BLDC Motor Sensor-Line Logging With Nested Microcontroller
Find Innovative SolutionsGenerate Solutions
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 data retrieval capability is improved, but device complexity increases
Solution Approach 1:
The patent implements a nested microcontroller architecture where a second microcontroller is integrated within the BLDC motor controller. This nested microcontroller contains its own memory for data storage and can operate independently to acquire and store operational data, while still being part of the overall motor control system. This allows data retrieval capability to be added without completely redesigning the entire control system.
Solution Approach 2:
The second microcontroller is designed with multi-functionality, serving both as a data acquisition device and as a storage unit. It can operate in different modes (data transmission mode and transparent mode) to perform multiple functions including monitoring sensor data, storing operational parameters, and communicating with external systems, thereby reducing the need for separate dedicated components.
2Reliability
If a second microcontroller is added to monitor and store sensor data, then operational history tracking is improved, but manufacturing complexity increases
Solution Approach 1:
The second microcontroller is pre-configured with memory allocation and data structure setup during manufacturing. Operational parameters and sensor data formats are predetermined, allowing the motor to immediately begin data acquisition upon deployment without requiring complex post-assembly configuration or calibration procedures.
3Productivity
If the second microcontroller transmits data through sensor lines during operation, then real-time monitoring is improved, but signal interference increases
Solution Approach 1:
The second microcontroller is designed to transmit data periodically rather than continuously, and specifically activates data transmission only when the motor is not operating. This periodic transmission approach allows real-time monitoring capabilities while avoiding continuous signal interference with the sensor lines during critical motor operation periods.
Data Source
Figure 1
Figure 2
Figure 3
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.