Motor Positioning Control Using a Sensorless Detent Mechanism

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Solution Overview

Problem

Conventional motor control devices for automatic transmission in vehicles rely on motor rotation angle sensors to position the rotation transmission system accurately, which can be costly and prone to errors, and they fail to function effectively without these sensors.

Innovation Solution

A motor control device that uses a detent mechanism with a detent member and an engaging member, along with a positioning determination unit and an energization control unit, to accurately position the output shaft without relying on a motor rotation angle sensor by determining the engaging member's position based on control parameters and motor current values.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a motor rotation angle sensor is used to detect the motor rotation angle, then the positioning accuracy of the output shaft is improved, but the device complexity and cost increase

Engineering Contradiction:
Improvepositioning accuracyVSAvoiddevice complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts and removes the motor rotation angle sensor from the system. Instead of using a sensor to detect the rotation angle, the invention uses a detent mechanism with valley portions and mountain portions that physically constrain and indicate the rotation position through the engagement of a detent member, thereby achieving positioning without the sensor

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a detent mechanism as an intermediary between the motor and the output shaft. The detent member engages with the valley portions and mountain portions on the detent plate, serving as a mechanical intermediary that provides positional information without requiring electronic sensors

Inventive Principle:
Principle #24Intermediary (Mediator)

2Measurement precision

If a motor rotation angle sensor is used to detect the motor rotation angle, then the positioning accuracy of the output shaft is improved, but the reliability decreases due to potential sensor errors

Engineering Contradiction:
Improvepositioning accuracyVSAvoidreliability
Core Design Contradiction:
Measurement precisionVSReliability

Solution Approach 1:

The detent mechanism is self-service in nature, providing positional information through its mechanical structure without requiring external sensors or electronic components. The valley portions and mountain portions on the detent plate automatically engage with the detent member to indicate position, making the system self-sufficient and more reliable

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent replaces the expensive and potentially unreliable motor rotation angle sensor with a simple mechanical detent mechanism that uses inexpensive components like springs and engagement members, achieving reliable positioning through mechanical means rather than electronic sensing

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Manufacturing precision

If a motor rotation angle sensor is used, then the control precision is improved, but the manufacturing cost increases

Engineering Contradiction:
Improvecontrol precisionVSAvoidmanufacturing cost
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent extracts and eliminates the motor rotation angle sensor from the system, replacing it with a mechanical detent mechanism that provides sufficient control precision for the application while significantly reducing manufacturing costs by removing expensive electronic sensing components

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The invention uses inexpensive mechanical components such as spring-loaded detent members and simple engagement surfaces instead of expensive rotation angle sensors, achieving the necessary control precision through mechanical means that are much more cost-effective to manufacture

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

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 precise positioning of the output shaft within the required range without a motor rotation angle sensor, enhancing reliability and reducing costs by using a DC motor with brush-based on/off control and eliminating the need for rotation angle sensors.

Implementation Method 1

a detent spring (25) which elastically deforms, and a detent roller (26) connected to the detent spring (25)

Methodology Applied
Scientific EffectElasticity: Elasticity

Implementation Method 2

a motor (10) and a detent mechanism (21, 25, 26)... The motor control device controls a drive of the motor (10)

Methodology Applied
Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Data Source

PatentUS11837987B2Motor control device
Publication Date: 2023.12.05 DENSO CORP
  • US11837987B2 patent drawing
  • US11837987B2 patent drawing
  • US11837987B2 patent drawing

AI summary

A motor control device controls a drive of a motor in a motor drive system including the motor and a detent mechanism. The detent mechanism has a detent member that rotates integrally with an output shaft to which the rotation of the motor is transmitted, and an engaging member that moves a valley portion by a rotation of the motor and positions the output shaft by stopping within a positioning range. The motor control device includes a positioning determination unit and an energization control unit. The positioning determination unit determines whether or not the engaging member is stopped within the positioning range based on control parameter other than a detection value of a motor rotation angle sensor that detects a motor rotation angle. When the energization control unit determines that the engaging member is stopped within the positioning range, the energization control unit turns off the energization of the motor.