Hybrid Machine Position Control Using Hall Sensor Offset Calibration
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Solution Overview
Problem
There is a need for improved hybrid machine systems and associated control systems that enhance operation, simplify system architecture, and reduce installation and overall system costs, particularly in systems with AC electrical machines and internal combustion engines.
Innovation Solution
Implementing a hybrid machine system with a single Hall sensor to provide mechanical angular position feedback, determining an offset between mechanical and electrical angular positions, and using this offset to generate machine control signals for the inverter, thereby enhancing operational efficiency and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple feedback devices (Hall sensors and resolvers) are used to provide mechanical and electrical angular position information, then measurement precision is improved, but device complexity and installation costs increase
Solution Approach 1:
The patent extracts and eliminates the resolver feedback device from the system, retaining only the Hall sensor. The control system compensates for the removed device by calculating electrical angular position from mechanical position measurements taken at specific offset intervals, thereby reducing device complexity while maintaining measurement precision through computational correction
Solution Approach 2:
The patent introduces an offset value as an intermediary parameter that mediates between the mechanical angular position measurements from the Hall sensor and the required electrical angular position information. This offset, determined during system calibration, enables accurate electrical position calculation without requiring additional feedback hardware
2Reliability
If multiple feedback devices are used to provide both mechanical and electrical angular position information, then reliability is improved, but installation costs and system complexity increase
Solution Approach 1:
The patent removes the resolver component from the feedback system, simplifying installation procedures. The single Hall sensor is easier to install and align compared to multiple devices, while the system maintains reliability through software-based electrical position calculation using the determined offset value
Solution Approach 2:
The control system performs self-calibration by automatically determining the offset between mechanical and electrical angular positions during initial operation or maintenance modes. This self-service capability eliminates the need for manual alignment procedures, thereby improving installation ease while maintaining system reliability
3Device complexity
If a single Hall sensor is used to provide only mechanical angular position information, then device complexity is reduced, but measurement precision of electrical angular position deteriorates
Solution Approach 1:
The patent performs preliminary calibration action by determining the offset between mechanical and electrical angular positions before normal operation begins. This pre-established offset value enables the control system to accurately calculate electrical angular position from Hall sensor measurements throughout operation, maintaining precision without increasing device complexity
Solution Approach 2:
The patent replaces the mechanical/electrical feedback system (multiple sensors) with a computational approach. The control system uses software algorithms to calculate electrical angular position based on mechanical position measurements and the stored offset, substituting hardware complexity with computational precision
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 system provides efficient and cost-effective operation by accurately determining angular positions and offsets, improving integration and performance of hybrid machines, especially in vehicles, with reduced installation complexity and costs.
Implementation Method 1
A Hall sensor, for example, is positioned to detect magnetic or other elements on a wheel or other structure that is mounted to and rotates with the drive shaft of the engine or the rotor shaft of the AC machine.
Data Source
AI summary
Embodiments include a method for operating a hybrid machine system including an electric machine coupled to an engine and an inverter in an offset determination mode, and in an operating mode when the electric machine is in a loaded electrical state. Operating the machine system in the offset determination mode may include (1) receiving mechanical angular position information representative of mechanical angular positions of the electric machine, (2) receiving electrical angular position information representative of electrical angular positions of electric signals in the electric machine when the electric machine is operating in an unloaded electrical state, (3) determining an offset between the mechanical angular positions and the electrical angular positions, and (4) storing the offset. Operating the machine system in an operating mode may include (1) receiving the mechanical angular position information, (2) generating machine control signals based on the mechanical angular position information and the stored offset, and (3) applying the machine control signals to the inverter.