Motor Control Device Managing Phase Shift and Power Consumption
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Solution Overview
Problem
Existing motor control devices face challenges in preventing phase shifts and maintaining operability when the motor is stopped due to excessive tension from conveyed sheets, particularly when switching between completely stopping current supply and supplying a weak current, which affects synchronization and power consumption.
Innovation Solution
A motor control device that switches among activated, activation stopped, and activation suspended states, using a temperature estimator to calculate temperature changes over time, performing specific calculations to manage motor state transitions and prevent phase shifts while optimizing power usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a weak current is supplied to the motor to prevent phase shift, then the phase shift is prevented, but power consumption increases and the motor takes longer to cool down
Solution Approach 1:
The patent applies dynamics by making the motor control state changeable based on conditions. The motor controller dynamically switches between three states: activation stopped state (no current, maximum cooling), activation suspended state (weak current, phase shift prevention), and activated state (normal operation). This dynamic adjustment resolves the contradiction by selecting the appropriate state based on whether phase shift risk exists, thereby preventing phase shift only when necessary while minimizing power consumption otherwise.
Solution Approach 2:
The patent changes the current parameter supplied to the motor based on operational conditions. By transitioning between complete current cutoff (activation stopped) and weak current supply (activation suspended), the system adjusts the electrical parameter to balance phase shift prevention with power consumption reduction. The temperature estimator also adjusts its calculation parameters based on the current control state, further optimizing the balance between reliability and energy use.
2Reliability
If a weak current is supplied to the motor to prevent phase shift, then the rotor is held in place, but the motor temperature decreases more slowly
Solution Approach 1:
The system dynamically adjusts the current supply based on the estimated motor temperature and operational state. When in activation stopped state, no current flows allowing maximum cooling. When transitioning to activation suspended state, a weak current is supplied to prevent phase shift while accepting reduced cooling rate. The temperature estimator adapts its calculation based on the current state, using appropriate cooling rates for each state to maintain accurate temperature estimation despite the changing thermal conditions.
Solution Approach 2:
The patent applies preliminary action by estimating the motor temperature in advance and predicting when phase shift risk will occur. The temperature estimator calculates future temperature based on current state and rate of change, allowing the controller to proactively transition between states before actual temperature issues arise. This predictive approach allows the system to maintain rotor stability only when necessary, optimizing the balance between rotor position stability and cooling efficiency.
3Use of energy by moving object
If the motor is completely stopped to reduce power consumption, then power consumption decreases, but phase shift may occur when the motor is reactivated
Solution Approach 1:
The patent implements a dynamic three-state control system that transitions between activation stopped state (no current, low power consumption, risk of phase shift), activation suspended state (weak current, moderate power consumption, phase shift prevention), and activated state (normal current, high power consumption, full operation). The controller dynamically selects the appropriate state based on estimated temperature and operational context, resolving the contradiction by using weak current only when phase shift risk is detected while maintaining low power consumption otherwise.
Solution Approach 2:
The system uses feedback from the temperature estimator to continuously monitor and adjust the motor control state. The temperature estimator provides real-time feedback on motor temperature and its rate of change, allowing the controller to determine when to transition between states. This feedback mechanism ensures that weak current is supplied only when necessary to prevent phase shift, while maintaining complete current cutoff when safe, thereby balancing synchronization reliability with power consumption efficiency.
Data Source
AI summary
Temperature-dependent motor control device, including: a motor controller configured to switch a motor control state among an activated state in which the motor is activated by a first current, an activation stopped state in which activation of the motor is stopped by stopping current supply, and an activation suspended state in which activation of the motor is suspended with a second current smaller than the first current kept supplied; and a temperature estimator configured to calculate an estimated motor temperature value and to perform a first calculation for gradually increasing the estimated value when the motor is in the activated state, a second calculation for gradually decreasing the estimated value when the motor is in the activation stopped state, and a third calculation for gradually decreasing the estimated value at a rate of decrease lower than that in the second calculation when the motor is in the activation suspended state.