High-speed hall-less three-phase vacuum cleaner motor
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Solution Overview
Problem
Conventional Hall sensor-less three-phase vacuum cleaner motors have low rotational speeds and complex stator structures, which limit their application in high-speed vacuum cleaners, and existing Hall sensor-based motors are costly, prone to damage, and require complex hardware and circuit control.
Innovation Solution
A high-speed Hall sensor-less three-phase vacuum cleaner motor design utilizing an analog electronic circuit to detect counter electromotive force as feedback for rotor magnetic pole position, featuring a simplified stator structure with a circular iron core, movable impeller, and MOS tube-cooled circuit board, achieving rotational speeds over 80,000 rpm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a Hall element is adopted to detect magnetic position for brushless motor control, then the motor control precision is improved, but the cost increases, reliability decreases, and the motor volume increases
Solution Approach 1:
The patent removes the Hall element from the motor system entirely, extracting the problematic component that caused reliability issues, cost increases, and volume expansion. Instead of detecting magnetic position directly with a Hall sensor, the invention uses back-EMF detection to infer rotor position, thereby eliminating the Hall element and its associated problems while maintaining control functionality.
Solution Approach 2:
The patent replaces the physical Hall element-based magnetic field detection system with an electronic back-EMF detection system. This substitution eliminates the need for additional hardware sensors and connecting lines, reducing complexity and improving reliability while achieving the same control objective through a different physical mechanism.
2Ease of manufacture
If a Hall sensor-less structure is adopted to reduce cost and complexity, then the manufacturing cost decreases, but the rotational speed becomes low (lower than 40000 rpm)
Solution Approach 1:
The patent changes key design parameters including adopting a surface-mounted permanent magnet structure, optimizing the stator winding configuration, and improving the back-EMF detection algorithm. These parameter changes enable the Hall sensor-less motor to achieve rotational speeds exceeding 80000 rpm, thereby resolving the speed limitation of conventional Hall sensor-less motors while maintaining cost-effectiveness.
3Productivity
If the rotational speed is increased to over 80000 rpm, then the dust collection performance is improved, but the commutation loss and stator structure complexity increase
Solution Approach 1:
The patent implements a precise back-EMF feedback detection system that accurately tracks rotor position and speed. This feedback mechanism enables optimized commutation timing and current control, reducing commutation losses even at rotational speeds exceeding 80000 rpm while maintaining high dust collection performance.
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
The design achieves high rotational speed, reduced commutation loss, increased reliability, and simplified production, resulting in a compact, energy-efficient motor with enhanced dust collection performance.
Implementation Method 1
The Hall sensor-less circuit adopts an analog electronic circuit to detect a counter electromotive force of the motor, and the counter electromotive force acts as a feedback signal for a rotor magnetic pole position
Implementation Method 2
A high-speed Hall sensor-less three-phase vacuum cleaner motor is provided, wherein the rotational speed of the motor controlled by the Hall sensor-less circuit is higher than 80000 rotations per minute
Implementation Method 3
US-A-5,664,282 discloses a high speed Hall sensor-less three-phase vacuum cleaner motor in accordance with the precharacterizing portion of claim 1
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Disclosed is a high-speed Hall-less three-phase vacuum cleaner motor, comprising an iron core (1) with a central circle, a rotor (2) running through the central circle, a first end cap (3) for fixing one end of the iron core, a second end cap (4) mating with the first end cap and fixing the other end of the iron core, a movable impeller (5) located at one side of the second end cap and driven by the rotor, an impeller cover (7) containing the movable impeller and fixed on the second end cap, a fixed impeller (8) located between the second end cap and the movable impeller, and a circuit board (6) located outside of the first end cover, the circuit board being provided with a Hall sensor-less circuit cooled by wind output by the motor, and the rotational speed of the motor controlled by the Hall sensor-less circuit being higher than 80000 rotations per minute. Since the Hall-less circuit board structure cooled by wind output by the motor is adopted, the structure is simple, the appearance is beautiful, and the reliability is high. Moreover, because the commutation frequency of the electronic elements is decreased, the commutation loss of the electronic elements is reduced. Furthermore, the stator structure is simple, winding is convenient, and therefore the efficiency of production is increased. The high-speed Hall-less three-phase vacuum cleaner motor also has the advantages of having a high rotational speed, being small in size, having a high performance, being convenient to carry, saving energy, having long service life, etc., can be applied to vacuum cleaners, and can achieve a super-high dust collection performance.