ECM Torque Calibration Using Legacy Motor Interpolation Mapping

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Solution Overview

Problem

Existing ECM motors from different manufacturers exhibit significant variations in constant torque performance due to disparities in motor material properties, drive hardware, and manufacturing processes, making it difficult to replace legacy motors with new ones that match the original performance.

Innovation Solution

A method involving selecting torque reference points from the legacy motor to form a desired torque value array, identifying corresponding torque adjustment points in the new motor, and using a linear interpolation module to calibrate the new motor's torque to match the legacy motor's performance, employing a piecewise linear interpolation method.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a new ECM motor is developed to replace a legacy motor, then the new motor can incorporate new technologies and materials, but the constant torque performance will differ from the original motor

Engineering Contradiction:

Improveability to incorporate new motor technologiesVSAvoidconstant torque performance consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by systematically adjusting motor control parameters (current limits, torque constants, flux linkage values) to compensate for differences in motor materials and construction. Through calibration processes, the control parameters are optimized to achieve matching constant torque performance between new and legacy motors, allowing technological updates while maintaining performance consistency.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If secondary development is performed to re-engineer a new motor to emulate legacy motor performance, then the new motor can be customized, but the development time and cost increase significantly

Engineering Contradiction:

Improvetorque performance matchingVSAvoidproject development timeline

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent employs copying by creating a calibration framework that replicates the legacy motor's torque characteristics through parameter adjustment rather than complete re-engineering. The calibration process copies the performance behavior of the original motor by mapping its torque curve and adjusting the new motor's control parameters to match, significantly reducing development time while maintaining performance fidelity.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent applies preliminary action by establishing a calibration framework and parameter mapping methodology before full-scale production. The calibration process pre-determines the optimal parameter adjustments needed to match legacy motor performance, allowing new motors to be quickly configured and deployed without extensive trial-and-error development cycles.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If traditional current control methods are used for constant torque applications, then the control algorithm is simple, but stringent tolerances on component parts are required to achieve consistent performance

Engineering Contradiction:

Improvecontrol algorithm simplicityVSAvoidcomponent part tolerances

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent implements feedback by using measured torque data from the legacy motor to calibrate the new motor's control parameters. The calibration process involves measuring actual torque output at various operating points and adjusting control parameters based on this feedback to achieve matching performance. This feedback-based calibration compensates for component variations without requiring stringent manufacturing tolerances.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS20260066833A1Method for calibrating constant torque of electronically commutated motor

Publication Date: 2026.03.05 ZHONGSHAN BROAD OCEAN

AI summary

A method for calibrating constant torque of an ECM motor. The method is applied to replacing a legacy motor with a new motor. The method includes: a) selecting m torque reference points based on torque values of the legacy motor to form a desired torque value array LUT_X[m], where m is an integer≥3; b) based on an actual torque of the new motor, identifying m torque adjustment points, where torque values of the torque adjustment points have a one-to-one correspondence with torque values of the torque reference points, to form a new target torque value array LUT_Y[m]; and c) receiving an externally input target torque T0, invoking a linear interpolation module function associated with the desired torque value array LUT_X[m] and the new target torque value array LUT_Y[m] to obtain a corresponding new torque target value T1, and allowing the new motor to operate under T1.