Brushless Motor Current Sensing Without Clarke Transform Noise

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Existing current-sensing architectures for brushless motors suffer from noise and computational complexity, with single-sensor designs producing audible noise and torque inconsistencies, while triple-sensor and standard dual-sensor designs introduce noise and require complex calculations.

Innovation Solution

A dual-sensor architecture that directly measures the Beta current using a difference operational amplifier, reducing noise by 50% and eliminating the need for the Clarke transform step, thus improving torque control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single-sensor design is used to reduce cost and complexity, then device complexity is reduced, but audible noise and torque inconsistencies are introduced

Engineering Contradiction:
Improvesensor architecture complexityVSAvoidaudible noise
Core Design Contradiction:
Device complexityVSObject-generated harmful factors

Solution Approach 1:

The patent divides the current sensing function into two separate sensors instead of using a single sensor, allowing independent measurement of two phase currents. This segmentation enables direct calculation of torque-producing current without the need for Clarke transform, eliminating the computational steps that cause audible noise while maintaining low device complexity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent replaces the computational Clarke transform mechanism with a direct mathematical calculation using two sensor measurements. By measuring two phase currents directly and calculating the torque-producing current through simple algebraic operations, the system eliminates the complex transform calculations that generate audible noise, substituting a simpler computational approach.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If triple-sensor or standard dual-sensor designs are used to improve measurement accuracy, then measurement precision is improved, but noise and computational complexity increase

Engineering Contradiction:
Improvecurrent sensing precisionVSAvoidcomputational complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts only the essential measurement information needed for torque control by using two sensors to directly measure the phase currents that produce torque. By taking out only the necessary measurements and calculating torque-producing current directly without full Clarke transform, the system achieves sufficient measurement precision while minimizing computational complexity and noise.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses partial action by measuring only two of the three phase currents instead of all three phases. This partial measurement approach provides sufficient information for torque control without the computational overhead and noise associated with processing all three phases through the complete Clarke transform, achieving the right balance between precision and complexity.

Inventive Principle:
Principle #16Partial or excessive action

Data Source

PatentUS12494725B2High performance current sensing architecture for brushless motors
Publication Date: 2025.12.09 BARRETT TECH LLC
  • US12494725B2 patent drawing
  • US12494725B2 patent drawing
  • US12494725B2 patent drawing

AI summary

A motor controller for controlling the operation of a three-phase permanent magnet synchronous electric motor, wherein the three-phase permanent magnet synchronous electric motor is characterized by three phases A, B, C, and further wherein the three-phase permanent magnet synchronous electric motor is driven by regulating three phase currents iA, iB and iC for the three phases A, B, C, respectively, the motor controller comprising: a three-phase power supply for supplying the three phase currents iA, iB and iC; a first sensor for sensing the phase current iA; a second sensor for sensing across the phase currents iB and iC; and a microcontroller for controlling the operation of the three-phase power supply so as to produce the three phase currents iA, iB and iC needed to operate the three-phase permanent magnet synchronous electric motor, wherein the microcontroller reads the outputs of the first sensor and the second sensor and adjusts operation of the three-phase power supply so as to produce phase currents iA, iB and iC which produce the desired torque in the three-phase permanent magnet synchronous electric motor.