Electric Winch Braking Apparatus Regenerative Control

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Solution Overview

Problem

Construction machines equipped with electric winches face challenges in simultaneously achieving sufficient braking force for safety while maximizing regenerative power generation, as existing technologies do not effectively control the balance between braking and regeneration.

Innovation Solution

An apparatus comprising a regenerative-power generation unit, a regenerative-power receiving unit, and a braking device, controlled by a braking control unit that calculates necessary braking and regeneration capacities to determine the appropriate action, using either regenerative braking or mechanical braking to ensure safe and efficient operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If regenerative braking is used to maximize power generation, then energy recovery is improved, but braking force may be insufficient for safety

Engineering Contradiction:

Improveregenerative power generationVSAvoidbraking force sufficiency

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The braking control unit dynamically adjusts the braking force distribution between regenerative braking and mechanical braking based on real-time comparison of regeneration capacity and necessary braking capacity, enabling the system to adaptively optimize both energy recovery and braking safety

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The braking control unit acts as an intermediary that coordinates between the regenerative-power generation unit and the mechanical braking device, managing the transition and combination of both braking methods to achieve optimal performance

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If mechanical braking is used to ensure sufficient braking force, then braking safety is improved, but regenerative power generation is reduced

Engineering Contradiction:

Improvebraking force sufficiencyVSAvoidregenerative power generation

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The system dynamically determines the auxiliary braking force needed by calculating the difference between necessary braking capacity and regeneration capacity, applying mechanical braking only to the extent necessary to supplement regenerative braking

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The braking control unit changes the operational parameters of both regenerative and mechanical braking systems based on real-time capacity assessments, optimizing the contribution of each system to achieve both safety and energy efficiency

Inventive Principle:

Principle #35Parameter changes

3Productivity

If only regenerative braking is used, then energy efficiency is improved, but braking control precision is reduced

Engineering Contradiction:

Improveoperation efficiencyVSAvoidbraking control precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The braking control unit implements a feedback mechanism that continuously monitors and compares regeneration capacity with necessary braking capacity, using this information to precisely control the auxiliary mechanical braking force to achieve exact braking performance

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system replaces pure mechanical braking control with an intelligent control system that calculates and coordinates both regenerative and mechanical braking forces, achieving more precise control than either system alone

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 apparatus ensures safe and effective braking of the electric winch with sufficient braking force while maximizing regenerative power generation, by selectively using regenerative or mechanical braking based on calculated capacities, thereby enhancing operational efficiency and safety.

Implementation Method 1

converting kinetic energy generated by a drop of a target object during lowering of the target object (rotation energy of the electric motor) into electric energy

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10087057B2Braking apparatus for electric winch

Publication Date: 2018.10.02 KOBE STEEL LTD

AI summary

Provided is a braking apparatus for braking of an electric winch of a construction machine, ensuring safe braking with much regeneration. The apparatus includes a regenerative-power generation unit, a regenerative-power receiving unit, a braking device for mechanical braking separately from the regenerative-power generation unit, and a braking control unit including a necessary-braking-capacity calculation section, a regeneration-capacity calculation section calculating a regeneration capacity, and a command section. The command section, when the regeneration capacity is not less than a necessary braking capacity, performs braking with only a regenerative action while not operating the braking device and, when the regeneration capacity is less than the necessary braking capacity, calculates an auxiliary braking force equivalent to a difference between the necessary braking capacity and the regeneration capacity and brings the braking device into braking action with the auxiliary braking force.