Electric Motor Vibration Control via Speed Reduction
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Solution Overview
Problem
Electric motors experience extreme vibration due to damage or external factors, leading to potential damage to the motors and surrounding equipment, with existing solutions like stronger motor mounts being costly and ineffective.
Innovation Solution
A system comprising an electric motor, a vibration sensor, a motor control subsystem, and an electronic control element that senses and limits vibration by reducing the motor's speed when exceeding predetermined limits, with options for communication of actions to a remote location and potential reversal of speed adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If motor mounts are made stronger to withstand vibration, then reliability of motor mounting is improved, but cost increases and effectiveness is limited
Solution Approach 1:
The system performs preliminary detection of vibration conditions using a vibration sensor before damage occurs. The control element receives vibration data and determines whether vibration exceeds predetermined limits, then proactively reduces motor speed to prevent damage to motor mounts and surrounding equipment, rather than relying on overly strong mounts designed for worst-case scenarios
Solution Approach 2:
The system implements a feedback loop where the vibration sensor continuously monitors motor vibration, the control element compares readings against predetermined limits, and the motor control subsystem adjusts motor speed in response. This closed-loop feedback enables dynamic adaptation to vibration conditions, replacing static over-engineered mounts with an active control system
2Reliability
If motor mounts are made stronger to withstand vibration, then reliability of motor mounting is improved, but extreme imbalance can still cause equipment damage
Solution Approach 1:
The system converts the harmful effect of vibration into a useful signal for control. The vibration sensor detects harmful vibrations, and the control element uses this information to reduce motor speed, thereby eliminating the harmful effect. The vibration that would otherwise cause damage is transformed into feedback that triggers protective action
Solution Approach 2:
The system takes preliminary action by detecting vibration conditions and reducing motor speed before extreme vibration can cause equipment damage. Rather than relying on motor mounts to withstand extreme forces, the system proactively prevents the extreme vibration conditions from occurring in the first place
3Object-affected harmful factors
If motor speed is reduced to limit vibration, then vibration damage is prevented, but productivity decreases
Solution Approach 1:
The system dynamically adjusts motor speed based on real-time vibration conditions rather than operating at a fixed reduced speed. The motor control subsystem modifies speed only when vibration exceeds predetermined limits and restores normal operation when conditions improve, enabling the system to maintain high productivity during normal operation while preventing damage during abnormal conditions
Solution Approach 2:
The system implements periodic monitoring of vibration conditions and intermittent speed reduction only when necessary. The vibration sensor continuously monitors, the control element periodically evaluates conditions against predetermined limits, and speed adjustment occurs only during periods when vibration exceeds thresholds, allowing full productivity during normal operation periods
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
Effectively prevents damage from extreme vibration by reducing motor speed when necessary, enhancing reliability and reducing costs compared to traditional solutions.
Implementation Method 1
The vibration sensor may be a three-axis accelerometer, wherein vibrations are sensed as accelerations
Data Source
AI summary
A system and method for limiting the vibration of an electric motor so as to avoid situations in which extreme vibration may result in damage to the motor or other equipment. A motor control subsystem runs the motor in accordance with a command specifying a speed or torque. A vibration sensor, such as a three-axis accelerometer, senses a vibration of the electric motor, or, alternatively, software indirectly detects the vibration based on phase or torque ripple. Such vibration may be caused by, e.g., a broken fan blade or an accumulation of snow or ice. A control element receives data regarding the vibration, determines whether the vibration exceeds a pre-determined limit, and if so, takes action to reduce the vibration of the electric motor below the pre-determined limit. Such action may involve slowing or stopping the motor, thereby avoiding damage, increasing reliability, and reducing cost.