Dual PCB Encoder Layout for Verified Electric Motor Braking
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Solution Overview
Problem
Existing electric motor systems face safety concerns due to single points of failure in braking mechanisms and require separate certification of multiple encoders, increasing time and expense, and assume matching reporting signals without verification.
Innovation Solution
A dual encoder system with first and second encoders on a single printed circuit board, using a single magnet, where each encoder generates feedback information for a motor controller and a safety controller, allowing independent verification and progressive multi-stage braking of the electric motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple encoders are used for motor control and safety monitoring, then safety and reliability are improved, but device complexity and certification cost increase
Solution Approach 1:
The patent combines two separate encoders into a single integrated encoder unit that provides both motor control feedback and safety monitoring feedback. This merging reduces device complexity and eliminates the need for separate certification of multiple encoder units while maintaining the reliability benefits of dual encoder functionality.
Solution Approach 2:
The integrated encoder is designed to serve multiple functions: it generates both motor control feedback signals and safety monitoring feedback signals from a single unit. This multi-functionality allows one encoder to replace what would traditionally require two separate encoders, reducing overall system complexity while maintaining safety and reliability.
2Reliability
If separate encoders are used for motor controller and safety controller, then independent feedback is achieved, but certification time and expense increase
Solution Approach 1:
The patent merges two separately certified encoder units into a single integrated encoder that provides independent feedback channels to both the motor controller and safety controller. This single unit certification approach eliminates the need for separate certification processes while maintaining the independence and reliability of feedback channels.
3Device complexity
If a single integrated encoder system is used, then device complexity and certification cost are reduced, but safety verification capability may be compromised
Solution Approach 1:
The integrated encoder is designed with segmented independent feedback channels that provide separate output signals to the motor controller and safety controller. This internal segmentation ensures that while the physical unit is integrated, the feedback paths remain independent, maintaining safety verification capability without requiring separate encoder units.
Solution Approach 2:
The system implements dual feedback channels from the integrated encoder - one channel provides feedback to the motor controller for normal operation, and another channel provides independent feedback to the safety controller for safety monitoring and verification. This dual feedback structure ensures that safety verification capability is maintained even with an integrated encoder design.
Data Source
AI summary
A dual encoder system includes first and second encoders on a single printed circuit board mounted on an electric motor. Each encoder independently generates feedback information used by motor and safety controllers for controlling the motor. A single magnet is mounted on the motor shaft. The first encoder cooperates with the magnet to provide first encoder information to the motor controller regarding magnetic alignment between a rotor and a plurality of stator windings of the motor and regarding real-time position and velocity. The second encoder cooperates with the same magnet to provide second encoder information to a safety controller, wherein the second encoder information should be identical to the first. The safety controller may receive the first encoder information from the motor controller, compare the second encoder information to the first encoder information, and brake the electric motor if the second encoder information is different from the first encoder information.