary systems
Solution Approach 2:
The system dynamically adjusts operational parameters based on real-time conditions. The control unit monitors hammer position, velocity, and acceleration, and only activates the braking or acceleration devices when specific threshold conditions are met, such as when rebound strength exceeds a predetermined level or when the linear motor cannot provide sufficient control alone
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
This method enables clean and controlled movement of the hammer, preventing damage to the linear motor components, optimizing hammer blows, and enhancing operational reliability while minimizing energy use and preventing sticky impacts.
Implementation Method 1
at least one linear motor (9, 10) accelerates the bear (3) before it hits a workpiece (16), with the control unit (13) switching off the linear motor(s) (9, 10) before it reaches a lower reversal point (U)
Implementation Method 2
the polarity of the field of the linear motor(s) (9, 10) is reversed, with the linear motor(s) (9, 10) then being activated again to take the bear (3) with it in its upward movement
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for operating a hammer (1, 2), comprising at least one ram (3) that can be driven by at least one linear motor (9, 10) and a regulating unit (13).