Integrated Controller Assembly for Accurate Overheating State Estimation
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Solution Overview
Problem
Existing condition monitoring systems struggle to accurately detect when devices, such as motors and generators, are at risk of overheating, leading to potential damage, failure, and malfunctions.
Innovation Solution
A device assembly with a temperature measurement controller that performs state estimation calculations using data from temperature and current measuring instruments, allowing for more accurate determination of overheating risks and triggering appropriate operational adjustments or shutdowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional temperature monitoring is used to detect overheating risks, then the monitoring system is simple, but the detection accuracy is insufficient leading to potential false negatives
Solution Approach 1:
The patent combines multiple monitoring functions (temperature monitoring, current monitoring, and state estimation) into a single integrated controller. This merging approach improves overheating detection accuracy by consolidating data from multiple sources while avoiding the complexity of multiple separate systems, as the controller processes all inputs through a unified state estimation algorithm.
Solution Approach 2:
The patent introduces a state estimation algorithm as an intermediary between raw sensor data and overheating detection decisions. This intermediary processes temperature and current measurements to calculate a comprehensive state estimate, improving detection accuracy by considering both direct temperature readings and indirect thermal conditions inferred from current levels, rather than relying on temperature sensors alone.
2Reliability
If temperature monitoring alone is used, then the system is simple, but it cannot accurately trigger shutdown at given times preventing failure
Solution Approach 1:
The patent implements a feedback mechanism where the controller continuously monitors both temperature and current, calculates state estimates, and adjusts device operation based on the inferred thermal conditions. This feedback loop improves reliability by triggering shutdowns based on comprehensive state estimation rather than simple temperature thresholds, accounting for both direct and indirect thermal indicators.
Solution Approach 2:
The patent performs preliminary state estimation calculations using current measurements to predict thermal conditions before actual overheating occurs. By analyzing current levels and inferring thermal states in advance, the system can trigger preventive shutdowns before damage occurs, improving reliability without requiring complex real-time temperature monitoring alone.
3Measurement precision
If multiple measuring instruments are used to generate comprehensive data, then the measurement accuracy improves, but the data processing complexity increases
Solution Approach 1:
The patent designs the controller to perform multiple functions: temperature monitoring, current monitoring, state estimation calculations, and shutdown control. This multi-functionality approach handles comprehensive data from multiple measuring instruments within a single processing framework, improving measurement precision while managing complexity through unified rather than separate processing paths.
Solution Approach 2:
The patent transforms raw measurement data (temperature and current) into a meaningful state estimate parameter that represents thermal conditions. This parameter transformation simplifies data processing by converting multiple raw inputs into a single comprehensive indicator that directly informs shutdown decisions, reducing processing complexity while maintaining high measurement precision.
Data Source
AI summary
A device assembly has one or more controllers that improve monitoring the condition of a device so that risks to the device are reduced. A controller of the device assembly calculates a state estimate of a device for a given time by performing a state estimation calculation based on data from a measuring instrument coupled to the device. The state estimate improves monitoring whether the device is at risk so that the controller can more accurately trigger the device to modify operation before failure, damage, and/or malfunctions of the device occurs. A controller of the device assembly more effectively monitors the condition of the device by merging data from one or more measuring instruments coupled to the device, and performing any state estimation calculation, such as to calculate a state of health estimate. The controller and measuring instrument are included in a system-in-package.