Motor Controller Backup Power Control for High-Voltage Flyback Reliability
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Solution Overview
Problem
The reliability of flyback conversion circuits in motor control systems is compromised when input voltage is high due to the poor performance of power switching transistors, leading to reduced service life and increased risk of damage.
Innovation Solution
A motor controller that dynamically controls the operating status of the flyback conversion circuit based on the bus voltage, stopping or starting it according to specific voltage thresholds to optimize reliability and reduce power consumption, thereby prolonging the service life of the power switching transistor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flyback conversion circuit operates continuously to ensure backup power supply, then the reliability of the safety state control circuit is improved, but the service life of the power switching transistor deteriorates under high voltage conditions
Solution Approach 1:
The patent implements dynamic control of the flyback conversion circuit by adjusting its operating status based on real-time bus voltage detection. When bus voltage exceeds a preset threshold, the circuit transitions from operating state to stopped state, and vice versa. This dynamic adjustment resolves the contradiction by adapting the circuit's operation to actual voltage conditions, protecting the transistor from high-voltage damage while ensuring backup power availability when needed.
Solution Approach 2:
The patent changes the operating parameter (operating status) of the flyback conversion circuit based on the bus voltage parameter. By detecting bus voltage levels and adjusting the circuit's operation accordingly, the system optimizes both the reliability of the safety control circuit and the service life of the power switching transistor under varying voltage conditions.
2Reliability
If the flyback conversion circuit operates continuously to provide backup power, then the power supply reliability is improved, but the power consumption increases
Solution Approach 1:
The patent implements periodic monitoring of bus voltage and adjusts the flyback conversion circuit operation accordingly. Instead of continuous operation, the circuit operates periodically based on voltage conditions - stopping when bus voltage is sufficient and resuming when voltage drops below the threshold. This periodic action maintains power supply reliability while significantly reducing unnecessary power consumption during high-voltage periods.
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 enhances the reliability of the flyback conversion circuit in high-voltage conditions, reduces power consumption, and extends the service life of the power switching transistor by dynamically adjusting its operating status based on bus voltage levels.
Implementation Method 1
The flyback conversion circuit is configured to: receive bus voltages at two ends of the switching bridge arm, convert the bus voltages, and supply power to the safety state control circuit
Data Source
AI summary
In accordance with an embodiment, a motor controller includes a power supply control circuit, a safety state control circuit, and switching bridge arms. The power supply control circuit is configured to control a backup power supply to supply power to the safety state control circuit. The backup power supply includes a flyback conversion circuit. The power supply control circuit is configured to: in response to an output voltage of a main power supply being greater than or equal to a second preset voltage and a bus voltage being greater than a first preset voltage, control the flyback conversion circuit to stop operating.