Fault tolerant motor and zone controller apparatus
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional dual-zone motor controllers are unable to operate both motors when one motor drive fails, leading to interruptions in industrial processes like conveyor belt systems, resulting in downtime and loss of production.
Innovation Solution
A fault-tolerant motor and zone controller apparatus with a switching network that alternates motor drive connections between two motors, allowing one motor drive to operate both motors in a backup mode when the other is in a fault condition, ensuring continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional dual-zone motor controllers are used with one motor drive per motor, then each motor operates independently and reliably, but when one motor drive fails, the system cannot operate both motors leading to production downtime
Solution Approach 1:
The patent implements a switching apparatus that enables one motor drive to control both motors when the other motor drive fails. The switching network reconfigures connections dynamically, allowing the operational motor drive to assume universal control of both motors, thereby maintaining system productivity despite component failure.
Solution Approach 2:
The system employs dynamic reconfiguration of the motor drive connections through the switching apparatus. When a fault is detected, the system transitions from a static one-to-one motor drive-motor mapping to a dynamic configuration where one motor drive can serve both motors, enabling continuous operation and eliminating production downtime.
2Reliability
If a switching apparatus is added to enable fault tolerance, then the system can continue operating with one motor drive controlling both motors, but the device complexity increases
Solution Approach 1:
The switching apparatus acts as an intermediary component between the motor drives and motors. This mediator enables flexible reconfiguration of connections without requiring direct modification of the motor drives themselves, simplifying the overall system architecture while achieving fault tolerance capabilities.
Solution Approach 2:
The control system is segmented into distinct functional modules: motor drives, switching apparatus with switching networks, and motors. This modular segmentation allows the switching apparatus to be independently controlled by zone controllers, enabling fault tolerance while maintaining manageable system complexity through clear separation of concerns.
Data Source
AI summary
A motor and zone controller apparatus includes: a first motor drive; a second motor drive; and a switching apparatus. The switching apparatus includes: a first switching network having at least a first state and a second state, the first switching network connects the first motor drive to a first motor when in the first state, and the first switching network connects the first motor drive to a second motor when in the second state; and a second switching network having at least a first state and a second state, the second switching network connects the second motor drive to the first motor when in the first state, and the second switching network connects the second motor drive to the second motor when in the second state.