Brushless Motor Drive Overcurrent Limiting Dynamics

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Solution Overview

Problem

Conventional motor drive devices using PWM drive methods experience sudden and large changes in duty factor when limiting overcurrent, leading to increased rotating sound and motor noise, especially under heavy loads.

Innovation Solution

A motor drive device with a duty limiter that updates the limit value at predetermined intervals, gradually adjusting the duty factor to suppress overcurrent without sudden changes, comprising a drive controller, duty calculator, PWM signal generator, drive output unit, current flow monitor, and limit value generator.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the duty factor is limited to a predetermined ratio when overcurrent is detected, then the motor is protected from overheating and burn-damage, but the duty factor changes instantaneously and greatly causing increased rotating sound and motor noise

Engineering Contradiction:
Improvemotor protection from overheatingVSAvoidrotating sound and motor noise
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies dynamics by making the duty factor limit value changeable over time rather than fixed. The control device dynamically adjusts the limit value based on the duration of overcurrent detection, initially setting it to a small value and gradually increasing it toward a predetermined target value. This dynamic adjustment prevents instantaneous and large changes in duty factor, thereby reducing rotating sound and motor noise while still protecting the motor from overheating.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent changes the parameter of duty factor limit value from a static predetermined ratio to a time-varying parameter. The control device modifies the limit value based on elapsed time during overcurrent conditions, transitioning it from a small initial value to a larger target value. This parameter change strategy allows the system to balance motor protection with noise reduction by controlling the rate of duty factor adjustment.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If the duty factor is limited to suppress overcurrent, then the motor current is reduced, but the motor may repeat switching between small and large duty factor modes causing motor noise and large impacts to mechanical components

Engineering Contradiction:
Improveovercurrent suppressionVSAvoidmotor noise and mechanical impacts
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies dynamics by implementing a time-dependent duty factor limit value that continuously evolves during overcurrent conditions. Instead of switching between fixed small and large duty factor modes, the control device gradually increases the limit value from a small initial value toward a predetermined target value based on elapsed time. This creates a smooth, monotonic transition that prevents repeated switching and the associated mechanical impacts and noise.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent uses feedback by continuously monitoring the overcurrent condition and adjusting the duty factor limit value accordingly. The control device detects overcurrent status and uses elapsed time as feedback to determine the appropriate limit value, ensuring the duty factor adjustment progresses smoothly from small to large values rather than oscillating between modes, thereby reducing mechanical impacts and noise.

Inventive Principle:
Principle #23Feedback

Data Source

PatentUS8796967B2Motor drive device, brushless motor, and motor drive method
Publication Date: 2014.08.05 PANASONIC HOLDINGS CORP
  • US8796967B2 patent drawing
  • US8796967B2 patent drawing
  • US8796967B2 patent drawing

AI summary

The disclosed device comprises a duty calculator for calculating a duty command value (Dty), a duty limiter for limiting the duty command value (Dty) to a value according to a limit value (L), a current flow monitor for determining that there is an overcurrent if a current value (Idet) flowing through a winding exceeds a predetermined threshold value (Ithr), and a limit value generator for generating the limit value (L). The limit value generator updates the limit value (L) at predetermined time intervals and for a value corresponding to a difference between the threshold value (Ithr) and the current value (Idet) at a time in order to decrease the current value (Idet) during a period in which the overcurrent is determined.