Motor Controller Braking Using Back-EMF During Power Loss
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Solution Overview
Problem
Existing motor control apparatuses with mechanical brakes are costly, require frequent maintenance, and are not suitable for applications like treadmills and escalators, as they lack flexibility and require additional power sources for controller operation during power interruptions.
Innovation Solution
A motor control apparatus utilizing a self-driven brake function, which includes an energy-consuming component and a switch component, coupled with an inverter and controller, converts DC power to drive motors and generates braking force using back electromotive force when power is interrupted, replacing mechanical clamping brakes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical brake apparatus is used for power failure braking, then the motor can be locked to avoid sliding when power is interrupted, but the device cost increases and regular maintenance is required
Solution Approach 1:
The patent replaces the mechanical brake apparatus with an electronic braking system that uses the motor controller to generate braking torque through electrical means. The controller directs current flow to create electromagnetic braking force, eliminating mechanical contact components and their associated maintenance requirements while maintaining reliable braking functionality during power failures.
Solution Approach 2:
The motor controller is designed to perform multiple functions: normal motor control during operation and braking control during power failures. By integrating both functions into a single electronic control unit, the system eliminates the need for separate mechanical brake apparatus, reducing overall device complexity while maintaining comprehensive braking capability.
2Reliability
If a mechanical brake apparatus is installed in a small treadmill control box, then braking function is provided, but the construction cost cannot be reduced and miniaturization is impossible
Solution Approach 1:
The motor controller serves dual purposes as both the motor drive controller and the braking system controller. This multi-functionality eliminates the need for separate mechanical brake components, allowing the entire braking function to be integrated into the existing control box without increasing its size or manufacturing cost.
Solution Approach 2:
The braking function is merged with the motor control function in a single integrated electronic system. By combining these functions, the patent eliminates the need for additional mechanical brake components that would increase construction cost and prevent miniaturization of the control box.
3Reliability
If the controller fails due to interrupted power electricity, then the controller cannot control the brake of the motor, but with additional power source the braking control can be maintained
Solution Approach 1:
The patent replaces the need for additional power sources by using electromagnetic braking through the existing power system. The braking torque is generated electrically through the motor controller, which can operate from residual power or energy storage already present in the system, eliminating the need for separate backup power sources while maintaining braking control reliability.
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 solution reduces maintenance costs, increases design flexibility, and ensures continuous braking functionality without the need for additional power sources, making it suitable for various motor control applications.
Implementation Method 1
a back electromotive force generated by the motor is consumed through the energy-consuming component
Data Source
AI summary
A motor control apparatus receives a DC power source through a DC terminal and is coupled to a motor. The motor control apparatus includes a brake, an inverter, and a controller. The brake is coupled to the inverter. The brake includes an energy-consuming component and a switch component. The controller controls the inverter to convert the DC power source to drive the motor. When the controller determines that the DC power source is interrupted, the controller stops controlling the inverter, and the switch component is self-driven turned on so that a back electromotive force generated by the motor is consumed through the energy-consuming component.