Shredder Power Split Transmission Torque Management
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Solution Overview
Problem
Existing shredding devices face high power losses (>30%) under changing loads and require structurally complex and costly power-split transmissions to achieve maximum torque, which affects throughput and granulate size quality.
Innovation Solution
A device with a power split system using a combination of a first motor, hydraulic transmission, and synchronous transmission, where the motor and hydraulic transmission are connected to provide efficient torque to the rotor shaft, with adjustable reduction gears and a clutch for overload protection, allowing for flexible torque adjustment without complex gearboxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic transmission is used to increase drive torque under changing loads, then the rotor shaft blocking or reversing is prevented, but power losses increase to more than 30%
Solution Approach 1:
The drive system is segmented into two independent power sources: a direct-drive motor for normal operation and a hydraulic transmission for high-torque situations. This segmentation allows each component to operate in its optimal efficiency range, reducing overall power losses while maintaining reliability during load changes.
Solution Approach 2:
The system dynamically switches between direct-drive mode and hydraulic transmission mode based on real-time load requirements. The control unit monitors torque demands and activates the hydraulic transmission only when additional torque is needed, minimizing energy losses during normal operation while ensuring reliable torque delivery when required.
2Power
If a power-split transmission with direct drive and hydraulic transmission is used, then maximum torque can be transmitted to the rotor shaft, but the structural complexity and maintenance requirements increase
Solution Approach 1:
Instead of integrating the hydraulic transmission into a complex power-split gearbox, the system segments the torque transmission paths by using a synchronous gear coupling that independently combines the direct-drive motor and hydraulic transmission outputs. This simplifies the overall structure while maintaining the ability to transmit maximum torque.
Solution Approach 2:
A synchronous gear coupling acts as an intermediary mechanism that combines the torque from the direct-drive motor and hydraulic transmission in a simple, maintenance-friendly manner. This intermediary component avoids the need for complex integrated power-split transmissions while still achieving maximum torque transmission capability.
3Power
If a complex power-split transmission is used to achieve high torque, then the rotor shaft can be driven under high load, but the cost and maintenance requirements increase
Solution Approach 1:
The system uses standard, off-the-shelf components for both the direct-drive motor and hydraulic transmission, avoiding the need for expensive custom-designed power-split transmissions. The synchronous gear coupling is a simple, cost-effective component that achieves the required torque transmission without the high manufacturing costs of integrated power-split systems.
Solution Approach 2:
The synchronous gear coupling serves multiple functions: it combines torque from two sources, provides speed synchronization, and enables smooth transition between direct-drive and hydraulic modes. This multi-functionality eliminates the need for separate complex mechanisms, reducing overall system cost while maintaining high drive torque capability.
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 solution enables energy-efficient, continuous operation with low power loss and high throughput, reducing costs and maintaining granulate size quality by efficiently managing torque across varying loads using standard components.
Implementation Method 1
Hydraulic gearboxes with an adjustable hydraulic pump and adjustable hydraulic motor are often used. Such hydraulic gearboxes offer the advantage of being able to increase the drive torque when load requirements change by reducing the speed and increasing the hydraulic pressure.
Implementation Method 2
a synchronous transmission (synchronized transmission) that is different from the hydraulic transmission and is designed to drive at least one rotor shaft or at least one drive shaft connected to a rotor shaft
Data Source
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AI summary
The present invention relates to a device for driving a rotor shaft of a shredding device. This device comprises a first motor, a hydraulic transmission, and a synchronous transmission, which is distinct from the hydraulic transmission and is designed to drive at least one rotor shaft or at least one drive shaft connected to a rotor shaft. The first motor and the hydraulic transmission are connected to the synchronous transmission.