Torque Converter Soft-Start System for Rotating Industrial Equipment
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Solution Overview
Problem
Large rotating industrial equipment with high inertia and operating loads often require powerful starter motors to reach operating speed, which necessitates complex and expensive variable frequency electrical supply and control systems.
Innovation Solution
A method and apparatus utilizing a torque converter and a shiftable mechanical lock to transmit torque from a rotating driver to the equipment, with gear mechanisms to synchronize speeds, allowing for start-up without a large starter motor, employing a torque converter during start-up and a mechanical lock during normal operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a powerful starter motor is used to accelerate large rotating industrial equipment from static conditions to full operating speed, then the equipment can reach operating speed, but the system requires complex variable frequency electrical supply and control systems that are very expensive
Solution Approach 1:
The patent replaces the electrical starter motor system with a mechanical soft-start system consisting of a torque converter and shiftable mechanical lock. The torque converter uses fluid dynamics to transmit and multiply torque mechanically, eliminating the need for complex variable frequency electrical supplies and control systems while still providing the necessary torque multiplication to accelerate high-inertia equipment.
Solution Approach 2:
The torque converter acts as an intermediary device between the driver and the rotating equipment, providing a mechanical means to multiply torque during the start-up phase. This intermediary mechanism allows smooth acceleration without requiring direct mechanical coupling, thus avoiding the complexity of electrical control systems while still achieving the desired soft-start effect.
2Ease of operation
If a torque converter is used to transmit torque during start-up, then the equipment can accelerate smoothly, but the speed synchronization between driver and equipment must be achieved
Solution Approach 1:
The patent employs a shiftable mechanical lock that can dynamically change its engagement state. During start-up, the lock is disengaged to allow the torque converter to provide smooth acceleration. Once the driver and equipment speeds are synchronized, the lock shifts to an engaged state to establish a direct mechanical connection, ensuring precise speed synchronization while maintaining operational smoothness.
Solution Approach 2:
The mechanical lock is preliminarily positioned in a disengaged state during the start-up phase, allowing the torque converter to perform its speed-matching function without constraint. Once speed synchronization is achieved, the lock is then engaged to lock in the synchronized speeds, ensuring that the preliminary speed-matching action is preserved and maintained during normal operation.
3Power
If a mechanical lock is used to transmit torque during normal operation, then efficient torque transmission is achieved, but the equipment cannot be started from static conditions
Solution Approach 1:
The mechanical lock is designed to be shiftable between engaged and disengaged states. During normal operation, it remains engaged to provide efficient direct torque transmission. During start-up from static conditions, it shifts to a disengaged state, allowing the torque converter to multiply torque and enable acceleration. This dynamic reconfiguration allows the system to overcome the start-up limitation of a fixed mechanical lock while maintaining efficient torque transmission during operation.
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
Enables efficient start-up of large rotating industrial equipment without the need for a powerful starter motor, reducing costs and complexity by using a torque converter for initial speed increase and a mechanical lock for synchronized operation.
Implementation Method 1
employing a fluid coupling to transmit torque from the rotational driver to the rotating industrial equipment
Implementation Method 2
employing a load-side gear mechanism to synchronize the rotational speeds of a drive-side element and a load-side element
Data Source
AI summary
A system that employs a torque converter and a shiftable mechanical lock to start up rotating industrial equipment. A gear mechanism is employed to account for rotational slippage inherent in the torque converter. The torque converter and gear mechanism are used during start-up to increase the speed of the rotating industrial equipment. When the speed of the rotating industrial equipment is substantially synchronized with the speed of the driver, the mechanical lock is engaged.