Motor Failure Detection Circuit for Open, Short, and Stall Faults
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Solution Overview
Problem
There is a need for a technology that can rapidly and accurately detect failures in motors, including open or short circuits in wires connected to the motor or the motor itself, to reduce maintenance and repair time and costs.
Innovation Solution
The apparatus includes a first motor failure detector to apply a reference voltage and detect changes, first and second motor power switches to switch terminal voltages, a gate amplifier to control the power switches, and a controller to diagnose failures based on detected voltages and power switch states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional motor failure detection methods are used, then the detection process is simple, but the detection accuracy and speed are insufficient
Solution Approach 1:
The detection system is segmented into multiple specialized detectors: open-circuit detector, short-circuit detector, and stall detector. Each detector is responsible for a specific failure mode, allowing for precise detection of different failure types while maintaining manageable system complexity through functional decomposition
Solution Approach 2:
A microcontroller serves as an intermediary that coordinates the operation of multiple detectors and power switches. It manages the detection sequence, processes signals from detectors, and controls the overall detection process, enabling accurate multi-faceted failure detection without requiring a monolithic complex system
2Reliability
If comprehensive failure detection is implemented, then all failure types can be detected, but the detection time increases
Solution Approach 1:
The system performs preliminary detection actions by checking multiple failure conditions in a coordinated sequence during motor startup and operation. The microcontroller pre-configures detection parameters and executes detection routines that efficiently cover all failure modes without requiring separate lengthy detection processes for each failure type
Solution Approach 2:
The detection system employs periodic action by continuously monitoring motor parameters at regular intervals during operation. Power switches are periodically activated to apply test voltages, and detectors continuously sample motor responses, enabling rapid detection of any failure type without requiring extended detection periods
3Adaptability or versatility
If multiple power switches are used for detection, then detection capability is enhanced, but the control complexity increases
Solution Approach 1:
Multiple power switches are designed with multi-functionality, serving both as motor control elements during normal operation and as detection actuators during failure detection. The same switches apply test voltages for open-circuit detection, short-circuit detection, and stall detection, eliminating the need for separate detection hardware and simplifying overall control architecture
Solution Approach 2:
The system implements feedback control where detectors monitor the responses from power switch operations and feed this information back to the microcontroller. The microcontroller adjusts power switch activation sequences based on detected conditions, creating a closed-loop control system that manages complexity through adaptive coordination of multiple switches
Data Source
AI summary
An apparatus for detecting a motor failure may include: a first motor failure detector configured to apply a reference voltage for failure detection to a motor, and then detect a changed voltage; a first motor power switch and a second motor power switch configured to switch both terminal voltages applied to drive the motor; a gate amplifier configured to apply a gate signal for controlling the turn on/off of the first and second motor power switches; and a controller configured to diagnose a failure of the motor controlled in one way, on the basis of voltages detected by the first and second motor power switches and the first motor failure detector, respectively.