Motor Controller Power-Saving Return Control

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Solution Overview

Problem

Conventional motor controllers for electrical drive-by-wire systems in vehicles consume excessive power and generate heat during the reverse rotation control after abutment control, affecting fuel efficiency and reliability.

Innovation Solution

A motor controller that utilizes a microcomputer to perform power-saving return control by stopping the motor's power supply after abutment control, allowing resilient deformation to reverse the motor's rotation position using stored energy, and then securely stopping the motor at the target position by supplying power to a preset phase.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the motor is rotated in reverse direction after abutment control to return the rotation position, then the resilient deformation of the rotation transmission system is resolved, but the electric power consumption and heat generation are increased

Engineering Contradiction:

Improveresolution of resilient deformationVSAvoidelectric power consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent utilizes the resilient force stored in the rotation transmission system during abutment control to automatically return the motor to the target rotation position. The system serves itself by converting the stored elastic energy into rotational motion, eliminating the need for additional electric power consumption for the return movement.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent converts the harmful effect of resilient deformation (which causes positioning errors) into a beneficial force that drives the motor back to the correct position. The elastic energy stored in the deformed transmission components is utilized as the driving force for return movement, transforming a problem into a solution.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

Engineering Contradiction:

Improveresolution of resilient deformationVSAvoidheat generation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The system uses the stored resilient energy to perform the return movement autonomously without requiring motor activation. This self-service mechanism avoids the heat generation that would result from electromagnetic losses and friction during motor-driven reverse rotation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the electromagnetic motor-driven return mechanism with a passive mechanical return mechanism based on elastic recovery. This substitution eliminates the need for electrical power conversion and reduces mechanical friction losses, thereby minimizing heat generation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Use of energy by moving object

If power supply is stopped during return control to save energy, then the power consumption is reduced, but the motor rotation must be stopped precisely at the target position

Engineering Contradiction:

Improvepower consumptionVSAvoidrotation position accuracy

Core Design Contradiction:

Use of energy by moving objectVSMeasurement precision

Solution Approach 1:

The patent employs feedback control by continuously monitoring the motor rotation position using encoder counts and comparing it with the target position. Based on this feedback, the control section determines when to stop power supply and when to activate the motor for precise positioning, ensuring accurate stopping at the target position while minimizing power consumption.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The control section calculates the expected return distance based on the abutment control parameters and prepares the stopping strategy in advance. By predicting the motor's return trajectory and timing the power supply cutoff appropriately, the system ensures the motor will naturally coast to the target position, achieving both energy savings and positioning accuracy.

Inventive Principle:

Principle #10Preliminary action

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 reduces power consumption and heat generation, enhancing fuel efficiency and reliability by leveraging the motor's resilient deformation to return to the target position without continuous electric power usage.

Implementation Method 1

the rotation transmission mechanism is resiliently twisted by the motor torque when the motor is rotated to move the range switch mechanism to the limit position

Methodology Applied

Scientific EffectResilient deformation: Elasticity

Data Source

PatentUS9843277B2Motor controller having a power-saving control, and a motor control system including the motor controller

Publication Date: 2017.12.12 DENSO CORP

AI summary

A motor controller that is configured to switch power supply phases of the motor, to perform a limit-position abutment control by rotating the motor to a movable limit of a movable range of the rotation object to learn a reference position of the motor, perform a power-saving return control afterwards, in which a power supply to the motor is stopped, thereby returning a rotation position of the motor toward a target rotation position, and stop the rotation of the motor by simultaneously supplying power to a preset phase of the motor, when the rotation position of the motor reaches the target rotation position. In such manner, the power consumption as well as the heat generation of the motor are reduced for returning the rotation position of the motor to a preset rotation position after the abutment control of the motor.