Backup Controller for Motor Relay Failure Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing backup systems for motor controllers fail to prevent unintended operations when switching relays malfunction, leading to motor rotation in both normal and reverse directions.
Innovation Solution
A backup controller system that includes a power source, motor, user-operable switches, a control unit, a monitoring circuit, and a backup circuit, which activates the appropriate relay to stop the motor and maintains power supply to the control unit even if the primary relay fails, using fuses and capacitors to ensure stable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a relay is activated to rotate the motor in a specific direction, then the motor operates in the intended direction, but if the relay fails (on-failure), the motor continues rotating in that direction even without control signals
Solution Approach 1:
The monitoring circuit continuously monitors the rotation direction of the motor and detects abnormal states before they cause harmful effects. When a relay failure is detected (motor rotating without relay activation), the system preemptively activates the opposite relay to create a counteracting effect that stops the unintended rotation.
Solution Approach 2:
The system converts the harmful effect of unintended motor rotation into a detectable signal. The monitoring circuit uses the abnormal rotation state as information to trigger the backup control mechanism, transforming the harmful symptom into a useful diagnostic signal that activates the correction procedure.
2Loss of energy
If the control unit power line is disconnected, then power consumption is reduced, but the control unit cannot function to stop the motor in case of relay failure
Solution Approach 1:
The backup circuit is pre-configured with capacitors that store electrical energy in advance. When the control unit power line is disconnected, these pre-charged capacitors immediately provide power to the control unit, enabling it to detect relay failures and activate the backup relay without interruption.
Solution Approach 2:
The system provides beforehand cushioning by incorporating capacitors in the backup circuit that serve as an energy buffer. These capacitors are charged during normal operation and provide temporary power supply when the main power line is disconnected, cushioning against the power interruption and ensuring continuous backup control capability.
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
Effectively suppresses unintended motor operations by activating the appropriate relay and maintaining power supply, ensuring the motor can be securely stopped in case of relay failures, thereby preventing unwanted rotation directions.
Implementation Method 1
a monitoring unit such as a monitoring circuit (which can also simply be referred to as a monitor) which monitors a rotation direction of the motor
Implementation Method 2
a backup circuit which is made supply power from the motor power line to the control unit power line by the control unit
Data Source
AI summary
A backup controller which is capable of suppressing an unintended operation performed by a motor which rotates in both of a normal rotation direction and a reverse rotation direction is provided. The control unit of the backup controller activates the second relay and the backup circuit in a case where a state in which the motor is rotating in the first direction even though the first relay is not activated is transmitted from the monitoring unit. Further, the control unit activates the first relay and the backup circuit in a case where a state in which the motor is rotating in the second direction even though the second relay is not activated is transmitted from the monitoring unit.