DC Motor Torque Boost Circuit for Ice Obstruction
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Solution Overview
Problem
Current DC motor designs, particularly in automotive applications like electronic throttle control (ETC) valves, require larger motors to handle peak torque needs due to obstructions like ice, leading to increased costs, weight, and packaging issues, as they need to generate high torque intermittently to overcome resistance.
Innovation Solution
A DC motor control circuit with a bipolar motor driver, a capacitor, and a switch in parallel, along with a motor monitor that senses torque deficiencies and momentarily increases torque by charging the capacitor and switching its polarity to provide a peak voltage boost when needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a larger motor is used to generate high torque for ice breaking, then the motor can overcome resistance imposed by ice obstructions, but the cost, weight, and packaging difficulty increase
Solution Approach 1:
The capacitor is pre-charged to a voltage equal to the motor driver voltage before the motor needs high torque. When ice breaking is detected, the pre-charged capacitor is connected in parallel with the motor driver, immediately providing the voltage boost needed for high torque without waiting for energy accumulation
Solution Approach 2:
The circuit changes the voltage parameter applied to the motor by switching from normal operating voltage to doubled voltage (Vmotor + Vcapacitor) when ice breaking is detected. This parameter change enables the motor to generate twice its normal torque temporarily, overcoming ice obstructions without requiring a physically larger motor
2Force
If a larger motor is used to generate high torque for ice breaking, then the motor can overcome resistance imposed by ice obstructions, but the cost increases
Solution Approach 1:
The capacitor is pre-charged to a voltage equal to the motor driver voltage before the motor needs high torque. When ice breaking is detected, the pre-charged capacitor is connected in parallel with the motor driver, immediately providing the voltage boost needed for high torque without waiting for energy accumulation
Solution Approach 2:
The circuit changes the voltage parameter applied to the motor by switching from normal operating voltage to doubled voltage (Vmotor + Vcapacitor) when ice breaking is detected. This parameter change enables the motor to generate twice its normal torque temporarily, overcoming ice obstructions without requiring a physically larger motor
3Force
If a larger motor is used to generate high torque for ice breaking, then the motor can overcome resistance imposed by ice obstructions, but packaging difficulty increases
Solution Approach 1:
The capacitor is pre-charged to a voltage equal to the motor driver voltage before the motor needs high torque. When ice breaking is detected, the pre-charged capacitor is connected in parallel with the motor driver, immediately providing the voltage boost needed for high torque without waiting for energy accumulation
Solution Approach 2:
The circuit changes the voltage parameter applied to the motor by switching from normal operating voltage to doubled voltage (Vmotor + Vcapacitor) when ice breaking is detected. This parameter change enables the motor to generate twice its normal torque temporarily, overcoming ice obstructions without requiring a physically larger motor
4Use of energy by moving object
If the capacitor is charged during normal operation, then the capacitor accumulates energy for ice breaking, but the charging time increases the response delay
Solution Approach 1:
The capacitor is pre-charged to a voltage equal to the motor driver voltage before the motor needs high torque. When ice breaking is detected, the pre-charged capacitor is connected in parallel with the motor driver, immediately providing the voltage boost needed for high torque without waiting for energy accumulation
Solution Approach 2:
The capacitor charging and discharging operates in periodic cycles: charging during normal operation at a reduced rate, then rapidly discharging when ice breaking is detected. The motor monitor continuously monitors motor current to detect ice breaking conditions and triggers the capacitor discharge at the precise moment needed
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 solution allows for a momentary doubling of motor torque to overcome obstructions without the need for larger motors, reducing costs, weight, and improving packaging efficiency by providing sufficient torque only when required.
Implementation Method 1
a parallel combination of a capacitor and a switch with a first terminal of the parallel combination coupled directly to a second terminal of the bipolar voltage source and a second terminal of the parallel combination coupled to a second terminal of the motor
Implementation Method 2
DC motor control circuit includes a bipolar motor driver which has a first terminal thereof coupled to a first terminal of the motor
Data Source
AI summary
A motor control circuit for supplying power to a DC motor which drives a mechanism having a driven shaft, the control circuit having a parallel combination of a capacitor and switch in series with the DC motor. When the movement of the driven shaft is obstructed, the motor driver and the switch are synchronized in a manner to first charge the capacitor and then to reverse the voltage generated by the motor driver to momentarily double the voltage applied to the DC motor so that the increased torque of the DC motor is able to overcome the obstruction. The mechanism having a shaft driven by the DC motor may be, for example, an ETC valve or a window regulator.