Multi-Winding Motor Current Detection for Lifespan Prediction
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Solution Overview
Problem
Existing image forming apparatuses face challenges in accurately predicting component lifespan and identifying abnormal parts, leading to increased running costs and downtime due to unnecessary component replacements and difficulty in specifying the source of abnormalities.
Innovation Solution
A driving device equipped with a drive source having multiple windings, driving components, a current detector, and at least one processor that determines the lifespan and presence of abnormalities in the drive source and driving components based on detected driving currents. The current detector uses low-pass filters with different cutoff frequencies to differentiate between currents flowing through different windings, allowing for precise analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single current detection method is used for all windings, then the device complexity is reduced, but the measurement precision of component lifespan and abnormality detection deteriorates
Solution Approach 1:
The current detection system is segmented into multiple detection paths, each with dedicated low-pass filters for different windings. This segmentation allows precise measurement of individual winding currents while maintaining overall system manageability through modular architecture.
Solution Approach 2:
The patent introduces a frequency dimension by using low-pass filters with different cutoff frequencies for different windings. This dimensional approach enables differentiation of current characteristics across frequency spectra, improving measurement precision without proportionally increasing circuit complexity.
2Measurement precision
If multiple low-pass filters with different cutoff frequencies are used for different windings, then the measurement precision of abnormality detection is improved, but the device complexity increases
Solution Approach 1:
Different low-pass filter characteristics are assigned to different windings based on their specific operational requirements. This local quality approach optimizes abnormality detection for each winding's particular current profile while avoiding unnecessary complexity in other parts of the system.
Solution Approach 2:
The patent varies the cutoff frequency parameter of low-pass filters across different windings to match their respective operational characteristics. This parameter differentiation enables precise abnormality detection tailored to each winding's electrical behavior without requiring completely separate detection systems.
3Reliability
If component replacement is performed based on predetermined lifespan, then the reliability of the system is maintained, but the loss of time due to unnecessary replacements increases
Solution Approach 1:
The system continuously monitors actual component conditions through current detection and provides feedback to determine replacement timing. This feedback mechanism replaces components based on their actual degradation state rather than predetermined schedules, eliminating unnecessary replacements and reducing downtime.
Solution Approach 2:
The patent performs preliminary detection of component abnormalities and lifespan degradation trends before actual failure occurs. This preliminary action enables proactive scheduling of replacements at optimal moments, preventing unexpected failures while avoiding premature replacements.
4Reliability
If abnormality detection sensors are used to monitor component operation, then the reliability of abnormality detection is improved, but the device complexity and initial cost increase
Solution Approach 1:
The motor windings themselves serve as the detection sensors by monitoring their own current characteristics. This self-service approach eliminates the need for separate external sensors, reducing device complexity and initial costs while maintaining reliable abnormality detection through intelligent analysis of operational currents.
Solution Approach 2:
The patent replaces physical abnormality detection sensors with an electrical measurement system that analyzes current characteristics. This substitution uses electrical fields and signal processing instead of mechanical or optical sensors, simplifying the overall system architecture while achieving comparable or superior detection reliability.
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 enables accurate prediction of component lifespan and identification of abnormal parts, reducing unnecessary replacements and downtime while minimizing initial costs by maintaining a compact circuit configuration.
Implementation Method 1
the current detector is configured to detect a first driving current flowing through a first winding with a first low-pass filter having a first cutoff frequency
Implementation Method 2
detect a second driving current flowing through a second winding with a second low-pass filter having a second cutoff frequency which is higher than the first cutoff frequency
Data Source
AI summary
A driving device includes a drive source including a plurality of windings, a plurality of driving components configured to transmit a driving force output from the drive source to a load, a current detector configured to detect a driving current flowing through the plurality of windings, and at least one processor configured to determine a lifespan and presence or absence of abnormality of the drive source and the plurality of driving components based on the driving current, wherein the current detector is configured to detect a first driving current flowing through a first winding with a first low-pass filter having a first cutoff frequency, and detect a second driving current flowing through a second winding with a second low-pass filter having a second cutoff frequency which is higher than the first cutoff frequency.