Brushless blower motor fan detection device

Abstract

The utility model provides a kind of brushless air-blast motor fan detection device, including supporting base, drive control mechanism, photoelectric sensing system and processing system.Drive control mechanism accurately stabilizes the fan speed to be detected at preset speed value;Photoelectric sensing system emits and collects light signal along the radial fan blade working area, and output light signal intensity value reflecting the degree of blade geometry shading;Processing system receives the intensity value and compares with preset determination threshold, and outputs fan model detection result.The device structure is simple, can be integrated with existing fan balancing station, uses photoelectric detection principle to realize full number, fast, high-precision determination under constant speed, effectively solves the problem of high risk of fan model misloading, low detection efficiency and poor high-speed detection stability in prior art, thereby significantly improves the quality and consistency of brushless air-blast motor product.

Description

Technical Field

[0001] This utility model relates to the field of motor testing technology, and in particular to a brushless blower motor fan testing device. Background Technology

[0002] After assembly, existing automotive brushless blower motors require a dynamic balancing test to ensure vibration levels meet requirements. Fans supplied to different customers or vehicle models vary in structural parameters such as blade count, blade angle, and blade curvature. Incorrect fan type installation during assembly will directly lead to abnormal airflow, air pressure, or noise performance in the HVAC (Heating, Ventilation, and Air Conditioning) system.

[0003] Currently, the industry mainly relies on manual visual inspection of model markings or barcode scanning to confirm whether the fan type has been installed incorrectly. These methods depend entirely on the operator's sense of responsibility and are prone to omissions or misjudgments.

[0004] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this utility model, and therefore may include information that does not constitute prior art known to those skilled in the art. Utility Model Content

[0005] In view of the problems in the prior art, the purpose of this utility model is to provide a brushless blower motor fan detection device, which overcomes the difficulties of the prior art and can solve the technical problems of poor accuracy and stability in the detection of brushless blower motor fans in related technologies.

[0006] This disclosure provides a brushless blower motor fan testing device, which includes: Support base; The drive control mechanism is electrically connected to the brushless blower motor and is used to drive the brushless blower motor to work and control the speed of the fan under test in the brushless blower motor to a preset speed value. The photoelectric sensing system is mounted on the support base and is radially opposite to the working area of ​​the blades of the fan under test. It is used to emit and collect light signals passing through the gap between the blades of the fan under test at a preset speed value, and output the light signal intensity value that characterizes the degree of light blocking of the blades. The processing system is electrically connected to the photoelectric sensing system. It is used to receive the light signal intensity value, compare the light signal intensity value with a preset judgment threshold range, and output the fan detection result.

[0007] Optionally, the photoelectric sensing system includes an optical fiber transmitter and an optical fiber receiver, with the optical fiber transmitter and receiver positioned opposite each other on opposite sides of the rotating track of the fan to be detected.

[0008] Optionally, the fiber optic transmitter and fiber optic receiver are wide-format photoelectric sensors, and the light-emitting surface or light-receiving surface of the wide-format photoelectric sensor extends radially or axially along the fan to be detected.

[0009] Optionally, the wide-area photoelectric sensor includes multiple photoelectric sensing paths distributed along the axial direction of the fan to be detected, for providing multi-point optical signal detection.

[0010] Optionally, the drive control mechanism includes a speed stabilization module electrically connected to the brushless blower motor. The speed stabilization module includes a PWM adjustment circuit for controlling the speed of the fan under test to a preset speed value by adjusting the PWM duty cycle of the brushless blower motor.

[0011] Optionally, the processing system includes: A signal amplification and shaping unit, electrically connected to the photoelectric sensing system, is used to process and amplify the intensity value of the optical signal; and The judgment output unit, connected to the signal amplification and shaping unit, is used to compare the processed light signal intensity value with the preset judgment threshold range and output the fan detection result.

[0012] Optionally, the determination output unit is integrated into the signal amplification and shaping unit; or, the determination output unit is a programmable controller or a microprocessor.

[0013] Optionally, the brushless blower motor fan detection device also includes: A temperature sensor, mounted on a support base and connected to the processing system, is used to monitor the ambient temperature and provide a temperature compensation signal to the processing system to adjust the preset judgment threshold range.

[0014] Optionally, the brushless blower fan detection device also includes a rotor position sensor, which is a Hall effect element or an encoder, electrically connected to the processing system, used to detect the instantaneous angular position of the fan under test, and to realize the synchronous triggering of optical signal acquisition and the rotational position of the fan under test.

[0015] The brushless blower motor fan detection device proposed in this disclosure has the following advantages: The brushless blower fan type detection device includes: a support base; a drive control mechanism for precisely controlling the fan speed under test to stabilize at a preset speed value; a photoelectric sensing system mounted on the base, radially opposite to the working area of ​​the fan blades; and a processing system. During operation, the drive control mechanism stabilizes the fan speed at the preset value, and the photoelectric sensing system emits and collects light signals passing through the blade gaps, outputting light signal intensity values ​​characterizing the degree of light shading by different blade geometries. The processing system receives these intensity values, compares them with a preset threshold range, and outputs the detection result for the fan type.

[0016] This brushless blower motor fan testing device has a simple structure and can be integrated with existing fan balancing stations. Utilizing photoelectric detection principles, it can quickly and accurately determine the fan model at a constant speed, solving the technical problems of high risk of incorrect fan model installation, low detection efficiency, and poor stability at high speeds in existing technologies. By analyzing the differences in how different fan blades block light signals, it effectively avoids incorrect model installation, significantly improving the factory quality and consistency of brushless blower motor products.

[0017] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure. Attached Figure Description

[0018] Other features, objects, and advantages of this invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings.

[0019] Figure 1 One of the perspective views of the brushless blower motor fan detection device provided in the embodiments of this disclosure; Figure 2 A second perspective view of the brushless blower motor fan detection device provided in the embodiments of this disclosure; Figure 3 A front view of the brushless blower motor fan detection device provided in this embodiment of the disclosure; Figure 4 A structural diagram of the drive control mechanism module in the brushless blower motor fan detection device provided in this embodiment of the disclosure; Figure 5 A modular structure diagram of the control system in the brushless blower motor fan detection device provided in this embodiment of the disclosure. Detailed Implementation

[0020] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the examples set forth herein; rather, they are provided so that this disclosure will be more comprehensive and complete, and will fully convey the concept of the exemplary embodiments to those skilled in the art. The described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0021] Figure 1 and Figure 2 A perspective view of a brushless blower motor fan detection device provided for an embodiment of this disclosure, as shown below. Figure 1 and Figure 2 As shown, this brushless blower motor fan detection device includes a support base 1, a drive control mechanism 2, a photoelectric sensing system 3, and a processing system (not shown in the figure).

[0022] The support base 1 is used to support and position the brushless blower motor 4. The support base 1 can be a plate or frame structure, and can be made of metal or high-strength engineering plastic. It is provided with a mounting position for installing the brushless blower motor 4, so that the brushless blower motor 4 remains stable during the test and avoids vibration from interfering with the photoelectric data acquisition.

[0023] The drive control mechanism 2 is electrically connected to the power supply terminal of the brushless blower motor 4, and is used to drive the internal fan 41 under test to work normally, and control the speed of the fan 41 under test to run to the preset speed value according to the set program.

[0024] The photoelectric sensing system 3 is mounted on the support base 1, radially opposite to the working area of ​​the blades 42 of the fan 41 under test, enabling it to collect optical signals during the rotation of the blades 42. The photoelectric sensing system 3 includes a transmitter 3a and a receiver 3b. The transmitter 3a projects a light beam onto the radial plane of the blades 42. When the fan 41 under test rotates, the periodic shading characteristics of the blades 42 cause periodic intensity changes in the light signal passing through the blade gaps. The receiver 3b receives the emitted light signal passing through the fan 41 under test. Therefore, the photoelectric sensing system 3 can be used to emit and collect light signals passing through the gaps between the blades 42 of the fan 41 under test at a preset rotational speed, and output a light signal intensity value characterizing the degree of shading by the blades. Different types of fans, with variations in the number of blades, curvature, reflective material, or structural features, exhibit identifiable differences in their corresponding optical signal waveforms and peak-to-valley amplitudes.

[0025] In this embodiment, the processing system is electrically connected to the photoelectric sensing system 3, and is used to collect the light signal intensity value of the fan 41 under test in real time, and compare and analyze it with a preset threshold. By pre-establishing preset judgment threshold ranges for different fans (such as establishing a range range by referring to the collection of multiple batches of samples), when the light signal intensity value is within the corresponding preset judgment threshold range, it is determined that the model is correct; if it exceeds the preset judgment threshold range, an abnormal detection result is output.

[0026] In actual use, the operator places the assembled brushless blower motor 4 on the support base 1, starts the drive control mechanism 2 to make the fan 41 to be tested reach the preset speed value, the photoelectric sensing system 3 samples the rotation process of the fan 41 to be tested, the processing system receives the light signal intensity value and compares it with the preset judgment threshold range, and can automatically give the fan detection result without manual scanning or visual confirmation.

[0027] Therefore, the brushless blower motor fan detection device provided in this embodiment can quickly identify whether the fan is installed incorrectly, reduce human error, improve detection accuracy and stability, and enhance the consistency of the HVAC production line.

[0028] like Figure 1 and Figure 2 As shown, the photoelectric sensing system can employ a fiber optic sensing structure consisting of a fiber optic transmitter 31 and a fiber optic receiver 32. The fiber optic transmitter 31 serves as the transmitting end 3a, and the fiber optic receiver 32 serves as the receiving end 3b.

[0029] Combination Figure 3 As shown, the fiber optic transmitter 31 and fiber optic receiver 32 are arranged in a through-beam configuration, positioned opposite each other on either side of the outer edge of the rotating track of the fan 41 under test, forming a light detection channel spanning the movement path of the fan blades. When the drive control mechanism 2 drives the fan 41 under test to rotate and reaches a preset speed value, the blades 42 periodically block the emitted light beam. The light signal intensity value detected by the fiber optic receiver 32 undergoes periodic changes in amplitude as the blades 42 pass by. By analyzing the waveform characteristics of the light signal intensity value, the detection sensitivity and anti-interference stability can be further improved.

[0030] In this embodiment, the fiber optic transmitter 31 and the fiber optic receiver 32 can be fixed on the support base 1, and their spacing can be adjusted according to the fan diameter to ensure that the optical path passes through the rotational radial region of the blade 42. The ends of the fiber optic transmitter 31 and the fiber optic receiver 32 can be equipped with a focusing lens structure to improve the light output energy and light signal recovery efficiency, thereby reducing measurement deviations caused by differences in fan material or surface reflection.

[0031] To overcome the problem that traditional narrow-beam point sensors are easily affected by fan vibration and oscillation during high-speed rotation detection, resulting in unstable signals, this embodiment uses a wide-area photoelectric sensor as the sensing structure for the fiber optic transmitter 31 and the fiber optic receiver 32.

[0032] In this embodiment, the emitting surface (emitting end 3a) and / or receiving surface (receiving end 3b) of the wide-area photoelectric sensor can be extended along the radial and / or axial direction of the fan 41 to be tested, forming a continuous light curtain area. This design enables the blades 42 to interact with the light curtain for a longer period of time during rotation, thereby significantly improving the problem of local signal loss that may occur in narrow beam point measurement methods, increasing the detection coverage, and effectively solving the technical problem that traditional point sensors are easily affected by fan vibration and oscillation during high-speed rotation detection, resulting in unstable signals.

[0033] For example, when the wide emitting surface extends radially along the fan 41 under test, the light curtain covers the entire blade tip trajectory, providing strong adaptability to fans with different curvatures and blade widths. When it extends axially, it can acquire light signals in the blade height direction, making the fan detection results more comprehensive.

[0034] This wide-area design enhances the ability to extract features that identify differences in fan models, thereby improving detection stability and resistance to attitude deviations.

[0035] like Figure 3 As shown, the wide-area photoelectric sensor can include multiple photoelectric sensing paths. The multiple photoelectric sensing paths are arranged in segments along the axial direction L of the fan 41 to be detected, forming a multi-point parallel optical signal acquisition structure.

[0036] When the fan 41 to be tested rotates, each photoelectric sensing path outputs light signal intensity values. The processing system performs fusion calculations on the multiple light signal intensity values. By comparing the waveform amplitude differences at different sampling points, it can extract fan type feature dimension information, such as blade height, differences in blade root structure, and changes in the reflection ratio of the outer edge of the fan.

[0037] In practical applications, the number of multiple photoelectric sensing paths can be customized and expanded according to the axial height of the fan 41 to be tested. This embodiment can obtain spatially distributed light signals in a single operation, effectively reducing the risk of misjudgment caused by contamination or local reflection in single-point sampling, further improving the fan detection accuracy, and ultimately realizing multi-dimensional parameter modeling and judgment.

[0038] In this disclosure, such as Figure 4 As shown, the drive control mechanism 2 includes a brushless blower motor 4 (such as...) Figure 1 and Figure 2The speed stabilization module 21 (shown) is electrically connected (concentrated inside the drive control mechanism 2 and not visible). Since the brushless blower motor 4 adopts electronic commutation technology, the speed stabilization module 21 includes a pulse width modulation (PWM) adjustment circuit, which can output PWM pulse signals and adjust the duty cycle, thereby realizing dynamic control of the power supply to the brushless blower motor 4.

[0039] In the fan detection process, an initial PWM signal is first output to the brushless blower motor 4, causing the fan under test 41 (e.g., ...) to start up the fan under test 41. Figure 1 and Figure 2 (As shown) The fan 41 is started and gradually increases in speed. When the speed of the fan under test 41 approaches the preset speed value, the PWM adjustment circuit adjusts the duty cycle through closed-loop control to stabilize the fan speed within the preset speed range. At this time, the speed control precision of the fan under test 41 is lower to reduce the optical signal fluctuation caused by the difference in fan damping.

[0040] In practical applications, the speed stabilization module 21 can acquire the real-time motor speed using Hall signal feedback or back-EMF zero-crossing detection. It can also be linked with a processing system to achieve precise speed regulation through a software proportional-integral-derivative (PID) algorithm. By stabilizing the fan speed, the photoelectric sensing system 3 (such as...) can ensure... Figure 1 and Figure 2 (As shown) Sampling under consistent operating conditions improves the distinguishability and reliability of optical signals from different fan models.

[0041] In this embodiment of the disclosure, combined with Figure 1 and Figure 2 As shown, the processing system and the photoelectric sensing system 3 can be connected by a wire. The processing system can be integrated into the drive control mechanism 2 or set up independently of the drive control mechanism 2. Figure 5 As shown, the processing system may include a signal amplification and shaping unit 51 and a decision output unit 52. The photoelectric sensing system 3 (such as...) Figure 1 and Figure 2 The intensity value of the light signal collected (as shown) is a simulated weak signal. It is processed by the signal amplification and shaping unit 51 to amplify the signal in one or more stages. RC filtering or digital filtering algorithms can be used to shape the waveform to make the signal pulsation smoother and the background noise reduced.

[0042] The shaped light signal intensity value is transmitted to the judgment output unit 52. The judgment output unit 52 stores preset judgment threshold ranges corresponding to different fan models. When the current light signal intensity value falls within the corresponding preset judgment threshold range, a "fan type correct" signal is output; if it deviates from the preset judgment threshold range, an "assembly error" alarm signal is output, and the workstation can be linked to stop release or trigger indicator lights and audible and visual alarms.

[0043] Optionally, the judgment output unit 52 can also record the light signal intensity value and fan detection results in real time and upload them to the production line manufacturing execution system (MES) for traceability and quality tracking, so as to achieve full error prevention detection and interception of abnormal products.

[0044] In this disclosure, such as Figure 5 As shown, the determination output unit 52 can be implemented in two ways: the determination output unit is integrated into the signal amplification and shaping unit 51; or, the determination output unit 52 is a programmable controller or a microprocessor.

[0045] In the first implementation, the signal amplification and shaping unit 51 integrates a judgment output unit 52. This means that while amplifying and shaping the optical signal, it directly performs threshold comparison and judgment on the processed optical signal intensity value. The judgment output unit 52 can be implemented using an analog comparator circuit, gated logic, or an integrated operational amplifier circuit. This approach results in a compact signal processing chain, a short signal transmission path, strong anti-interference capability, and fast detection response speed, making it suitable for real-time and rapid judgment of fan assembly lines.

[0046] In the second implementation, the processed optical signal intensity value is output by the signal amplification and shaping unit 51 to a programmable logic controller (PLC) or a microcontroller unit (MCU). The microcontroller can use its internal analog-to-digital converter (ADC) to acquire the optical signal and complete threshold judgment, status determination, and alarm output through software logic. This solution has the advantages of high flexibility, adjustable threshold, upgradable firmware, and networking with the production line manufacturing execution system (MES), enabling the acquisition, recording, and remote monitoring of fan detection data.

[0047] In practical applications, users can choose the appropriate solution based on the production line conditions: for high-frequency, high-speed production lines, the integrated solution provided by the first implementation method can be used first to shorten the response time; for conditions that require data tracking, remote management, or multi-model fan detection, the programmable controller or microprocessor solution provided by the second implementation method can be used.

[0048] Through the above implementation methods, the fan detection device can achieve high-precision optical signal determination and meet the application requirements of different production environments, ensuring that the fan under test is reliably determined at the preset speed value, reducing manual intervention and improving the level of assembly quality control.

[0049] In this disclosure, such as Figure 1 and Figure 2 As shown, to improve the accuracy and reliability of fan detection, this fan detection device may also include a temperature sensor (not shown in the figure), which is mounted on the support base 1 and electrically connected to the processing system. The temperature sensor is used to monitor the ambient temperature in real time, such as temperature changes in the production workshop or local temperature rises generated during fan operation.

[0050] After receiving the temperature signal from the temperature sensor, the processing system can automatically adjust the preset judgment threshold range of the photoelectric sensing system 3 according to temperature changes (temperature compensation). For example, the photosensitive element of the photoelectric sensor may experience a decrease in sensitivity under high temperature conditions, or the output light intensity of the LED light source may fluctuate with temperature. The temperature compensation mechanism can automatically correct the preset judgment threshold range to ensure that the fan detection results remain stable and reliable under different ambient temperatures.

[0051] In practical applications, temperature sensors can be negative temperature coefficient (NTC) thermistors, digital temperature sensors, or industrial-grade thermistors, which provide high measurement accuracy and ensure that compensation strategies are precise and effective.

[0052] In this embodiment, the fan detection device may further include a rotor position sensor (not shown in the diagram), which is electrically connected to the processing system. The rotor position sensor may be a Hall effect element or a rotary encoder, used to detect the instantaneous angular position of the fan 41 to be detected.

[0053] Using the position signal provided by the rotor position sensor, the processing system can achieve synchronous triggering of optical signal acquisition and fan rotation position. Specifically, the processing system triggers sampling based on the angle signal each time the blade 42 passes through the photoelectric detection area, ensuring that the optical signal corresponds to the precise blade position, thereby avoiding signal errors caused by the start-up or slight vibration of the fan 41 under test and improving the accuracy of fan type determination.

[0054] In applications, the rotor position sensor and processing system can be synchronously triggered via interrupt or timed sampling. Hall effect elements can be directly mounted on the motor rotor or fan shaft, and the encoder can be mounted on the shaft and connected to the microprocessor interface to achieve precise acquisition of multiple signals. This structure enables photoelectric sensing results to not only reflect changes in light intensity but also accurately correspond to the fan's rotational position, achieving high-precision fan detection.

[0055] Based on the brushless blower fan testing device provided in this disclosure, a photoelectric sensing system, a drive control mechanism, and a processing system are arranged on a support base. These, along with a temperature sensor and a rotor position sensor, enable high-precision testing of the fan at a preset speed. The device has a simple structure, no moving parts, and can accurately determine the fan type in a full-scale testing mode, preventing assembly errors and improving the performance stability and production quality reliability of the HVAC system. Furthermore, the various embodiments of this disclosure can be flexibly combined or adjusted according to different production needs, making it suitable for testing multiple fan models and providing an efficient, reliable, and easy-to-operate automated testing solution for automotive brushless blower motor assembly. This technical solution not only effectively reduces manual inspection errors but also possesses scalability and environmental adaptability, providing a complete implementation reference for those skilled in the art.

[0056] Other embodiments of this disclosure will readily occur to those skilled in the art upon consideration of the specification and practice of the utility models disclosed herein. This disclosure is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the appended claims.

Claims

1. A brushless blower motor fan detection device, characterized in that, include: Support base; A drive control mechanism is electrically connected to the brushless blower motor, used to drive the brushless blower motor to work and control the speed of the fan under test in the brushless blower motor to a preset speed value. A photoelectric sensing system is mounted on the support base and is radially opposite to the working area of ​​the blades of the fan under test. It is used to emit and collect light signals passing through the gap between the blades of the fan under test at the preset rotational speed value, and output a light signal intensity value that characterizes the degree of light shading of the blades. The processing system is electrically connected to the photoelectric sensing system, and is used to receive the light signal intensity value, compare the light signal intensity value with a preset judgment threshold range, and output the fan detection result.

2. The brushless blower motor fan detection device according to claim 1, characterized in that, The photoelectric sensing system includes an optical fiber transmitter and an optical fiber receiver, with the optical fiber transmitter and the optical fiber receiver positioned opposite each other on opposite sides of the rotating track of the fan to be tested.

3. The brushless blower motor fan detection device according to claim 2, characterized in that, The fiber optic transmitter and the fiber optic receiver are wide-area photoelectric sensors, and the light-emitting surface or light-receiving surface of the wide-area photoelectric sensor extends along the radial or axial direction of the fan to be detected.

4. The brushless blower motor fan detection device according to claim 3, characterized in that, The wide-area photoelectric sensor includes multiple photoelectric sensing paths, which are distributed along the axial direction of the fan to be detected, and are used to provide multi-point optical signal detection.

5. The brushless blower motor fan detection device according to claim 1, characterized in that, The drive control mechanism includes a speed stabilization module electrically connected to the brushless blower motor. The speed stabilization module includes a PWM adjustment circuit, which is used to control the speed of the fan under test to a preset speed value by adjusting the PWM duty cycle of the brushless blower motor.

6. The brushless blower motor fan detection device according to claim 1, characterized in that, The processing system includes: A signal amplification and shaping unit, electrically connected to the photoelectric sensing system, is used to process and amplify the intensity value of the optical signal; and The determination output unit, connected to the signal amplification and shaping unit, is used to compare the processed light signal intensity value with the preset determination threshold range and output the fan detection result.

7. The brushless blower motor fan detection device according to claim 6, characterized in that, The determination output unit is integrated within the signal amplification and shaping unit; or, the determination output unit is a programmable controller or a microprocessor.

8. The brushless blower motor fan detection device according to claim 1, characterized in that, The brushless blower motor fan detection device also includes: A temperature sensor, mounted on the support base and connected to the processing system, is used to monitor the ambient temperature and provide a temperature compensation signal to the processing system to adjust the preset judgment threshold range.

9. The brushless blower motor fan detection device according to claim 1, characterized in that, The brushless blower motor fan detection device also includes a rotor position sensor, which is a Hall effect element or an encoder, electrically connected to the processing system, used to detect the instantaneous angular position of the fan under test, and to realize the synchronous triggering of the optical signal acquisition and the rotational position of the fan under test.

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