Rotary Transformer Decoding Chip Fault Estimation
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Solution Overview
Problem
Existing motor-position detection systems using rotary transformers face reliability issues due to high decoding failure risks with software decoding and excessive protection alarms when using decoding chips, which can disrupt motor operation and position detection accuracy.
Innovation Solution
A method and system that delay fault reporting from the decoding chip, allowing fault-tolerant operation by estimating the rotor-position value in real-time using pre-alarm rotational speed data and controlling the motor based on a fault threshold, thereby reducing unnecessary alarms and improving system reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a decoding chip is used to decode sine and cosine signals, then decoding convenience and protection functions are improved, but fault alarm frequency increases and operation reliability deteriorates
Solution Approach 1:
The patent introduces a fault judgment module as an intermediary between the decoding chip and the motor control system. This module receives alarm information from the decoding chip but does not immediately trigger fault shutdown. Instead, it estimates rotor position based on historical data and only shuts down the motor when the estimation error exceeds a threshold, thereby mediating between the decoding chip's protective alarms and the motor control system's operational continuity requirements
Solution Approach 2:
The system performs preliminary actions by continuously collecting and storing rotational speed data before faults occur. When an alarm is triggered, the fault judgment module uses this pre-collected historical data to estimate the rotor position and determine whether the alarm represents a true fault or a transient anomaly, allowing the system to prepare for potential faults rather than reacting immediately
2Measurement precision
If fault alarm triggers immediate motor shutdown, then position detection accuracy is protected, but system operation reliability deteriorates
Solution Approach 1:
The patent implements a dynamic fault judgment mechanism where the response to alarm information is not fixed but adapts based on real-time conditions. The system dynamically estimates rotor position using historical rotational speed data and compares it with actual position feedback. Only when the deviation exceeds a dynamically set threshold does the system trigger motor shutdown, making the fault response flexible and context-dependent rather than rigid and immediate
Solution Approach 2:
The system establishes a feedback loop where alarm information from the decoding chip is continuously monitored, rotor position is estimated based on historical data, and the estimated position is compared with actual position feedback. This closed-loop feedback mechanism allows the system to distinguish between transient anomalies and true faults, triggering shutdown only when necessary to maintain position detection accuracy
3Adaptability or versatility
If software decoding with peripheral circuits is used, then decoding flexibility is improved, but circuit complexity and failure risk increase
Solution Approach 1:
The patent merges the fault judgment and rotor position estimation functions directly into the control processor, eliminating the need for separate peripheral decoding circuits. The control processor reads sine and cosine signals, performs decoding, monitors for faults, and controls the motor in an integrated manner, reducing circuit complexity while maintaining decoding flexibility through software programmability
Data Source
AI summary
Disclosed are a method and a system for processing fault information of a decoding chip in a rotary transformer. The method includes: reading data information transmitted by the decoding chip according to a preset period; determining whether the data information includes alarm information; when the data information includes the alarm information, estimating a rotor-position value after an alarm occurs in real time according to a rotational speed in the data information obtained before the alarm occurs; determining whether a difference between a current rotor-position value and the estimated rotor-position value is greater than a fault threshold; and when the difference between the current rotor-position value and the estimated rotor-position value is greater than the fault threshold, controlling a motor using the estimated rotor-position value.