Rebar Binding Machine Motor Control for Stable Binding Time
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Solution Overview
Problem
The existing reinforcing bar binding machines face challenges in maintaining consistent binding time and reducing motor load and heat generation due to fluctuations in battery voltage, leading to inefficiencies in the binding process.
Innovation Solution
A binding machine with a control circuitry that limits motor current in response to battery voltage, ensuring consistent operation by managing current flow during high and low current sections, thereby optimizing motor performance and reducing heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the motor operates at high rotating speed immediately after battery charging, then the binding operation time is shortened, but the motor load and heat generation increase
Solution Approach 1:
The patent applies dynamics by making the motor rotating speed variable rather than constant. The control circuitry dynamically adjusts the motor speed based on real-time battery voltage detection, allowing the system to optimize between speed and heat generation at different operational stages. This resolves the contradiction by enabling high speed when battery voltage is high (reducing binding time) while preventing excessive heat when battery voltage drops.
Solution Approach 2:
The patent changes the operating parameters of the motor based on battery voltage levels. When battery voltage is high, the motor operates at higher rotating speed to reduce binding time. When battery voltage decreases, the rotating speed is reduced to control heat generation. This parameter adjustment strategy directly addresses the contradiction between productivity and temperature control.
2Temperature
If the motor rotating speed is reduced to suppress heat generation, then the load is reduced, but the binding operation time increases
Solution Approach 1:
The system dynamically adjusts motor speed based on battery voltage rather than using a fixed low speed. This allows the motor to operate at higher speeds when battery voltage is sufficient (improving productivity) while automatically reducing speed when heat generation becomes excessive (controlling temperature). The dynamic control resolves the contradiction by optimizing both parameters throughout the operational cycle.
Solution Approach 2:
The control circuitry continuously detects battery voltage and uses this feedback to adjust motor rotating speed. When voltage drops indicating heat generation or battery depletion, the system reduces speed to control temperature. When voltage is high, it increases speed to improve productivity. This feedback mechanism resolves the contradiction by continuously optimizing both temperature and productivity based on real-time system state.
3Productivity
If the motor operates at high speed to shorten binding time, then productivity improves, but the load applied to the motor increases
Solution Approach 1:
The patent changes the motor operating parameters (rotating speed) based on battery voltage levels. High speed operation is permitted when battery voltage is high, improving productivity. When battery voltage decreases, the speed is reduced to decrease motor load and prevent overheating. This parameter adjustment resolves the contradiction between productivity and motor load.
Solution Approach 2:
The system transitions from static motor speed control to dynamic control based on real-time battery voltage detection. The motor speed is continuously adjusted to optimize the balance between productivity (requiring high speed) and motor load (increasing with high speed). This dynamic approach resolves the contradiction by adapting motor performance to available power supply capacity.
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 a smoother and more efficient binding process by maintaining consistent operation regardless of battery voltage fluctuations, reducing the time required for binding and minimizing motor load and heat generation.
Implementation Method 1
an amount of heat generation of the motor also increases
Implementation Method 2
limit a current flowing through the motor, in response to a battery voltage of a battery
Data Source
AI summary
A binding machine including a wire feeding unit configured to feed a wire, a cutting unit configured to cut the wire wound on an object, a binding unit configured to twist the wire wound on the object and cut by the cutting unit, at least one motor configured to drive one or more of the wire transfer unit, the cutting unit and the binding unit, and control circuitry configured to limit a current flowing through the motor, in response to a battery voltage of a battery, in a section in which a large amount of current flows through the motor, as compared with a section in which a small amount of current flows through the motor, while the current flows from the battery to the motor.