Fan Self-Diagnosis via Speed and Current Thresholds

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Solution Overview

Problem

Conventional fan management technologies fail to accurately diagnose abnormal fan operations caused by environmental variations, such as blocked air inlets, leading to misjudgment of fan reliability and lifespan.

Innovation Solution

A microcontroller-based system that monitors fan rotation speed and current in real-time, calculates speed and current change thresholds, and generates environmental anomaly signals when these thresholds are exceeded, allowing for immediate identification of blockages and prevention of misjudgment regarding fan lifespan.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional fan management technology uses single indicator (power consumption) to define reliability, then the management system is simple, but it cannot accurately identify abnormal fan operations caused by environmental variations

Engineering Contradiction:

Improvefan reliability diagnosis accuracyVSAvoiddiagnosis system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent segments the fan diagnosis into multiple independent monitoring dimensions: power consumption monitoring, rotation speed monitoring, and environmental condition monitoring. Each dimension is evaluated separately with its own thresholds and warning mechanisms, allowing comprehensive diagnosis without requiring a single complex system

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control unit is designed to perform multiple functions: it monitors power consumption, measures rotation speed, detects environmental conditions, and generates different types of warnings (performance degradation warning, abnormal operation warning, lifespan warning). This multi-functional approach consolidates what could be multiple separate systems into a single universal diagnosis device

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If conventional technology monitors only power consumption, then the monitoring system is simple, but it misjudges fan reliability when environmental abnormalities occur

Engineering Contradiction:

Improvefan reliability assessment accuracyVSAvoidenvironmental condition information

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The system continuously monitors power consumption and rotation speed, comparing real-time data against expected values. When deviations occur, the control unit generates feedback warnings (performance degradation warning or abnormal operation warning) that provide information about the fan's actual condition, preventing misjudgment of reliability

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent establishes multiple warning thresholds and conditions in advance. Before actual failure occurs, the system detects early signs of abnormality through power consumption patterns and rotation speed variations, issuing preliminary warnings that allow preventive maintenance before reliability is compromised

Inventive Principle:

Principle #10Preliminary action

3Difficulty of detecting and measuring

If real-time monitoring of rotation speed and current is implemented, then environmental abnormalities can be detected, but the device complexity increases

Engineering Contradiction:

Improveenvironmental abnormality detection capabilityVSAvoidmonitoring device complexity

Core Design Contradiction:

Difficulty of detecting and measuringVSDevice complexity

Solution Approach 1:

The fan system performs self-diagnosis by monitoring its own power consumption and rotation speed. The control unit within the fan evaluates its own operational parameters and generates warnings about its own condition, eliminating the need for external complex monitoring equipment

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent combines the monitoring functions, measurement capabilities, and warning generation into a single integrated control unit that works with the existing fan motor. This merging of functions into one compact device avoids the complexity of separate monitoring systems while maintaining comprehensive detection capability

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11566629B2Device for real-time self diagnosis of a fan and the method using the same

Publication Date: 2023.01.31 PROLIFIC TECH INC

AI summary

A device for real-time self-diagnosis of a fan and a method are disclosed for detecting whether a fan body encounters an environment abnormal situation. The fan body includes a motor, a fan and a tachometer. The fan body further includes a microcontroller for receiving a speed signal of the tachometer and calculating a speed value of the fan, and detecting a current value of the motor during operation. The microcontroller can control the motor to drive the fan according to a monitoring period and a control signal transmitted from the control board, and can calculate a speed change amount according to the monitoring period, and can calculate a current change amount. When the speed change amount exceeds a speed change threshold and the current change amount exceeds a current change threshold for a period of time, the microcontroller generates an environmental anomaly signal.