Interleaved Motor Controllers for Precise Commutation
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Solution Overview
Problem
Conventional motor controllers are limited by their inability to manage a large number of phase connections, leading to inefficient motor operation and increased costs, as they struggle to differentiate and control electrical conductors at a finer level than traditional single-phase or three-phase connections.
Innovation Solution
The implementation of a controller system that divides the motor winding into multiple subwindings, each electrically insulated, allowing for synchronized energization and precise control through monitoring phase voltages to estimate back electromotive force (EMF) and determine commutation timing, enabling more accurate motor position estimation and improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a controller manages a large number of phase connections to enable finer-level control of electrical conductors, then motor operation efficiency and performance are improved, but controller complexity and cost increase significantly
Solution Approach 1:
The patent divides the motor winding into multiple electrically isolated subwindings, each controlled by a separate control part. This segmentation allows the system to manage conductors at a finer level (subwinding level) while keeping each individual controller simple. The overall motor benefits from the combined control of multiple subwindings, achieving high efficiency without requiring a single complex controller to handle all connections simultaneously.
2Measurement precision
If a controller differentiates and controls a large number of phase connections at a finer level, then motor control precision and position estimation accuracy are improved, but the controller's ability to manage connections becomes overwhelmed
Solution Approach 1:
Each control part monitors phase voltages and estimates back EMF for its specific subwinding independently, achieving precise position estimation for that subwinding. The multiple control parts work in parallel, each handling a manageable number of connections, yet collectively providing fine-level control and high precision position estimation for the entire motor.
Solution Approach 2:
The patent combines the outputs of multiple control parts to achieve comprehensive motor control. Each control part's position estimation and control signals are integrated, allowing the system to leverage information from all subwindings to improve overall control precision without overloading any single controller.
3Device complexity
If conventional controllers use traditional single-phase or three-phase connections, then controller complexity is reduced, but motor operation efficiency and performance are limited
Solution Approach 1:
Instead of using a single conventional controller with limited phase connections, the patent segments the winding into multiple subwindings, each with its own control part. This allows the system to achieve better motor efficiency through finer-level control while maintaining relatively simple individual controller designs, effectively breaking the trade-off between complexity and 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
This approach allows for more accurate motor position estimation and optimal commutation timing, enhancing motor efficiency, reducing noise, and improving peak torque and power capabilities while reducing the complexity and cost of controller components.
Implementation Method 1
monitor phase voltages of the associated subwinding, between phase connections, and to determine therefrom a commutation timing for the subwinding
Implementation Method 2
estimate a motor position based on the value of overall back EMF; and estimate a commutation event timing based on the estimated motor position
Data Source
AI summary
A motor system comprises a motor comprising: a stator with a plurality of subwindings each having a plurality of phase connections for receiving phase voltages, wherein each of the subwindings is electrically insulated from each of the other subwindings; a rotor comprising a plurality of permanent magnets or energisable electromagnets; a controller comprising a plurality of control parts, each control part associated with a respective subwinding, each control part being configured to monitor phase voltages of the associated subwinding, between phase connections. The system further comprises a controller configured to: obtain, from each control part, at set discrete time intervals, a plurality of back measured electromotive force, EMF, readings for each of the respective subwindings; using the plurality of measured back EMF readings and an a priori knowledge of the motor's construction to estimate a commutation event timing.