Motor Control Device Thermal Estimation for Image Forming Apparatus
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Solution Overview
Problem
Existing motor control technologies in image forming apparatuses face challenges in accurately estimating motor temperature rise during intermittent operation and varying load fluctuations, leading to potential overheating issues.
Innovation Solution
A motor control device that calculates input values based on output values and operation modes, using a thermal model to estimate temperature rise and adjust operation modes to prevent overheating, incorporating a controller unit, estimation unit, and notification unit to manage power supply and motor operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If motor controller separates from motor and integrates with apparatus controller, then motor overheating is prevented through estimation, but temperature estimation accuracy deteriorates during intermittent operation
Solution Approach 1:
The system performs preliminary actions by storing operation history data (duty ratios, rotation rates, time intervals) before intermittent operation occurs. When the motor restarts after stopping, this pre-stored data enables accurate estimation of temperature rise by accounting for heat dissipation during the stop period and heat storage upon restart, resolving the accuracy deterioration problem during intermittent operation
Solution Approach 2:
The system implements feedback by continuously monitoring motor operation parameters (duty ratio, rotation rate, time intervals) and using this information to dynamically adjust temperature estimation. The operation history storage and retrieval mechanism provides feedback about past thermal conditions, enabling the controller to refine temperature predictions during intermittent operation cycles
2Device complexity
If simple duty ratio threshold counting is used for temperature estimation, then device complexity is reduced, but temperature estimation accuracy deteriorates under varying load conditions
Solution Approach 1:
The system applies dynamics by transitioning from static threshold counting to dynamic temperature estimation that adapts to varying load conditions. The controller dynamically adjusts estimation parameters based on real-time operation data (duty ratio, rotation rate, time intervals), enabling accurate temperature prediction across different operating conditions without requiring complex hardware modifications
3Temperature
If motor rotation rate is reduced to prevent overheating, then motor temperature is controlled, but apparatus productivity deteriorates
Solution Approach 1:
The system performs preliminary thermal assessment by estimating temperature rise before it becomes critical. By analyzing operation history and predicting future temperature trends, the controller can proactively adjust rotation rates only when necessary, maintaining high productivity during safe operating conditions while preventing overheating before it occurs
Solution Approach 2:
The continuous temperature estimation feedback enables the controller to make informed decisions about rotation rate adjustments. Rather than blanket speed reductions, the system provides feedback-driven selective control, maintaining optimal speeds when temperature is acceptable and applying gentle reductions only when thermal limits are approached, thus preserving productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances the accuracy of temperature estimation and prevents overheating by dynamically adjusting motor operation modes, ensuring reliable and efficient operation of image forming apparatuses.
Implementation Method 1
an estimation unit configured to estimate an amount of rise in temperature of the motor by applying the input value for the motor to a thermal model of the motor
Data Source
AI summary
In a device for controlling a motor mounted on a system with different operation modes, a controller unit calculates an input value for the motor based on an output value of the motor and a target value depending on operation modes of the system, and instructs a driver circuit of the motor to apply the input value to the motor. An estimation unit estimates an amount of rise in temperature of the motor by applying the input value for the motor to a thermal model of the motor. A notification unit compares a value estimated by the estimation unit with a threshold value. When the estimated value exceeds the threshold value, the notification unit sends a request for change of operation mode to the system.