Electric Blower Motor Control With Two-Point Airflow Calibration
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Solution Overview
Problem
Calibrating electric motors for constant airflow output in blower systems is a time-consuming and labor-intensive process requiring expensive, sophisticated equipment, and existing motor controllers need numerous calibration points, making it prone to errors.
Innovation Solution
A motor controller that uses only two calibration points to generate an operating profile for electric blower systems, approximating airflow based on torque, speed, and system resistance, reducing the need for complex equipment and minimizing labor and time through a polynomial algorithm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional calibration methods with numerous calibration points are used, then manufacturing precision of constant airflow output is improved, but loss of time and productivity deteriorate
Solution Approach 1:
The patent applies partial action by using only two calibration points instead of the traditional numerous calibration points. This reduces the calibration process to the minimum necessary data points while still achieving accurate constant airflow control through the polynomial algorithm that interpolates between these points.
Solution Approach 2:
The patent changes the calibration approach from using many discrete calibration points to using a continuous polynomial algorithm that generates airflow values based on torque and speed parameters. This parameter-based approach maintains precision while dramatically reducing calibration time and data requirements.
2Manufacturing precision
If traditional calibration methods with numerous calibration points are used, then manufacturing precision of constant airflow output is improved, but device complexity deteriorates
Solution Approach 1:
The patent extracts the essential calibration information needed for constant airflow control, reducing it to just two calibration points. This extraction eliminates the need for complex calibration equipment and procedures while maintaining the ability to achieve precise airflow control through the polynomial algorithm.
Solution Approach 2:
The patent replaces expensive, sophisticated calibration equipment with a simpler system that uses basic measurements at two points. The complexity is shifted from physical equipment to computational algorithms, making the calibration process more accessible and less resource-intensive.
3Manufacturing precision
If traditional calibration methods are used, then manufacturing precision of constant airflow output is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent reduces calibration to the minimum necessary action - just two data points - while still achieving the manufacturing precision goal. This partial action approach makes calibration much easier to perform while maintaining accurate constant airflow output control.
4Adaptability or versatility
If motor operates at variable speed and torque, then adaptability to different airflow demands is improved, but maintaining constant airflow becomes more difficult
Solution Approach 1:
The patent uses feedback control where the polynomial algorithm continuously calculates the relationship between motor speed, torque, and airflow. By monitoring actual operating conditions and comparing them against the calibrated polynomial model, the system adjusts motor parameters to maintain constant airflow despite variable speed and torque requirements.
Solution Approach 2:
The patent changes motor operating parameters (speed and torque) dynamically while using the polynomial algorithm to maintain constant airflow output. The algorithm allows the system to adapt to different airflow demands by adjusting parameters while compensating for system resistance changes, achieving both adaptability and constant airflow control.
Data Source
AI summary
An electric blower system is described. The blower system includes a blower, an airflow system, a sensor, and an electric motor. The electric motor includes a motor controller. The motor controller is configured to operate the motor at a first torque and a first speed to generate a first airflow, determine a first airflow value wherein the first airflow value, the first torque, and the first speed define a first benchmark data point. The motor controller is also configured to operate the motor at a second torque and a second speed to generate a second airflow and determine a second airflow value wherein the second airflow value, the second torque, and the second speed define a second benchmark data point. The motor controller is further configured to generate an operating profile for the blower system defining torque, speed, and airflow points for different system resistances.