Material Testing Actuator Energy Recovery for Lower Thermal Load
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Solution Overview
Problem
Material testing machines waste regenerative energy as heat through dynamic braking resistors, contributing to thermal loads and inefficiency, rather than reusing it within the system.
Innovation Solution
A material testing apparatus that stores regenerative energy output from actuators using energy storage devices like capacitors, allowing this energy to be reused for subsequent operations and reducing waste, with a controller managing the energy flow between storage and consumption components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If dynamic braking resistors are used to dissipate regenerative energy, then the machine can control deceleration and stopping, but energy is wasted as heat and thermal load increases
Solution Approach 1:
The patent recovers regenerative energy that would otherwise be discarded as heat through dynamic braking resistors. The energy storage device captures this regenerative energy during deceleration phases and stores it for later reuse, transforming a waste stream into a valuable resource that reduces both energy loss and thermal load.
Solution Approach 2:
The patent converts the harmful thermal load from dynamic braking resistors into a beneficial resource. By capturing regenerative energy at the source before it becomes waste heat, the system transforms what was previously a harmful thermal byproduct into stored energy that can be reused to power machine operations, thereby eliminating the need for dissipation and reducing thermal load on climate control systems.
2Productivity
If dynamic braking resistors dissipate regenerative energy as heat, then deceleration control is achieved, but energy efficiency decreases
Solution Approach 1:
The patent implements energy recovery by capturing regenerative energy during deceleration instead of allowing it to be wasted. The energy storage device stores this recovered energy for subsequent reuse in powering machine operations, directly improving energy efficiency by eliminating the need to generate new energy for tasks that could be powered by recovered energy.
Solution Approach 2:
The system serves itself by recovering and reusing its own regenerative energy. The energy storage device enables the machine to power its own operations using energy it generates during deceleration, reducing dependence on external power sources and improving overall energy efficiency through self-sustaining energy recycling.
3Loss of energy
If regenerative energy is stored and reused, then energy efficiency improves, but device complexity increases due to energy storage devices and control systems
Solution Approach 1:
The energy storage device serves multiple functions: it stores regenerative energy, provides power during high-demand operations, and acts as a buffer between energy generation and consumption. This multi-functionality justifies the added complexity by delivering multiple benefits from a single component rather than requiring separate systems for each function.
Solution Approach 2:
The energy storage device acts as an intermediary between the regenerative energy source (actuators during deceleration) and the energy consumers (machine operations). This intermediary component manages the timing and distribution of energy flow, smoothing out discrepancies between energy generation and consumption patterns while enabling efficient energy reuse.
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 solution effectively reduces energy waste by storing and reusing regenerative energy, improving the efficiency of the material testing apparatus and minimizing thermal loads on climate control systems.
Implementation Method 1
At least some energy used by the actuator to apply the force is retained in the material testing apparatus. When the force applied by the actuator is released, at least some retained energy is received by the material testing apparatus as regenerative energy.
Implementation Method 2
The regenerative energy output by the actuator is stored in an energy storage device of the material testing apparatus
Data Source
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AI summary
According to an embodiment of the present invention there is provided a material testing apparatus (100), comprising: guide means (110); sample holding means (120) for holding a sample (130); force means (140) comprising a first actuator (210) for applying a releasable force to the sample (130); a crosshead (150) supported on the guide means (110) and arranged to support at least a portion of one or both of the sample holding means (120) and the force means (140); an energy store (220) arranged to store regenerative energy from at least the first actuator (210); an energy consumer (230) arranged to, at least in part, consume energy from the energy store (220), wherein the energy consumer (230) comprises the first actuator (210); and a controller (170) configured to control the first actuator (210) to release the force applied to the sample (130), wherein the first actuator (210) is arranged to output the regenerative energy in dependence on the release of the force.