Motor Control System Sensor Fault Detection and Torque Ripple Management
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Solution Overview
Problem
Current motor control systems face complexity in sensor fault detection, leading to excessive torque ripple and system configuration complications, especially when multiple sensors are used, making it necessary to simplify the system configuration.
Innovation Solution
A motor control method and system that acquire measured and estimated torque angles using position sensors and sensorless control algorithms, determine errors for combinations of these angles, and select control modes (sensor mode, sensorless mode, or shutdown mode) based on a table of reference patterns to control the motor accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple sensors are used for sensor fault detection, then detection reliability is improved, but system configuration complexity increases
Solution Approach 1:
The patent segments the sensor fault detection function into multiple independent detection algorithms (first sensorless control algorithm, second sensorless control algorithm, and sensor-based detection). Each algorithm independently evaluates sensor health, allowing the system to detect faults through multiple pathways without requiring a monolithic complex detection system. This segmentation maintains high reliability while keeping individual detection modules manageable in complexity.
Solution Approach 2:
The control circuit is designed with multi-functionality, serving both motor control and sensor fault detection purposes. The same control circuit that executes motor control algorithms also performs sensor fault detection by comparing results from different sensorless control algorithms and sensor measurements. This universal design eliminates the need for separate dedicated fault detection hardware, reducing system configuration complexity while maintaining detection reliability.
2Measurement precision
If complex sensor fault detection methods are implemented, then fault detection accuracy is improved, but torque ripple increases
Solution Approach 1:
The patent implements dynamic switching between different control modes (sensorless control, sensor-based control, and fallback modes) based on real-time sensor health assessment. When sensor faults are detected, the system dynamically transitions to alternative control strategies without abrupt changes in torque output. This dynamic adaptation maintains accurate fault detection while minimizing torque ripple by smoothly transitioning between control methodologies.
Solution Approach 2:
The system employs feedback mechanisms where the control circuit continuously monitors the outputs of multiple sensorless control algorithms and compares them against sensor measurements. When discrepancies indicate sensor faults, the feedback loop triggers appropriate fallback control strategies. This closed-loop feedback ensures accurate fault detection while maintaining smooth torque delivery through adaptive control adjustments, preventing excessive torque ripple.
Data Source
AI summary
A motor control method includes acquiring at least one measured torque angle and two estimated torque angles, obtaining all combinations of two torque angles that are combinable with respect to a set of the at least one measured torque angle and the two estimated torque angles and performing an arithmetic operation to determine an error for each combination, selecting a control mode of the motor from control modes including a sensor mode, a sensorless mode, and a shutdown mode, the selecting being performed by referring to a table representing a relationship between the control modes and reference patterns relating to the calculated error group, and controlling the motor in accordance with the selected control mode.