Self-Sensing Feedback for Electromechanical Actuator Fault Tolerance
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Solution Overview
Problem
Current motion control systems in industrial settings face challenges in achieving fault tolerance and safety certification due to the need for additional hardware and complex redundancy configurations, which increase manufacturing costs and time-to-market.
Innovation Solution
Implementing self-sensing feedback within electromechanical actuators using spatial saliencies to generate redundant position and velocity measurements, eliminating the need for external sensors and reducing hardware requirements, thereby simplifying certification and manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional sensors and redundant hardware are added to achieve fault tolerance and safety certification, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The motor controller performs self-diagnostics by monitoring its own operational parameters (current, voltage, temperature, position) to detect faults and initiate safe states, eliminating the need for separate diagnostic sensors and reducing system complexity while maintaining reliability
Solution Approach 2:
The motor controller integrates multiple functions including position sensing, velocity measurement, fault detection, and safety monitoring within a single device, allowing one component to serve multiple safety-critical functions rather than requiring separate dedicated sensors for each function
2Reliability
If additional sensors and redundant hardware are added to achieve fault tolerance and safety certification, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The motor controller performs self-diagnostics by monitoring its own operational parameters (current, voltage, temperature, position) to detect faults and initiate safe states, eliminating the need for separate diagnostic sensors and reducing system complexity while maintaining reliability
Solution Approach 2:
The system creates virtual redundant sensing channels through software-based estimation algorithms that replicate the function of physical sensors using mathematical models and available measurement data, providing fault tolerance without duplicating expensive hardware
3Reliability
If additional sensors and redundant hardware are added to achieve fault tolerance and safety certification, then reliability is improved, but time to market increases due to additional testing and certification
Solution Approach 1:
The motor controller performs self-diagnostics by monitoring its own operational parameters (current, voltage, temperature, position) to detect faults and initiate safe states, eliminating the need for separate diagnostic sensors and reducing system complexity while maintaining reliability
Solution Approach 2:
The system creates virtual redundant sensing channels through software-based estimation algorithms that replicate the function of physical sensors using mathematical models and available measurement data, providing fault tolerance without duplicating expensive hardware
4Reliability
If traditional redundant sensor configuration is used, then fault tolerance is achieved, but the actuator requires extra cabling and bulk
Solution Approach 1:
The motor controller performs self-diagnostics by monitoring its own operational parameters (current, voltage, temperature, position) to detect faults and initiate safe states, eliminating the need for separate diagnostic sensors and reducing system complexity while maintaining reliability
Solution Approach 2:
The system combines multiple sensing functions (position, velocity, fault detection) into the existing motor controller unit, eliminating the need for separate sensor packages and their associated cabling, thereby reducing actuator bulk and weight
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
This approach enhances fault tolerance and safety compliance while reducing costs and time-to-market by leveraging existing components and eliminating the need for additional sensors and cabling, allowing for more efficient and cost-effective motion control systems.
Implementation Method 1
The feedback can be generated from within the electromechanical actuator (such as a motor) using spatial saliencies associated with the actuator. For example, a high frequency signal can be injected into the electromechanical actuator (such as from a drive or a component thereof) and sampled to measure a current, voltage, or other electrical parameter. Using the known saliencies, a position can be calculated based on the parameter.
Data Source
AI summary
Self-sensing feedback functionality for electromechanical actuators/motors is provided for use in operation and/or as a redundant safety mechanism to attain safety certification without adding extra bulk or wiring to the motor. An actuator can be manufactured having one or more saliencies that cause a spatial variance of inductance. A high frequency signal can be injected into the actuator and sampled to determine a current, voltage, or other electrical parameter. The parameter can be evaluated against the known saliencies of the actuator to determine a position of the actuator and/or an associated rotor. Additionally, the position can be evaluated as a function of time to determine a velocity. This can provide an alternative method for operating the electromechanical actuator according to the position/velocity provided. Additionally, this can provide a redundant feedback channel for safety certification without requiring additional actuator parts.