Integrated Resolver Simulation for Motor Controller Fault Testing
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Solution Overview
Problem
Existing motor systems with integrated resolvers have a short service life due to extreme rotational conditions, leading to frequent replacements and increased costs. Additionally, the need for connection to a resolver complicates their use.
Innovation Solution
A motor-integrated resolver transformer simulation device is developed, comprising a resolver transformer module and a motor module, where the motor rotor extends into the resolver rotor. This device includes primary and secondary interfaces for connection to an external motor controller, allowing for the transmission of rotary information and adjustment of motor speed and steering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If motors are used in extreme rotational conditions for motor controller testing, then the testing coverage and reliability are improved, but the service life of motors decreases and replacement costs increase
Solution Approach 1:
The patent creates a simulation device that copies the essential functionality of a motor-resolver system without requiring an actual motor. The simulation device generates resolver signals based on simulated rotor position and speed, providing a cost-effective alternative to physical motor testing that eliminates wear and replacement costs while maintaining testing reliability
Solution Approach 2:
The patent introduces a simulation device as an intermediary between the motor controller under test and the physical motor. This intermediary provides the necessary resolver feedback signals without requiring the motor to physically rotate, thereby protecting the motor from extreme testing conditions while enabling comprehensive controller validation
2Reliability
If motors are connected to resolvers for motor controller testing, then the commutation control functionality is verified, but the device complexity and connection requirements increase
Solution Approach 1:
The patent merges the motor and resolver functionalities into a single integrated simulation device. The simulation device simultaneously provides motor phase signals and resolver feedback signals, eliminating the need for separate motor-resolver connections and simplifying the overall testing setup while maintaining commutation control verification capability
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 device improves the service life of the motor module by enhancing the brush device and reduces testing costs by simulating the resolver transformer functionality, thus determining the qualification of the motor controller effectively.
Implementation Method 1
The rotor winding acts as the secondary side of the transformer and receives the induced voltage through electromagnetic coupling
Data Source
AI summary
The present invention involves in the technical field of resolver transformers, specifically in a motor-integrated resolver transformer simulation device and the simulation method thereof. The present invention obtains the current sinusoidal and cosinusoidal signals of a motor module through a resolver transformer module provided therein, and compare them with the excitation signals inputted by a motor controller, so as to determine whether the resolving circuit of the motor controller is faulty, and, by improving the brush device of the motor module, the service life of the motor module is increased and the testing cost is reduced.