Brushless Switchgear Motor Control for Relay-Free Reversing
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Solution Overview
Problem
Conventional motor devices in high-voltage switchgear suffer from complex structures, unsound functions, short carbon brush service life, electrical sparks, inflammability, excessive noise, and low efficiency, particularly in controlling forward and reverse rotation which requires complex relay control loops.
Innovation Solution
A motor device comprising a DC brushless motor with a microprocessor-controlled semiconductor switch, a gear transmission system, and a clutch with a pin shaft for energy storage and power cutoff, integrated with a communication module for efficient control and communication, eliminating mechanical commutation and open flames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional brush motors (DC permanent magnet motors or series-excited motors) are used, then the motor can operate in high-voltage switchgear, but the structure becomes complicated and requires auxiliary electronic and electrical devices (relays, rectifier bridges, position switches)
Solution Approach 1:
The patent replaces the mechanical commutation system (carbon brushes and commutators) with an electronic commutation system using Hall sensors and transistors. This substitution eliminates the need for mechanical contact components while achieving the same function of commutation, thereby reducing structural complexity and improving reliability.
Solution Approach 2:
The patent integrates multiple functions into a single brushless DC motor system, including commutation control, position sensing, and speed regulation, all managed by a microcontroller. This multi-functionality eliminates the need for separate auxiliary devices like relays and position switches, reducing overall device complexity.
2Ease of manufacture
If carbon brush motors are used, then the motor can provide mechanical commutation, but the carbon brush has limited service life and produces electrical sparks and inflammability
Solution Approach 1:
The patent replaces the mechanical commutation system (carbon brushes and commutators) with an electronic commutation system using Hall sensors and transistors. This substitution eliminates the need for mechanical contact components while achieving the same function of commutation, thereby reducing structural complexity and improving reliability.
Solution Approach 2:
The patent extracts and removes the carbon brush commutation system from the motor design, eliminating the source of sparks and limited service life. The essential commutation function is retained through electronic means, while the harmful mechanical contact components are completely removed.
3Ease of operation
If conventional brush motors are used, then the motor can be controlled, but it produces excessive noise and has low motor efficiency
Solution Approach 1:
The patent replaces the mechanical commutation system (carbon brushes and commutators) with an electronic commutation system using Hall sensors and transistors. This substitution eliminates the need for mechanical contact components while achieving the same function of commutation, thereby reducing structural complexity and improving reliability.
Solution Approach 2:
The patent changes the operating parameters of the motor by using electronic commutation to achieve more precise control over current waveform and timing. This allows for optimized motor operation at different speeds and loads, improving overall efficiency and reducing noise compared to mechanical commutation systems.
4Ease of operation
If relay control loop is used for forward and reverse rotation, then the motor direction can be controlled, but the control device becomes complicated structurally and costly
Solution Approach 1:
The patent integrates multiple functions into a single brushless DC motor system, including commutation control, position sensing, and speed regulation, all managed by a microcontroller. This multi-functionality eliminates the need for separate auxiliary devices like relays and position switches, reducing overall device complexity.
Solution Approach 2:
The patent replaces the mechanical commutation system (carbon brushes and commutators) with an electronic commutation system using Hall sensors and transistors. This substitution eliminates the need for mechanical contact components while achieving the same function of commutation, thereby reducing structural complexity and improving reliability.
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
The solution provides a long-lasting, high-efficiency motor with reduced noise and vibration, capable of continuous operation for over 5,000 hours, achieving 70% efficiency and smooth speed regulation, while simplifying the system and reducing costs.
Implementation Method 1
a DC brushless motor, comprising a rotor and a stator; the rotor is sleeved in the stator and mounted in a motor housing
Implementation Method 2
both ends of the rotor are respectively sleeved with a rolling bearing, and the bearing is sleeved on a motor drive shaft
Implementation Method 3
the decelerator comprises a gear transmission system composed of a plurality of mutually meshing gears as well as an output shaft
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A motor apparatus for a high voltage switch device, comprising a brushless DC motor (20), a drive and control apparatus (30), and a speed reduction apparatus (40). The brushless DC motor (20) comprises a rotor (202) and a stator (203). The rotor (202) is sleeved in the stator (203) and mounted in a motor housing (201). Two ends of the rotor (202) are respectively sleeved with rolling bearings (204), and the bearings (204) are sleeved on a motor drive shaft (208). The drive and control apparatus (30) comprises a microprocessor (301), a semiconductor switch (302), and a power supply module (303) for powering the microprocessor (301). The microprocessor (301) controls the start, stop, and forward and reverse rotation of the brushless DC motor (20) via the semiconductor switch (302). The speed reducer (40) comprises a gear transmission system (401) composed of a plurality of mutually meshing gears as well as an output shaft (402). The gear transmission system (401) transmits motion of the motor drive shaft (208) to the output shaft (402).