Interface Module for Electric Motor Communication Expansion

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Solution Overview

Problem

The existing electric motor control systems require significant development and testing cycles and costs to implement new or advanced communication interfaces, limiting the ability to adapt to customer demands for new interfaces or control functionalities without replacing the motor controller.

Innovation Solution

An interface module is integrated into the electric motor and control circuit assembly, enabling the expansion of communication and control interfaces without replacing the motor controller, by coupling a processing device with multiple communication interfaces to receive and convert input signals into control signals for transmission to the motor controller.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a new motor controller is designed to implement new communication interfaces, then communication capabilities are improved, but development time and costs increase

Engineering Contradiction:

Improvecommunication interface capabilitiesVSAvoiddevelopment cycle length

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system is divided into two independent parts: the existing motor controller and the add-on interface module. The interface module is a separate, self-contained unit that can be attached to the motor controller without modifying its internal structure. This segmentation allows the interface module to be developed, tested, and deployed independently, significantly reducing development time while maintaining communication capability improvements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The interface module acts as an intermediary device between the motor controller and external communication systems. It receives signals from the motor controller via a serial port and translates them into the desired communication protocols (Ethernet, wireless, etc.). This mediator approach enables new communication capabilities without requiring changes to the motor controller itself, thus avoiding lengthy development and certification cycles.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If a new motor controller is designed to implement new communication interfaces, then communication capabilities are improved, but design and testing costs increase

Engineering Contradiction:

Improvecommunication interface capabilitiesVSAvoiddesign and field testing costs

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

By segmenting the communication functionality into a separate interface module, the patent enables independent development and testing of the communication features without involving the motor controller. This reduces manufacturing costs as the interface module can be produced separately and attached to existing motor controllers, avoiding the need for expensive re-certification of the entire motor controller system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The interface module is designed as a cost-add-on component rather than integrating expensive changes into the motor controller. The module can be independently manufactured, tested, and replaced if needed, making the system more economical for implementing new communication capabilities compared to redesigning the entire motor controller.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If the motor controller is replaced to add new interfaces, then communication capabilities are improved, but system complexity and installation requirements increase

Engineering Contradiction:

Improvecommunication interface capabilitiesVSAvoidsystem configuration complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The interface module is designed as a standalone add-on device that connects to the motor controller through a standard serial port. This segmentation allows the existing motor controller to remain unchanged while adding new communication capabilities through the external module, thereby reducing system complexity and simplifying installation compared to replacing the entire motor controller.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The interface module is designed with universal compatibility to work with existing motor controllers through standard serial communication protocols. It can provide multiple communication interfaces (Ethernet, wireless, etc.) through a single add-on device, reducing the need for multiple different motor controllers and simplifying the overall system configuration.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP2632033B1Interface module and method for communicating with an electric machine

Publication Date: 2020.05.27 REGAL BELOIT AMERICA INC

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AI summary

An interface module (110) configured to be releaseably coupled to an electric machine (20) is described. The interface module (110) includes a processing device (112), a first communication interface (114) coupled to the processing device (112) and configured for coupling with a motor controller (22) of the electric machine (20), and a second communication interface (116) coupled to the processing device (112) and configured to receive a control signal.