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A System And Method For Determining Impending Faults In A Motor

Abstract: The present invention relates to a system (100) and method (200) for determining impending faults in a motor (200). The system (100) includes a first set of hall effect sensors (H), a second set of hall effect sensors (H’) and a control unit (Mc). The first set of hall effect sensors (H) being configured to provide a first output corresponding to a position of a rotor (R) of the motor (200). The second set of hall effect sensors (H’) being configured to provide a second output corresponding to the position of the rotor (R) of the motor (200). The control unit (Mc) being configured to analyse the first output and the second output to check for redundancy in the first output and the second output and determine an impending fault in the motor (200). Reference Figure 2

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Patent Information

Application #
Filing Date
12 March 2024
Publication Number
38/2025
Publication Type
INA
Invention Field
PHYSICS
Status
Email
Parent Application

Applicants

ATOMBERG TECHNOLOGIES PRIVATE LIMITED
Office No. 1205, Millennium Business Park, MIDC Industrial Area, Sector 1, Kopar Khairane, Navi Mumbai- 400710, India.

Inventors

1. Manoj Meena
Office No. 1205, Millennium Business Park, MIDC Industrial Area, Sector 1, Kopar Khairane, Navi Mumbai- 400710, India.
2. Jasraj Dalvi
Office No. 1205, Millennium Business Park, MIDC Industrial Area, Sector 1, Kopar Khairane, Navi Mumbai- 400710, India.
3. Mohit Chand
Office No. 1205, Millennium Business Park, MIDC Industrial Area, Sector 1, Kopar Khairane, Navi Mumbai- 400710, India.

Specification

DESC:FIELD OF THE INVENTION
[001] The present invention relates to a system and method for determining impending faults in a motor.

BACKGROUND OF THE INVENTION
[002] Brushless Direct Current (BLDC) motors are widely used for their noiseless operation and durability. For the proper functioning of BLDC motors, accurate determination of the position of a rotor with respect to stator coils in the motor is necessary in order to energize the correct stator winding/coil. The rotor position determination is typically carried out by three hall effect sensors. According to the rotor position determined by the hall effect sensors, a motor controller in the BLDC motor activates the stator coils to drive the rotor using electromagnetic force.
[003] A common cause of failure of BLDC motors is due to the faults in the functioning of any of the hall effect sensors. If any of the hall effect sensors do not function properly the sequence and timing of the stator coil activation is disrupted, causing failure of the BLDC motor.
[004] BLDC motors are commonly used as hub motors in electric vehicles. Hub motors are BLDC motors incorporated in a wheel hub of the electric vehicle. The hub motor act as a traction motor, and is advantageous as it obviates the need for complex power transmission mechanisms in the electric vehicle. As mentioned hereinbefore, faults in functioning of hall effect sensors causes failure in the BLDC motors. Such failure will cause breakdown of the electric vehicle, and is thus undesirable.
[005] Another problem leading to failure of BLDC motors when used as hub motor is high motor temperature caused due to continuous operation, faulty operation or other external factors. Water seepage into the motor casing also causes faults in the functioning of the hub motor.
[006] The hub motor is usually enclosed in a sealed casing making it difficult to inspect the hub motor frequently for faults in its operation. The mounting of the hub motor to the wheel hub causes additional difficulty in inspection.
[007] Hence there is a need in the art for a system and method for determining impending faults in motors which solves at least the aforementioned problems.

SUMMARY OF THE INVENTION
[008] In an aspect, the present invention is directed towards a system for determining impending faults in a motor. The system includes a first set of hall effect sensors, a second set of hall effect sensors and a control unit. The first set of hall effect sensors is configured to provide a first output corresponding to a position of a rotor of the motor. The second set of hall effects sensors is configured to provide a second output corresponding to the position of the rotor of the motor. The control unit is communicatively coupled to the first set of hall effect sensors and the second set of hall effect sensors. The control unit is configured to receive the first output and the second output from the first set of hall effect sensors and the second set of hall effect sensors respectively. The control unit is configured to analyse the first output and the second output to check for redundancy in the first output and the second output. The control unit is configured to determine an impending fault in the motor.
[009] In an embodiment of the invention, the first set of hall effect sensors is having a plurality of hall effect sensors and the second set of hall effect sensors having a plurality of hall effect sensors. Each of the hall effect sensors of the first set of hall effect sensors has a corresponding hall effect sensor in the plurality of hall effect sensors of the second set of hall effect sensors. The corresponding hall effect sensors being in phase with each other. The control unit being configured to check for redundancy in the outputs of the corresponding hall effect sensors and the control unit being configured to determine an impending fault in the motor if redundancy is not observed in the outputs of the corresponding hall effect sensors.
[010] In an embodiment of the invention, the control unit is configured to determine a fault in the functioning of the hall effect sensors if any of the first set of hall effect sensors or the second set of hall effect sensors is not providing an output, if all the hall effect sensors of the first set of hall effect sensors or the second set of hall effect sensors is providing either high or low output, if a sequence of positions of the rotor identified by the first set of hall effect sensors or the second set of hall effect sensors is not corresponding to a predetermined sequence of the positions of the rotor, or if a delay between the first output of the first set of hall effect sensors and the second output of the second set of hall effect sensors is more than a predetermined value.
[011] In an embodiment of the invention, the control unit is configured to neglect the first output or the second output if a fault is determined in the functioning of the first set of hall effect sensors or the second set of hall effect sensors respectively.
[012] In an embodiment of the invention, system comprising at least one temperature sensor configured to monitor a temperature of the motor and at least one humidity sensor configured to monitor a moisture content in the motor, wherein the control unit is configured to determine an impending fault in the functioning of the motor if the temperature or moisture content of the motor is more than threshold values.
[013] In an embodiment of the invention, the system comprises a communication module. The communication module is provided with a Controller Area Network (CAN) or Local Interconnect Network (LIN) connection. The communication module being configured to enable communication between the control unit and one or more electronic devices.
[014] In another aspect, the present invention is directed towards a method for determining impending faults in a motor. The method includes the steps of receiving, by a control unit, a first output and a second output corresponding to a position of a rotor of the motor from a first set of hall effect sensors and a second set of hall effect sensors respectively. Thereafter, the method includes the step of analysing, by the control unit, the first output and the second output to check for redundancy in the first output and the second output. Thereafter, the method includes the step of determining, by the control unit, an impending fault in the motor if redundancy is not observed in the first output and the second output.
[015] In an embodiment of the invention, the method includes the step of checking, by the control unit, the outputs of corresponding hall effect sensors in a plurality of hall effect sensors of the first set of hall effect sensors and a plurality of hall effect sensors of the second set of hall effect sensors for redundancy. Thereafter, the method includes the step of determining, by the control unit, an impending fault in the motor.
[016] In an embodiment of the invention, the method includes the steps of determining, by the control unit, a fault in the functioning of either the first set of hall effect sensors or the second set of hall effect sensors if any of the hall effect sensors of the first set of hall effect sensors or the second set of hall effect sensors is not providing an output, if all the hall effect sensors of the first set of hall effect sensors or the second set of hall effect sensors are providing either high or low output, if the sequence of positions of the rotor identified by the first set of hall effect sensors or the second set of hall effect sensors is not corresponding to a predetermined sequence of the positions of the rotor, or if a delay between the first output of the first set of hall effect sensors and the second output of the second set of hall effect sensors is more than a predetermined value.
[017] In an embodiment of the invention, the method includes the steps of neglecting, by the control unit, the first output or second output if a fault is determined in the functioning of the first set of hall effect sensors or the second set of hall effect sensors respectively.
[018] In an embodiment of the invention, the method includes the steps of monitoring, by at least one temperature sensor, a temperature of the motor and monitoring, by at least one humidity sensor, a moisture content in the motor. Thereafter, the method includes the steps of determining, by the control unit, an impending fault in the functioning of the motor if the temperature and/or moisture content of the motor is more than a threshold value.

BRIEF DESCRIPTION OF THE DRAWINGS
[019] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 shows a block diagram of a system for determining impending faults in a motor, in accordance with an embodiment of the invention.
Figure 2 shows a schematic representation of the system for determining impending faults in the motor, in accordance with an embodiment of the invention.
Figure 3 shows output graph of hall effect sensor, in accordance with an embodiment of the invention.
Figure 4 shows a flow diagram of a method of determining impending faults in a wheel hub motor, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[020] The present invention is directed towards a system and method for determining impending faults in a motor. The present invention enables timely redressal of an impending fault or failure of the motor.
[021] Figure 1 shows a block diagram of a system 100 for determining impending faults in a motor 200 in accordance with an embodiment of the invention. The motor 200 is a Brushless Direct Current (BLDC) motor. As discussed hereinabove, the BLDC motor 200 is adapted as a wheel hub motor whereby the motor is adapted to a wheel hub of at-least one wheel of an electric vehicle, and the wheel hub motor when operated rotates the wheel. The wheel hub motor comprises of a housing/casing adapted to be rotatably mounted on a central shaft of a wheel and rotate therewith. Further, a stator is mounted on the central shaft and a rotor is mounted relative to the stator, and rotation of the rotor causes the housing and thereby the wheel to rotate.
[022] The system 100 for determining impending faults in a motor 200 comprises a first set of hall sensors H, a second set of hall sensors H’, at-least one temperature sensor Ts, at-least one humidity sensor Hs, a control unit Mc, and a communication module Cm.
[023] Figure 2 shows a schematic representation of the system 100 for determining impending faults in the motor 200. As shown, the first set of hall sensors H and the second set of hall sensors H’ are disposed adjacent to a rotor R of the motor 200. In an embodiment, the first set of hall effect sensors H comprises three hall effect sensors HA, HB and HC, and the second set of hall effect sensors H’ comprises three hall effect sensors HA’, HB’ and HC’. The disposition of the hall effect sensors HA’, HB’ and HC’ is such that each of these hall effects sensors are in phase with their corresponding hall effect sensors HA, HB and HC in the first set of hall effects sensors H, whereby each of the corresponding sensors provide identical outputs at any time during the operation of the motor 200. Further, a motor controller 210 is provided, whereby depending upon rotor position determined by the hall effect sensors, the motor controller 210 activates the stator coils S in the BLDC motor 200 to drive the rotor R using electromagnetic force.
[024] During the operation of the motor 200, the first and second set of hall effect sensors H and H’ continuously monitor the rotor position and return a first output and a second output respectively. The first output and the second output correspond to a position of the rotor R of the motor 200 at any point of time. Outputs of the individual hall effect sensors HA, HB, HC, HA’, HB’ and HC’ in the first and second set of hall effect sensors H and H’ are in the form of digital high or low. Figure 3 shows the output graph for each of the three hall effect sensors HA, HB and HC. The output of each of the hall effects sensors HA, HB and HC and HA’, HB’ and HC’ at any point in time during the operation of the motor 200 is in the form of a digital high or low. The combination of the outputs of the three hall effects sensors HA, HB and HC or HA’, HB’ and HC’, i.e the first output or the second output, uniquely identify the rotor R to be in one of the positions identified as segments S1-S6 of 360 degrees electrical. The segments S1-S6 signify the rotor position with an accuracy of 60 degrees electrical. The segments S1-S6 repeats itself over 360 degrees electrical in the operation of the motor 200. A time t for which the rotor R will be in each of the segments S1-S6 depends on the speed or Rotations Per Minute (RPM) of the rotor R. The time t reduces while an electric vehicle is accelerating, and it increases as the electric vehicle is decelerating. For example, when the three hall effect sensors HA, HB and HC or HA’, HB’ and HC’ return the output of digital high, low and high respectively, the rotor position is identified by the control unit Mc to be in segment S1. Similarly, if the output of the three hall effect sensors HA, HB and HC or HA’, HB’ and HC’ are digital low, high and high respectively, the rotor position is in segment S5. Based on the rotor position identified the coils of the stator S are energised to form a magnetic field which is adequate to drive the rotor R forward or backward as required. As discussed hereinbefore, accurate determination of the rotor position is necessary for the proper functioning of the motor 200 as the stator S coil activation sequence and timing depends on the rotor position. Faults in the functioning of the set of hall effect sensors H or H’ will affect the functioning of the motor 200 as the rotor position determined by the motor controller 210 will be inaccurate, and hall effect sensor failure is a common cause of failure of motors. The hall effect sensor failure is an indicator for an impending fault in the motor 200 as the stator coil activation will be inaccurate and continued operation of the motor 200 with inaccurate stator coil activation will cause impending faults in the functioning of the motor 200.
[025] The present inventions solve the problem of hall effect sensor failure in motor 200 by providing the first and second set of hall effect sensors H and H’ whereby the output of individual hall effect sensors HA, HB and HC and HA’, HB’ and HC’ from the first and second set of hall effect sensors H and H’ are provided to the control unit Mc and the first output of the first set of hall effect sensors H and the second output of the second set of hall effect sensors H’ are analysed by the control unit Mc. The control unit Mc is a micro-controller. The control unit Mc analyse the first output and the second output to check for redundancy in the first output and the second output. Redundancy in the first output and the second output refers to a situation where the first output of the first set of hall effect sensors H and the second output of the second set of hall effect sensors H’ are same or similar subject to a delay which may be caused due to the circuit tolerances. The control unit Mc is configured to determine an impending fault in the motor 200 if redundancy is not observed in the first output and the second output.
[026] In an embodiment, the analysis by the control unit Mc includes comparing the output received from the corresponding hall effect sensors HA-HA’, HB-HB’ and HC-HC’ from the first and second set of hall effect sensors H and H’ to see if their outputs are same or similar subject to a delay which may be observed due to circuit tolerances. In this regard, the control unit Mc checks for redundancy in the outputs of the corresponding hall effect sensors HA-HA’, HB-HB’ and HC-HC’. Redundancy in the output of the corresponding hall effect sensors HA-HA’, HB-HB’ and HC-HC’ refers to situation wherein the outputs of the corresponding hall effect sensors HA-HA’, HB-HB’ and HC-HC’ are same or similar subject to a delay which may be caused due to the circuit tolerances. For example, at any instance in the operation of the motor 200 the output received from corresponding hall effect sensors HA and HA’ should be same or similar subject to a delay which may be caused due to the circuit tolerances.
[027] If redundancy is observed between the outputs of the corresponding hall effect sensors HA-HA’, HB-HB’ and HC-HC’, it is determined that the hall effect sensors are functioning properly. If redundancy is not observed between any of the corresponding hall effect sensors HA-HA’, HB-HB’ and HC-HC’, it is determined that the hall effect sensors are not functioning properly.
[028] If the first output of the first set of hall effect sensor H and second set of hall effect sensors H’ are not redundant, a faulty condition is detected in at least one of the hall effects sensors within either of the first or second set of hall effect sensors H or H’. Once the faulty condition is detected by the control unit Mc, the outputs of the individual hall effect sensors HA, HB, HC, HA’, HB’ and HC’ are checked. If any of the individual hall effect sensors HA, HB, HC, HA’, HB’ or HC’ is not providing output, a fault in the functioning of that hall effect sensor HA, HB, HC, HA’, HB’ or HC’ is identified. Further, if the output of all the three hall effect sensors HA, HB and HC or HA’, HB’ and HC’ in the first or second set of hall effects sensors H or H’ is a digital high or low, the control unit Mc detects a fault in that set of hall effect sensors H or H’. An error in the functioning of the hall effect sensors HA, HB, HC, HA’, HB’ or HC’ can also be detected by the control unit Mc if the hall sequence is incorrect. Hall sequence refers to a predetermined sequence of the positions of the rotor R under normal operation of the motor 200. Further, if the time delay between the outputs of the corresponding hall effect sensors HA-HA’, HB-HB’ or HC-HC’ is more than the expected delay determined by the control unit Mc, an error is detected in the functioning of a hall effect sensor HA, HB, HC, HA’, HB’ or HC’ of the two corresponding hall effect sensors HA-HA’, HB-HB’ or HC-HC’. Accordingly, faults in the functioning of hall effect sensors HA, HB, HC, HA’, HB’ or HC’ can be identified by the control unit Mc from the output of the first and second set of hall effect sensors H and H’. The identified faults are communicated via the communication module Cm to an external source such as a display unit or an electronic device.
[029] Once a faulty condition of the hall effect sensors HA, HB, HC, HA’, HB’ or HC’ is determined by the control unit Mc, the fault is identified to be associated with either of the first or second set of hall effect sensors H or H’ by checking the individual hall effect sensors HA, HB, HC, HA’, HB’ or HC’ for faults in their operation. In an embodiment of the invention, when a fault is detected, by the control unit Mc, with any of the hall effect sensors HA, HB, HC, HA’, HB’ or HC’ in the first or the second set of hall effect sensors H or H’, the output from that faulty set of hall effect sensor H or H’ is neglected and the activation of the stator S coils by the motor control unit 210 is done based on the rotor position determined from the output of the set of hall effect sensors H or H’ which does not contain any faulty hall effect sensors. This enables the system 100 to be robust against the failure of any of the set of hall effect sensors H or H’. The present invention thus enables that the motor 200 to continue to operate normally despite the faulty operation of one of the hall effect sensors HA, HB, HC, HA’, HB’ or HC’. Further, the present invention allows to prevent the impending fault of the motor 200 by neglecting the output of the faulty set of hall effect sensors H or H’ and by ensuring that the activation of the stator S coils is done based on the rotor position determined from the output of the set of hall effect sensors H or H’ which does not contain any faulty hall effect sensors.
[030] In an embodiment of the present invention, at least one temperature sensor Ts is disposed within the casing of the motor 200. In case of a wheel hub motor, the temperature sensor Ts is disposed within the casing of the wheel hub motor. The temperature sensor Ts aid in the diagnostic and prediction of faults in operation of the motor 200. The temperature of the motor 200 rises as it is operated at peak power conditions. Uncontrolled rise in temperature of the motor 200 will have a damaging effect on the motor 200. The temperature of the motor 200 may also rise due to the faults in the operation of the motor 200. The temperature sensor Ts continuously monitors the temperature of the motor 200 and provides the temperature information to the control unit Mc. When the temperature of the motor 200 as monitored by the temperature sensor Ts rises above a threshold value, the control unit Mc generates an alert regarding existing and/or possible fault in the operation of the motor 200.
[031] In another embodiment of the present invention, at least one humidity sensor Hs is also disposed within the casing of the motor 200. In case of a wheel hub motor, the temperature sensor Ts is disposed within the casing of the wheel hub motor. The motor 200 is encased in a watertight casing, however, there can be seepage of water or moisture into the casing of the motor 200. The presence of moisture in the casing of the motor 200 affects the functioning of the electronic components of the motor 200. The humidity sensor Hs detects moisture content within the motor 200 casing and provides the information to the control unit Mc. When the moisture content or humidity detected is more than a threshold value, the control unit Mc generates an alert regarding existing and/or possible fault in the operation of the motor 200. The alerts are communicated via the communication module Cm to an external source such as a display unit or an electronic device.
[032] In an embodiment of the invention, the sensors, the control unit Mc and the motor controller 210 are connected via vehicle Controller Area Network (CAN) or Local Interconnect Network (LIN). Such connections reduce the number of connections and wires used in the system 100 and allows for updating of firmware used in the system 100.
[033] Figure 4 shows flow diagram of a method 400 for determining impending faults in a motor 200 in accordance with an embodiment of the invention. The method 400 is carried out on a system discussed hereinbefore. The method 400 starts at step 402 whereby during the operation of the motor 200, a first and second set of hall effect sensors H and H’ continuously monitor a rotor position and return a first output and a second output respectively. The first output and the second output correspond to the position of the rotor R of the motor 200 at any point in time. At step 404, the first output and the second output from two sets of hall effect sensors - the first set of hall sensors H, the second set of hall sensors H’ - is received by a control unit Mc. Next at step 406, the method 400 involves analysing the first output and second output of the two sets of hall effect sensors H and H’. The analysis includes comparison of the first output and the second output from the two sets of hall effect sensors H and H’, wherein the first output and the second output are checked for redundancy. Further, the method 400, determines an impending fault in the motor 200 if redundancy is not observed in the first output and the second output. In an embodiment, the method 400 checks for redundancy between the outputs of the corresponding hall effect sensors HA-HA’, HB-HB’ and HC-HC’. If redundancy is observed between the outputs of the corresponding hall effect sensors HA-HA’, HB-HB’ and HC-HC’, it is determined that the hall effect sensors HA, HB, HC, HA’, HB’ and HC’ are functioning properly. If redundancy is not observed between any of the corresponding hall effect sensors HA-HA’, HB-HB’ and HC-HC’, it is determined that the hall effect sensors HA, HB, HC, HA’, HB’ and HC’ are not functioning properly. If the output of the first and second set of hall effect sensors H and H’ are not redundant, a faulty condition is detected in at least one of the hall effects sensors HA, HB, HC, HA’, HB’ or HC’ within either of the first or second set of hall effect sensors H or H’. Once the faulty condition is detected by the control unit Mc, the outputs of the individual hall effect sensors HA, HB, HC, HA’, HB’ or HC’ are checked. If any of the individual hall effect sensors HA, HB, HC, HA’, HB’ or HC’ is not providing output, a fault in the functioning of that hall effect sensor is identified. Further, if all the three hall effect sensors in the first or second set of hall effects sensors H or H’ is a digital high or low, the control unit Mc detects a fault in that set of hall effect sensors. An error in the functioning of the hall effect sensors HA, HB, HC, HA’, HB’ or HC’ can also be detected by the control unit Mc if the hall sequence is incorrect. Further, if the time delay between the corresponding hall effect sensors HA-HA’, HB-HB’ or HC-HC’ is more than the expected delay determined by the control unit Mc, an error is detected in the functioning of a hall effect sensor HA, HB, HC, HA’, HB’ or HC’ of the two corresponding hall effect sensors HA-HA’, HB-HB’ or HC-HC’. Accordingly, faults in the functioning of hall effect sensors can be identified by the control unit Mc from the output of the first and second set of hall effect sensors H and H’.
[034] Once a faulty condition of the hall effect sensors HA, HB, HC, HA’, HB’ or HC’ is determined by the control unit Mc, the fault is identified to be associated with either of the first or second set of hall effect sensors H or H’ by checking the individual hall effect sensors HA, HB, HC, HA’, HB’ and HC’ for faults in their operation. In an embodiment of the invention, when a fault is detected, by the control unit Mc, with any of the hall effect sensors HA, HB, HC, HA’, HB’ or HC’ in the first or the second set of hall effect sensors H or H’, the output from that faulty set of hall effect sensor H or H’ is neglected and the activation of the stator S coils is done based on the rotor position determined from the output of the set of hall effect sensors H or H’ which does not contain any faulty hall effect sensors. This enables the system 100 to be robust against the failure of any of the set of hall effect sensors H or H’. The present invention thus enables the motor 200 to continue to operate normally despite the faulty operation of one of the hall effect sensors HA, HB, HC, HA’, HB’ or HC’. Therefore, the present invention prevents the impending fault of the motor 200.
[035] In another embodiment of the invention, the method 400 further comprises of the steps of monitoring the temperature and humidity conditions of the motor 200. The method 400 then checks whether the values of the temperature and humidity are within the threshold values. If the temperature and humidity values are not within the threshold values it indicates a fault in functioning of the motor 200 or an impending fault in the functioning of the motor 200.
[036] Advantageously, the present invention enables the motor to be robust against hall effect sensor failure by adding a redundant sensing path. The present invention by determining failure of hall effect sensors provides for the identification of impending faults in the functioning of motors. Further, the temperature and humidity sensors enable the identification of existing and/or impending faults which may be caused due to high operating temperature and humidity of the motor.
[037] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.
,CLAIMS:1. A system (100) for determining impending faults in a motor (200), the system (100) comprising:
a first set of hall effect sensors (H) configured to provide a first output corresponding to a position of a rotor (R) of the motor (200);
a second set of hall effect sensors (H’) configured to provide a second output corresponding to the position of the rotor (R) of the motor (200); and
a control unit (Mc) being communicatively coupled to the first set of hall effect sensors (H) and the second set of hall effect sensors (H’), the control unit (Mc) being configured to receive the first output and the second output from the first set of hall effect sensors (H) and the second set of hall effect sensors (H’) respectively, analyse the first output and the second output to check for redundancy in the first output and the second output, and determine an impending fault in the motor (200).

2. The system (100) as claimed in claim 1, wherein the first set of hall effect sensors (H) having a plurality of hall effect sensors (HA, HB, HC) and the second set of hall effect sensors (H’) having a plurality of hall effect sensors (HA’, HB’, HC’), each of the hall effect sensors (HA, HB, HC) of the first set of hall effect sensors (H) having a corresponding hall effect sensor in the plurality of hall effect sensors (HA’, HB’, HC’) of the second set of hall effect sensors (H’), the corresponding hall effect sensors (HA-HA’, HB-HB’, HC-HC’) being in phase with each other, the control unit (Mc) being configured to check for redundancy in the outputs of the corresponding hall effect sensors (HA-HA’, HB-HB’, HC-HC’), and determine an impending fault in the motor (200) if redundancy is not observed in the outputs of the corresponding hall effect sensors (HA-HA’, HB-HB’, HC-HC’).

3. The system (100) as claimed in claim 2, wherein the control unit (Mc) being configured to determine a fault in the functioning of either the first set of hall effect sensors (H) or the second set of hall effect sensors (H’):
if any of the hall effect sensors (HA, HB, HC, HA’, HB’, HC’) of the first set of hall effect sensors (H) or the second set of hall effect sensors (H’) is not providing an output; or
if all the hall effect sensors (HA, HB, HC, HA’, HB’, HC’) of the first set of hall effect sensors (H) or the second set of hall effect sensors (H’) is providing either high or low output; or
if a sequence of the positions of the rotor (R) identified by the first set of hall effect sensors (H) or the second set of hall effect sensors (H’) is not corresponding to a predetermined sequence of the positions of the rotor (R); or
if a delay between the first output of the first set of hall effect sensors (H) and the second output of the second set of hall effect sensors (H’) is more than a predetermined value.

4. The system (100) as claimed in claim 3, wherein the control unit (Mc) being configured to neglect the first output or the second output if a fault is determined in the functioning of the first set of hall effect sensors (H) or the second set of hall effect sensors (H’) respectively.

5. The system (100) as claimed in claim 1, comprising:
at least one temperature sensor (Ts) configured to monitor a temperature of the motor (200); and
at least one humidity sensor (Hs) configured to monitor a moisture content in the motor (200), wherein the control unit (Mc) being configured to determine an impending fault in the functioning of the motor (200) if the temperature or moisture content of the motor (200) is more than threshold values.

6. The system (100) as claimed in claim 1, comprises a communication module (Cm), the communication module (Cm) being provided with a Controller Area Network (CAN) or Local Interconnect Network (LIN) connection, the communication module (Cm) being configured to enable communication between the control unit (Mc) and one or more electronic devices.

7. A method (400) for determining impending faults in a motor (200), the method (400) comprising the steps of:
receiving, by a control unit (Mc), a first output and a second output corresponding to a position of a rotor (R) of the motor (200) from a first set of hall effect sensors (H) and a second set of hall effect sensors (H’) respectively;
analysing, by the control unit (Mc), the first output and the second output to check for redundancy in the first output and the second output; and
determining, by the control unit (Mc), an impending fault in the motor (200).

8. The method (400) as claimed in claim 7, comprising the steps of:
checking, by the control unit (Mc), the outputs of corresponding hall sensors (HA-HA’, HB-HB’, HC-HC’) in a plurality of hall effect sensors (HA, HB, HC) of the first set of hall effect sensors (H) and a plurality of hall effect sensors (HA’, HB’, HC’) of the second set of hall effect sensors (H’) for redundancy; and
determining, by the control unit (Mc), an impending fault in the motor (200) if redundancy is not observed in the outputs of the corresponding hall effect sensors (HA-HA’, HB-HB’, HC-HC’).

9. The method (400) as claimed in claim 8, comprising the step of:
determining, by the control unit (Mc), a fault in the functioning of either the first set of hall effect sensors (H) or the second set of hall effect sensors (H’):
if any of the hall effect sensors (HA, HB, HC, HA’, HB’, HC’) of the first set of hall effect sensors (H) or the second set of hall effect sensors (H’) is not providing an output; or
if all the hall effect sensors (HA, HB, HC, HA’, HB’, HC’) of the first set of hall effect sensors (H) or the second set of hall effect sensors (H’) are providing either high or low output; or
if the sequence of the positions of the rotor (R) identified by the first set of hall effect sensors (H) or the second set of hall effect sensors (H’) is not corresponding to a predetermined sequence of the positions of the rotor (R); or
if a delay between the first output of the first set of hall effect sensors (H) and the second output of the second set of hall effect sensors (H’) is more than a predetermined value.

10. The method (400) as claimed in claim 9, comprising the step of:
neglecting, by the control unit (Mc), the first output or second output if a fault is determined in the functioning of the first set of hall effect sensors (H) or the second set of hall effect sensors (H’) respectively.

11. The method (400) as claimed in claim 7, comprising the step of:
monitoring, by at least one temperature sensor (Ts), a temperature of the motor (200);
monitoring, by at least one humidity sensor (Hs), a moisture content in the motor (200); and
determining, by the control unit (Mc), an impending fault in the functioning of the motor (200) if the temperature or moisture content of the motor (200) is more than a threshold values.

Documents

Application Documents

# Name Date
1 202421017852-STATEMENT OF UNDERTAKING (FORM 3) [12-03-2024(online)].pdf 2024-03-12
2 202421017852-PROVISIONAL SPECIFICATION [12-03-2024(online)].pdf 2024-03-12
3 202421017852-POWER OF AUTHORITY [12-03-2024(online)].pdf 2024-03-12
4 202421017852-FORM 1 [12-03-2024(online)].pdf 2024-03-12
5 202421017852-DRAWINGS [12-03-2024(online)].pdf 2024-03-12
6 202421017852-Proof of Right [11-09-2024(online)].pdf 2024-09-11
7 202421017852-FORM-5 [11-03-2025(online)].pdf 2025-03-11
8 202421017852-FORM 18 [11-03-2025(online)].pdf 2025-03-11
9 202421017852-DRAWING [11-03-2025(online)].pdf 2025-03-11
10 202421017852-CORRESPONDENCE-OTHERS [11-03-2025(online)].pdf 2025-03-11
11 202421017852-COMPLETE SPECIFICATION [11-03-2025(online)].pdf 2025-03-11
12 Abstract.jpg 2025-04-30