Electric Reel Mower Controller Auto-Configuring Motor Speeds
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Solution Overview
Problem
Traditional turf mowers require separate traction units for different-sized reel cutting units due to varying hydraulic requirements, leading to increased manufacturing and operational costs for customers and manufacturers.
Innovation Solution
A turf mower with electrically driven reel cutting units, where each unit is powered by a separate variable speed motor, and a microprocessor-based controller automatically adjusts motor speeds based on the diameter of the cutting reels, allowing for a single traction unit to accommodate multiple reel sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hydraulic motors are used to power reel cutting units of different diameters, then cutting performance is improved, but device complexity increases and manufacturing costs increase due to requiring separate traction units for each reel size
Solution Approach 1:
The patent applies universality by designing a single electric motor controller that can accommodate and control motors of different sizes and power ratings. The controller is configured to recognize various motor types through identification signals and automatically adjust control parameters, enabling one controller to serve multiple motor configurations rather than requiring separate controllers for each motor size.
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting control parameters such as current limits, voltage thresholds, and protection settings based on the identified motor characteristics. The controller modifies its operational parameters according to the connected motor's specifications, allowing optimal performance across different motor types without hardware changes.
2Reliability
If separate traction units are manufactured for each reel size, then reliability is improved by ensuring proper hydraulic matching, but manufacturing cost increases and ease of manufacture deteriorates
Solution Approach 1:
The patent applies universality by creating a single standardized electric motor controller platform that can reliably control various motor types. This universal controller eliminates the need to manufacture separate hydraulic systems for different reel sizes, simplifying production while maintaining reliability through electronic control adaptation rather than mechanical customization.
Solution Approach 2:
The patent replaces the traditional mechanical-hydraulic matching approach with an electronic control system. Instead of designing separate hydraulic systems for different motor sizes, the patent uses an electric motor controller that electronically adapts to different motor characteristics, substituting mechanical customization with electronic reconfiguration.
3Adaptability or versatility
If customers purchase multiple traction units for different reel sizes, then adaptability is improved, but cost increases
Solution Approach 1:
The patent applies universality by designing a single traction unit with a controller that can accommodate multiple motor and reel configurations. Customers need only one versatile traction unit rather than multiple specialized units, as the controller can be electronically reconfigured to match different motor sizes and power requirements through automatic identification and parameter adjustment.
4Power
If hydraulic systems are customized for each reel size, then power matching is improved, but loss of time increases due to system changes when switching reel sizes
Solution Approach 1:
The patent replaces time-consuming mechanical hydraulic system reconfiguration with instant electronic parameter adjustment. When switching between different motor or reel configurations, the controller automatically detects the new configuration through identification signals and instantly adjusts control parameters, eliminating the downtime required for physical hydraulic system changes.
Solution Approach 2:
The patent applies preliminary action by pre-programming multiple motor profiles and control parameter sets within the controller. When a motor is connected, the controller proactively identifies the motor type and automatically loads the appropriate pre-configured parameters, eliminating the need for manual setup or time-consuming adjustments during operation.
Data Source
AI summary
A gang reel mower comprises a frame that carries a plurality of variable speed, electrically powered reel cutting units. Cutting units having different reel diameters may be installed on the frame. Upon system power up, a mower controller on the frame automatically acquires information identifying the reel size of the cutting units then installed on the frame and uses the acquired reel size information to properly set the speed of the electric motors driving the cutting units to a desired value, such as that needed to maintain a desired clip. Thus, the cutting units can be changed in size with the mower controller automatically recognizing the change in a plug and play manner.