Stepper Motor Current Control for Labeling Apparatus
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing labeling devices face high power consumption despite requiring high labeling output, as they are typically designed for maximum load and speed, leading to inefficient energy use and unwanted heating.
Innovation Solution
A labeling device with a control unit that adjusts the current consumption of stepper motors based on required speed and acceleration, using pulse width modulation and current limitation to optimize power usage, allowing for adaptive control of multiple stepper motors and reducing power loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If stepper motors are designed for maximum load and speed to achieve high labeling output, then productivity is improved, but power consumption increases
Solution Approach 1:
The patent applies dynamics by making the current supply to stepper motors variable rather than constant. The control unit dynamically adjusts the current magnitude based on the actual movement requirements (speed and acceleration) of the applicator, allowing the system to achieve high labeling output when needed while consuming less power during normal operation.
Solution Approach 2:
The patent changes the electrical parameter (current) supplied to the stepper motors based on operational requirements. By calculating the necessary current from the required speed and acceleration of the applicator, the system optimizes power consumption while maintaining the ability to achieve high labeling output when required.
2Speed
If high current is supplied to stepper motors to achieve maximum labeling speed, then speed is improved, but heat generation increases
Solution Approach 1:
The patent dynamically adjusts the current supplied to stepper motors based on actual speed requirements. Instead of continuously supplying high current for maximum speed, the control unit calculates and applies only the necessary current level, thereby achieving required labeling speeds while minimizing heat generation in the motors.
Solution Approach 2:
The patent converts the potential harm of excessive current (heat generation) into a benefit by using current calculation based on actual movement requirements. The control unit calculates the precise current needed for the required speed and acceleration, ensuring high labeling speed is achieved only when necessary while reducing unnecessary heat generation.
3Productivity
If constant high power is supplied to stepper motors to maintain high labeling speed, then productivity is improved, but energy efficiency deteriorates
Solution Approach 1:
The patent changes the power parameter dynamically by calculating the required current from the applicator's speed and acceleration requirements. This ensures that high power is supplied only when necessary for high-speed labeling operations, while lower power is used during normal operation, thereby improving energy efficiency without sacrificing productivity when needed.
Solution Approach 2:
The patent implements a feedback mechanism where the control unit continuously monitors the required movement parameters (speed and acceleration) of the applicator and adjusts the current supplied to stepper motors accordingly. This feedback-based control ensures optimal energy efficiency while maintaining the capability for high productivity when required.
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 effectively reduces power consumption and heat generation in stepper motors by dynamically adjusting current according to the specific labeling process, achieving efficient energy use and maintaining high labeling speeds while minimizing power loss.
Implementation Method 1
The power consumption of the stepper motor can be controlled by influencing the actuation of the stepper motor by pulse width modulation at a constant voltage, in that the control unit adjusts the width of the individual pulses according to the current consumption.
Implementation Method 2
According to the invention and the current consumption is controlled by limiting the maximum current of a pulse via a current limiter.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The invention relates to a labelling apparatus (1) having an applicator (9), which is driven via at least one stepping motor (23) and is intended for applying labels, and a control unit (8), for activating the applicator (9). In order to reduce the power consumption of the apparatus (1), it is provided that the control unit (8) defines the operating current of the stepping motor (23) in accordance with the necessary speed and/or the necessary acceleration of the applicator (9).