Brushless Motor Pole Adaptation Using Geared Position Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost of recertifying control electronics for electric motors with different pole configurations in aerospace applications, due to the complexity and expense of the certification process, necessitates a method to reuse certified control electronics without modification.
Innovation Solution
Implementing a reducer or multiplier arrangement between the motor shaft and the rotor, coupled with a position sensor, allows control electronics originally designed for a different number of poles to operate a motor with a new pole configuration by adjusting the angular position feedback, thus avoiding the need for recertification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If control electronics are modified to control a motor with a different number of poles, then the motor can be controlled with the correct pole configuration, but the certification cost increases significantly
Solution Approach 1:
A position sensor is introduced as an intermediary component between the motor and the control electronics. The position sensor detects the angular position of the motor shaft and provides feedback to the control electronics, enabling the controller to adapt to different pole configurations without modifying the control electronics themselves. This intermediary allows the system to maintain certification validity while achieving adaptability.
2Measurement precision
If control electronics are redesigned for a specific motor configuration, then control precision is optimized, but the device complexity and recertification requirements increase
Solution Approach 1:
The control electronics are designed to be universal and multi-functional, capable of controlling motors with different pole configurations through software configuration rather than hardware redesign. The position sensor provides the necessary feedback to enable this universality, allowing a single control electronics design to serve multiple motor configurations without requiring recertification.
3Productivity
If a motor with a different number of poles is used, then the motor can meet new performance requirements, but the control system requires modification and recertification
Solution Approach 1:
The control system is made dynamic and adaptable through the position sensor feedback mechanism. Instead of requiring static, fixed configuration for each motor type, the system dynamically adjusts to different pole configurations through sensor feedback, enabling performance optimization without manufacturing complexity increases.
Data Source
AI summary
A motor system includes a brushless motor with a stator, a rotor having a first number of rotor poles, and a motor shaft connected to the rotor. The motor system also includes control electronics configured to control a brushless motor that has a second, number of rotor poles, different from the first number of rotor poles. The second number of rotor poles is an integer multiple, N, of the first number of rotor poles. A position sensor is communicatively connected to the control electronics. A first gear is mounted on the motor shaft and connected for rotation with the motor shaft, the first gear having a first number of teeth. A second gear is engaged with the first gear, the second gear having a second number of gear teeth. The position sensor is configured to detect an angular position of the second gear and provide it to the control electronics.