Actuator Regeneration Dissipation Control
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Solution Overview
Problem
In aerospace and automotive applications, the conventional methods for regulating regenerative energy in actuators, such as using large dump resistors or energy storage devices, are cumbersome due to size and weight constraints, and existing motor control methods like Field Oriented Control and Flux Weakening require current feedback, which is not always feasible.
Innovation Solution
The Regeneration Dissipation Control (RDC) method dissipates regenerative energy within the motor windings of actuators, using asynchronous or synchronous RDC signals to increase power losses without affecting dynamic performance, and integrates with motor controllers to manage energy dissipation, optionally using a small dump circuit for transient events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large dump resistors or energy storage devices are used to regulate regenerative energy, then the power supply can handle regeneration current, but the size and weight increase significantly
Solution Approach 1:
The motor windings themselves are utilized to dissipate regenerative energy through controlled current circulation, eliminating the need for external dump resistors or energy storage devices. The motor serves its own energy management function by converting regenerative energy into heat within its windings, thereby solving the weight and space problem while maintaining power supply reliability.
Solution Approach 2:
The invention extracts the energy dissipation function from external components (dump resistors, energy storage devices) and relocates it to the motor windings themselves. By circulating current through the motor windings during regeneration, the system eliminates heavy external energy management components while achieving the same regulatory effect.
2Ease of operation
If conventional FOC or flux weakening methods are used, then motor control is achieved, but current feedback is required which is not always feasible
Solution Approach 1:
The invention replaces the electrical measurement system (current feedback) with a sensorless control approach. By using voltage commands and motor parameters to estimate the required control actions, the system eliminates the need for physical current sensors while maintaining motor control capability through mathematical modeling and estimation techniques.
3Object-affected harmful factors
If regenerative energy is dissipated through external devices, then voltage supply increase is prevented, but the system becomes cumbersome and heavy
Solution Approach 1:
The invention merges the energy dissipation function with the motor windings themselves. Instead of using separate external dump resistors or energy storage devices, the motor windings are utilized as the dissipation path by circulating appropriate currents, thereby combining two functions (motor operation and energy dissipation) into a single integrated 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
RDC effectively reduces or eliminates the need for external energy dissipation devices by utilizing motor windings as resistors for heat dissipation, maintaining performance and preventing voltage surges, thus addressing the weight and space limitations in critical applications.
Implementation Method 1
The RDC method dissipates regenerative energy within the motor windings of actuators, using asynchronous or synchronous RDC signals to increase power losses without affecting dynamic performance
Data Source
Figure 1A~1B
Figure 2A~3
Figure 4A~4B
AI summary
Actuators are components of machines, which move and/or control a mechanism or system. During operation, actuators can experience regeneration events, with the actuator actually generating excess energy (e.g., regenerative energy) which must be stored or dissipated to avoid damaging the power supply. An actuator motor controller is configured to implement field oriented voltage control and flux weakening voltage control without current sensors. Dissipating regenerative energy includes providing a motor controller to command a motor drive to modify an input voltage, or to dissipate regenerative energy in a dump circuit. This command can cause motor windings to dissipate regenerative energy. Systems having a plurality of actuators distribute regenerative energy from one actuator to another. A central controller provides centralized regeneration dissipation control for the plurality of actuators. A power distribution unit includes a dump resistor to dissipate regenerative energy in addition to or instead of in the actuators.