Motor Hotspot Detection Using Virtual Temperature Sensing
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Solution Overview
Problem
Existing methods for identifying motor hotspots require multiple temperature sensors, which increase costs, complexity, and weight, making them unsuitable for applications where weight is a concern, such as in motorcycles.
Innovation Solution
A correlation model is used to map motor operating condition signals to temperature measurement data, allowing for the reduction or elimination of temperature sensors by generating hypothetical temperature measurements based on the correlation model, enabling hotspot identification without the need for direct temperature measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple temperature sensors are used to directly measure motor temperature at various locations, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent creates a virtual copy of temperature sensing capability through a correlation model that maps motor operating conditions to temperature measurements. Instead of physically installing multiple temperature sensors throughout the motor, the system uses a mathematical model that replicates the measurement function of multiple sensors using data from fewer physical sensors, thereby reducing device complexity while maintaining measurement precision
Solution Approach 2:
The patent replaces the mechanical/physical system of multiple temperature sensors with an electronic/software-based correlation model. The model uses motor operating condition signals (current, speed, voltage) and correlates them with temperature measurements through a pre-established relationship, substituting physical sensing infrastructure with computational analysis
2Reliability
If multiple temperature sensors are installed in the motor, then temperature monitoring capability is improved, but weight increases
Solution Approach 1:
The patent creates virtual temperature measurements through a correlation model, eliminating the need for multiple physical temperature sensors. This virtual copying approach maintains comprehensive temperature monitoring capability across multiple motor locations without adding the physical weight of additional sensors, cables, and mounting hardware
Solution Approach 2:
The patent extracts the essential temperature information from motor operating conditions (current, speed, voltage) rather than relying on direct physical measurement at multiple points. By taking out only the critical operating parameters and using a correlation model to derive temperature, the system reduces weight while preserving monitoring capability
3Reliability
If multiple temperature sensors are used to monitor hotspots, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses a correlation model to generate virtual temperature measurements at multiple locations, replacing the need for multiple expensive physical temperature sensors. This approach maintains reliable hotspot detection capability while significantly reducing the bill of materials cost associated with multiple sensor assemblies
Solution Approach 2:
The correlation model serves multiple functions simultaneously: it provides temperature estimation at multiple locations, enables hotspot detection, and works with a reduced set of physical sensors. This multi-functionality consolidates what would otherwise require multiple specialized components, reducing overall manufacturing cost
Data Source
AI summary
Methods, systems, and apparatuses for motor hotspot identification. One system includes a first motor installed in a vehicle, the first motor including a stator having at least one stator winding corresponding to one phase of the first motor. The system also includes a first set of temperature sensors coupled to the first motor and a controller. The controller receives a motor operating condition signal of the first motor, accesses a stored correlation model, and generates hypothetical temperature measurement data for a hypothetical temperature sensor of the first motor based on the stored correlation model and the motor operating condition signal. The stored correlation model is generated based on motor operating condition signals associated with a second motor operating in a test environment. In response to identifying a hotspot within the first motor based on the hypothetical temperature measurement data, the controller modifies operation of the first motor.