Electric Motor Test Rig Using Low-Voltage Fault Signatures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional diagnostic methods for electric motors in appliances are time-consuming, costly, and risky due to the need for testing entire appliances, often missing faulty universal motors, especially when using mains voltages, which can be hazardous.
Innovation Solution
A test rig that supplies electric motors with a safe operational voltage below mains voltage, using a power supply and processing means to capture operational data, determine an operational signature, and provide a visual indication of faults, such as voltage spikes or rotational speed variance, to easily detect issues with motor brushes, commutators, and bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional diagnostic methods test the electrical appliance as a whole using mains voltage, then comprehensive fault detection is achieved, but the testing process becomes time-consuming and hazardous
Solution Approach 1:
The patent extracts the motor from the complete appliance system for standalone testing. The motor is removed from the appliance and tested independently using a test rig, allowing focused diagnostic evaluation without testing other appliance components, thereby reducing testing time while maintaining fault detection accuracy
Solution Approach 2:
The patent introduces a specialized test rig as an intermediary device between the motor and the diagnostic process. This test rig provides a controlled testing environment with specialized sensors and processing means that can quickly identify motor faults without requiring full appliance assembly, thus reducing testing time while maintaining reliability
2Reliability
If conventional diagnostic methods use mains voltage for testing, then operational conditions are accurately simulated, but safety hazards increase due to high voltage
Solution Approach 1:
The patent changes the voltage parameter from mains voltage (230V) to a lower safe voltage (6-59V) for motor testing. This parameter change maintains the ability to detect faults through operational signatures while eliminating the safety hazards associated with high voltage, allowing accurate fault detection without exposing users to dangerous electrical levels
3Measurement precision
If specialized training is required to interpret raw operational data, then accurate fault diagnosis is achieved, but the process becomes time-consuming and expensive
Solution Approach 1:
The patent implements self-service through automated processing means that automatically interpret operational data and generate fault diagnoses without requiring user expertise. The processing means analyzes tachometer signals, identifies operational signatures, and provides clear fault indications, allowing untrained users to perform accurate motor diagnostics independently
Solution Approach 2:
The patent replaces the need for human expert analysis with an automated electronic processing system. Instead of requiring trained technicians to interpret raw tachometer data, the processing means electronically analyzes the signals, identifies fault patterns, and provides automated diagnoses, thereby maintaining measurement precision while dramatically improving ease of operation
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
Facilitates quick, safe, and cost-effective detection of motor faults without specialized training, using lower voltages and reduced current, providing visual indicators for user-friendly fault identification.
Implementation Method 1
a power supply means for supplying electrical power to the electric motor
Implementation Method 2
the data capture means is a tachometer of the electric motor
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A test rig for detecting a fault in an electric motor comprising: a power supply means for supplying electrical power to the electric motor; and a processing means configured to: cause the power supply means to supply the electric motor with an operational voltage; operate the electric motor; receive operational data of the electric motor that is captured by a data capture means; determine an operational signature of the electric motor from the operational data, wherein the operational signature comprises an indication of a fault with the electric motor; and provide an indication of the fault to a user based on the determined operational signature.