VFD Mixer Diagnostics for Power Anomaly Detection
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Solution Overview
Problem
Existing commercial mixers require mechanical adjustments to change speed settings, which can be inconvenient and lead to service/repair issues due to harsh operating conditions, and lack effective diagnostic capabilities for power system issues.
Innovation Solution
A commercial mixer equipped with a variable frequency drive (VFD) and embedded sensors for analyzing power conditions, providing alerts for potential issues like brownout, surge, short circuits, and motor phase anomalies, allowing for real-time diagnostic monitoring and recommended service actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If mechanical adjustments are used to change speed settings, then speed control is achieved, but service/repair issues arise due to harsh operating conditions
Solution Approach 1:
The patent replaces mechanical speed adjustment mechanisms (gears, belts, pulleys) with an electronic variable frequency drive (VFD) system that controls motor speed through electrical parameters. This substitution eliminates mechanical wear and adjustment issues while maintaining speed control capability, directly resolving the contradiction between ease of operation and reliability.
2Loss of information
If VFD with embedded sensors is implemented, then diagnostic capabilities are improved, but device complexity increases
Solution Approach 1:
The patent merges the diagnostic control functions and sensor processing capabilities directly into the existing VFD unit. By integrating these diagnostic capabilities within the VFD rather than adding separate monitoring systems, the patent improves diagnostic information availability while minimizing the increase in overall device complexity.
3Measurement precision
If multiple embedded sensors are added for monitoring, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent designs the VFD with multi-functional embedded sensors that can detect multiple power system parameters (voltage, current, frequency, power factor) and diagnose various conditions (brownout, surge, short circuit, phase loss) using a unified sensing and processing architecture. This universal approach improves measurement precision across multiple parameters while avoiding the complexity of separate dedicated sensors for each function.
Data Source
AI summary
A mixing machine includes a head extending over a bowl receiving location, a rotatable output shaft for receiving a mixer tool, and a gear system for effecting rotation of the rotatable output shaft about its axis and orbiting of the shaft axis about another axis. An electric motor includes an output operatively connected to drive the gear system. A variable frequency drive is connected to deliver 3-phase power to the electric motor to achieve variable speed and torque. The variable frequency drive includes a plurality of embedded sensors, including embedded current sensors and embedded voltage sensors. A diagnostic control is configured and operable to analyze outputs from the embedded sensors and produce an alert indication upon identification of a characteristic indicative of at least one of input power brownout, input power surge, machine short circuit, motor phase insulation arch, motor phase to ground arch or motor loss of phase.