Fan Motor Input Power Estimation Using Speed and Torque Measurement
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Solution Overview
Problem
Conventional climate control systems require dedicated sensors and specialized equipment for measuring input power to fan motors, increasing costs and complexity, and relying on third-party vendors for commissioning, which is time-consuming and costly.
Innovation Solution
A method and system for estimating input power to fan motors by determining an input power function for fan motor classes, selecting the appropriate class, operating the fan, measuring speed and torque, and using these measurements to estimate input power without the need for dedicated sensors or specialized equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If dedicated sensors and specialized equipment are used to measure input power to fan motors, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces dedicated electrical power measurement sensors with a computational model that uses mechanical measurements (speed and torque) to estimate input power. The controller calculates input power using the formula P = τ × ω, where τ is torque and ω is angular velocity, substituting complex electrical measurement hardware with simpler mechanical sensing and computation.
Solution Approach 2:
The patent creates a virtual model of the fan motor's power consumption characteristics through pre-established input power functions that relate speed and torque to input power. This virtual copy allows the system to estimate power consumption without direct electrical measurement, using the relationship: P_input = f(ω, τ) where the function is determined during system commissioning.
2Reliability
If third-party vendors are used for commissioning, then measurement reliability is improved, but loss of time and cost increase
Solution Approach 1:
The patent enables the climate control system to perform its own commissioning by automatically determining input power functions through self-testing procedures. The controller executes a series of tests at different operating points, collects speed and torque data, and autonomously fits the input power functions without requiring external technicians or specialized equipment.
Solution Approach 2:
The patent performs preliminary characterization of the fan motor's power consumption characteristics during the initial system setup by establishing input power functions that relate speed and torque to input power. This preliminary action creates a lookup table or mathematical model that enables rapid power estimation during normal operation, eliminating the need for time-consuming field measurements.
3Measurement precision
If dedicated sensors are installed for power measurement, then measurement precision is improved, but ease of manufacture and installation worsen
Solution Approach 1:
The patent extracts the power measurement function from dedicated electrical sensors and relocates it to the existing controller by implementing a computational estimation algorithm. This extraction eliminates the need for additional sensor installation, wiring, and calibration, as the controller uses its existing communication interfaces to measure speed and torque and compute power consumption.
Data Source
AI summary
Methods and related systems for estimating input power supplied to a fan motor of a climate control system are disclosed. In an embodiment, the method includes selecting an input power function of a fan motor class. Additionally, the method includes operating a fan of the climate control system to produce an airflow, wherein the fan includes the fan motor of the selected fan motor class. Further, the method includes measuring a speed and a torque of the fan motor, and estimating an input power of the fan motor by entering the speed and the torque of the fan motor into the selected input power function.