Electric Fluid Motor Control for In-Field Flow Characterization
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Solution Overview
Problem
Existing constant fluid flow systems require complex and costly characterization processes in a lab setting, which are impractical for in-field configuration and calibration of electric motors driving fluid moving apparatuses, leading to inefficiencies and variations in fluid flow output due to environmental and physical constraints.
Innovation Solution
A control system for electric motors that uses a processor to operate at multiple speed and torque settings, determining fluid flow rates and defining algorithms based on measured data points to compute operating set points, allowing for in-field characterization and simplified configuration of fluid moving apparatuses, utilizing correlations between torque, speed, and fluid flow to approximate demanded fluid flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If lab-based characterization is used to quantify fluid flow output for given speed and torque, then manufacturing precision is improved, but device complexity and ease of operation worsen due to complex and costly procedures
Solution Approach 1:
The patent replaces complex mechanical lab-based characterization procedures with an electronic/computational system. The controller executes algorithms that compute fluid flow values based on motor speed and torque using stored relationships, substituting physical measurement equipment and manual procedures with electronic data processing.
Solution Approach 2:
The patent performs preliminary characterization during the manufacturing process, storing the relationships between motor speed, torque, and fluid flow in the controller's memory. This preliminary action eliminates the need for complex field characterization procedures, as the data is pre-captured and stored for later use.
2Manufacturing precision
If lab-based characterization is used to quantify fluid flow output, then manufacturing precision is improved, but loss of time increases due to impractical field application
Solution Approach 1:
The patent performs the characterization process during manufacturing rather than in the field during installation or maintenance. By capturing the relationships between motor speed, torque, and fluid flow output in advance and storing them in the controller, the system eliminates time-consuming field characterization procedures.
Solution Approach 2:
The patent replaces time-consuming physical measurement and characterization procedures with electronic data storage and computational algorithms. The controller uses stored relationships to quickly compute fluid flow values without requiring actual physical measurement equipment or procedures in the field.
3Productivity
If polynomial or constant fluid flow algorithms are used to determine motor torque or speed, then productivity is improved, but measurement precision worsens due to variations in fluid flow output
Solution Approach 1:
The patent implements a feedback mechanism where the controller continuously monitors motor speed and torque, then uses stored relationships to compute the corresponding fluid flow output. This feedback loop allows the system to adjust motor operation to maintain desired fluid flow rates, compensating for variations in the fluid mover construction or output path restrictions.
Solution Approach 2:
The patent changes the approach from using fixed polynomial or constant fluid flow algorithms to using computed fluid flow values based on actual measured motor speed and torque combined with stored characterization data. This parameter change allows the system to adapt to specific operating conditions and maintain higher precision across varying loads and system restrictions.
Data Source
AI summary
A control system for an electric motor for a fluid moving apparatus includes a drive circuit and a processor. The drive circuit regulates power supplied to the motor to generate fluid flow. The processor is coupled to the drive circuit and controls the drive circuit to operate the motor at a first speed and torque, and at a second speed and torque, receive a first flow corresponding to the first speed and torque, determine a second flow based on a ratio of the first flow to the first speed, and corresponding to the second speed and torque. The processor is configured to define an algorithm based on the first and second speed, torque, and flow, compute a set point for a demanded flow using the algorithm, and control the drive circuit based on the set point to supply power to the motor and generate the flow.