Improved dust extractor motor control

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Solution Overview

Problem

Dust extractors used in construction sites face challenges such as high energy consumption during startup, filter clogging, and frequent filter replacements, leading to operational inefficiencies and increased costs.

Innovation Solution

A method for controlling the fan motor of dust extractors by reducing airflow to a pre-determined level when operating in a high airflow range, using sensor data from pressure, airflow, and current sensors to optimize motor usage and extend filter life, while maintaining sufficient dust extraction capability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the fan motor operates at maximum capacity to maintain dust extraction capability, then dust extraction performance is improved, but peak power consumption increases

Engineering Contradiction:

Improvedust extraction capabilityVSAvoidpeak power consumption

Core Design Contradiction:

ProductivityVSPower

Solution Approach 1:

The patent applies dynamics by making the airflow level adjustable and variable based on operating conditions. The system transitions from a fixed maximum airflow mode to a dynamic control mode where airflow is reduced to an optimized level during normal operation and increased to maximum only when dust generation is detected, resolving the contradiction between maintaining extraction capability and reducing peak power consumption.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the airflow parameter from a fixed maximum value to a variable parameter with at least two distinct levels: an optimized reduced level for energy efficiency and a maximum level for high dust extraction. This parameter change allows the system to adapt power consumption to actual operational needs while maintaining sufficient dust extraction capability.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If high airflow is maintained to ensure dust extraction capability, then dust collection performance is improved, but filter clogging occurs more frequently

Engineering Contradiction:

Improvedust extraction capabilityVSAvoidfilter replacement interval

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system dynamically adjusts airflow based on actual dust generation conditions. During normal low-dust operation, airflow is reduced to an optimized level that maintains extraction capability while significantly reducing the rate at which filters accumulate dust, thereby extending filter replacement intervals and improving reliability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent applies partial action by providing more airflow than the absolute minimum needed for dust extraction. The optimized airflow level is maintained at or above the minimum required for effective dust collection, ensuring sufficient performance while avoiding the excessive airflow that would cause rapid filter clogging.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS20220400923A1Improved dust extractor motor control

Publication Date: 2022.12.22 HUSQVARNA AB

AI summary

A method for controlling operation of a dust extractor, the method comprising; obtaining (S1) sensor data (235) related to an airflow (240) into the dust extractor, determining (S2) if the dust extractor is operating in a high airflow operating range based on the sensor data (235), and if the dust extractor is operating in the high airflow operating range, controlling (S3) a fan motor (210) of the dust extractor to reduce the airflow (240) to a reduced flow level (330, 3301) at or above a pre-determined airflow level (340) and below an obtainable flow level (310), wherein the pre-determined airflow level (340) is associated with a dust extraction capability of the dust extractor (100).