Motor controller, motor control system, and motor control method
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Solution Overview
Problem
Existing motor control systems fail to predictively manage downtime in compressors due to unforeseen degradation of inverter and motor components, leading to unpredictable and prolonged maintenance interruptions.
Innovation Solution
A motor controller with degradation estimation circuitry that compares estimated degradation levels to a reference level, switching between normal and low-noise pulse operation modes to reduce switching loss and delay component degradation, thereby minimizing unexpected downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If normal operation mode is used, then productivity is maintained, but switching loss increases causing accelerated degradation of inverter and motor components
Solution Approach 1:
The system dynamically adjusts the operation mode based on real-time degradation level assessment. When degradation exceeds the threshold, the controller switches from normal operation to low-noise pulse operation, creating a dynamic adaptation mechanism that responds to the actual condition of the motor and inverter components.
Solution Approach 2:
The invention changes the operational parameters by switching between two distinct operation modes: normal operation with higher productivity but higher switching loss, and low-noise pulse operation with reduced productivity but reduced switching loss. This parameter change allows the system to optimize the trade-off between output and component degradation.
2Reliability
If continuous monitoring and operation mode switching is implemented, then component degradation is delayed, but device complexity increases
Solution Approach 1:
The system implements a feedback mechanism where the controller continuously monitors the degradation level of motor and inverter components based on operational data. This feedback loop enables the controller to assess the current state of the components and automatically switch operation modes to prevent further degradation, thereby extending component lifespan through intelligent monitoring.
Solution Approach 2:
The motor controller performs self-assessment of component degradation levels and autonomously decides when to switch operation modes without requiring external intervention. This self-service capability allows the system to manage its own maintenance needs, reducing the need for complex external monitoring systems while extending component life.
3Reliability
If low-noise pulse operation is used to reduce switching loss, then component degradation is delayed, but productivity decreases
Solution Approach 1:
The system applies low-noise pulse operation partially, only when and where needed based on the degradation level assessment. Rather than continuously operating in low-productivity mode, the system uses the reduced-power operation only when degradation exceeds the threshold, thereby minimizing the impact on overall productivity while still achieving the goal of delaying component degradation.
Data Source
AI summary
A motor controller is provided with degradation estimation circuitry configured to calculate an estimated degradation level obtained by estimating a degradation level of a device on which a motor is mounted or a degradation level of an inverter; operation decision circuitry configured to compare the estimated degradation level and a reference degradation level, which is predetermined, and set an operation mode of the motor, in a case in which the estimated degradation level is lower than the reference degradation level, to an normal operation, and set the operation mode, in a case in which the estimated degradation level is higher than or equal to the reference degradation level, to a low-noise pulse operation; and control circuitry configured to control the inverter according to the operation mode. The low-noise pulse operation is designed to reduce switching loss to be less than does the normal operation.