Rotor Position Encoder Reference Sensor Angular Offset

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Solution Overview

Problem

Existing methods for determining the angular offset of a rotor position encoder in electronically commutated electric machines require complex software implementations and often necessitate special operating states or visits to a repair shop, making them inefficient and costly.

Innovation Solution

Incorporating a reference encoder, such as a Hall sensor, to detect reference values of the magnetic flux density, allowing continuous determination and updating of the angular offset during operation, eliminating the need for additional software complexity and repair shop visits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional rotor position encoder methods are used, then the angular offset can be determined, but complex software implementations and special operating states are required

Engineering Contradiction:
Improveangular offset determinationVSAvoidsoftware complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

A reference encoder is introduced as an intermediary component that provides reference values for the angular offset determination. This reference encoder acts as a mediator between the rotor position encoder and the control unit, enabling offset determination through hardware-based reference signals rather than complex software algorithms. The reference encoder generates reference values that directly indicate the angular relationship between the rotor and stator, simplifying the control software's task to merely comparing sensor signals with these reference values.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Measurement precision

If conventional rotor position encoder methods are used, then the angular offset can be determined, but visits to a repair shop are necessary

Engineering Contradiction:
Improveangular offset determinationVSAvoidmaintenance accessibility
Core Design Contradiction:
Measurement precisionVSEase of repair

Solution Approach 1:

The rotor position encoder system performs self-service by automatically determining and updating the angular offset during normal operation. The reference encoder enables the system to self-calibrate without external intervention, eliminating the need for repair shop visits. The control unit continuously compares the rotor position sensor signal with the reference encoder signal and automatically adjusts the offset value, making the system self-maintaining and eliminating dependency on specialized service centers.

Inventive Principle:
Principle #25Self-service

3Productivity

If continuous angular offset determination is implemented, then operational efficiency is improved, but additional hardware components are required

Engineering Contradiction:
Improveoperational efficiencyVSAvoidhardware complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The reference encoder serves multiple functions: it provides reference values for angular offset determination, enables continuous calibration during operation, and eliminates the need for separate calibration procedures. By making this single component multi-functional, the system achieves continuous operational efficiency improvement without proportionally increasing hardware complexity. The reference encoder is integrated into the existing rotor position sensing system, sharing the same magnetic field environment and mechanical mounting structure.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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

Enables continuous availability of instantaneous angular offset data for commutation, reducing time and cost by allowing offset determination during normal operation without special operating states, thus improving operational efficiency and reducing maintenance needs.

Implementation Method 1

Incorporating a reference encoder, such as a Hall sensor, to detect reference values of the magnetic flux density

Methodology Applied
Scientific EffectHall effect: Hall Effect

Data Source

PatentUS10177638B2Rotor position encoder for an electronically commutated electric machine having a reference encoder
Publication Date: 2019.01.08 SCHAEFFLER TECHNOLOGIES AG & CO KG
  • US10177638B2 patent drawing

AI summary

A rotor position encoder (01) for an electronically commutated electric machine (02) having a stator and a rotor (03) and including a rotor position sensor (05) which is mounted on the stator so as to rotate therewith and has the purpose of detecting the rotational position of the rotor (03) with respect to the magnetic field of the stator, and a signal encoder (07) which is mounted on the rotor (03) so as to rotate therewith. The rotor position encoder is defined in that it has a reference encoder (08) for detecting reference values of the magnetic flux density of the rotor field, wherein the reference values (09) serve to determine an angular offset (11) between the signal encoder (07) and the position of the rotor (03). Furthermore, a method for determining an angular offset (11) between a signal encoder (07) of a rotor position encoder (01) and a rotor position of an electronically commutated electric machine (02) is provided.