BLDC Motor Sensor-Line Data Logging for Offline Diagnostics
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Solution Overview
Problem
Conventional BLDC motors lack easy identification and data logging capabilities, making it difficult to determine the operational history and performance metrics when a motor is removed for analysis.
Innovation Solution
Integration of a second microcontroller with sensor lines to monitor and store operational data, allowing data transmission and retrieval when the motor is not in operation, along with additional sensors for force, temperature, and vibration monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If a second microcontroller is integrated into the BLDC motor for data acquisition and storage, then the ability to retrieve operational data and performance metrics is improved, but the device complexity increases
Solution Approach 1:
The patent integrates a second microcontroller directly into the BLDC motor assembly, merging data acquisition, storage, and transmission functions into the motor itself. This consolidation eliminates the need for external data logging devices and enables direct retrieval of operational data through existing sensor lines, resolving the contradiction by embedding the information management capability within the motor structure.
Solution Approach 2:
The second microcontroller is designed to perform multiple functions: acquiring data from sensors, storing operational metrics in memory, and transmitting information through sensor lines. This multi-functional component addresses the information retrieval need while utilizing existing motor infrastructure, thereby limiting the increase in overall system complexity.
2Measurement precision
If additional sensors and a second microcontroller are added to the motor, then measurement precision and data monitoring capability are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent divides the motor control system into two distinct microcontroller units: the first microcontroller handles primary motor control functions, while the second microcontroller specializes in data acquisition and logging. This segmentation allows each component to be optimized independently and facilitates modular manufacturing, where the data monitoring module can be developed and tested separately before integration.
Solution Approach 2:
The second microcontroller and additional sensors are integrated within the existing motor structure, nesting the data monitoring functionality inside the motor assembly. This approach allows the monitoring system to be manufactured as a compact integrated unit, reducing the overall manufacturing complexity compared to assembling separate monitoring equipment with the motor.
3Loss of information
If the second microcontroller continuously transmits data through sensor lines, then data availability is improved, but interference with motor operation may occur
Solution Approach 1:
The second microcontroller is configured to transmit stored data periodically or at predetermined intervals rather than continuously. This periodic transmission approach ensures that operational data becomes available for retrieval while minimizing the time that sensor lines are occupied by data transmission, thereby reducing potential interference with real-time motor control operations and maintaining system reliability.
Data Source
AI summary
A brushless direct current motor system includes a brushless direct current motor including a plurality of sensors and corresponding sensor lines for transmitting signals from the plurality of sensors. A first microcontroller is configured to the signals from the sensor lines and control the motor based on the received signals. A second microcontroller is operatively connected to the sensor lines between the sensors and the first microcontroller, the second microcontroller being configured to save data in a memory based on signals from the sensors sent through the sensor lines.