Electromagnetic Switch Coil Current Reversal for Heat Reduction
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Solution Overview
Problem
Electromagnetic switches in sliding shoe sorter conveyor systems require substantial electrical power and can generate heat, reducing reliability, especially at higher conveyor speeds.
Innovation Solution
The design alternates electrical current flow through the electromagnetic coil to recover energy during energization, using an H-bridge circuit and MOSFETs to manage current flow, allowing for efficient energy recovery and reduced heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electromagnetic coil is energized to generate strong magnetic field for reliable shoe diversion at higher conveyor speeds, then diversion reliability is improved, but power consumption increases and heat generation increases
Solution Approach 1:
The patent applies periodic action by implementing oscillating current flow through the electromagnetic coil instead of continuous DC current. The controller alternates the direction of current flow, creating periodic magnetic field reversals that maintain shoe diversion reliability while reducing overall power consumption. This periodic excitation allows the magnetic field to be regenerated efficiently during each cycle rather than requiring sustained high power input.
Solution Approach 2:
The patent changes the electrical parameters by switching from constant DC current to alternating current with variable frequency and amplitude. By adjusting the oscillation frequency and current magnitude dynamically, the system optimizes the balance between generating sufficient magnetic field strength for reliable diversion and minimizing power consumption and heat generation in the coil.
2Reliability
If electromagnetic coil is energized to generate strong magnetic field for reliable shoe diversion at higher conveyor speeds, then diversion reliability is improved, but heat generation increases reducing component reliability
Solution Approach 1:
By using periodic oscillating current instead of continuous DC current, the coil experiences intermittent heating rather than continuous thermal stress. The periodic nature of current flow allows thermal dissipation during the off-periods of each cycle, preventing excessive temperature buildup that would compromise coil reliability while maintaining adequate magnetic field strength during the active periods for reliable shoe diversion.
Solution Approach 2:
The patent dynamically adjusts current parameters including frequency and amplitude to optimize thermal management. By controlling the duty cycle and oscillation frequency of the current, the system ensures that the coil generates sufficient heat for effective magnetic field production during active periods while allowing adequate cooling intervals, thereby preventing excessive temperature rise and maintaining component reliability.
3Reliability
If substantial electrical power is supplied to electromagnetic coil for high-speed conveyor operation, then shoe diversion reliability is improved, but energy efficiency deteriorates
Solution Approach 1:
The oscillating current approach creates periodic magnetic field cycles that are more energy-efficient than continuous DC excitation. During each oscillation cycle, the magnetic field is built up and collapsed in a controlled manner, allowing energy to be stored and returned to the circuit during the collapse phase rather than being continuously dissipated. This periodic operation maintains diversion reliability while significantly improving overall energy efficiency by reducing wasted energy.
Solution Approach 2:
The patent employs dynamic parameter adjustment of the electrical input, varying frequency, amplitude, and duty cycle based on operational requirements. This allows the system to use minimal energy during low-speed operation while providing sufficient power for reliable diversion only when needed at higher speeds, thereby optimizing the balance between reliability and energy efficiency across different operating conditions.
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 enhances the reliability and efficiency of electromagnetic switches by reducing power consumption and heat generation, improving performance at higher conveyor speeds.
Implementation Method 1
energizing an electromagnetic coil of the electromagnetic switch to generate a magnetic field urging the shoe towards the diverting path
Implementation Method 2
reversing current flow through the electromagnetic coil to recover energy from the electromagnetic coil
Data Source
AI summary
A method, electromagnetic switch, controller and program product, when energizing an electromagnetic coil to urge a selected shoe into a diverting path downstream of the electromagnetic switch, reverse current flow during at least a portion of the time that the electromagnetic coil is energized to recover energy from the electromagnetic coil.