Vacuum Cleaner Unified Controller for Brushless and Brushed Motors
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Solution Overview
Problem
Vacuum cleaners with separate controllers for brushless and brushed motors are costly and inefficient, as they require distinct control systems, leading to increased complexity and expense.
Innovation Solution
A single controller generates control signals for both brushless and brushed motors, using PWM signals with adjustable duty cycles and conduction periods to maintain consistent performance across varying supply voltages, reducing the need for multiple controllers and improving power management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate controllers are used for brushless and brushed motors, then each motor receives dedicated control, but the device complexity and cost increase
Solution Approach 1:
The patent combines separate control functions for brushless and brushed motors into a single integrated controller. The controller includes a first control signal generation unit for the brushless motor and a second control signal generation unit for the brushed motor, both within one controller device. This merging reduces device complexity and cost while maintaining the ability to independently control each motor type through dedicated control signal generation units.
Solution Approach 2:
The single controller is designed with multi-functional capability to handle both brushless and brushed motor control. It incorporates multiple control signal generation units that can generate appropriate control signals for different motor types, making the controller universal and eliminating the need for separate dedicated controllers for each motor type.
2Device complexity
If a single controller controls both brushless and brushed motors, then cost and complexity are reduced, but control precision for each motor type may be compromised
Solution Approach 1:
The controller is segmented into distinct control signal generation units: a first control signal generation unit for brushless motors and a second control signal generation unit for brushed motors. Each unit is specialized to generate precise control signals for its specific motor type, maintaining control precision while operating within a single integrated controller structure.
3Adaptability or versatility
If supply voltage varies, then battery operation is flexible, but motor performance consistency deteriorates
Solution Approach 1:
The controller incorporates a voltage detection unit that continuously monitors the supply voltage level. Based on the detected voltage, the controller dynamically adjusts control parameters for both brushless and brushed motors to maintain consistent performance. This feedback mechanism ensures that motor performance remains stable despite variations in supply voltage during battery operation.
Solution Approach 2:
The controller dynamically adjusts control signals based on real-time supply voltage conditions. When voltage varies, the controller modifies excitation duty cycles and control parameters adaptively, transforming the static control approach into a dynamic one that maintains performance consistency across different voltage levels.
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 solution reduces the overall cost of the vacuum cleaner by simplifying control systems while ensuring consistent suction and agitation performance despite changes in supply voltage, maintaining performance as the battery discharges.
Implementation Method 1
the second control signal is a PWM signal having a constant period, and the controller adjusts the conduction period and the duty cycle of the PWM signal in response to changes in a supply voltage
Implementation Method 2
the first control signal causes a winding of the first motor to be excited for a conduction period over an electrical half-cycle of the first motor
Data Source
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AI summary
A vacuum cleaner comprising a suction source, a cleaner head, and a controller. The suction source comprises an impeller and a first motor for driving the impeller, and the cleaner head comprises an agitator and a second motor for driving the agitator. The first motor is a brushless motor and the second motor is brushed motor. The controller is configured to generate control signals for controlling simultaneously the excitation of the first motor and the second motor.