Motor Control Voltage Stability via Regenerative Energy Mitigation
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Solution Overview
Problem
Conventional motor drives face challenges in managing regenerated energy, as they either result in loss of active motor control or increased system complexity and cost when trying to prevent overvoltage due to absorbed energy, especially in applications with limited regeneration needs.
Innovation Solution
A system that includes a power supply output sensor and a motor controller, which senses the output level of the power supply and adjusts the electrical current to the motor by reducing the torque-producing component as the output voltage approaches a predetermined limit, thereby mitigating overvoltage without interrupting active motor control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a regenerative energy dissipator is used to manage regenerated energy, then power supply voltage can be maintained within acceptable levels during rapid deceleration, but circuit and system complexity, size, and cost increase
Solution Approach 1:
The patent extracts only the essential function of voltage limitation from the complex regenerative energy dissipator system. Instead of using a large resistor switched across the power supply, the invention selectively limits voltage by controlling motor current during regeneration, removing unnecessary circuit components while maintaining voltage stability.
Solution Approach 2:
The motor controller uses the motor's own electrical characteristics and control capabilities to manage regenerated energy. By adjusting the current supplied to the motor during deceleration, the system self-regulates voltage levels without requiring external dissipator circuits, thereby reducing system complexity.
2Reliability
If active motor control is interrupted to prevent overvoltage, then power supply and drive are protected from damage, but active motor control is lost and motor coasts until voltage decays
Solution Approach 1:
The patent implements continuous feedback control by monitoring power supply voltage during regeneration and dynamically adjusting motor current in real-time. This closed-loop control prevents overvoltage conditions while maintaining uninterrupted active motor control, eliminating the need to interrupt control or allow coasting behavior.
3Reliability
If a large resistor is switched into the circuit to dissipate regenerative energy, then excess energy is removed from the power supply, but system size and cost increase
Solution Approach 1:
The invention removes the large resistor component from the system entirely. Instead of physically dissipating energy through a resistive element, the system uses electronic control to manage regenerated energy by adjusting motor current, achieving voltage protection without adding bulky hardware.
Solution Approach 2:
The patent replaces the mechanical/electrical dissipator system (large resistor) with an electronic control system. By using the motor controller to manage energy flow and limit voltage through current control, the invention substitutes physical energy dissipation with electronic regulation, reducing system size.
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
This approach allows for continuous active motor control while preventing overvoltage, reducing system complexity and cost by leveraging power losses to manage regenerated energy, even in applications with modest energy management needs.
Implementation Method 1
During active motor control, the motor may behave as a generator, and stored or potential energy from the motor may be converted back into electrical energy (regenerated energy) that is absorbed by the power supply
Implementation Method 2
the motor may behave as a generator, and stored or potential energy from the motor may be converted back into electrical energy (regenerated energy) that is absorbed by the power supply
Data Source
AI summary
A system includes a power supply output sensor that senses an output level of a power supply during active motor control of a motor using the power supply and generates a signal indicative thereof. The motor regenerates energy and the power supply absorbs energy regenerated by the motor. The system also includes a motor controller that, in response to the signal satisfying a predetermined threshold, controls an electrical current supplied to the motor for active control of the motor based on a set of instructions that mitigate increases in the output level of the power supply from the absorption of the energy regenerated in the motor.