Electric Motor Load Determination via Current and Speed Integration

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Solution Overview

Problem

Existing methods for determining load values of objects driven by electric motors are inadequate for complex and non-uniform conditions, particularly during ongoing operation, and do not allow for continuous or real-time evaluation without specialized measurement runs.

Innovation Solution

A method that calculates energy and angular momentum using motor current and angular velocity over time, with adaptable motor constants, enabling the determination of load variables such as moment of inertia and friction torque, which can be evaluated online and repeatedly during operation without requiring specific boundary conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a defined measurement run is used to determine load values, then measurement precision is improved, but productivity deteriorates due to requiring special measurement procedures and inability to determine loads during ongoing operation

Engineering Contradiction:
Improveload value determination accuracyVSAvoidoperational efficiency
Core Design Contradiction:
Measurement precisionVSProductivity

Solution Approach 1:

The patent applies preliminary action by pre-calculating and storing motor constants (such as inertia and friction coefficients) during a defined measurement run, so that during ongoing operation the controller can directly use these pre-determined values without requiring additional measurement procedures. This allows load values to be determined during normal operation while maintaining measurement accuracy.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent uses copying by creating a mathematical model (copy) of the motor's mechanical characteristics through the relationship between current, speed, and torque. Instead of performing physical measurements during operation, the system copies the load information through calculations based on measured electrical parameters and the pre-stored motor constants, enabling continuous load determination without interrupting operation.

Inventive Principle:
Principle #26Copying

2Productivity

If load values are determined during ongoing operation, then productivity is improved, but measurement precision deteriorates under complex and non-uniform boundary conditions

Engineering Contradiction:
Improvereal-time load determination capabilityVSAvoidload value accuracy under varying conditions
Core Design Contradiction:
ProductivityVSMeasurement precision

Solution Approach 1:

The patent applies dynamics by making the motor constants adaptable rather than fixed. The controller can update the motor constants (inertia, friction) based on changing operating conditions, allowing the system to maintain measurement precision even when boundary conditions become complex or non-uniform during ongoing operation. This dynamic adaptation enables accurate load determination across varying operational states.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent uses parameter changes by modifying the motor constants used in load calculations based on the actual operating conditions. When boundary conditions change (such as different door masses, friction conditions, or acceleration profiles), the system adjusts the motor parameters to reflect current conditions, thereby maintaining measurement precision despite the variability in operational environment.

Inventive Principle:
Principle #35Parameter changes

3Adaptability or versatility

If multiple load variables are determined simultaneously, then adaptability is improved, but device complexity increases due to requiring multiple measurements and calculations

Engineering Contradiction:
Improvemultiple load variable determinationVSAvoidmeasurement and calculation system complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies merging by combining the determination of multiple load variables (torque, power, inertia, friction) into a unified calculation process. Instead of requiring separate measurement runs or additional sensors for each variable, the system calculates all load variables simultaneously from the same set of measured parameters (current and speed) and pre-stored motor constants, thereby reducing device complexity while maintaining adaptability.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent uses universality by creating a multi-functional calculation framework where the same motor constants and measurement data serve multiple purposes. The pre-determined motor characteristics are used to calculate different load variables (torque, power, inertia effects) depending on the operational context, allowing a single measurement and calculation system to provide comprehensive load information for various control and monitoring applications.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method provides robust and accurate determination of load variables, enhancing control and regulation of electric motors by accounting for dynamic loads, improving system performance and allowing for live monitoring and error detection.

Implementation Method 1

The invention relates to a method for determining load values of an object that can be driven by an electric motor during operation, using a motor current and an angular velocity of the motor

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3296755B1Determination of load sizes in current operation
Publication Date: 2022.03.23 SIEMENS AG
  • EP3296755B1 patent drawingFigure 1
  • EP3296755B1 patent drawingFigure 2~4
  • EP3296755B1 patent drawing

AI summary

The invention relates to a method for determining at least one load parameter (J, MR) of an object (100) driven by an electric motor (MOT) during operation, using a motor current (I), an angular velocity (ω) of the motor (MOT), and/or equivalent parameters. The invention further relates to a control method, a motor control system, and a drive system. To provide a method that enables the determination of load parameters even under complex and/or non-uniform boundary conditions, e.g.,To robustly determine one or more load variables during operation and multiple times during a journey, the following steps are proposed: • Determine an energy (E) in a first interval (t1E, t2E) as a first integral function (fE) of motor current (I) and angular velocity (ω) over a time (t) and a first motor constant (kMOT1) of the electric motor (MOT), • Determine an angular momentum (L) in a second interval (t1L, t2L) as a second integral function (fL) of motor current (I) over time (t) and a second motor constant (kMOT2) of the electric motor (MOT), • Determine at least one of the load variables (J, MR) in the respective interval (t1E, t2E, t1L, t2L) using the energy (E) and the angular momentum (L).