BEMF Reconstruction for Sinusoidal Motor Drive Synchronization

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Solution Overview

Problem

Permanent magnet motors experience acoustic noise due to torque ripple caused by the abrupt transition of phase current to zero during tri-stating of the motor drive voltage, leading to distortion in the motor phase current and torque ripple.

Innovation Solution

A system that reconstructs the BEMF signal to synchronize the motor drive without tri-stating the drive voltage, using phase current sensing circuitry, BEMF reconstruction, and PWM circuitry to generate an error-corrected synchronization signal and motor drive signal, eliminating the need for complex microcontrollers like DSPs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the motor drive voltage is tri-stated to synchronize BEMF and drive signal, then the motor can be driven with proper synchronization, but the phase current abruptly transitions to zero causing torque ripple and acoustic noise

Engineering Contradiction:
Improvesynchronization accuracyVSAvoidacoustic noise
Core Design Contradiction:
ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies preliminary action by measuring and storing the BEMF zero-crossing timing information in advance, then using this pre-acquired data to synchronize the drive signal without requiring tri-stating during operation. This allows the system to prepare synchronization data beforehand and apply it smoothly, avoiding the abrupt current transitions that cause acoustic noise.

Inventive Principle:
Principle #10Preliminary action

2Measurement precision

If the pull-up and pull-down transistors are simultaneously turned off during tri-stating, then the BEMF can be measured on the output conductor, but the drive voltage conductors are no longer driven causing phase current distortion

Engineering Contradiction:
ImproveBEMF measurementVSAvoidphase current waveform
Core Design Contradiction:
Measurement precisionVSStability of the object's composition

Solution Approach 1:

The patent uses copying by creating a reconstructed BEMF signal from measured data and zero-crossing timing information, rather than directly using the physical BEMF signal obtained during tri-stating. This copy allows the system to maintain continuous drive voltage while still having access to synchronization information, avoiding the need to turn off the drive transistors and thereby maintaining stable phase current waveforms.

Inventive Principle:
Principle #26Copying

3Ease of manufacture

If conventional tri-stating method is used to synchronize drive signal, then simple hardware implementation is achieved, but complex microcontrollers like DSPs are required increasing device complexity and cost

Engineering Contradiction:
Improvehardware implementationVSAvoidmicrocontroller complexity
Core Design Contradiction:
Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent replaces the complex mechanical/electronic system of tri-stating and DSP-based synchronization with a simplified electronic system using a state machine and basic arithmetic operations. Instead of using complex microcontrollers to manage tri-stating sequences and BEMF measurement, the invention substitutes these with a streamlined digital approach that uses simple timing measurements and calculations to achieve the same synchronization function with reduced complexity.

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

This approach eliminates phase current distortion, reducing torque ripple and associated acoustic noise, while automatically determining motor parameters and eliminating the complexity and cost of using DSPs.

Implementation Method 1

Permanent magnet motors generate a sinusoidal back electro-motive force (BEMF)

Methodology Applied
Scientific EffectBack electro-motive force (BEMF): Electromagnetic Induction

Data Source

PatentUS8624532B2System and method for synchronizing sinusoidal drive to permanent magnet motor without distorting drive voltage
Publication Date: 2014.01.07 TEXAS INSTRUMENTS INC
  • US8624532B2 patent drawing
  • US8624532B2 patent drawing
  • US8624532B2 patent drawing

AI summary

A system for controlling a motor (3) includes a driver circuit (5) for generating a drive voltage (v) to generate a phase current (i) in the motor. Phase current sensing circuitry (10,21) digitizes the phase current. A first circuit (23) provides a reconstructed digital representation of a BEMF signal (vbemf) of the motor to generate an error-corrected synchronization signal (SYNC) in response to the phase current and a detected error in the motor speed, an amplitude feedback signal (15), and information (iR,iL,ΔiL,vL) indicative of a resistance (Rm) and an inductance (Lm) of the motor. A motor drive signal (15) having an error-corrected frequency is generated in response to the synchronization signal. A PWM circuit (16) produces a PWM signal (17) having a frequency equal to the error-corrected frequency of the synchronization signal (SYNC) and a duty cycle controlled according to the detected error.