Motor Power Conversion Circuit for Accurate Efficiency in Regeneration
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Solution Overview
Problem
Existing motor power conversion devices struggle to accurately calculate motor average efficiency and loss power in repetitive load use, leading to inefficiencies and increased energy consumption, particularly in applications like forging machines and surface mounting machines.
Innovation Solution
A motor power conversion device with an average efficiency/loss calculation circuit that classifies input and output power during powering and regeneration states, integrates these values, and calculates motor average efficiency and loss power using formulas that account for both states, ensuring accurate efficiency measurement even during dynamic operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If efficiency data is obtained from manufacturer at rated torque, then efficiency value is available, but it cannot be applied to repetitive load continuous use with high-speed forward and reverse rotation
Solution Approach 1:
The patent changes the measurement parameters from static rated torque conditions to dynamic repetitive load conditions with high-speed forward and reverse rotation. The system measures efficiency under actual operating parameters including variable torque, speed, and direction changes, making the efficiency data applicable to repetitive load continuous use scenarios.
2Loss of energy
If power and power consumption are reduced by halving hit rate or tact time, then energy saving is achieved, but speed decreases and productivity declines
Solution Approach 1:
The patent implements a feedback mechanism where the efficiency measurement system continuously monitors motor performance under actual repetitive load conditions. This feedback enables identification of optimal operating parameters that minimize power consumption while maintaining required productivity levels, allowing energy saving without sacrificing processing speed.
3Productivity
If motor operates in repetitive load continuous use with frequent acceleration and deceleration, then productivity improves, but efficiency calculation becomes inaccurate
Solution Approach 1:
The patent transitions from static efficiency measurement to dynamic efficiency measurement that accounts for motor operation during acceleration, deceleration, and direction changes. The system calculates efficiency in real-time under varying load conditions, capturing the true energy consumption characteristics of motors operating in repetitive load continuous use with high-speed acceleration and deceleration.
Data Source
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AI summary
The purpose of the present invention is to obtain a motor power conversion device capable of accurately calculating motor average efficiency and motor loss power amount in a driving operation in which a motor frequently repeats a powering state and a regeneration state. To achieve the purpose, the motor power conversion device is configured to comprise: a synchronized switching circuit in which an input power detection value of a motor is used as upstream-side power and an output power detection value of the motor is used as downstream-side power during powering, and in which an output power detection value is used as upstream-side power and an input power detection value is used as downstream-side power during regeneration, in the rotating operation of the motor when the direction in which power flowing in the motor flows from a power source toward a load is referred to as powering and the direction in which power flowing in the motor flows from the load toward the power source is referred to as regeneration; an absolute value circuit for processing the upstream-side power and the downstream-side power as absolute values; an integration circuit for integrating each of the upstream-side power and the downstream-side power processed as absolute values, and outputting the integration values as an upstream-side power amount and downstream-side power amount, respectively; a division circuit for obtaining the average efficiency of the motor by dividing the downstream-side power amount by the upstream-side power amount; and a subtraction circuit for obtaining the loss power amount of the motor by subtracting the downstream-side power amount from the upstream-side power amount.