Recuperating Power Supply for Transport Drives With Peak Current Buffering
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Solution Overview
Problem
Power supply systems in linear automats used in furniture manufacturing face challenges in managing peak power requirements, leading to current peaks that can be two to three times the nominal current, which strains the power supply grid and requires inefficient energy conversion to heat through braking resistors.
Innovation Solution
A power supply system utilizing a recuperating energy storage unit connected to a charging device fed from an alternating- or three-phase low-voltage grid, allowing the system to absorb and release high current values without large voltage changes, and an intelligent charging device to maintain a 60-90% charging capacity, thereby mitigating current peaks by storing and reusing kinematic energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional power supply units are used to supply motors of transport carriages, then the system can operate with nominal current, but current peaks occur when motors are switched off quickly causing voltage rise and requiring braking resistors to convert excess energy to heat
Solution Approach 1:
The patent converts the harmful effect of kinetic energy during braking into useful electrical energy that can be stored and reused. Instead of dissipating energy as heat through braking resistors, the system uses regenerative braking to convert the motors into generators, feeding electrical energy back into the power supply unit, thereby transforming a harmful energy loss into a beneficial energy recovery mechanism
Solution Approach 2:
The system recovers energy that would otherwise be discarded during deceleration and braking operations. The power supply unit incorporates energy storage capability to capture and retain the electrical energy generated during regenerative braking, making it available for future use and preventing energy waste
2Power
If power supply is designed to meet peak power requirements, then enough electrical energy is available during sharp acceleration, but the current peak becomes two to three times the nominal current straining the power supply grid
Solution Approach 1:
The power supply unit is designed with preliminary energy storage capability that accumulates energy during low-demand periods and releases it during peak demand. This preliminary preparation of energy reserves allows the system to meet peak power requirements without subjecting the power supply grid to excessive current strains
Solution Approach 2:
The power supply unit acts as an intermediary between the power supply grid and the motor drives, buffering and smoothing current fluctuations. It decouples the grid from direct exposure to peak currents by absorbing and releasing energy as needed, thereby protecting the grid from strain while ensuring adequate power delivery
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 system effectively draws up to 50% more power from the grid without peak strain, protecting the on-board and sensor grids from current peaks by feeding back stored kinematic energy as electrical energy during negative acceleration processes.
Implementation Method 1
the voltage increases when the motors are switched off quickly, since the motors run in generator mode until the kinetic energy of the transport carriages is used up
Implementation Method 2
the supply grid of the drive units is supplied via at least one recuperating energy storage unit
Data Source
AI summary
A power supply system for at least one system for transporting and/or machining workpieces having a plurality of electric drive units is disclosed. The supply grid of the drive units is supplied via at least one recuperating energy storage device, which is electrically connected to a charging device that is fed from an alternating- or three-phase low-voltage grid. The power supply system for a transport and/or machining system draws maximally 50 percent more power from the power supply grid compared to the regular nominal supply current regardless of the occurrence of current peaks.