Motorized Roller Conveyor Regenerative Braking Energy Recovery
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Solution Overview
Problem
Conveyor rollers experience excessive heating during operation due to inefficiencies in heat dissipation and energy management, leading to increased production costs and potential damage from thermal radiation, especially during frequent switching cycles.
Innovation Solution
The system converts braking energy into electrical energy, which is fed back into the energy supply system and used to accelerate other conveyor rollers, eliminating the need for additional cooling measures and reducing thermal load by utilizing metallic frame profiles as heat sinks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If braking energy is converted into heat using a braking resistor, then the conveyor roller can be braked effectively, but the roller body experiences excessive heating and requires additional cooling measures
Solution Approach 1:
The patent converts the harmful braking energy that would otherwise be dissipated as heat into useful electrical energy by using the motor as a generator during braking. This electrical energy is fed back into the energy supply system to power other conveyor rollers during acceleration phases, thereby eliminating the need for braking resistors and excessive cooling measures while maintaining effective braking capability
2Temperature
If additional cooling measures are implemented to prevent excessive heating, then the conveyor roller can operate within temperature limits, but the device complexity and production cost increase
Solution Approach 1:
The patent enables the conveyor system to self-regulate thermal load by using regenerative braking to convert kinetic energy into electrical energy that powers other rollers during acceleration phases. This internal energy recycling mechanism eliminates the need for external cooling systems such as fans or heat sinks, thereby reducing device complexity while maintaining temperature control
3Strength
If the motorized conveyor roller is held in frame profiles via bearing devices with metallic contact surfaces, then the roller can be securely mounted, but heat loss from the drive motor is not effectively dissipated
Solution Approach 1:
The patent converts the thermal management problem into an energy recovery opportunity by using the motor as a generator during braking phases. The electrical energy generated is fed back into the energy supply system, thereby converting what would be wasted heat into useful work and eliminating the need for additional heat dissipation measures while maintaining secure mounting
4Adaptability or versatility
If frequent switching cycles of driving and braking are performed, then the conveyor roller can respond to changing material flow conditions, but high heating of the roller body occurs
Solution Approach 1:
The patent converts the thermal burden of frequent braking into an energy recovery opportunity by using regenerative braking to generate electrical energy that powers other rollers during acceleration phases. This internal energy recycling mechanism allows frequent switching cycles to be performed without excessive heating, as the energy that would normally be dissipated as heat is instead reused to power the system
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 approach prevents excessive heating, reduces production costs, and ensures reliable operation with high switching cycles by effectively managing energy and heat, while maintaining a stable voltage level in the energy supply system.
Implementation Method 1
the braking energy generated during braking by the moving mass of a load is converted from the electric machine into electrical energy
Implementation Method 2
the roller conveyor to operate reliably even with a high number of switching cycles (starting up/braking a motorized conveyor roller)
Data Source
Figure 1
Figure 2
Figure 2a
AI summary
The invention relates to a roller conveyor and a method for operating same, said conveyor comprising an electrical power supply system (67, 73) and a plurality of conveyor rollers (5, 6). At least one of the conveyor rollers (5) comprises a roller element and an electrical machine arranged inside said roller element. The electrical machine of the conveyor roller (5) is supplied with electrical power by the electrical power supply system (67, 73) and produces electrical power inside said conveyor roller in the manner of a generator during the deceleration phase when a conveyed item (83) is braked. The electrical power generated by the electrical machine is fed from the conveyor roller (5) into the power supply system (67, 73) via a power supply line (74).