Note: Descriptions are shown in the official language in which they were submitted.
1
Brushless Motor in Activate Relax States
The Brushless Motor_in_Activate_Relax_States (BMARS) designed here is a
computer brushless
DC fan modified into the BMARS to operate in harsh environment, where
integrated circuits are
forbidden to be operated, such as to tolerate some presence of water. And to
operate in high
temperature ranges similar to electrical transformers.
The computer brushless DC' fan found in computers of present time has some
integrated circuits
where it has also a software embedded into an integrated circuit to
synchronize and to control
the rotation of the fan. In fact, there is a printed circuit board attached to
the stator of the fan;
where the high humidity or the presence of water or the high temperature would
damage the
components on the printed circuit board and will disable the fan.
By memory, the testing was done for two fans ARX CeraDynaTA4 FD 1270-A0053C /
12V-0.42A
and ARX CeraDynaT FD 1260-A2033C / 12V-0.16A. Where the 0.42A with the rotor
attaching
the blades removed and by making a parallel electrical connection to the 0.16A
-from printed
circuit board to printed circuit board (PCB). That is the PCB of 0.42A is
controlling the fan of
0.16A where four connections from PCB 0.42A are connected to the PCB 0.16A for
controlling
the coil of the Jan 0.16A. The electrical power is powered to the PCB of the
0.42A, and the
observations have shown that the fan 0.16A blades oscillated in small angle
much less than 30
degrees; but when putting the rotor containing the magnet and blades of 0.42A
closed to its
PCB; then some rotation of the rotor in the 0.16A can happen when said magnet
are rotated by
hands near the said PCB.
Later a few fans ARX CeraDynam FD 1260-A1033E / 12V-0.12A are bought to do the
research
on making a fhn capable to tolerate some presence of water and to be operated
in high
temperature. This fan had been disassembled and all measurements were made
that are
discussed in this document. Where the coil was electrically cut from the PCB
and presented to
the controlling electronic components located far away from the fan itself
that can be tolerated
in some presence of water and high temperature since the only parts that are
embedded in such
environment are the coils of stator, the rotor magnet and blades.
Where from the "Handbook of Transformer Applications"; William M Flanagan,
ISBN: 0-07-
021290-2, TK2791F583(NRC, Ottawa, Canada). Where the chapter 17 on page 17.1,
on the
first paragraph where is noted "Specification MIL-HDBK-217A assigned 2.46
failures per 106 h
.for transfOrmer operating 105 C". Where by the principle described in this
document where the
PCB removed and the /an has only output as two terminals of the coil of the
stator and the
magnet in the rotor with rotating blades. The said fan has a feature very
similar to a
transformer, where the coils are electronically powered at afar distance, to
conclude that the
new modified fan can tolerate some presence of water but not corrosion proof
and can operate at
higher temperature than normally when the PCB are attached.
The original purpose of producing such fan is to operate in food delivery from
restaurants. With
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the event of stainless steel vacuum materials that is very good heat
insulation is the future
insulation of thermal energy material. The operation of such fan is to provide
heat source
energy to be spread away from the source location such that the source
location shall not be too
high in temperature: and also to accelerate the warming up in temperature
where the fan
produces convection of the medium such as air confined in the insulated
thermal materials.
The thermal energy insulation can be of any type including the new vacuum
stainless steel. The
fan developed in this invention, BMARS, is a complement to the project
Low_Voltage_Heater_Plate (LVHP: 2,610,390) and thus it will be used mostly for
the project
LVHP.
The principle described in producing the BMARS is very useful for.fast.food
delivery application
since it is to use a used fan with removing the PCB or some electrical
components on the PCB
and to connect the coil terminals of the fan to an external controlling
electronic unit. And to the
most reducing the intervening design upon the material of the original
computer .fan.
Therefore, the fan BMARS operates in an active mode by receiving electrical
power into the coil
to convert it into mechanical torque output in an instant then the controlling
electronic unit puts
the coil terminals in High Impedance to acquisition the coil polarity to
prepare for the next
polarity of applying power to the coil terminals.
Usually for the case of transformer that has early initial defect like early
defect such as
imperfection, but after the transformer has operated for a while then the life
duration is very
promising as mentioned earlier. And since the BMARS has similarity to the
transformer, to
reuse the computer fan fOr a second life in a recycling process and not to
waste computer fans in
junk yards, the product BMARS allows to me build it more easily that is no
need to redo
substantial redesigning of rotor and stator processes.
Brief description of figures:
Fig. 1: rotor and stator of ARX CeraDynam FD 1260-Al 033E / 12V-0.12A.
Fig._2:relation of electromotive force and rotating magnetic flux in relaxed
mode.
Fig._3:circuit providing activation and relaxation of brushless motor coil.
Fig._4: experimental data from oscilloscope.
Fig. _5: temperature controlled of heat generation for operation along BMARS.
Fig._1 shows the internal rotor-stator of the fan FD 1260-A1033E. The labels
Li, L2 and L3
are the ones labeled on the printed circuit board (PCB) located to the stator
that is fixed. The
terminals 2 and 3 correspond to where L2 and L3 are on the PCB. The terminals
2,3 are cut
away from the PCB and they are the coil terminals of the stator.
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I have dismantled one of the fan to estimate the number turns in the stator as
indicated in the
figure.
The rotor indicated by the circle which also represents the circular magnet of
the rotor, the poles
are as shown in an estimation. The rotor on the outside has the blades
attached to it to cause air
flow.
For an activation of poles polarity by powering terminals 3,2 the poles in the
stator are as
indicated; with the position of the stator as in figure; then with no power to
terminals 3,2; the
rotor will rotate counterclockwise for about 45 ; that is equivalent to
holding the rotor and
release it to rotate that angle and it is a mechanical input energy to turn
the rotor. So therefore
to keep it to turn in same direction the polarity of electrical input to
terminal 3,2 must be the
same as when the release of the rotor that turns to induce polarity in the
terminals 3,2.
The coil terminals 3,2 are activated in electrical power by transistors during
a time interval and
followed by a High Impedance State of the transistors allowing the extraction
of coil signal in
relaxed mode to permit to impose the right polarity of electrical power into
the coil on the next
time instant to result in a rotating motor.
There are pulses that activate power into the coils where at crossing of zero
the action can act
such to negatively accelerate actual rotation of rotor; but the effect is not
great since when the
0r=n-/2 all the magnetic forces are radially; but away from 7r/2 an incorrect
application of power
polarity can slow the rotation but not substantially; the induced voltage by
rotor alone has small
voltage near 7r/2; it is observable of small reduction in rotation when at
crossing to zero an
applying polarity in the pulse is opposite to the relax polarity. The relax
polarity is the polarity
of terminals 3,2 induced due to rotation of the rotor with no applying voltage
at said terminals.
The experiment used timer NE555 with the fast diode across timer terminals 6,7
allows the
pulses with near 50% duty cycle. The SE555 can operate to 18V better than 16V
for NE555.
And for a capacitor used as 3.311F and R1=R2=0.997KS7 of NE555 give
f=219.2945Hz at nearly
50% duty cycle. Where there were two modes: of crossing zero and no crossing
zero were
obtainable; such as to blow the blades allowing to escape from crossing zero
due to an
application of wrong polarity powered to motor coils terminals 3,2. Where the
mechanical
noises of the motor in both cases do not allow to feel it and by touching the
motor to conclude
that the vibration is from the square pulses of power applying to the coils by
transistors.
The BMARS in normal operation where signals at coils terminals 3,2 by
oscilloscope at the relax
time intervals; where the frequency and amplitude of the relax mode vary by
dragging the
blades. The amplitude decreases in the relax mode, the period increases since
it is related to
rotor mechanical rotation.
Due to the inductance of the motor coils that the frequency of the NE555
cannot go higher than
typically 2.68KHz with 0.271IF, R1=R2=0.997K.Q. However, the higher in
frequency reduces
the negative acceleration of rotor at crossing zero. Also making low frequency
for far from
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crossing zero and high frequency of power source near crossing zero helps
reducing the effect of
negative acceleration of rotor already mentioned.
Fig.], the terminals 3-2 with such polarity will produce stator poles
indicated and when the
application ofpower in reverse of polarity to 3-2 then the poles will reverse.
The rotor has the permanent magnet with north and south magnetic poles as Nro
Sr Nr1 and
Sr1 The Or is the angle of rotation of Nro , and for Or =0 the magnetic
flux density B [Tesla or
Wb/m2] goes along in same direction with Nso to Sso where it is the maximum
flux inducing emf
of Faraday's law into coils No and Ni ; when rotor rotates 7r/2> Or >0
counterclockwise part of
the magnetic field from Nro -Sro embraces coils No and N1 so there is a
reduction in magnetic
flux yt,,, [Wb] to induce emf with polarity indicated to terminals 3-2. Due to
symmetry the
remaining three other quadrants behave similarly. And it is the relax mode so
in order to
provide same rotation the applied voltage must have same polarity as indicated
on the figure for
7r/2> Or >0.
So with respect to the Fig.], the applying voltage terminals 3-2 shall be
reversed in 7r> Or >7r/2;
then positive again 37r/2> Or >7r; then negative for 2 71-> Or >37/2. There is
an application of a
power pulse input then a relaxation time where the relation time will give
same polarity as the
applied voltage. The result is the rotor rotates counter clockwise.
Fig. _2 shows a situation where the rotor rotates by external mechanical
torque counterclockwise
without application of electrical power. The function II. (wtj=cos(wt) is
typically stood for the
rotating magnetic flux cum [Wb] embracing the stator coils to yield emf at
terminals 3-2. From
Fig._2 for theta=0r,from 0 to rc/2, there is decreased of cum embracing the
stator coils because of
distribution location of the poles in the rotor; the corresponding derivative
is equal to f2(wt)=-
sin(wt) where the emf=f2(wt). And so the polarity in Fig.] of terminals 3-2 is
in negative sign
with fAvt) of Fig._2 as the rotor rotates.
The objective of this design is to apply polarity electrical power pulse to
terminals 3-2 of Figi
by targeting -f2(wt) function to cause the rotor to rotate in same direction.
There is a repetition
of active pulse then a relaxed time interval to check the emf voltage to then
apply with same
polarity as the emf at terminals 3-2. The amplitude in Fig._2 is not a concern
and is put
normalized to].
Fig. _3 shows the motor coil terminals 3-2 from Fig.] with resistance Rm=26.2Q
connecting to
GNI). The transistors Q5 and Q6 operate in sequence of one of Q5 or Q6 is
active following
with High Impedance State of Q5 and Q6 presenting to motor coil then either Q5
or Q6 is active
thus to produce a same direction in rotor rotation. The High Impedance State
allows the circuit
to acquisition polarity of motor coil to trigger the next active power pulse
to motor coil by Q5 or
Q6 circuit.
The limiting electrical power into the coil Lm of terminals 3-2 of Fig.] is by
the transistors 05
and Q6: thus they can be put in parallel for more power or the use of power
transistors in the
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same manner will do to increase amperage of brushless motor control.
The timer NE555 has nearly 50% duty cycle due to a fast diode across its
terminals 7-6; the use
of C3=3.31uF and R2=0.997KQ give T=2*(0.693*R2*C3) =4.56 msec and f=219.2945
Hz.
When the output NE555 is High the Q3 output is Low to set Q5 & Q6 in High
Impedance State;
where the coil voltage is amplified by NTE889M with negative sign and having a
set able gain
for the comparator NTE922M Thus for a relax voltage of the coil as positive
the comparator
outputs a Low then Q4 outputs a Low as data into DoA of 4508B SYL_ECG CMOS
DUAL 4-Bits
Latch; a Low of NE555 into StrobeA of the latch sets a Low DoA signal to
output QoA =Low into
the base of Q1 to set the bases of Q5 & Q6 to High thus an application of
positive voltage to the
coil Lm in the same polarity as at the first acquisition.
When the NE555 is High into StrobeA that lets DoA out to QoA but the Q3 sets
High Impedance
State into Q5 & Q6. It is at the end of the relax state of the coil that a
latch is executed to save
the coil voltage polarity. In terms of delay, the coil polarity is available
by comparator
NTE922M; a Low transition of NE555 latches QoA of 4508B first before the logic
signal QoA
travels to the motor coil.
The supply voltages /Tice = / Vee /¨ 3 to 7.5V and are liniited to the NE555
maximum voltage
of 16V The derivative amplifier NTE857M was part of few tests and can be
useful for future
use.
Fig. _4 shows electrical signals of Fig. J sketched from oscilloscope. The
three curves are on
the same time scale. The top curve is the timer NE555 where when it is High
the motor coil
terminals is in High Impedance State for detecting the polarity of the coil
then a Low is the
application of a pulse Low or High caused by Q6 & Q5 of Fig. _3.
The curve in frill line is the motor coil terminal and is the same as
terminals 3-2 of Fig. _1. Prior
to ti there is an application of a positive pulse to the coil, then a High of
NE555 sets the system
into High Impedance State, where the coil instantaneously changes in polarity
to pursue its
current in current source nature state where there is a signal from to to t1;
then after t1 is the
relax state of the coil that is induced by emf due to its rotor rotation. Then
at the end of the relax
state the NE555 goes Low, a latch Low of the later relax signal is stored so
the application of
Low pulse is immediately next.
The intervals ti -to-0.4ms and t3-t2= 0.5ms is to estimate inductance of the
coil. Also it is to
determine the frequency of the NE555 where too fast in frequency the system
can latch the coil
inductance current source state and this is a wrong mechanism that would stall
the Fan rotation.
Experimental capacitor C3 values of NE555 with relax state maximum voltage
are: 0.27pF
(1.5V), 0.47,uF (2.02 V), .1),IF (2.94 fr), 2. 2F (-2.94V), 3.3,uF (2.94V),
4.7,uF (2.352V), 1014F
(-2.057V). It is descending in NE555 frequency where the higher the voltage
means higher
rotational velocity to induce err?f. Therefore, the C3=3.3,uF is chosen for
f=219.2945 Hz for the
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use of ARX CeraDynaTA4 FD 1260-A1033E / 12V-0.12A.
Observing from t3 to t5 where the relax state supposed to cross to zero but
the negative pulse is
applied, where the coil natural current source voltage changes instantaneously
into positive at t4
and where the stator coils poles are in opposition to accelerate the rotor but
it is in position of
negative acceleration, where a decreasing rotor flux adds to same polarity as
the coil natural
current source that is why there is a longer time decreasing from t4 to t5.
A derivative function NTE857M of Fig. _3 can be used to detect the instant
just after t4 to
increase or decrease the NE555 frequency to escape such zero crossing. The
Pulse-Width-
Modulation (PWM) type source power is to be considered, the multi-vibrator as
NTE4538B and
the Voltage-Control-Oscillator may become part to reduce the crossing zero
effects. Also if by
addition, the stator has a simple coil with magnetic flux in perpendicular
direction to coils flux
of the stator of Fig. 1 to detect to coming pole of the rotor allows to
determine in priory the zero
crossing thus to avoid it.
When there is no crossing to zero the vibration is about the same, what makes
more vibration is
the sharp rising of the applied pulses. For transistors Q5 & Q6 of Fig._3 with
collectors
resistors and the bases with resistors-capacitors to smooth the beginning of
pulses will reduce
vibrations.
The curve of motor coil signal to GND in dotted line is when a 2.2,uF across
motor coil terminals
where there is conservation of energy where the capacitor stored the energy
and causes
oscillation effect where seemingly provides more amplitude in relax state to
provide more output
mechanical torque however the oscillation adds harmonics and thus more
hysteresis losses; so
without the shunt capacitor will give higher efficiency. Higher in increasing
in capacitor
extends the oscillation period hut can jam the system to halt the rotor
rotation.
During many tests, a 1052 is inserted at the collector of Q5 & Q6 of Fig. _3
to measure a small
current. At crossing over zero effect such as between t4 and t5 in another
instant and test, just
after crossing zero the voltage of 0.909V across 100 to yields 1=90.9mA; with
the motor coil
voltage of 4.88V to yield P(t)=4.436E-1W the coil resistance is Rm=26.20
dissipating PA=
0.21649W the net power output is P(t)-PR(t)=0.2271W. For a total input power
the
instantaneous output power is 51.19% typically just after crossing zero
effect.
For the ARX CeraDynaT 114 FD 1260-A1033E / 12V-0.12A gives P(t)=12*0.12=1.44W,
for
1.44W*51.19%=0.737W comparing to 4.436E-1W*51.19%=0.2271W, it means the coil
voltage
in this BMARS can be. further augmented without burning the motor.
Fig. 5 shows the circuit permitting to control a temperature at a desired
value. The R20=25KS2
and R21-500K52 allows to set a desired temperature anywhere from about 88
Celsius to minus
13 Celsius in conjunction with thermal-resistor of Digital Thermometer Taylor
1478-49, 5009
V3043. The circuit shown is to provide heat above or equal to ambient
environment
temperature.
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The potentiometer R15 is to adjust such that when Qj4 emitter is not connected
to inverting input
the inverting input voltage is higher than the non-inverting input, also the
R15 is to set about not
smaller than 20mV higher than non-inverting input.
A large C3=C2+ 150014F with to make delay R15-C3 larger than R17-C2 since
supply voltages
fluctuate during switching of comparator NTE922M. And for same reason the
C9=66uF at the
base of Qj5 to maintain more constant the base for switching when supply
voltages fluctuate due
to using capacitors-Zeners configuration such as C4, C5, Vz3 and Vz4.
Fig. _5 shows the circuit capacitors-Zeners to provide equivalent two voltage
sources. The use of
Zeners 5.1V -1W NTE135A is cheaper with better constant voltage 5.1V with
fluctuation in
current than the 3.3V NTE5066A. The Vz5=11V is to protect the entire circuit.
The use of comparator 1,11393N which seemingly slower than the NTE922M, which
has a Low
near Veeo then Vz1=Vz2=2.5V are not needed.
The Qj I can be modified using relay DF005, 30A, however such relay makes
noise, along with
small signal transistor PNP for higher current load for more heat power.
The power adaptor _from 120Vrms into 9V will be used to charge the batteries
and to keep the
temperature at desired temperature. Once the adaptor is removed, the batteries
takes over.
The system needs to be thermally efficient by using stainless steel vacuum
materials insulation
for keeping thermal energy as long as possible.
For hot heat source [Joule] going to cold source [Joule]. For a serial
connection of high
thermal resistance with low thermal resistance yields an equivalent of high
thermal resistance.
Hot heat source propagates radially but not inward by analysis that two
infinite planes with
same temperature then no net heat flow from one to the other.
Therefore, the Fig. _5 has been used to keep liquid hot where the heat source
is made of
R2=R3=5.6,Q, located near the center, not exactly in the center for a case of
providing cooling,
of the Thermos food jar 290m1Thermax stainless steel with US Pat. 5153977.
Also to cool
down the Nitrogen will be used, it is faster and more efficient; where
Nitrogen gas expands near
the center of the said food jar since hot heat cannot go inward so the near
center location of the
cold source allows inside the jar hot heat to propagate to the cold heat
located near the center,
away the center is better.
The application of this type BMARS along with Fig. _5 to control the
temperature where a Fan
capable to operate in high temperature and capable to sustain operation by
some presence of
water is to use the brushless motor modified into the mechanism BMARS. The Fan
accelerates
heat exchange faster. BMARS tolerate some presence of water but not
permanently and not
corrosion progf.
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It is good for keeping electric car battery warmed inside a stainless steel
vacuum thermal
insulator, the same for delivery fast foods.
In conclusion, the CMOS integrated circuits offer a variation in supply
voltage for logic circuits
but more expensive than Transistor Transistor Logic (TTL) of 5.1V circuits.
Actually, the Fig_3 allows, at power On, one direction of rotation of the
blades. Where the
rotation can be reversed by hands. However, it is possible to obtain the
blades that are radially
perpendicular to axis of rotation such that for both direction of rotation the
flow of air is in the
same direction. Also by observing the Fig.] and Fig. _2 it is easy to set an
only one direction of
rotation.
If the motor coils are made with corrosive proof materials such as gold and an
electrical
insulation tough for a particular environment then this BMARS principle is a
choice since the
power can be arbitrary augmented by choosing a larger motor coil.
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