Motor Control PCB With Integrated Rotary Encoder Sensing
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Solution Overview
Problem
Existing electric motors driving wheels in robotized handling devices face challenges in achieving compactness, reliability, and ease of repair due to separate motor and encoder components, which complicates their operation and maintenance.
Innovation Solution
Integrating rotary encoder sensors directly onto the motor's electronic circuit board, which includes power electronics and angle encoders, allowing for a compact, modular, and easily replaceable motor control block with self-calibration capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the encoder sensor is fixed to the motor and linked by wire to the motor control electronics, then the motor control system can accurately measure rotor position and speed, but the overall assembly becomes more complex and less compact
Solution Approach 1:
The encoder sensor is integrated directly onto the electronic circuit board that controls the motor, merging the measurement function with the control function. This eliminates the need for separate wiring between the encoder and control electronics, reducing assembly complexity while maintaining measurement precision.
2Reliability
If the encoder sensor is fixed to the motor with separate wiring, then reliable position sensing is achieved, but the assembly becomes less compact and harder to repair
Solution Approach 1:
By integrating the encoder sensor onto the same circuit board as the motor control electronics, the system becomes more compact and modular. The circuit board can be easily removed and replaced as a single unit for repair or maintenance, improving ease of operation without compromising reliability.
3Adaptability or versatility
If separate encoder and motor components are used, then each component can be optimized independently, but the overall system size increases and compactness is reduced
Solution Approach 1:
The encoder sensor and motor control electronics are merged onto a single circuit board, which is then integrated with the motor assembly. This consolidation reduces the overall volume of the motor assembly while maintaining the ability to optimize the circuit board design for both encoding and control functions.
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
The integrated solution results in a more compact, reliable, and maintainable motor system with improved accuracy and robustness against vibrations, facilitating easy installation and repair while ensuring precise motor control.
Implementation Method 1
The angle encoding element is advantageously a multi-pole magnet and the sensors of the magnetic field sensors
Data Source
AI summary
The invention relates to an electric motor including a drive shaft carrying a rotor, a device for powering and controlling winding phases of a stator of the motor on an electronic board fixed to the motor, and one or more angle encoders, the angle encoders including sensors positioned on the electronic board and an angular encoding element disposed facing the sensors on the drive shaft, and the electronic board includes power electronics for controlling the windings and a unit for computing and controlling the phase of the windings.