Cleaner and control method thereof
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Solution Overview
Problem
Vacuum cleaners with BrushLess Direct Current (BLDC) motors face start-up failures due to cogging torque and require energy-efficient operation to meet new energy regulation standards, which existing technologies have not adequately addressed.
Innovation Solution
The vacuum cleaner employs a control method that supplies rearrangement power to align the rotor without detecting its position, followed by start-up power, and adjusts energy supply based on cleaning detection to minimize energy consumption, using a combination of hall sensors, contact sensors, and current sensors to determine cleaning activity and adjust power accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a BLDC motor uses permanent magnets as a rotor, then the motor efficiency is improved and brush replacement is eliminated, but cogging torque is generated causing start-up failures
Solution Approach 1:
The controller supplies rearrangement power to the motor before normal operation to rotate the rotor to a proper position, eliminating the harmful effect of cogging torque that would otherwise cause start-up failure. This preliminary action ensures the rotor is in a favorable position before the motor begins its intended operation.
2Reliability
If the rotor position is detected using a position sensor, then the start-up control is improved, but the device complexity increases
Solution Approach 1:
The invention extracts and eliminates the need for a position sensor by using a simplified control approach. Instead of detecting rotor position with additional sensors, the controller uses a predetermined rearrangement power supply method that works effectively without position feedback, thereby reducing device complexity while maintaining start-up reliability.
3Productivity
If the vacuum cleaner operates continuously to maintain suction force, then cleaning effectiveness is improved, but energy consumption increases
Solution Approach 1:
The controller periodically monitors cleaning state through sensing units and adjusts motor operation accordingly. The motor operates at full power when cleaning is detected and reduces power or stops when cleaning is not performed, creating a periodic on-demand operation pattern that maintains cleaning effectiveness while reducing overall energy consumption.
4Reliability
If the motor is started with high power to overcome cogging torque, then start-up reliability is improved, but energy consumption increases
Solution Approach 1:
The controller supplies rearrangement power that is sufficient to overcome cogging torque and rotate the rotor to a proper position, but not excessively high. This partial action approach provides just enough power for reliable start-up without the energy waste of continuous high-power operation, optimizing the balance between start-up reliability and energy consumption.
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 reduces start-up failures and minimizes energy consumption by ensuring the rotor is properly aligned before starting and by reducing power usage when not in use, enhancing the efficiency and reliability of the vacuum cleaner.
Implementation Method 1
a sensing unit including a hall sensor to detect a position of the rotor
Implementation Method 2
a driving unit including a motor including a rotor and a stator
Data Source
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Figure 2
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AI summary
Disclosed herein are a cleaner and a control method thereof. The control method of the cleaner includes: supplying predetermined rearrangement power to a motor for a predetermined time period; detecting a position of a rotor using a hall sensor; and supplying start-up power according to the detected position of the rotor.