Motor-Vibrator Assembly With Electronic Shaft Synchronization
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Solution Overview
Problem
Existing motor-vibrator assemblies for vibrating machines face challenges such as difficult installation, high maintenance costs due to mechanical joints, and significant mechanical wear from numerous moving parts, leading to frequent replacements.
Innovation Solution
A motor-vibrator assembly using synchronous motors with integrated position sensors and electronic control units to synchronize eccentric masses, eliminating the need for mechanical joints and reducing mechanical wear by employing brushless motors and accelerometers to adjust vibratory motion based on load and vibration sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical joints are used to connect motor shafts for synchronization, then the motor-vibrators can be synchronized to generate desired vibratory motion, but the installation, protection, set-up and maintenance become difficult and economically burdensome
Solution Approach 1:
The patent replaces mechanical joints with electronic synchronization control. Each motor-vibrator is equipped with position sensors that detect the angular position of their shafts, and an electronic control unit processes these signals to independently control each motor's rotation phase and speed, eliminating the need for mechanical universal joints while achieving precise synchronization of the eccentric masses
Solution Approach 2:
The patent introduces position sensors and electronic control signals as intermediaries between the motors and the synchronization function. The sensors detect shaft position and convert it to electrical signals, which the electronic control unit processes to generate control commands that synchronize the motor-vibrators without direct mechanical connection
2Productivity
If a large number of moving parts are used in oil-bath transmission members, then the vibrating units can be operated through a transmission shaft, but significant mechanical wear occurs leading to frequent replacements and maintenance
Solution Approach 1:
The patent replaces the mechanical transmission shaft and oil-bath transmission members with direct electronic control of each motor-vibrator. Each motor-vibrator is independently controlled by the electronic control unit based on position sensor feedback, eliminating the transmission shaft and its numerous moving parts that were subject to mechanical wear
Solution Approach 2:
The patent extracts and removes the transmission shaft and oil-bath transmission members from the system. By directly controlling each motor-vibrator independently through electronic signals, the patent eliminates the intermediate transmission mechanism that caused mechanical wear, while still achieving the desired coordinated vibration operation
3Power
If asynchronous motors with eccentric masses are used, then the motor-vibrators can generate vibratory motion, but precise control and synchronization of the eccentric masses is difficult
Solution Approach 1:
The patent implements feedback control by equipping each motor-vibrator with position sensors that continuously detect the angular position of their shafts. These sensor signals are fed back to the electronic control unit, which processes them and adjusts each motor's rotation in real-time to maintain precise synchronization of the eccentric masses, enabling accurate control of the generated vibratory motion
Solution Approach 2:
The patent replaces mechanical synchronization mechanisms with electronic control systems. The electronic control unit independently controls each asynchronous motor's rotation based on position sensor feedback, allowing precise control of the eccentric mass synchronization without requiring mechanical joints or complex mechanical 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
Facilitates quick setup, reduces mechanical wear, and enables precise control of complex vibratory motions, allowing for efficient operation with minimal maintenance and improved synchronization of eccentric masses.
Implementation Method 1
synchronous motors with integrated position sensors
Implementation Method 2
accelerometers to adjust vibratory motion based on load and vibration sensing
Implementation Method 3
synchronous motors with integrated position sensors
Implementation Method 4
synchronize eccentric masses, eliminating the need for mechanical joints
Data Source
AI summary
Motor-vibrator assembly for a vibrating machine having a plurality of motor-vibrators, each having a synchronous motor and at least one eccentric mass divided into two bodies fixed to two respective free ends of the shaft of the motor. The motor-vibrator assembly comprises position sensing means to sense the angular position and the angular velocity of the shafts of the synchronous motors, electronic drive devices to operate the synchronous motors and an electronic control unit, which is configured to control the electronic drive devices based on the angular positions and on the angular velocities sensed, so that the motor-vibrator assembly generates a predetermined vibratory motion.