Asynchronous Motor Rotor Thermal Modeling for Overload Protection

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Solution Overview

Problem

Traditional motor thermal overload protection lacks a separate rotor thermal model and fails to consider heat exchange between the rotor and other motor parts, leading to inaccurate rotor thermal overload protection.

Innovation Solution

A control method for thermal overload protection of asynchronous motors that determines the rotor's thermal level using different formulas based on the motor's state (starting, running, or shutdown) and incorporates a stator thermal balance heating quantity term to improve accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a simple adiabatic rotor thermal model is used, then the device complexity is reduced, but the measurement precision of rotor thermal level deteriorates

Engineering Contradiction:
Improvethermal model complexityVSAvoid rotor thermal level accuracy
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The patent applies dynamics by transitioning from a static adiabatic thermal model to a dynamic thermal model that accounts for heat exchange between rotor and stator. The thermal model dynamically adjusts based on operational parameters including heat transfer coefficients and thermal capacities, allowing accurate representation of transient thermal processes during motor startup, operation, and shutdown.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements parameter changes by introducing variable thermal parameters including heat transfer coefficient (k), thermal capacity (C), and thermal time constant (τ). These parameters are adjusted based on motor operating conditions, enabling the model to adapt to different thermal states and accurately calculate rotor thermal levels under varying load and speed conditions.

Inventive Principle:
Principle #35Parameter changes

2Device complexity

If a single thermal model is used for all motor states, then the device complexity is reduced, but the measurement precision of rotor thermal level deteriorates

Engineering Contradiction:
Improvethermal model uniformityVSAvoid rotor thermal level accuracy
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The patent applies segmentation by dividing the motor operation into three distinct states: startup state, running state, and shutdown state. Each state has its own specific thermal model and calculation formula, allowing precise thermal level determination tailored to the characteristics of each operational phase. This segmented approach accurately captures the different thermal behaviors during motor acceleration, steady-state operation, and deceleration.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent implements dynamics by creating a state-dependent thermal modeling system that dynamically selects appropriate thermal models based on motor operating conditions. The system transitions between different thermal calculation approaches depending on whether the motor is starting, running, or shutting down, ensuring optimal accuracy for each operational phase.

Inventive Principle:
Principle #15Dynamics

3Device complexity

If heat exchange between rotor and stator is not considered, then the device complexity is reduced, but the measurement precision of rotor thermal level deteriorates

Engineering Contradiction:
Improvethermal model simplicityVSAvoid rotor thermal level accuracy
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The patent applies the intermediary principle by introducing a heat transfer mechanism that mediates thermal energy exchange between the rotor and stator. The heat transfer coefficient (k) and thermal capacity (C) act as intermediary parameters that quantify the thermal coupling between rotor and stator, enabling accurate calculation of rotor thermal levels by accounting for heat flow paths through the motor structure.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 method provides more accurate thermal overload protection by monitoring heating quantities across all operational stages, reducing the risk of accidental tripping and overheating damage.

Implementation Method 1

determining a thermal level of the rotor according to a first formula based on a fact that the asynchronous motor is in a starting state; determining the thermal level of the rotor according to a second formula different from the first formula based on a fact that the asynchronous motor is in a running state

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

incorporates rotor losses and heat transfer between the rotor and the stator

Methodology Applied
Scientific EffectHeat transfer: Convection

Data Source

PatentEP4148978B1Control method for thermal overload protection of asynchronous motor
Publication Date: 2025.02.12 SCHNEIDER ELECTRIC IND SAS
  • EP4148978B1 patent drawingFigure 1
  • EP4148978B1 patent drawing
  • EP4148978B1 patent drawing

AI summary

The present disclosure relates to a control method for thermal overload protection of an asynchronous motor, wherein the asynchronous motor includes a rotor and a stator, and the control method includes: determining a current state of the asynchronous motor; determining a thermal level of the rotor according to a first formula based on the fact that the asynchronous is in a starting state; determining the thermal level of the rotor according to a second formula different from the first formula based on the fact that the asynchronous motor is in a running state; determining the thermal level of the rotor according to a third formula different from the first formula and the second formula based on the fact that the asynchronous motor is in a shutdown state; comparing the thermal level of the rotor with a first predetermined threshold value and a second predetermined threshold value greater than the first predetermined threshold value, and if the thermal level of the rotor is greater than the first predetermined threshold value and less than the second predetermined threshold value, issuing an overheat alarm; if the thermal level of the rotor is greater than a second predetermined threshold, shutting down the asynchronous motor.