Motor Constant-RPM Control Using Current Feedback for Vacuum Cleaners
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Solution Overview
Problem
Cleaning systems, such as vacuum cleaners, face reduced operational quality due to varying speeds caused by changing loads, which can lead to issues like brush roll stalling on carpeted surfaces, and require different speed settings based on the load encountered during operation.
Innovation Solution
A cleaning system equipped with a motor, current sensor, and controller that filters current signals to maintain a substantially constant rotational speed of the impeller, adjusting the motor control based on sensed current to compensate for varying loads, thereby ensuring consistent performance across different floor types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the motor operates at varying speeds to adapt to different loads, then the system can handle different floor types, but the rotational speed becomes unstable and may stall
Solution Approach 1:
The system uses a current sensor to continuously monitor the current drawn by the motor and feeds this information back to the controller. The controller adjusts the motor control signal based on the filtered current signal to maintain constant rotational speed, preventing stalling while adapting to different loads through closed-loop feedback control
Solution Approach 2:
The system changes the control parameter from fixed speed to current-based adaptive control. By monitoring current variations that indicate load changes and adjusting the control signal accordingly, the system maintains stable rotation while adapting to different floor types and load conditions
2Productivity
If the motor runs at high speed to maintain cleaning performance, then cleaning quality is improved, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts motor speed based on actual load conditions rather than operating at fixed high speed. The controller continuously adapts the control signal to maintain optimal cleaning performance while consuming only the necessary energy, avoiding wasteful high-speed operation when loads are light
3Stability of the object's composition
If the system uses a current sensor and controller to maintain constant speed, then rotational speed stability is improved, but device complexity increases
Solution Approach 1:
The system uses the motor's own current draw as the sensing parameter to determine load conditions and adjust control. This self-service approach uses existing electrical parameters rather than requiring additional mechanical sensors, maintaining speed stability while minimizing added system complexity
Data Source
AI summary
A cleaning system including a motor configured to provide rotational energy, a current sensor configured to sense current provided to the motor, and a controller having an electronic processor. The controller is configured to receive, from the current sensor, a current signal indicative of the current provided to the motor, filter the current signal to produce a filtered current signal, and control the motor based on the filtered current signal.