Reel Braking Control With Torque Split for Cardboard Machines
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Solution Overview
Problem
Existing braking systems for large paper reels in cardboard production machines are inefficient due to high energy consumption, large dimensions, and slow reaction times, leading to energy dispersion and limited universality across different machine types.
Innovation Solution
A braking system integrating a motor-generator device and a pneumatic mechanical brake, with a command and control unit, pressure transducer, electro-pneumatic converter, and solenoid valve, which splits braking torque between the motor-generator device and mechanical brake based on real-time tension detection, optimizing energy recovery and response times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical brake is used to brake the reel, then the braking action is simple and reliable, but kinetic energy is transformed into thermal energy and lost by dissipation
Solution Approach 1:
The patent converts the harmful effect of friction (thermal energy loss) into a beneficial effect by using the motor-brake to recover kinetic energy during braking and convert it back into electrical energy for storage or reuse, thereby transforming energy waste into energy recovery
Solution Approach 2:
The patent changes the energy conversion parameter from unidirectional (kinetic to thermal loss) to bidirectional (kinetic to electrical recovery), allowing the system to operate in both motor and generator modes depending on the operational phase
2Loss of energy
If a motor-brake is used to brake the reel, then energy recovery is possible, but the dimensions are large and energy consumption is high during launching and rewinding
Solution Approach 1:
The patent segments the braking function into two distinct components: a mechanical brake for high-energy consumption phases (launching, rewinding) and a motor-brake for energy recovery phases, allowing each component to operate optimally in its designated phase
Solution Approach 2:
The patent implements periodic switching between mechanical braking and motor-braking based on the operational phase, using the mechanical brake during high-energy consumption periods and the motor-brake during energy recovery periods
3Loss of energy
If a combined mechanical brake and motor-brake system is used, then energy recovery is optimized, but the system cannot be universally applied to machines with integrated control and lengthy reaction times
Solution Approach 1:
The patent designs the control system to be universally applicable to different machine types by implementing adaptive control strategies that can handle both machines with quick response times and those with lengthy reaction times, making the system multi-functional across different application scenarios
Solution Approach 2:
The patent implements dynamic control parameters that adapt to the specific machine's response characteristics, allowing the system to optimize braking force distribution based on the actual reaction time of the integrated control system
4Device complexity
If the braking force is not modified within a wide range of tensioning forces, then the integrated control system is simple, but the braking system has limited use in machines with quick response time requirements
Solution Approach 1:
The patent implements a feedback control mechanism that continuously monitors tensioning forces and automatically adjusts the braking force distribution between the mechanical brake and motor-brake, enabling the system to respond quickly to changing tension requirements while maintaining simple operation
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 reduces energy consumption, minimizes thermal energy loss, and provides quick response times, making it universally applicable and cost-effective for various cardboard production machines by efficiently splitting braking torque between motor-generator and mechanical brake devices.
Implementation Method 1
a pressure transducer configured to read a pressure of the air along a line coming from the machine for producing cardboard and to translate it into an electrical signal to be sent to the command and control unit
Implementation Method 2
an electro-pneumatic converter integrated into said system, different from the optional electro-pneumatic converter of said machine, and operatively connected to said command and control unit, the electro-pneumatic converter of the system being configured to adjust the pressure of the air at a delivery pressure
Implementation Method 3
a solenoid valve pneumatically connected: i) at the input, to said output line of the electro-pneumatic converter and to a derivation of the air line at the pressure coming from the machine for producing cardboard, and ii) at the output, to a delivery line for delivering air at a braking pressure
Implementation Method 4
The mechanical brake has the drawback of transforming the kinetic energy, through friction, into thermal energy, which is lost by dissipation into the external environment
Implementation Method 5
a motor-generator device and a pneumatic mechanical brake device, where said system comprises: a command and control unit... it commands the braking torque CM of the motor-generator device according to said calculation
Data Source
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AI summary
The present invention relates to a machine for producing multi-layer cardboard or paper, or a machine for either printing or converting, starting from a reel of paper, cardboard or other material. In general, the invention can be applied to machines, in which a reel of different materials is unwound and which requires a contrast system to adjust the tensioning of the ribbon. In particular, the invention relates to a braking system for braking said reel. More specifically, the invention relates to a system for controlling the braking (110) for a machine for producing cardboard or corrugated cardboard, having or in which at least one braking system (2) has been installed, comprising a motor-generator device (8) and a pneumatic mechanical brake device (9), wherein said system (110) comprises: - a command and control unit (11); - a pressure transducer (16) configured to read a pressure (Pm) of the air along a line (15) coming from the machine for producing cardboard and to translate it into an electrical signal to be sent to the command and control unit (11), wherein the pressure (Pm) of the line (15) is optionally calculated by an electro-pneumatic converter (14) of said machine outside said system (110); - an electro-pneumatic converter (19) integrated into said system (110) and operatively connected to said command and control unit (11), the electro-pneumatic converter (19) of the system (110) being configured to adjust the pressure of the air at a delivery pressure (P2) and being connected at the input to an airline (18) at a fixed pressure (P1), which is greater than the delivery pressure (P2), and, at the output, to an output line (18') for sending to a mechanical brake device (9) of the machine for producing cardboard according to a preset braking torque (CL) value to be supplied; - a user interface (12) operatively connected to the command and control unit (11); - optionally, a solenoid valve (17) pneumatically connected: i) at the input, to said output line (18') of the electro-pneumatic converter (19) and to a derivation (15') of the air line (15) at the pressure (Pm) coming from the machine for producing cardboard, and ii) at the output, to a delivery line (20) for delivering air at a pressure (P3), wherein said delivery line (20) connects the solenoid valve (17) to a mechanical brake device (9) and wherein said pressure (P3) is equal to said pressure (Pm) when the system (110) is in the deactivated state or to said pressure (P2) when the system (110) is in the activated state; wherein said command and control unit (11) calculates a splitting of the preset braking torque (CL) to be supplied between a braking torque (CF) of the mechanical brake device (9) and a braking torque (CM) of a motor-generator device (8) according to the pressure detected by the pressure transducer (16) and it commands the braking torque (CM) of the motor-generator device (8) according to said calculation.