Motor Control Center Dual Integrated Modules
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Solution Overview
Problem
The complexity of process and cost increase in motor control center systems due to the dual structure requirement for integrated modules and internal communication, which can lead to partial or complete loss of motor control when failures occur, especially when the internal communication line is disconnected.
Innovation Solution
A motor control center system with a dual structure of integrated modules and internal communication, where a multipoint bus connects protection control modules to form a serial communication network, with one integrated module operating as active and the other as standby, and using bridge sockets to share communication ports and switch between states via solenoid switches, ensuring continuous communication even with internal line disconnections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dual structure is implemented for both the integrated module and all protection control modules to improve reliability, then the system reliability is improved, but the cost and device complexity increase excessively
Solution Approach 1:
The system segments the dual structure requirement to apply it only to the integrated module level rather than every protection control module. The inlet unit contains two integrated modules in active-standby configuration, while motor units use single integrated modules. This segmentation resolves the contradiction by providing redundancy where it matters most (central communication control) while avoiding excessive complexity at the distributed motor unit level.
Solution Approach 2:
Instead of implementing a full dual structure across all components, the patent applies partial redundancy only to the integrated module layer. This partial action provides sufficient reliability improvement for the critical communication function without the excessive cost and complexity of duplicating every protection control module, thus resolving the contradiction between reliability and device complexity.
2Device complexity
If only the integrated module of the inlet unit is placed in a dual structure to prevent total loss of motor control, then the cost increase is reduced, but the process complexity increases due to communication wiring and switching requirements
Solution Approach 1:
The patent introduces a communication switching mechanism that acts as an intermediary between the dual integrated modules and the protection control modules. The switching device automatically routes communication signals between the active integrated module and all protection control modules, or switches to the standby module when needed. This intermediary mechanism manages the communication complexity internally, resolving the contradiction by hiding the process complexity from the user while maintaining the simplified dual-module structure.
3Device complexity
If communication lines are shared between active and standby integrated modules to reduce wiring complexity, then the wiring complexity is reduced, but the reliability decreases when internal communication lines are disconnected
Solution Approach 1:
The patent implements a dynamic communication architecture where the connection topology changes based on operational status. During normal operation, the active integrated module uses a single communication line to all protection control modules. When the active module fails, the standby module dynamically switches to become the active communicator, maintaining the same simplified wiring structure. This dynamic switching resolves the contradiction by maintaining wiring simplicity while adapting to failure conditions to preserve reliability.
Data Source
AI summary
A motor control center system according to the present invention includes a first integrated module and a second integrated module which are provided in correspondence with a motor control center and in a dual structure; a plurality of protection control modules provided in correspondence with respective motor units; and a multipoint bus to which the protection control modules are connected such that a serial communication network is formed between the first integrated module and second integrated module and the plurality of protection control modules, wherein one end of the multipoint bus is commonly connected to a first serial communication port of the first integrated module and a first serial communication port of the second integrated module, and the other end of the multipoint bus is commonly connected to a second serial communication port of the first integrated module and a second serial communication port of the second integrated module.