Electric Valve Stepper Motor Positioning via Stator Waveform Feedback
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Solution Overview
Problem
Existing electric valve control devices require a long initialization operation duration and generate excessive noise due to repeated collisions of the movable stopper with the fixed stopper during rotor positioning, particularly when the rotor is near the reference position.
Innovation Solution
An electric valve control device that determines the rotation restricted state of the rotor based on the waveform of the voltage or current generated in the stator, using a state determiner to identify when the rotor is at the reference position, thereby stopping further rotation and reducing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the electric valve control device inputs pulses to the stepping motor until the number of pulses reaches the initialization number, then the rotor is positioned at the reference position, but the initialization operation duration becomes long and noise is generated due to repeated collisions of the movable stopper with the fixed stopper
Solution Approach 1:
The control device monitors the voltage generated in the stator during rotor rotation and uses this feedback signal to detect when the rotor reaches the reference position. By comparing the measured voltage waveform characteristics (area, amplitude, periodic patterns) against expected patterns, the system dynamically determines when to stop pulse input, replacing the fixed initialization number approach with an adaptive feedback-based stopping condition that reduces unnecessary operation time
Solution Approach 2:
The patent replaces the purely mechanical stopper-based position detection method with an electrical sensing method. Instead of relying on mechanical collision between the movable stopper and fixed stopper to indicate position, the system uses voltage generation in the stator (electromagnetic induction) to detect rotor position, thereby eliminating the harmful mechanical collisions while maintaining positioning accuracy
2Ease of operation
If pulses are input to the stepping motor after the rotor is positioned at the reference position, then the rotor continues to rotate, but the movable stopper repeatedly collides with the fixed stopper causing noise
Solution Approach 1:
The control device continuously monitors the voltage generated in the stator and uses this feedback to detect the rotation restricted state. When the voltage waveform characteristics indicate that the rotor has reached the reference position (through area comparison, amplitude analysis, or periodic pattern recognition), the system automatically stops pulse input, preventing further rotation and the associated stopper collisions that generate noise
Solution Approach 2:
The patent replaces mechanical collision-based position indication with electrical voltage signal-based detection. By using the voltage generated in the stator during rotor rotation to determine positioning status, the system eliminates the need for repeated mechanical collisions between stoppers, thereby suppressing noise while maintaining operational simplicity
3Manufacturing precision
If the rotor is near the reference position immediately before the initialization operation, then positioning is nearly complete, but the noise lasts a long time due to continued pulse input and repeated stopper collisions
Solution Approach 1:
The control device uses voltage waveform feedback from the stator to detect when the rotor is near or at the reference position. By analyzing characteristics such as the area of the voltage waveform, amplitude of periodic waves, or appearance of new distinct waves, the system can identify the rotation restricted state and stop pulse input promptly, preventing prolonged noise even when the rotor starts near the reference position
Solution Approach 2:
The patent replaces mechanical collision detection with electrical voltage signal detection to determine rotor position. This substitution allows the system to recognize when the rotor has reached the reference position without relying on mechanical stopper collisions, thereby eliminating prolonged noise while maintaining precise positioning
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
The solution reduces the duration of the initialization operation and suppresses long-lasting noise by accurately determining the rotor's state using waveform analysis, ensuring precise positioning without unnecessary rotor movement.
Implementation Method 1
voltages that are generated in stators by rotations of rotors (voltages induced in stators due to electromagnetic induction)
Data Source
AI summary
An electric valve control device inputs a pulse to a stepping motor to rotate a rotor in a first direction. The electric valve control device obtains a voltage generated in a stator by rotation of the rotor. The electric valve control device determines whether an electric valve is in a first-rotation restricted state where the rotation of the rotor in the first direction is restricted, based on a degree of difference between a waveform of the voltage and a reference waveform of the voltage.