BLDC Actuator Positioning via Space Vector Phasing
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Solution Overview
Problem
Existing brushless DC motor (BLDC) actuator systems require continuous rotor position detection, which is costly and occupies significant installation space, and fail to reliably adjust the actuator if position information is lost.
Innovation Solution
A method where the actuator system uses a space vector with a differential phase position of less than 45° and sufficient amplitude to adjust the actuator to a predefined position without continuous rotor position determination, utilizing a permanent magnet rotor and electrically commutated stator, and includes means for detecting the rotor position to ensure accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If continuous rotor position detection is used to adjust the actuator, then the actuator can be precisely positioned, but expensive sensors are required and installation space increases
Solution Approach 1:
The patent extracts the position detection function from dedicated sensors and implements it through software-based methods using the electronically commutated actuator's existing components. The rotor position is determined indirectly through electrical measurements and computational algorithms rather than direct mechanical sensing, eliminating the need for separate position sensors.
Solution Approach 2:
The patent replaces the mechanical sensor-based position detection system with an electrical and software-based system. Instead of using mechanical encoders or Hall effect sensors to detect rotor position, the system uses electrical current measurements, voltage signals, and mathematical algorithms to calculate position information, substituting mechanical detection with electrical intelligence.
2Ease of operation
If sensors are installed for rotor position detection, then positioning can be achieved, but installation space and system cost increase
Solution Approach 1:
The patent makes the electronically commutated actuator multi-functional by enabling it to perform both its primary function of generating rotational torque and the secondary function of determining rotor position. The same actuator components (stator, rotor, electrical connections) used for motion generation are also utilized for position detection through electrical measurements and signal processing, eliminating the need for separate sensing components.
Solution Approach 2:
The actuator system determines its own rotor position using its own electrical components and internal processing capabilities, without requiring external sensing devices. The control unit within the actuator performs the position calculation based on electrical measurements taken from the actuator's own windings and circuitry, making the system self-sufficient for positioning tasks.
3Reliability
If the actuator uses a space vector with differential phase position less than 45° and sufficient amplitude, then the actuator can be adjusted without continuous position sensing, but the control complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing optimal space vector parameters (amplitude and differential phase position) that enable reliable actuator adjustment. These pre-determined control parameters are prepared in advance based on the actuator's characteristics, allowing the system to execute adjustments without real-time position feedback while maintaining reliability through the use of these pre-optimized control settings.
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
Enables reliable and precise adjustment of the actuator without continuous position sensing, reducing the need for expensive sensors and installation space, allowing the actuator to be moved to any desired position, including an emergency position, and operates efficiently with reduced power consumption.
Implementation Method 1
The stator can be energized with a space vector, the space vector having an electrical phase and an amplitude... the space vector being aligned around a different phase position with respect to the first axis of the rotor... generating a suitable torque acting on the rotor
Implementation Method 2
the actuator having a permanent magnet rotor, the rotor having a first axis which extends along a pole axis of the rotor... generating a suitable torque acting on the rotor
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
A method is proposed for adjusting an actuator (300) of a positioning system (100). The positioning system (100) has an electronically commutated actuator drive (200) which is coupled to the actuator (300), wherein the actuator drive (200) has a permanent magnetic rotor (210), wherein the rotor (210) has a first shaft (212) which extends along a pole axis (290) of the rotor (210). The actuator drive (200) additionally has an electronically commutated stator (230), wherein the stator (230) can be energized using a space phasor (260), wherein the space phasor (260) has an electric phase and an amplitude, wherein the space phasor (260) is aligned with respect to the first shaft (212) of the rotor (210) around a difference phasing. In order to be able to actuate a predefined position of the actuator, even without sensors to determine the position of the first shaft (212) of the rotor (210), the following steps of the method are thereby provided: setting the difference phasing of the space phasor (260) to an operating difference phasing; setting the amplitude to an operating amplitude, wherein the operating difference phasing and the operating amplitude are set in such a way that the operating difference phasing is less than 45º and that a torque is generated at the rotor (210) suitable for starting up the predefined position of the actuator (300). The invention further relates to a device for adjusting an actuator (300) of a positioning system (100) and a computer program product which contains a program code which, when it is executed by a data processing unit, implements the method according to the invention.