Motor Shaft Torque Measurement Using Dual-End Position Sensors
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Solution Overview
Problem
Current systems for measuring motor shaft torque in real-world conditions are inaccurate due to factors not accounted for in lab settings, such as aging, temperature, and debris, leading to unrealistic parameter monitoring and prediction.
Innovation Solution
A system comprising two sensors at opposite ends of the motor shaft, with a controller to determine mechanical torsional deflection and calculate torque, enhancing accuracy by accounting for real-world conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex multi-input tables mapping frequency, current, and voltage against torque are used, then torque estimation can be provided, but the measurement precision deteriorates because the tables are generated in lab settings that do not account for real-world factors like aging, temperature, and debris
Solution Approach 1:
The system uses position sensors to provide feedback on the actual angular position of the motor shaft and compares it against the expected position based on command signals. This feedback mechanism allows the system to detect and compensate for torque variations caused by real-world factors such as aging, temperature changes, and debris, thereby maintaining measurement precision in dynamic operating conditions.
Solution Approach 2:
The patent replaces complex mechanical torque sensing systems with an electronic control system that uses position sensors and signal processing to calculate torque. This substitution allows the system to account for real-world factors through software algorithms rather than being limited by physical sensor constraints, improving both precision and adaptability.
2Reliability
If position sensors are positioned on the opposite side of the motor relative to the load, then feedback for speed and torque control loops can be provided, but the device complexity increases due to the need for additional sensors and control mechanisms
Solution Approach 1:
The position sensors serve multiple functions: they provide feedback for speed control, torque measurement, and position monitoring. By making the sensors multi-functional, the system reduces the need for separate dedicated sensors for each function, thereby reducing overall device complexity while maintaining reliability.
Solution Approach 2:
The control system uses the position sensor data to automatically adjust motor operation without requiring external intervention. The system self-regulates speed and torque based on real-time position feedback, reducing the need for complex external control mechanisms and simplifying the overall system architecture.
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 system provides accurate real-time torque measurement by correcting for sensor alignment and environmental factors, ensuring precise motor operation.
Implementation Method 1
The system includes a first sensor arranged at a first end of the motor and a second sensor at a second end of the motor, opposite the first end... the controller to determine a mechanical torsional deflection of a shaft of the motor
Implementation Method 2
calculate a torque of the motor... the torque may be calculated via feedback from the sensors
Data Source
AI summary
Methods and systems are provided for an electric motor. The system includes a first sensor arranged at a first end of a motor and a second sensor at a second end of the motor, opposite the first and a controller with instructions stored in memory that cause the controller to determine a deflection of a shaft of the motor and calculate a torque of the motor.