Spiral Conveyor Drive Control for Balanced Chain Torque
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Solution Overview
Problem
In spiral conveyor systems, the use of a single variable frequency drive for both inner and outer drive chains leads to unbalanced gear ratios and uneven wear, resulting in inefficient torque distribution and improper lubrication, which accelerates chain wear and affects motor performance.
Innovation Solution
Separate variable frequency drives are used for the inner and outer drive motors, with a processor to coordinate their operation and lubrication based on torque load and travel distance data, ensuring balanced torque distribution and optimized lubrication for each chain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single variable frequency drive unit is used to control both inner and outer drive motors, then device complexity is reduced, but torque distribution becomes unbalanced and drive chain wear increases
Solution Approach 1:
The patent divides the single variable frequency drive unit into two separate variable frequency drive units, with each unit independently controlling one drive motor. This segmentation allows independent adjustment of torque and speed for inner and outer drive chains, resolving the torque distribution imbalance caused by the unified drive system while maintaining manageable system complexity through modular architecture.
2Reliability
If nonstandard gears are used to achieve proper gear ratios between drive motors, then torque distribution is improved, but manufacturing cost increases and torque capacity is reduced
Solution Approach 1:
Instead of changing the physical gear parameters to achieve proper torque distribution, the patent changes the operational parameters by using separate variable frequency drive units that can independently adjust motor speed and torque output. This allows standard gears to be used while achieving the desired torque balance through electronic control, avoiding the need for costly nonstandard gear manufacturing.
3Device complexity
If lubrication is based on single variable frequency drive data, then lubrication system simplicity is maintained, but lubrication effectiveness decreases due to uneven wear and torque load
Solution Approach 1:
The patent implements separate lubrication control for inner and outer drive chains based on data from their respective variable frequency drive units. Each drive chain receives lubrication optimized for its specific torque load and wear conditions, rather than using a unified lubrication schedule. This localizes the lubrication quality to match the actual needs of each drive chain, improving effectiveness without significant increase in system complexity.
Data Source
AI summary
The bottom tier (24) of a conveyor belt (22) arranged in a spiral stack (26) is supported by and driven by inner and outer drive chains (28) and (30). The inner and outer drive chains are supported on and ride along support rails (32) and (34). The inner and outer drive chains are driven by a drive system (35) composed of inner and outer drive systems (36) and (38), each including a drive motor with a drive gear engaged with the inner and outer drive chains. Each of the motors is controlled by a separate variable frequency drive unit (114) and (116) which in turn are controlled by a control system (44). The control system (44) also controls the operation of a lubrication system (40) that supplies lubricant to the drive chains.