Brushless Motor Control via Zero-Cross Point Timing

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Solution Overview

Problem

Existing brushless motor control devices require costly triangular wave generation and voltage detection circuits, which can lead to precision issues due to component fluctuations, especially when estimating rotor position without rotational position sensors.

Innovation Solution

A brushless motor control system that detects phase voltage in one phase of a three-phase motor, estimates zero-cross points of other phases using time intervals, and controls conduction without triangular wave generation or voltage detection circuits, allowing for rotor position estimation and phase voltage control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If triangular wave generation circuit and voltage detection circuit are provided to estimate rotor position, then rotor position detection precision is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:
Improverotor position detection precisionVSAvoidcircuit complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the triangular wave generation circuit and voltage detection circuit from the system by using an alternative approach: detecting zero-cross points of phase voltages directly and estimating rotor position based on timing relationships between phases. This removes unnecessary components while maintaining detection precision.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The system uses the motor's own phase voltage signals and their natural zero-cross points to determine rotor position, eliminating the need for external sensors or complex detection circuits. The motor's electrical characteristics serve the dual purpose of driving the motor and providing position information.

Inventive Principle:
Principle #25Self-service

2Measurement precision

If triangular wave generation circuit and voltage detection circuit are provided to estimate rotor position, then rotor position detection precision is improved, but manufacturing cost increases

Engineering Contradiction:
Improverotor position detection precisionVSAvoidmanufacturing cost
Core Design Contradiction:
Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent removes the costly triangular wave generation and voltage detection circuits from the manufacturing bill of materials. Instead, it uses simple zero-cross point detection of existing phase voltages combined with timing-based estimation, significantly reducing component costs while maintaining adequate position detection precision.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces expensive, complex circuits with simpler, more economical alternatives that achieve the same functional outcome through software-based timing analysis rather than hardware-based voltage detection, reducing manufacturing costs.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Measurement precision

If sensor drive control circuit with multiple hole devices is used to detect rotor position, then rotor position detection precision is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:
Improve rotor position detection precisionVSAvoidsensor circuit complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts and removes all physical position sensors (hole devices) from the motor system. Instead of detecting position mechanically or optically, it uses electrical signal analysis - specifically zero-cross point timing of phase voltages - to estimate rotor position, eliminating sensor-related complexity.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces mechanical/optical sensing systems (hole devices that physically detect rotor position) with an electrical field-based system that uses voltage signal timing. This substitutes physical sensor mechanisms with electronic signal processing.

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

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables accurate rotor position estimation and phase voltage control in three-phase brushless motors without the need for costly triangular wave generation and voltage detection circuits, improving precision and reducing manufacturing costs.

Implementation Method 1

a sub-coil Su included in the three-phase brushless motor 1... detects the phase voltage (sine wave voltage) of one phase induced to that sub-coil

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP2704307B1Brushless motor control device and brushless motor control method
Publication Date: 2021.10.13 SHINDENGEN ELECTRIC MANUFACTURING CO LTD
  • EP2704307B1 patent drawingFigure 1
  • EP2704307B1 patent drawingFigure 2
  • EP2704307B1 patent drawingFigure 3A~3B

AI summary

Regarding a brushless motor control device and a control method, the phase voltage Vsu of any one phase of the three-phase brushless motor is detected by a sub-coil (Su) (6). A time interval between adjacent zero-cross points a1 and a2 thereof is measured. Based on the time interval between the zero-cross points, a time T/3 and a time 2T/3 are calculated. Then, based on the time t/3 and the time 2T/3, phases of zero-cross points b1 and c1 of the two other phases are estimated. Then, based on the estimated zero-cross points b1 and c1, phases of the phase voltages of the two other phases are estimated, thereby controlling conduction on each phase coil of the three-phase brushless motor.