Motor Roller Circuit Externalizing Electronics
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Solution Overview
Problem
Existing power supply and control circuits for motor-driven conveying rollers face challenges with high operational heat generation and limited assembly space due to the large number of terminals and heat encapsulation, which restricts the use of high-power electric motors and complicates assembly.
Innovation Solution
A power supply and control circuit that generates a second potential for position sensors using additional circuitry connected to the electric motor coils, allowing digital encoding and reducing the number of terminals needed, enabling the electronics to be located externally and improving cooling, with only four wires required to pass through the hollow shaft component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the electric motor is incorporated inside the hollow body of the roller, then the roller can be driven directly, but heat generated by the motor cannot be discharged effectively due to encapsulation
Solution Approach 1:
The electronic commutation device and position sensors are extracted from the hollow body of the roller and placed in an external control device. This extraction removes the heat-generating electronics from the enclosed space, allowing better heat management for the motor while maintaining the integrated drive configuration.
2Adaptability or versatility
If the connector incorporates multiple terminals for coils, position sensors, and signals, then all components can be connected, but the number of terminals becomes excessively large (eight terminals)
Solution Approach 1:
The power supply for position sensors is merged with the motor power supply by taking the second potential directly from the motor coil terminals. This eliminates the need for separate power terminals for sensors, reducing the total terminal count from eight to four while maintaining full functionality.
Solution Approach 2:
The motor coil terminals serve multiple functions: they provide power to the motor coils and simultaneously provide the second potential for powering position sensors. This multi-functionality reduces the need for dedicated terminals and simplifies the connector design.
3Volume of moving object
If the hollow shaft component assembly orifice is kept small for compact design, then the roller dimensions are reduced, but assembly becomes difficult and space is limited
Solution Approach 1:
The electronic commutation device is extracted from the hollow body and placed externally, which simplifies the internal space requirements and assembly process. This extraction allows for easier assembly through the hollow shaft component while maintaining compact roller dimensions.
4Power
If high-power electric motors are used, then operational loads can be increased, but heat generation increases and cannot be discharged due to encapsulation
Solution Approach 1:
The electronic commutation device is extracted from the hollow body to an external location, removing the heat-generating electronics from the enclosed space. This allows high-power motors to operate without the heat accumulation problem caused by encapsulated electronics, as the extracted electronics can be cooled separately.
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 solution allows for higher operational loads, easier assembly, and improved cooling by reducing the number of terminals and relocating electronics outside the roller body, enabling the use of high-power motors while maintaining compact dimensions.
Implementation Method 1
a second potential, generated by an additional circuitry, connected to at least one of the coils (8) of the electric motor (4), with a view to providing the second potential
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention is intended for industry as component of cargo conveyors. In it the relevant commutation electronics is located outside the roller body. The invention provides that only four wires pass through the axial element for easy assembling, using four-terminal connectors. Roller (1) has a hollow body (3), in which an electric motor (4) is located, coupled to the body by driving and torque transferring (5). A cable (6) with terminals (7) from the coils (8) of the motor (4) and a first-potential terminal (9) powers the position sensors (10). Power to sensors is applied by first (9) and second-potential (12). The sensor signal terminals (11) are connected to a digital encoding device (17), powered by the first (9) and second (12) potential. This encoding device has one common encoded output (19) connected to the first potential terminal (9).