Compressor Motor Controller Lifetime Monitoring via Load Switching
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Solution Overview
Problem
Existing methods for monitoring the remaining lifetime of semiconductor elements in motor control systems are inefficient due to high computational loads and are not applicable to all types of industrial equipment that use motors, as they rely on estimating temperature changes and calculating various values, which can lead to errors and are not adaptable to different motor control methods and timing variations.
Innovation Solution
A compressor system that includes a motor control system with a motor controller and a running controller, which calculates the relative temperature of semiconductor elements using temperature sensors and pressure sensors to monitor the remaining lifetime by switching between load and no-load running, reducing processing load and enhancing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature change is estimated based on output current and multiple calculations are performed, then monitoring of remaining lifetime is achieved, but calculation amount increases and error of estimated lifetime increases
Solution Approach 1:
The patent extracts only the essential temperature information needed for lifetime monitoring by directly sensing temperature at switching moments, rather than performing multiple complex calculations based on current. This reduces computational complexity while maintaining monitoring capability.
Solution Approach 2:
The patent replaces the computational approach (estimating temperature from current) with a direct sensing approach (measuring temperature directly at critical moments). This substitution eliminates the need for complex calculations and reduces error accumulation.
2Reliability
If temperature change is estimated based on output current, then remaining lifetime monitoring is achieved, but precision of remaining lifetime monitoring decreases
Solution Approach 1:
The patent replaces indirect temperature estimation through current calculations with direct temperature sensing using temperature sensors. This direct measurement approach significantly improves precision by eliminating estimation errors and calculation inaccuracies.
Solution Approach 2:
The patent performs temperature sensing at predetermined critical moments (when switching from no-load to load running) before degradation occurs. This timing-based approach ensures accurate capture of temperature stress events that most affect semiconductor lifetime.
3Reliability
If conventional monitoring method is used, then semiconductor element monitoring is achieved, but adaptability to different industrial equipment decreases
Solution Approach 1:
The patent creates a universal monitoring approach that works across different industrial equipment by focusing on the common element (semiconductor elements in motor control systems) and using generic sensing and evaluation methods that are not specific to any particular application.
Solution Approach 2:
The patent changes the monitoring parameter from application-specific operational parameters to universal semiconductor temperature and lifetime parameters. This allows the same monitoring methodology to be applied across different industrial equipment regardless of their specific functions.
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 monitors the remaining lifetime of semiconductor elements with reduced processing load and improved precision, making it suitable for various industrial equipment that use motors by utilizing relative temperature calculations during specific operational state changes.
Implementation Method 1
a temperature sensor that senses a temperature of the semiconductor element
Implementation Method 2
a pressure sensor that is provided on a discharge side of the compressor body, and senses a pressure of the compressed gas
Data Source
AI summary
A compressor, a monitoring system and a method of monitoring a compressor that make it possible to monitor the remaining lifetime of a semiconductor element of a motor control system while the processing load is reduced are provided. A compressor (1) includes: a motor control system (10) that controls the rotation speed of a motor (2); a compressor body (3) that compresses air by being driven by the motor (2); a pressure sensor (20) that is provided on the discharge side of the compressor body (3); and a running controller (11) that performs switching between load running and no-load running on the basis of the pressure sensed by the pressure sensor (20). A motor controller (26) of the motor control system (10) calculates a relative temperature of a semiconductor element relative to a reference temperature by using a temperature of the semiconductor element sensed by a temperature sensor (27) at the time of switching from no-load running to load running, and calculates an amount of change in a remaining lifetime of the semiconductor element corresponding to the relative temperature of the semiconductor element, whereby monitoring the remaining lifetime of the semiconductor element.