SBIR Phase II: Low-Cost Ultra-Efficient 50-gm, 300-W Servoelectronics Module with Integral Sensors

这个小型企业创新研究（SBIR）第二阶段研究项目旨在将创新的节能超小型无刷伺服电子模块的制造成本从1,000美元降至100美元。该模块将驱动额定功率高达300 W（均方根）和2 KW（峰值）的高性能无刷伺服电机所需的所有转子位置传感、基于矢量的换向、控制和电源集成到一个50克的模块中，该模块比瓶盖大不了多少。成本的降低依赖于一系列创新，这些创新是通过用测量校准目标磁体的磁场传感器阵列取代用于转子位置传感的激光光学器件来实现的。第一阶段表明，良好的屏蔽，即使在附近的高开关电流和旋转转子磁铁位于电机体内，距离传感器阵列只有毫米产生的杂散磁场，也可以实现高精度和出色的换向性能。这种伺服电子模块符合丹纳赫/科尔摩根、西门子、发那科和安川等老牌企业对颠覆性技术的定义，同时它将使数十家原始设备制造商（OEM）能够以具有竞争力的价格提高其机器的性能、紧凑性、功率效率和可靠性。随着机器通过嵌入式处理和传感器融合变得更加智能，它不仅会提高工业生产力，还会随着社会老龄化提高生活质量。虽然嵌入式处理器和基于MEMS的传感器已经变得非常小巧、高效且价格实惠，但伺服电机的类似改进进展缓慢。在小马力的水平，电力电子显着贡献总电机系统的体积和复杂性。提供更小、更高效的伺服电子设备将使原始设备制造商能够提高其产品的竞争力。机器人将变得更加灵活，具有更多的自由度和更少的质量来加速。

This Small Business Innovation Research (SBIR) Phase-II research project aims to cut the manufacturing cost of an innovative power-efficient ultra-miniature, brushless-servo-electronics module from $1,000 to $100. The module integrates all rotor-position sensing, vector-based commutation, controls, and power supplies needed to drive high-performance brushless servomotors rated up to 300 W (Root Mean Square) and 2 KW (peak) into a single 50-gram module not much bigger than a bottle cap. The cost reduction relies on a set of innovations led by replacement of laser optics used for rotor-position sensing with an array of magnetic field sensors measuring a calibrated target magnet. Phase I demonstrated that well-placed shielding enables high precision and excellent commutation performance even in the proximity of stray fields produced by high switched currents and spinning rotor magnets located in the motor body only millimeters from the sensor array. This servo-electronics module fits the definition of disruptive technology for entrenched players, such as Danaher/Kollmorgen, Siemens, Fanuc, and Yaskawa, while it will enable scores of original equipment manufacturers (OEMs) to improve the performance, compactness, power efficiency, and reliability of their machines at competitive prices. As machines become more intelligent through embedded processing and sensor fusion it will improve not only industrial productivity, but quality of life as society ages. While embedded processors and MEMS-based sensors have become tiny, highly effective, and affordable, similar improvements in servomotors have evolved more slowly. At fractional-horsepower levels the power electronics contribute significantly to total motor-system bulk and complexity. Providing smaller and more efficient servo-electronics will enable OEMs to increase the competitiveness of their products. Robots will become more agile with additional degrees of freedom and less mass to accelerate.