Drive Sensor Integration Without Galvanic Isolation
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Solution Overview
Problem
Existing drive systems for electric motors require galvanic isolation between sensor electronics and signal electronics, leading to increased complexity and cost, while also necessitating additional components and potential electrical breakdowns due to high potential differences.
Innovation Solution
The drive system eliminates galvanic isolation by directly connecting sensor signals to signal electronics at the same potential, using an insulating means between the scale and sensor to maintain electrical insulation, allowing for a compact and cost-effective design without additional bearings, and utilizing a sensor with Hall and Wiegand sensors integrated into the motor housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If galvanic isolation is implemented between sensor electronics and signal electronics, then electrical insulation is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the galvanic isolation components from the system. By directly connecting the sensor electronics to the signal electronics without isolation barriers, the patent removes the complexity and cost associated with galvanic isolation while maintaining system functionality through alternative insulation approaches.
Solution Approach 2:
The patent merges the sensor electronics and signal electronics into a single potential domain, eliminating the need for galvanic isolation. The sensor chip is integrated directly with the controller, sharing the same electrical potential, which simplifies the overall system architecture while maintaining reliability through careful design of the integration interface.
2Reliability
If galvanic isolation components are used, then electrical insulation is improved, but manufacturing cost increases
Solution Approach 1:
The patent removes galvanic isolation components from the manufacturing process, eliminating their associated costs. The direct integration approach simplifies the bill of materials and manufacturing steps while maintaining electrical insulation through alternative means such as integrated circuit design and potential management.
Solution Approach 2:
The integrated sensor chip serves its own insulation needs through its internal design. The sensor electronics are configured to operate at the same potential as the signal electronics, with insulation requirements handled internally by the integrated circuit design rather than requiring separate isolation components.
3Volume of moving object
If distance between measuring standard and sensor is reduced for compactness, then device volume is reduced, but electrical breakdown risk increases
Solution Approach 1:
The patent merges the sensor and measuring standard into a closely integrated arrangement where they share the same electrical potential. This eliminates the electrical breakdown risk that would normally constrain the distance between components, as there is no potential difference across the small gap. The compact design is achieved through this potential unification rather than relying on large insulation distances.
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 configuration enables a compact, cost-effective design with improved electrical insulation, eliminating the need for galvanic isolation and associated time delays, allowing for precise pulse-width-modulated control signals and enhanced angular position detection within the motor.
Implementation Method 1
the magnetic fields penetrate the insulating material essentially undisturbed
Implementation Method 2
an insulating means, in particular for electrical insulation, is arranged between the scale and the sensor
Implementation Method 3
the sensor includes sensor electronics, ie a printed circuit board equipped with electronic components, which processes signals from the Hall sensors
Implementation Method 4
processes signals from the Hall sensors and Wigand sensors included in the sensor electronics
Data Source
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AI summary
The invention relates to a drive comprising an inverter-fed electric motor on which is arranged a sensor for detecting the angle position of a shaft, in particular a rotor shaft, of the electric motor. According to the invention, the inverter has a signal electronics, comprising essentially a controller, and a power electronics, comprising essentially an inverter feeding the motor, wherein the sensor signals are fed to the signal electronics, essentially in a direct manner and thus without galvanic separation.