Dual-Channel Hall Sensor Layout for Redundant Rotor Position Sensing
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Solution Overview
Problem
Existing rotor location sensing apparatuses in motors are prone to failure due to single sensor failures, require additional structures for installation, and have limited sensing signal resolution, leading to economic losses and imprecise rotor location detection.
Innovation Solution
The apparatus employs a dual-channel sensing configuration with first and second sensors disposed at specific angles relative to the sensing magnet, allowing continued operation even with sensor failures and enhancing signal resolution without additional structures, utilizing Hall sensors to generate continuous sensing signals for U-, V-, and W-phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single sensor is used for rotor location sensing, then the device complexity is reduced, but the reliability deteriorates because the entire apparatus fails when one sensor fails
Solution Approach 1:
The patent combines multiple sensing functions into a single integrated sensor unit. The single sensor incorporates multiple sensing elements that can detect rotor location through different sensing channels, allowing the system to maintain operation even when one sensing element fails. This merging approach improves reliability without proportionally increasing device complexity.
Solution Approach 2:
The patent changes the sensing parameters by using a single sensor capable of detecting multiple magnetic field parameters simultaneously. By monitoring different magnetic field characteristics through the same sensor, the system achieves redundant sensing capability without adding multiple separate sensors, thus improving reliability while controlling complexity.
2Measurement precision
If additional sensors are added to increase sensing resolution, then the measurement precision is improved, but the device complexity and space requirements increase
Solution Approach 1:
The patent transitions from spatial multiplication (adding more sensors in different locations) to functional multiplication (enabling a single sensor to perform multiple sensing functions). By utilizing different sensing channels and measurement dimensions within the same sensor, the system achieves higher measurement precision without increasing physical complexity or space requirements.
Solution Approach 2:
The single sensor is designed with multi-functional capability to perform multiple sensing tasks. It can detect rotor location through different magnetic field parameters and sensing modes, effectively replacing what would traditionally require multiple specialized sensors. This universality improves measurement precision while avoiding the complexity of arranging multiple sensors.
3Reliability
If sensors are additionally installed in a different region, then the sensing coverage is improved, but the ease of operation deteriorates due to separate installation requirements
Solution Approach 1:
The patent merges multiple sensing functions into a single sensor unit that can be installed in one location. This single sensor incorporates the capability to provide comprehensive sensing coverage that would otherwise require multiple sensors distributed across different regions. The merging approach maintains reliable sensing coverage while dramatically simplifying installation operations.
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
Enables accurate rotor location sensing with increased signal resolution and operational redundancy on existing printed circuit boards, reducing economic losses and improving motor precision.
Implementation Method 1
the sensor grasps a present location of the rotor by sensing a magnetic force of the sensing magnet installed to be rotatable in conjunction with the rotor
Data Source
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AI summary
The present invention provides an apparatus for sensing rotor location, the apparatus comprising: a sensing magnet; and a substrate arranged above the sensing magnet, wherein the sensing magnet comprises a main magnet and sub-magnet, the substrate comprises a first sensor and second sensor arranged along the same circular path with respect to the center of the sensing magnet, the first sensor comprises a plurality of first hole sensors adjacent to each other on the circular path, the second sensor comprises a plurality of second hole sensors adjacent to each other on the circular path, the plurality of first hole sensors are arranged separated by a first angle along the circumference of the circular path, the plurality of second hole sensors are arranged separated by the first angle along the circumference of the circular path, and the adjacent first hole sensor and second hole sensor are arranged separated by a second angle different from the first angle along the circumference of the circular path.