Motor-Driven Conveyor Lifting Mechanism With Current Sensing
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Solution Overview
Problem
Conventional transfer apparatuses require sensors or limit switches to sense conveyor heights, increasing component count, complicating assembly and adjustment, and are prone to failure, with motor collision noise and excessive load on mechanical elements.
Innovation Solution
A transfer apparatus that eliminates sensors by using a physical collision method to stop the motor at a predetermined height, employing a lifting mechanism with a motor and electric current sensing unit to control rotation speed and prevent overcurrent, thereby reducing noise and mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor or limit switch is used to sense conveyor height, then the conveyor can be positioned at a predetermined height, but the number of components increases and assembly becomes more complex
Solution Approach 1:
The system uses the motor's own electric current characteristics to detect the physical operation limit position. The motor serves dual purposes: both actuation and sensing, eliminating the need for separate sensors or limit switches. The control unit detects when the conveyor reaches the predetermined height by monitoring changes in the motor's electric current.
Solution Approach 2:
The patent replaces mechanical sensing systems (sensors, limit switches) with an electrical sensing method. Instead of using mechanical components to detect position, the system uses electrical current monitoring to sense when the conveyor has reached its target height, thereby reducing mechanical complexity.
2Productivity
If the motor rotation speed is high during physical limit identification, then the positioning can be completed quickly, but collision noise and motor roar increase causing user discomfort
Solution Approach 1:
The motor operation is divided into two distinct phases: an initial high-speed phase for rapid positioning, and a final low-speed phase for precise stopping. This periodic variation in rotation speed allows the system to achieve both quick positioning and low noise during the critical stopping moment when the conveyor reaches its destination.
Solution Approach 2:
The system dynamically adjusts the motor rotation speed based on the operational phase. The rotation speed is not constant but changes according to the needs of the operation: high speed during the approach phase for efficiency, and low speed during the final positioning phase to minimize noise and mechanical impact.
3Productivity
If the motor rotation speed is high during physical limit identification, then the positioning process is faster, but excessive load is applied to mechanical elements and overcurrent flows into the motor
Solution Approach 1:
The motor operation is divided into two distinct phases: an initial high-speed phase for rapid positioning, and a final low-speed phase for precise stopping. This periodic variation in rotation speed allows the system to achieve both quick positioning and low noise during the critical stopping moment when the conveyor reaches its destination.
Solution Approach 2:
The system dynamically adjusts the motor rotation speed based on the operational phase. The rotation speed is not constant but changes according to the needs of the operation: high speed during the approach phase for efficiency, and low speed during the final positioning phase to minimize noise and mechanical impact.
4Measurement precision
If a sensor or limit switch is used to sense conveyor height, then the conveyor can be positioned accurately, but position adjustment and wiring are required complicating assembly
Solution Approach 1:
The system uses the motor's own electric current characteristics to detect the physical operation limit position. The motor serves dual purposes: both actuation and sensing, eliminating the need for separate sensors or limit switches. The control unit detects when the conveyor reaches the predetermined height by monitoring changes in the motor's electric current.
Solution Approach 2:
The patent replaces mechanical sensing systems (sensors, limit switches) with an electrical sensing method. Instead of using mechanical components to detect position, the system uses electrical current monitoring to sense when the conveyor has reached its target height, thereby reducing mechanical complexity.
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 allows for precise conveyor height adjustment without sensors, minimizing collision noise, reducing the risk of motor damage, and lowering the load on mechanical elements, enhancing durability and simplifying assembly.
Implementation Method 1
a motor (50), the lifting mechanism (8) converting a rotation force of the motor (50) to movement in a lifting direction
Implementation Method 2
a position where the electric current flowing into the motor (50) changes abruptly or a position where the electric current flowing into the motor (50) exceeds a fixed value is the physical operation limit
Data Source
AI summary
In a transfer apparatus, a lifting unit has a lifting mechanism having a plurality of combined members and a motor. The lifting mechanism converts the rotation force of the motor to movement in the lifting direction, transmits the movement to at least one of first and second conveyors, raises or lowers at least one of first and second conveyors, and stops rotation of the motor when one of conveying paths reaches a predetermined height. In that process, a physical limit identification operation is executed in which the motor is rotated to operate the lifting mechanism to a physical operation limit and is then stopped, and control of the motor is changed so that the motor is rotated at low speed until the lifting mechanism reaches the physical operation limit.