Motor Control IC Abnormality Diagnosis via Segmented Function Checking
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Solution Overview
Problem
Existing motor control systems fail to accurately detect abnormalities in integrated ICs, leading to erroneous replacement of encoders or motors, as they cannot distinguish between IC and encoder abnormalities, especially when power source voltage falls below the operational guarantee voltage.
Innovation Solution
A motor control apparatus with an abnormality diagnosis part that checks the signal receiving and current supply functions of the integrated IC, allowing for precise detection of IC abnormalities by determining if both functions are impaired, thereby preventing incorrect identification of the encoder or motor as faulty.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an integrated IC is used to receive encoder output signals and supply currents to motor phases, then device complexity is reduced and ease of manufacture is improved, but reliability deteriorates because the IC cannot be individually diagnosed when power source voltage falls below operation guarantee voltage
Solution Approach 1:
The abnormality diagnosis part segments the diagnosis process into two distinct phases: potential abnormality detection (checking individual functions) and confirmed abnormality determination (checking based on multiple function failures). This segmentation allows the system to maintain reliability by requiring multiple failed function checks before confirming IC abnormality, thereby reducing false positives while still using the integrated IC structure.
2Ease of operation
If abnormality detection relies on a single function check of the integrated IC, then ease of operation is improved, but measurement precision deteriorates leading to erroneous encoder replacement
Solution Approach 1:
The abnormality diagnosis part implements feedback by continuously monitoring the results of function checks and using these results to determine whether to declare IC abnormality. The system checks multiple functions (encoder output signal reception, motor phase current supply) and only confirms abnormality when multiple checks fail, providing feedback-based verification that improves measurement precision and prevents erroneous encoder replacement.
3Reliability
If the system checks multiple functions of the integrated IC for abnormality, then reliability is improved by reducing false diagnoses, but device complexity increases
Solution Approach 1:
The abnormality diagnosis part utilizes the multi-functionality of the integrated IC by checking multiple functions (encoder output signal reception, motor phase current supply) within the same diagnostic component. This approach improves reliability through comprehensive checking while avoiding additional device complexity by performing all checks within the existing control circuit rather than adding separate diagnostic hardware for each function.
Data Source
AI summary
An integrated IC provided in an SBW-ECU has plural functions such as a receiving function of receiving output signals of an encoder and a current supply function of supplying current to each phase of the motor. A microcomputer checks individually whether the signal receiving function and the current supply function are potentially abnormal and checks whether the integrated IC is abnormal based on the check results about the signal receiving function and the current supply function. For example, when it is determined that only the signal receiving function of the integrated IC is potentially abnormal, the encoder is determined to be abnormal. When it is determined that the signal receiving function and the current supply function of the integrated IC are both potentially abnormal, the integrated IC is determined to be abnormal.