Pulsed Torque Control for Rotating Machines at Variable Frequency

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Solution Overview

Problem

Control systems for rotating electrical machines are not efficient at regulating torque and speed, leading to energy loss, particularly at specific angular speeds or torque levels.

Innovation Solution

A method involving the generation of a continuously time varying torque command, conversion to a dynamic frequency pulsed torque command, and adjustment based on energy output comparisons to minimize energy loss, with the dynamic frequency pulsed torque command being provided to the rotating electrical machine at varying frequencies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If a continuously time varying torque command is used to regulate the rotating electrical machine, then the machine can reach the desired angular velocity, but energy loss increases at particular angular speeds or torque levels

Engineering Contradiction:
Improveangular velocityVSAvoidenergy loss
Core Design Contradiction:
SpeedVSLoss of energy

Solution Approach 1:

The patent applies periodic action by converting the continuously time varying torque command into a pulsed torque command with varying frequency. The control system determines optimal pulse frequencies based on operating conditions (angular speed and torque levels), applying torque in periodic pulses rather than continuous application. This reduces energy loss at particular operating points while maintaining the ability to reach desired angular velocities, directly resolving the technical contradiction between speed achievement and energy efficiency.

Inventive Principle:
Principle #19Periodic action

2Stability of the object's composition

If the control system regulates torque and speed continuously, then the machine operates smoothly, but efficiency decreases at specific operating points

Engineering Contradiction:
Improveoperational stabilityVSAvoidenergy efficiency
Core Design Contradiction:
Stability of the object's compositionVSUse of energy by moving object

Solution Approach 1:

The patent applies dynamics by making the torque command frequency adaptive rather than fixed. The control system dynamically adjusts the pulse frequency of the torque command based on real-time operating conditions (angular speed and torque levels). This dynamic adaptation allows the system to maintain operational stability while improving energy efficiency at specific operating points, resolving the contradiction between continuous regulation stability and energy efficiency.

Inventive Principle:
Principle #15Dynamics

3Loss of energy

If a pulsed torque command is used to reduce energy loss, then energy efficiency improves, but the complexity of the control system increases

Engineering Contradiction:
Improveenergy lossVSAvoidcontrol system complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The patent applies feedback by implementing a control system that continuously monitors operating conditions (angular speed and torque levels) and uses this information to determine optimal pulse frequencies for the torque command. The system compares actual performance with desired performance and adjusts the pulsed torque command frequency accordingly. This feedback mechanism enables energy loss reduction through pulsed commands while managing control complexity through systematic decision-making based on real-time data.

Inventive Principle:
Principle #23Feedback

Data Source

PatentUS20240372490A1Variable frequency pulsed electric machine control system
Publication Date: 2024.11.07 BORGWARNER INC
  • US20240372490A1 patent drawing
  • US20240372490A1 patent drawing
  • US20240372490A1 patent drawing

AI summary

A method of controlling a rotating electrical machine includes the steps of generating a continuously time varying torque command, configured to command the rotating electrical machine to reach an angular velocity; converting the continuously time varying torque command to a dynamic frequency pulsed torque command having a dynamic torque value; and providing the dynamic frequency pulsed torque command to the rotating electrical machine at a varying frequency.