Sensor Module for Electrical Machines with Failure Detection
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Solution Overview
Problem
Conventional electrical machine controllers using Hall Effect sensors cannot reliably detect or account for sensor failures, leading to off-nominal operation and potential complete failure in motor applications.
Innovation Solution
A system with a sensor module that includes a failure detection module to identify failed sensors and a virtual sensor module to output simulated signals, allowing the control module to continue operating the electrical machine effectively even with sensor failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three HED sensors are placed 120 degrees apart in conventional electrical machines, then position information for motor commutation is obtained, but the system cannot detect or account for sensor failures leading to off-nominal operation
Solution Approach 1:
The failure detection module continuously monitors sensor signals and compares them against expected operational ranges, providing feedback about sensor health status. When a sensor signal falls outside acceptable parameters, the system detects the failure and switches to using signals from the remaining functional sensors, maintaining reliable operation throughout the sensor lifecycle
Solution Approach 2:
The system creates virtual copies of failed sensor signals by interpolating or extrapolating from the signals of the two remaining functional sensors. This copying approach allows the control system to continue receiving all necessary position information even when one physical sensor fails, effectively replacing the failed sensor's function through software-based signal generation
2Reliability
If conventional sensor systems are used without failure detection, then the system structure remains simple, but sensor failures cause excessive current draw, noisy operation, and complete failure
Solution Approach 1:
The failure detection module performs preliminary monitoring and identification of sensor failures before they can cause harmful effects such as excessive current draw or noisy operation. By detecting failures early in the degradation process, the system can switch to backup sensing modes proactively, preventing the development of off-nominal operating conditions
Solution Approach 2:
The sensor module acts as an intermediary layer between the physical HED sensors and the motor control system. This intermediate layer provides failure detection, signal validation, and virtual sensor generation capabilities, isolating the control system from direct exposure to failed sensors and their harmful effects while maintaining seamless operational continuity
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 reliable detection and handling of sensor failures, ensuring continued nominal operation of electrical machines by simulating sensor signals from functioning sensors, thereby improving motor reliability and preventing operational failures.
Implementation Method 1
Certain electrical machine controllers (e.g., space based DC brushless motor controllers) can utilize Hall Effect (HED) sensors to provide position information of the rotor of the electrical machine
Data Source
AI summary
A system for detecting sensor failure and/or operating with a failed sensor in an electrical machine includes an electrical machine, three or more sensors configured to connect to the electrical machine, and a sensor module operatively connected to each sensor to receive sensor signals from the sensors. The sensor module includes a failure detection module operatively connected to each sensor and configured to determine if each sensor is a failed sensor or a functioning sensor. The sensor module also includes a virtual sensor module operatively connected to the failure detection module and configured to output simulated sensor signals for the failed sensor, wherein the sensor module is configured to output the sensor signals for each functioning sensor. The system includes a control module operatively connected to the sensor module and the electrical machine to receive sensor signals and simulated sensor signals to control operation of the electrical machine.