External Motor Control Module for Fan Assembly Back-EMF Detection
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Solution Overview
Problem
Traditional cooling fan assemblies require physical access to the motor housing to alter or replace fan electronics, including printed circuit boards (PCBs) with Hall-effect sensors, which limits flexibility and increases size due to the need to accommodate the PCB.
Innovation Solution
The implementation of external motor control modules that can be accessed and altered without opening the motor housing, eliminating the need for Hall-effect sensors and minimizing PCB size by integrating detection and control functions separately from the fan assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If Hall-effect sensors and PCBs are mounted inside the motor housing to control motor speed, then motor control functionality is achieved, but the fan assembly size increases and physical access is required for any electronic modifications
Solution Approach 1:
The control system is segmented into two parts: the motor housing containing only the motor, and a separate external control module containing the PCB and Hall-effect sensors. This segmentation allows the electronics to be accessed and modified independently without disassembling the motor housing, while the motor housing remains compact and simple.
Solution Approach 2:
The electronic control components (PCB and Hall-effect sensors) are extracted from the motor housing and placed in a separate external control module. This extraction eliminates the need to open the motor housing for electronic modifications and reduces the complexity of the motor housing structure.
2Reliability
If a PCB with Hall-effect sensors is mounted inside the motor housing, then motor position detection is achieved, but the fan assembly requires physical disassembly for sensor replacement or reprogramming
Solution Approach 1:
The system is divided into the motor unit and a separate control module unit. The Hall-effect sensors and PCB are located in the external control module, which can be accessed independently for maintenance or replacement without affecting the motor housing integrity.
Solution Approach 2:
The Hall-effect sensors and control electronics are extracted from the motor housing and placed in an externally accessible control module, enabling easy replacement and maintenance while maintaining motor control accuracy through preserved sensor-motor coupling via magnetic fields.
3Ease of manufacture
If the motor housing is designed to accommodate internal PCB mounting, then integrated control is achieved, but the overall fan assembly size increases
Solution Approach 1:
The control system is segmented into a compact motor housing and a separate external control module. The motor housing is optimized for motor components only, while the PCB and electronics are housed externally, allowing each component to be optimized for its specific function and reducing overall assembly volume.
Solution Approach 2:
The control electronics are moved from the internal three-dimensional space of the motor housing to an external location, utilizing additional spatial dimensions. This allows the motor housing to maintain a compact size while the control module can be positioned optimally outside the main assembly.
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
This design allows for smaller fan assemblies with reduced component count, enabling easier replacement and reprogramming of motor control modules without disassembling the fan, while maintaining control over fan speed and efficiency.
Implementation Method 1
a detection module separate from the fan assembly. The detection module is configured to detect (i) a voltage induced in a first coil of the motor, or (ii) a back electromotive force received from the first coil of the motor
Data Source
AI summary
An integrated circuit for controlling operation of a motor of a fan assembly. The fan assembly includes a housing and a fan. The motor is in the housing. The housing is void of sensors. The motor is configured to rotate the fan. The integrated circuit includes a detection module and a first control module. The detection module is separate from the fan assembly. The detection module is configured to detect a voltage induced in a first coil of the motor or a back electromotive force received from the first coil of the motor. The first control module is configured to receive a control signal from a second control module and control the operation of the fan based on (a) the control signal, and (b) the voltage induced in the first coil of the motor or the back electromotive force. The second control module is separate from the integrated circuit.