Radial Hall Sensor Layout for Redundant Rotor Position Detection
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Solution Overview
Problem
Existing rotor location sensing apparatuses in motors are prone to failure due to single sensor failures, require additional structures for installation, and have limited sensing signal resolution, leading to economic losses and precision issues.
Innovation Solution
A rotor location sensing apparatus with a magnet and substrate configuration that includes a main magnet and sub-magnet, where first and second Hall sensors are strategically placed on circular tracks to provide redundant sensing channels and increased resolution without additional structures, allowing the apparatus to function even with sensor failures and improve signal accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional sensors are added to increase redundancy and resolution, then reliability and measurement precision improve, but device complexity and space requirements increase
Solution Approach 1:
The patent combines multiple sensors (first sensor and second sensor) into a single integrated sensor unit that functions as one component. This merging approach provides redundant sensing capabilities and improved reliability while avoiding the complexity of managing separate sensor installations, as the combined sensor is treated as a single replaceable unit with unified signal processing
2Measurement precision
If additional sensors are added to increase redundancy and resolution, then reliability and measurement precision improve, but the apparatus requires separate installation regions increasing space constraints
Solution Approach 1:
The patent merges multiple sensing functions into a single sensor unit that occupies one installation region. The first sensor and second sensor are combined into one component that provides both redundant sensing and high-resolution measurement capabilities, eliminating the need for separate installation regions while maintaining improved measurement precision
Solution Approach 2:
The patent utilizes the radial dimension by positioning sensors at different radial distances from the rotor center. The first sensor and second sensor are arranged at different radial positions, allowing both to detect rotor location within the same circumferential region, thereby achieving high resolution and redundancy without requiring additional circumferential or axial space
3Measurement precision
If magnetizing accuracy is improved to increase sensing resolution, then measurement precision improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent divides the sensing function into multiple independent sensors (first sensor and second sensor) rather than relying on a single high-precision magnet. Each sensor provides partial sensing information, and their combined output achieves high measurement precision. This segmentation shifts the precision requirement from the magnet to the sensor system, simplifying magnet manufacturing while maintaining high resolution
Solution Approach 2:
The patent changes the approach to achieving high resolution by transitioning from improving magnetizing parameters (magnet accuracy) to optimizing sensor arrangement parameters (sensor positions, radial distances, and angular separations). By adjusting these geometric parameters, the system achieves high measurement precision through sensor configuration rather than magnet manufacturing complexity
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 solution enables the apparatus to maintain functionality with sensor failures and enhance sensing resolution, allowing precise rotor location detection without additional structures, thus reducing economic losses and improving precision.
Implementation Method 1
a sensor including a magnetic element is disposed inside the motor as a rotor location sensing apparatus. The sensor grasps a present location of the rotor by sensing a magnetic force of the magnet
Data Source
AI summary
The present invention provides an apparatus for sensing rotor location, the apparatus comprising: a central shaft; a magnet coupled to the central shaft; a sensor portion is disposed correspond to the magnet; wherein the sensor portion comprising a substrate, a first group including a first Hall sensor and a third Hall sensor disposed on the substrate, and a second group including a second Hall sensor and a fourth Hall sensor, the first Hall sensor and the third Hall sensor are arranged to overlap in a radial direction about the central shaft and the second Hall sensor and the fourth Hall sensor are arranged to overlap in a radial direction about the central shaft.