Adaptive PWM Controller for Fan Motor Waveform Optimization

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Solution Overview

Problem

Existing methods for adjusting motor driving current waveforms in fan control systems are time-consuming and cost-ineffective, as they require physical adjustments of HALL sensors or hardware modifications to adapt to different fan characteristics, leading to inefficient operation, especially at low speeds and imbalanced current waveforms.

Innovation Solution

A controller with a motor speed/period detection unit and a PWM signal advance/delay calculation unit dynamically adjusts the PWM driving signal's ON and OFF times based on HALL signal parameters, allowing for adaptive waveform adjustments without hardware modifications, using firmware to determine optimal timing for improved efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the physical location of the HALL sensor is fine-tuned to adjust the control signal of the driver circuit, then the motor driving current waveform can be optimized, but the adjustment process becomes time-consuming and cost-ineffective for different fan characteristics

Engineering Contradiction:
Improvemotor driving current waveform qualityVSAvoidfine-tuning time for different fans
Core Design Contradiction:
Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent changes the control parameter from fixed physical HALL sensor location to dynamically adjustable PWM switching timing parameters. The controller modifies the ON and OFF timing points of the PWM signal based on detected motor speed and period, allowing optimization of the motor driving current waveform without physical sensor repositioning. This resolves the contradiction by enabling waveform optimization through software parameter adjustment rather than time-consuming physical fine-tuning for each fan.

Inventive Principle:
Principle #35Parameter changes

2Manufacturing precision

If the PWM driving signal is adjusted by hardware circuitry to improve motor driving current waveform, then the waveform can be tuned, but hardware modification is required for different fans which is time-consuming and cost-ineffective

Engineering Contradiction:
Improvemotor driving current waveform qualityVSAvoidhardware modification requirement
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces the hardware circuitry adjustment approach with a firmware-based PWM signal generation system. Instead of modifying hardware circuits for different fan characteristics, the controller uses firmware to dynamically calculate and adjust the PWM switching timing based on motor speed and period detection. This substitution eliminates the need for hardware modifications while maintaining waveform optimization capability, resolving the contradiction between waveform quality and ease of manufacture.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If the PWM driving signal is turned OFF early to advance the OFF time, then the motor driving current waveform can be adjusted, but an imbalance occurs in the motor driving current waveform

Engineering Contradiction:
Improvemotor driving current waveform adjustmentVSAvoidmotor driving current waveform balance
Core Design Contradiction:
Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The patent implements dynamic adjustment of both the ON time and OFF time of the PWM driving signal based on real-time motor speed and period detection. Rather than statically advancing only the OFF time, the system dynamically coordinates both switching events to maintain waveform balance. The controller calculates appropriate timing adjustments that preserve current waveform symmetry while achieving optimization, resolving the contradiction between waveform adjustability and balance stability.

Inventive Principle:
Principle #15Dynamics

4Device complexity

If the location of the HALL sensor is fixed according to full speed operation characteristics, then the control system is simple, but the current becomes too high and operation efficiency is low at low speed

Engineering Contradiction:
Improvecontrol system simplicityVSAvoidfan operation efficiency at low speed
Core Design Contradiction:
Device complexityVSProductivity

Solution Approach 1:

The patent transforms the fixed HALL sensor location control system into a dynamic control system that adapts to different operating speeds. The firmware detects motor speed and period, then dynamically adjusts PWM switching timing parameters accordingly. At low speeds, the system automatically modifies the timing to prevent excessive current and maintain efficiency, while preserving the simplicity of the physical sensor placement. This resolves the contradiction by adding computational adaptability without increasing physical system complexity.

Inventive Principle:
Principle #15Dynamics

Data Source

PatentUS8159171B2Controller and method for adaptively adjusting motor driving current waveforms
Publication Date: 2012.04.17 PADAUK TECH
  • US8159171B2 patent drawing
  • US8159171B2 patent drawing
  • US8159171B2 patent drawing

AI summary

The present invention discloses a controller and a method for adaptively adjusting motor driving current waveforms. According to the present invention, the controller receives multiple different control parameters which may be determined according to the characteristics of a fan to be controlled, and adjusts the delayed ON time and advanced OFF time of a PWM driving signal based on the control parameters and the present rotation speed of the fan motor, so that the fan operates under an optimum driving current waveform.