Motor Drive Controller Locking Pattern Switching
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Solution Overview
Problem
Conventional motor drive controllers using locking energization methods face issues with excessive heat generation in coils due to repeated locking energization operations, particularly when starting or restarting motors, which can lead to coil burnout or insulator damage.
Innovation Solution
A motor drive controller that switches the locking energization pattern after a predetermined number of operations to distribute the lock current across different phases, preventing excessive heat buildup in any single coil by alternating the energization pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If locking energization is performed repeatedly to position the rotor during motor start or restart operations, then the motor can be reliably started even when dust is caught, but the same coil repeatedly generates heat without sufficient cooling, leading to coil burnout or insulator damage
Solution Approach 1:
The patent combines multiple locking energization patterns into a selection pool, and merges the functionality of multiple coils by allowing different coils to share the locking energization duty through pattern switching, thereby distributing heat generation across multiple components
Solution Approach 2:
The patent dynamically switches between different locking energization patterns based on operation count, making the system adaptive rather than static. The control section monitors how many times locking energization has been performed and automatically selects appropriate patterns to prevent overheating
2Device complexity
If locking energization is always performed with the same switching element combination, then the control logic is simple, but a large lock current flows in a particular coil causing excessive heat generation in that specific coil
Solution Approach 1:
The patent segments the locking energization process into multiple distinct patterns, each using different combinations of switching elements and coils. By dividing the overall locking energization function into these segments, no single coil bears the full burden repeatedly
Solution Approach 2:
The patent implements periodic switching between different locking energization patterns based on operation count. This periodic action ensures that different coils are used in different cycles, allowing each coil to cool down during periods when it is not carrying the lock current
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 effectively prevents coil overheating and reduces the risk of damage by ensuring that the lock current flows in different coils during repeated locking energization operations, maintaining motor functionality without the need for shutdowns.
Implementation Method 1
A component such as a coil generates heat when the locking energization is performed for a long period of time
Data Source
AI summary
Provided is a motor drive controller capable of a locking energization operation while preventing increase in temperature of a coil. The motor drive controller includes a motor drive section selectively energizing coils with a plurality of phases of a motor and a locking energization control section. The locking energization control section performs a locking energization operation when the motor is started or restarted and holds a rotor of the motor in a position corresponding to the coil in which the lock current flows. In case of performing the locking energization operation, the locking energization control section switches a locking energization pattern for applying the lock current in the coil from a locking energization pattern when the preceding locking energization operation was performed. The locking energization control section controls the motor drive section so that the lock current flows in the coil in accordance with the switched locking energization pattern.