Brushless Motor Steering Control with Hall and Limit Feedback
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Solution Overview
Problem
Current steering devices in aerial work platforms rely on hydraulic power or brushed motors, which are inefficient, noisy, and unsuitable for precise and fast operations in special environments, and brushless motors lack mature steering and positioning control technologies for high-speed scenarios.
Innovation Solution
A brushless motor system with a motor controller, Hall sensor, micro limit switches, and a steering cylinder for precise positioning and steering control, utilizing ramp control strategies and current detection to manage motor speed and direction based on detected revolutions and switch signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hydraulic power steering is used, then steering function is achieved, but device complexity and space occupation increase
Solution Approach 1:
The patent replaces the hydraulic power steering system with an electric brushless motor-driven ball screw steering system. This substitution eliminates the need for hydraulic pumps, reservoirs, and fluid pathways, significantly reducing device complexity while maintaining the steering function. The motor controller directly drives the ball screw mechanism to achieve precise steering control.
2Ease of operation
If brushed motor is used, then steering function is achieved, but lifespan is limited due to carbon brush wear
Solution Approach 1:
The patent replaces the brushed motor with a brushless motor, eliminating the carbon brush component that is subject to wear. The brushless motor uses electromagnetic induction to generate rotation without physical contact between commutator and brushes, thereby dramatically extending the operational lifespan and improving reliability of the steering system.
3Ease of operation
If brushed motor is used, then steering function is achieved, but rotational speed is limited
Solution Approach 1:
The patent replaces the brushed motor with a brushless motor that can achieve higher rotational speeds due to the absence of commutator limitations. The brushless motor's electronic commutation system allows for higher RPM operation, enabling faster steering response and improved performance in time-critical aerial work scenarios.
4Ease of operation
If hydraulic power steering is used, then steering function is achieved, but power consumption is high
Solution Approach 1:
The patent replaces the hydraulic power steering system with an electric brushless motor system. Electric motors are inherently more energy-efficient than hydraulic systems as they directly convert electrical energy to mechanical motion without the energy losses associated with hydraulic fluid pumping, pressure maintenance, and leakage. This substitution significantly reduces overall power consumption.
5Device complexity
If brushless motor is used without positioning control, then simple structure is maintained, but positioning precision is insufficient
Solution Approach 1:
The patent incorporates a Hall sensor that provides real-time feedback on the rotational position of the brushless motor to the motor controller. This feedback mechanism enables the controller to precisely control the motor's rotation and stop position, achieving accurate positioning of the ball screw without requiring complex mechanical positioning structures. The feedback loop allows for closed-loop control that ensures precise positioning while maintaining relatively simple overall system architecture.
6Device complexity
If brushless motor is used without control system, then device complexity is reduced, but control accuracy in high-speed scenarios is insufficient
Solution Approach 1:
The patent implements a control system with Hall sensor feedback that continuously monitors motor rotation and provides real-time position information to the motor controller. This feedback enables precise control of the brushless motor during high-speed operation, ensuring accurate positioning of the ball screw even under dynamic conditions. The control system maintains simplicity while achieving high control accuracy through intelligent feedback-based motor control algorithms.
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
Enables precise and reliable steering and positioning control in high-speed special working scenarios, reducing motor failure risks and improving control accuracy through combined Hall sensor and switch signal feedback.
Implementation Method 1
The Hall sensor is configured to detect a revolution of the brushless motor body in real time
Implementation Method 2
a motor controller, a brushless motor body, a steering cylinder... The motor controller is electrically connected to the brushless motor body, the brushless motor body is in meshing connection with the steering cylinder
Data Source
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AI summary
The present invention discloses a brushless motor and a positioning and steering control method thereof, and an aerial work vehicle. The brushless motor comprises a motor controller, a brushless motor body, a steering cylinder, a Hall sensor, a first micro limit switch and a second micro limit switch. The first and second micro limit switches are disposed at first and second stroke positions of a ball screw in the steering cylinder, respectively, and are both communicatively connected with the motor controller. Upon receiving the switch signals output by the first and second micro limit switches, the motor controller respectively controls the brushless motor body to stop driving the ball screw to move in a first direction or a second direction. The Hall sensor detects a revolution of the brushless motor body in real time, and sends the revolution to the motor controller. The motor controller also controls the brushless motor body to stop driving the ball screw to move in the first direction or second direction when the revolution reaches a first preset revolution or a second preset revolution, wherein the first preset revolution is determined according to the first stroke and a preset ball screw motion relationship, and the second preset revolution is determined according to the second stroke and the preset ball screw motion relationship.