Motor Load Controller Displaying Output Ratios
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Solution Overview
Problem
Existing motor controllers struggle to effectively display information about both maximum output and continuous rating output, especially when the base velocities of these outputs are different, making it difficult for operators to determine the margin between present motor output and continuous rating output.
Innovation Solution
A controller that stores data on the relationship between motor rotation frequency and both maximum output and continuous rating output, calculates and displays two ratios representing these values on the same screen, either as mathematical values or bar graphs, allowing operators to easily monitor the load status and margins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the base velocities of maximum output characteristic and continuous rating output characteristic are different, then the motor can operate more flexibly across different velocity ranges, but it becomes difficult to simultaneously determine both load meter values and convert between them
Solution Approach 1:
The patent divides the load monitoring function into two separate load meters: one for maximum output reference and another for continuous rating output reference. Each load meter independently calculates and displays its respective ratio, allowing operators to monitor both aspects without complex conversion requirements. This segmentation resolves the contradiction by making the monitoring system adaptable to different base velocities while keeping each individual monitoring function simple.
2Device complexity
If only a single load meter referencing maximum output is used, then the controller structure remains simple, but operators cannot easily determine the margin between present output and continuous rating output
Solution Approach 1:
The patent combines two load meter functions into a single integrated display interface. Both the maximum output-referenced load meter and continuous rating output-referenced load meter are displayed simultaneously on the same screen, with their respective ratios shown together. This merging approach maintains relatively simple controller structure while providing complete load margin information, allowing operators to see both Pm/Pmax and Pc/Pmax values and understand the relationships between present output, maximum output, and continuous rating output.
3Ease of operation
If two separate load meters are displayed on the same screen, then operators can easily recognize both maximum output margin and continuous rating output margin, but the display system becomes more complex
Solution Approach 1:
The patent applies different visual characteristics to different load meter displays to enhance readability and understanding. The maximum output-referenced load meter and continuous rating output-referenced load meter are displayed with distinct visual properties (such as different positions, formats, or visual cues), allowing operators to easily distinguish between the two types of load information. This local differentiation improves ease of operation while keeping the overall display system manageable through consistent design patterns.
Data Source
AI summary
A low-cost controller having a function for effectively displaying information of present motor output regarding the maximum output and the continuous rating output of the motor. The controller includes first and second storing parts which store first and second data, representing a relationship between a rotation frequency and a maximum output of the motor, and a relationship between the rotation frequency and a continuous rating output of the motor, respectively; first and second ratio calculating parts which calculate first and second ratios, corresponding to a ratio of one of the maximum output and the continuous rating output to the other at a present rotation frequency, and a ratio of a present actual output of the motor to the one of the maximum output and the continuous rating output at the present rotation frequency, respectively; and a displaying part which displays the first and second ratios on the same screen.