Integrated Motor Controller for Low Voltage Start-Stop Reliability
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Solution Overview
Problem
Unreliable electric power supply during start/stop operations in vehicles causes low voltage events, disrupting motor operations and increasing customer dissatisfaction due to potential motor malfunctions and the high cost and complexity of external electronic modules for motor control.
Innovation Solution
Incorporating a microcontroller and non-volatile memory within the motor to monitor power supply voltage, store energy, and manage motor state during low voltage events, allowing for seamless operation and reduced reliance on external control modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external electronic modules are used to control motors during start/stop operations, then motor reliability during low voltage events is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the motor controller, non-volatile memory, and power supply into an integrated motor assembly. This merging eliminates the need for separate external electronic modules while maintaining motor reliability during low voltage events, as the integrated design ensures coordinated operation of all control functions within the motor itself.
Solution Approach 2:
The motor assembly serves itself by incorporating all necessary control functions (controller, memory, power supply) within the motor. This self-service capability allows the motor to autonomously manage its operation during low voltage events without requiring external control modules, thereby reducing system complexity while maintaining reliability.
2Reliability
If external electronic modules are used to control motors during start/stop operations, then motor behavior during low voltage events is improved, but manufacturing cost increases
Solution Approach 1:
By merging the controller, memory, and power supply into the motor assembly, the patent reduces the total component count and assembly steps required. This integrated approach simplifies manufacturing processes and reduces costs compared to assembling separate external modules, while still achieving reliable motor operation during low voltage events.
Solution Approach 2:
The self-service motor assembly eliminates the need for additional external control modules, thereby reducing parts costs, assembly costs, and testing costs. The integrated design requires fewer manufacturing steps and quality control checks, making the system more cost-effective to produce while maintaining improved motor behavior during start/stop operations.
3Ease of operation
If motors operate during low voltage events, then motor functionality is maintained, but power supply voltage stability deteriorates
Solution Approach 1:
The controller detects voltage drops before they become critical and preemptively responds by controlling motor operation. This preliminary action allows the motor to maintain functionality during early stages of voltage drop while preventing operations that would exacerbate the voltage instability, thus balancing ease of operation with voltage stability.
Solution Approach 2:
The controller continuously monitors power supply voltage and uses this feedback to adjust motor operation in real-time. When voltage drops are detected, the controller modulates motor operation to maintain functionality while preventing further voltage degradation, and when voltage is restored, it manages the motor restart to avoid in-rush current issues.
4Reliability
If motor state is continuously monitored and stored, then motor operation reliability is improved, but energy consumption increases
Solution Approach 1:
The controller monitors motor state and power supply voltage continuously but stores information in non-volatile memory only when voltage drops occur or when the motor stops. This periodic updating approach maintains reliability by capturing critical state information at key moments while minimizing energy consumption by avoiding continuous writing operations to memory.
Solution Approach 2:
The system uses non-volatile memory to store motor state information only when necessary (during voltage drops or motor stops), treating these storage operations as discrete, low-cost events rather than continuous operations. This approach maintains reliability by preserving critical state information while consuming minimal energy, as the memory is updated only when the motor operation state changes significantly.
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
Improves motor behavior during start/stop events by ensuring correct operation and reducing costs and complexity, maintaining functionality even with aged batteries or low temperatures without external control modules.
Implementation Method 1
storing energy within the motor
Data Source
AI summary
A motor system and a method of operating an electric motor that includes monitoring a voltage of power supplied to the motor by a mircrocontroller located in the motor; storing energy within the motor; detecting if the voltage drops below a nonzero threshold; and if the voltage drops below the threshold, immediately operating the microcontroller with the stored energy to store a state of the motor in non-volatile memory located within the motor, and ceasing operation of the motor. This motor operation may be employed with multiple motors in vehicles where voltage drop may occur during an engine start of a vehicle stop/start event.