Circular Force Generator With Integrated Rotor Position Sensing
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Solution Overview
Problem
Existing vibration cancellation systems in machines are inefficient in counteracting unwanted vibrations due to the lack of precise control over rotor positions and eccentricities, leading to inconsistent and ineffective cancellation of vibrational forces.
Innovation Solution
A circular force generator with a self-contained positioning sensor assembly, comprising two rotors with eccentric bodies and a stator assembly, a central shaft, and a controller with an accelerometer and rotor-position sensor, which adjusts electrical currents to the stators to maintain counterbalance and optimize vibration cancellation forces by monitoring and adjusting rotor positions and speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rotor positions and speeds are not precisely monitored and adjusted, then the system structure remains simple, but vibration cancellation effectiveness deteriorates
Solution Approach 1:
The positioning sensor assembly is nested within the housing of the circular force generator, with the sensor assembly containing the sensor, magnet, and circuit board integrated into the motor structure. This nesting approach adds the necessary sensing capabilities while minimizing the increase in overall system complexity and size.
Solution Approach 2:
The system uses its own rotor position and speed information, obtained through the integrated sensor assembly, to automatically adjust and optimize its vibration cancellation performance. The controller uses feedback from the sensor to dynamically adjust rotor operations, enabling the system to self-optimize without external intervention.
2Measurement precision
If rotor positions are precisely controlled using sensor assemblies, then vibration cancellation precision is improved, but manufacturing complexity increases
Solution Approach 1:
The positioning sensor assembly is merged with the motor structure, sharing common components such as the housing, magnet, and circuit board. This merging reduces the number of separate parts that need to be manufactured and assembled, thereby reducing manufacturing complexity while maintaining precise measurement capabilities.
Solution Approach 2:
The magnet serves dual purposes: it is part of the motor's electromagnetic structure for generating rotational force and simultaneously serves as the sensing element for the positioning sensor assembly. This multi-functionality reduces the need for additional specialized components, simplifying manufacturing.
3Adaptability or versatility
If dynamic adjustment of rotor positions is implemented, then vibration cancellation adaptability is improved, but system complexity increases
Solution Approach 1:
The positioning sensor assembly provides real-time feedback on rotor position and speed to the controller, which dynamically adjusts the electrical current to the stator assembly. This feedback mechanism enables the system to adapt to varying vibration conditions while using a relatively simple control approach based on measured position data.
Solution Approach 2:
The system replaces complex mechanical positioning and adjustment mechanisms with an electromagnetic control system. By using electrical current control based on sensor feedback, the system achieves dynamic adaptability without requiring complex mechanical linkages or adjustment devices.
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 system effectively cancels vibrations by dynamically adjusting rotor positions and speeds, providing a consistent and adjustable vibration cancellation force in multiple directions, enhancing the stability and performance of mechanical assemblies.
Implementation Method 1
The rotor-position sensor assembly includes a magnet affixed to the rotor assembly and a sensor positioned on a circuit board
Implementation Method 2
The controller includes an accelerometer assembly and a rotor-position sensor assembly
Implementation Method 3
A controller delivers an electrical current to the stator assembly at least based upon the accelerometer assembly
Data Source
AI summary
A vibration-cancelling module includes a first rotor having a first eccentric body, a second rotor having a second eccentric body, and a stator assembly in electromagnetic communication with the first and second rotors. A central shaft extends between the first and second rotors. The first and second rotors rotationally operate about a common rotational axis with respect to one another between a balanced position and a plurality of eccentric positions. A controller has an accelerometer assembly and a rotor-position sensor assembly. The controller delivers an electrical current to the stator assembly at least based upon the accelerometer assembly. A common housing contains the first and second rotors, the stator assembly, the central shaft and the controller.