Embedded Solid State Controller for Industrial Electrical Machines
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Solution Overview
Problem
Industrial electrical machines often require complex and bulky control systems, which can complicate installation and operation, especially in harsh environments, and lack integrated solutions for efficient cooling and diagnostics.
Innovation Solution
An industrial electrical machine with an embedded solid state controller that integrates power semiconductor switching devices, communication interfaces, and diagnostic capabilities, allowing direct connection to the power grid without intermediate contactors and providing advanced control, monitoring, and cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional control systems are used in industrial electrical machines, then control functionality is provided, but device complexity and installation complexity increase
Solution Approach 1:
The patent embeds the solid state controller directly into the electrical machine, merging the control system with the motor assembly. This integration eliminates the need for separate control panels and intermediate contactors, reducing device complexity while maintaining full control functionality. The controller is housed within the machine's existing structure, combining multiple functions into a single unified system.
Solution Approach 2:
The embedded solid state controller performs multiple functions including power switching, diagnostics, protection, and communication within a single device. This multi-functional approach replaces what would traditionally require multiple separate components (contactors, relays, control panels), thereby reducing overall system complexity while preserving comprehensive control capabilities.
2Reliability
If intermediate contactors are used for power switching, then reliable power control is achieved, but device complexity and number of components increase
Solution Approach 1:
The patent extracts the power switching function from external intermediate contactors and integrates it directly into the embedded solid state controller. This eliminates the need for separate contactor components while maintaining reliable power control through the controller's integrated power semiconductor switching devices, thereby reducing the total number of components in the system.
Solution Approach 2:
The controller merges power switching, control logic, and protection functions into a single integrated unit, replacing the traditional distributed architecture of multiple contactors and control devices. This consolidation maintains reliable power control while significantly reducing device complexity and component count.
3Temperature
If separate cooling systems are provided for motor and controller, then cooling effectiveness is maximized, but device complexity increases
Solution Approach 1:
The patent combines the cooling functions for both the motor and the embedded controller into a single integrated cooling system. The controller is positioned to utilize the motor's existing cooling airflow, eliminating the need for a separate cooling system for the controller. This merged approach maintains effective temperature control for both components while reducing overall system complexity.
Solution Approach 2:
The embedded controller is positioned and designed to utilize the motor's own cooling airflow for its thermal management. The controller's heat dissipation is integrated into the motor's cooling circuit, allowing the motor's cooling system to serve dual purposes - cooling both the motor windings and the embedded controller, thereby eliminating redundant cooling components.
4Ease of operation
If conventional control panels are used, then control functionality is provided, but installation time and complexity increase
Solution Approach 1:
The patent merges the entire control panel functionality into the embedded solid state controller, which is integrated directly into the electrical machine. This eliminates the need for separate control panel installation, wiring, and configuration, thereby maintaining full control functionality while dramatically reducing installation time and complexity.
Solution Approach 2:
The control functions are segmented and integrated directly into the motor assembly rather than being housed in a separate control panel. This segmentation allows the control system to be installed as part of the motor itself, eliminating the need for separate control panel installation steps and reducing overall installation time.
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
Simplifies installation and operation by eliminating the need for conventional control panels, enhances reliability through integrated diagnostics and protection, and optimizes cooling for both the motor and controller, improving performance and efficiency in harsh industrial settings.
Implementation Method 1
the power semiconductor switching device is operative to provide switching during operation of the industrial electrical machine, and is operative to turn the electrical machine on and to turn the electrical machine off
Implementation Method 2
a thermal interface thermally coupling the controller and the frame
Implementation Method 3
a first cooling system operative to cool the stator and the rotor... optimized cooling for both the motor and controller
Data Source
AI summary
An industrial electrical machine includes a stator; a rotor in magnetic communication with the stator; a plurality of windings disposed in the rotor and/or the stator; and an embedded solid state controller. The solid state controller is operative to control the operation of the industrial electrical machine. The solid state controller includes a power semiconductor switching device coupled to the plurality of windings, and includes a communication interface. The power semiconductor switching device is operative to provide switching during operation of the industrial electrical machine, and is operative to turn the electrical machine on and to turn the electrical machine off in response to a control input received by the communication interface.