Motor Controller Using Power Lines for Command Signal Transmission
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Solution Overview
Problem
The existing electric motor systems require expensive and inconvenient wiring harnesses to transmit command signals for multiple speed operations, especially in applications like ceiling fans and HVAC systems where motors are often inaccessible.
Innovation Solution
An electronic control module with a processor and current supply lines that transmit both power and command signals over the same lines, allowing for efficient communication with motors and reducing the need for extensive wiring, and can be programmed for near-field communications and various operating modes such as constant air flow, torque, or speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate wiring harnesses are used to transmit command signals from the user interface to the motor, then reliable signal transmission is achieved, but manufacturing cost and installation complexity increase significantly
Solution Approach 1:
The patent combines the power transmission function and command signal transmission function into a single wiring harness. The processor modulates command signals onto the power supply lines using load modulation techniques, allowing both power and control signals to travel through the same physical medium, thereby eliminating the need for separate signal wiring harnesses and reducing overall system complexity
Solution Approach 2:
The wiring harness is designed to serve multiple functions simultaneously: it provides electrical power to the motor and also transmits bidirectional command signals between the user interface and the motor controller. This multi-functional approach eliminates the need for dedicated signal transmission wires, reducing installation complexity while maintaining reliable communication
2Ease of operation
If a wiring harness is installed to connect the user interface to the motor in existing structures, then command signals can be transmitted, but installation convenience deteriorates due to accessibility issues
Solution Approach 1:
By merging power and signal transmission into a single wiring harness, the patent reduces the number of installation steps and materials required. The existing power wiring infrastructure can be utilized for both power delivery and control signaling, making installation in existing structures much more convenient and accessible
3Productivity
If multiple speed control functions are implemented in the motor, then energy savings and performance improvement are achieved, but the wiring requirements and manufacturing cost increase
Solution Approach 1:
The patent replaces traditional mechanical or electrical speed control mechanisms (which would require additional wiring and components) with an electronic control system that communicates through the existing power lines. The processor implements multiple speed control functions by modulating signals on the power supply, eliminating the need for separate wiring harnesses for each control function
Solution Approach 2:
The single wiring harness is designed to support multiple speed control functions and bidirectional communication simultaneously. The same physical infrastructure enables complex motor control operations including speed regulation, direction control, and diagnostic communications without requiring additional dedicated wires for each function
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 manufacturing and installation costs, improves serviceability, and enhances performance by enabling convenient and efficient control of electric motors with reduced labor costs and improved energy management.
Implementation Method 1
The processor is configured to modulate the command signal onto the power supply lines
Implementation Method 2
Electrical energy applied to coils within the machine initiates the relative motion that transfers the power to the shaft
Data Source
AI summary
An electronic control module is provided. The electronic control module is operably connected to a power supply for providing power to a motor. The electronic control module includes an input device, a processor coupled to the input device, and first and second current supply lines. The processor is configured to generate a command signal in response to an input supplied by the input device and transmit the command signal to the motor. The command signal controls an operating point of the motor. The first and second current supply lines are operably connectable to the motor and the processor. At least one of the current supply lines, the input device and the processor are adapted to utilize the current supply lines both to transmit power to the motor and to transmit the command signal to the motor over the current supply lines.