Electric Actuator Vibration Table With Regenerative Power Recovery
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Solution Overview
Problem
Vibration test devices using hydraulic actuators face issues such as low energy efficiency, large equipment requirements, and environmental contamination due to oil leakage, while servomotor-based devices still have room for improvement in reducing electric power consumption, especially when switching rotation direction in short cycles.
Innovation Solution
A vibration test device equipped with an electric actuator and a controller that includes a power regenerative converter to regenerate and reuse electric power from the electric motor, reducing energy consumption by efficiently managing the power supply and regenerative energy in devices like vibration test devices, tire test devices, torsion test devices, and hedge trimmers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If hydraulic actuators are used in vibration test devices, then the device can generate sufficient power for vibration testing, but energy efficiency is low and environmental contamination occurs due to oil leakage
Solution Approach 1:
The patent replaces hydraulic actuators with electric actuators (servomotors) in the vibration test device. This substitution eliminates hydraulic oil and associated environmental contamination while improving energy efficiency. The electric motor directly drives the vibration table through a drive device, converting electrical energy to mechanical vibration without the energy losses inherent in hydraulic systems.
2Loss of energy
If servomotors are used to vibrate the table, then energy efficiency improves compared to hydraulic actuators, but electric power consumption increases when switching rotation direction in short cycles
Solution Approach 1:
The patent implements a power regenerative converter that recovers electric power generated during the deceleration phase of servomotor operation. When the servomotor decelerates, it generates regenerative power that is captured and stored in a capacitor. This recovered power is then reused during subsequent acceleration phases, significantly reducing overall electric power consumption during short-cycle direction switching operations.
Solution Approach 2:
The system uses its own deceleration energy to fuel its next acceleration phase. The power regenerative converter enables the servomotor to serve itself by capturing and storing the energy it generates during deceleration, then reusing this energy for the next acceleration, creating a self-sustaining energy cycle that minimizes external power requirements.
3Power
If hydraulic actuators are used, then sufficient driving power is provided, but large-scale hydraulic supply equipment such as oil tanks and hydraulic piping must be installed
Solution Approach 1:
The patent replaces the entire hydraulic system (actuators, oil tanks, piping) with an electric actuator system. The electric motor with integrated power regenerative converter and capacitor provides all necessary driving power without requiring external hydraulic infrastructure. This substitution dramatically simplifies the device structure while maintaining sufficient driving power for vibration testing.
4Duration of action of stationary object
If hydraulic oil is used, then the hydraulic system can operate continuously, but periodic maintenance is required to change large amounts of hydraulic oil and prevent leakage
Solution Approach 1:
The patent replaces the hydraulic system with an electric actuator system that eliminates hydraulic oil entirely. The electric motor, power regenerative converter, and capacitor system requires no periodic oil changes or leakage prevention maintenance. This substitution dramatically improves ease of repair and maintenance while ensuring continuous operation without the drawbacks of hydraulic fluid management.
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 significantly reduces electric power consumption in these devices by effectively regenerating and reusing energy, achieving energy saving rates of over 70% and improving the overall efficiency of the test processes.
Implementation Method 1
a power regenerative converter that accumulates, in a capacitor, electric power regenerated from the electric motor during a deceleration process
Implementation Method 2
a power regenerative converter that accumulates, in a capacitor, electric power regenerated from the electric motor during a deceleration process
Data Source
AI summary
A vibration test device includes a vibrating table on which an object to be vibrated is to be attached, an electric actuator that vibrates the vibrating table in a predetermined direction, and a controller that controls the electric actuator. The electric actuator includes an electric motor of which rotation can be switched between forward and reverse rotations, and a drive device that is supplied with electric power from a power source and controlled by the controller to supply driving electric power for vibrating the vibrating table at desired amplitude and frequency to the electric motor. The drive device includes a power regenerative converter that regenerates electric power that is not consumed by acceleration of the electric motor, among electric power regenerated from the electric motor when the vibrating table is vibrated at the desired amplitude and frequency, to the power source.