Motor deflection monitoring for unmanned aerial vehicles

Patent metadata

Field	Value
Publication number	US-9828095-B1
Application number	US-201514967094-A
Country	US
Kind code	B1
Filing date	Dec 11, 2015
Priority date	Dec 11, 2015
Publication date	Nov 28, 2017
Grant date	Nov 28, 2017

Abstract

Deflection of a rotor of a motor, such as a brushless motor, of an unmanned aerial vehicle (“UAV”) during operation may cause the magnets coupled to the interior surface of the rotor to move or walk down the surface, imbalancing the motor and potentially creating an unsafe flying condition for the UAV. The described methods and apparatus monitor rotor deflection of the motor during operation and alter one or more flight characteristics of the UAV if the deflection exceeds a tolerance range. By altering flight characteristics, external forces acting on the motor may be reduced, thereby reducing the deflection of the rotor.

First claim

What is claimed is:

1. An unmanned aerial vehicle (UAV), comprising:
a motor arm;
a motor, including:
a base coupled to the motor arm:
a stator affixed to the base and including a plurality of electromagnets; and
a rotor having an interior surface and an exterior surface that form a cavity and substantially encompass the stator, the rotor includes a plurality of magnets affixed to the interior surface, and the rotor is configured to rotate about the stator when a current is applied to the plurality of electromagnets of the stator;

a propeller coupled to the rotor and configured to rotate with the rotation of the rotor;
a deflection sensor configured to measure a distance between the deflection sensor and the rotor and provide the measured distance to a deflection controller, wherein a deflection of the rotor is caused at least in part by an external force applied to at least one of the exterior surface of the rotor, or the propeller; and
the deflection controller configured to at least:
determine that the measured distance exceeds an upper threshold or a lower threshold; and
cause an action to be performed in response to determining that the measured distance exceeds the upper threshold or the lower threshold.

2. The UAV of claim 1 , wherein:
a first magnet of the plurality of magnets affixed to the interior surface of the rotor moves from a first position on the interior surface of the rotor to a second position of the rotor when the deflection exceeds the upper threshold; and
the motor becomes unstable when the first magnet is in the second position.

3. The UAV of claim 1 , wherein the action includes altering a flight characteristic of the UAV such that the external force applied to at least one of the exterior surface of the rotor or the propeller is decreased.

4. The UAV of claim 3 , wherein the flight characteristic is at least one of a heading of the UAV, an orientation of the UAV, a velocity of the UAV, an acceleration of the UAV, a speed of the UAV, a rotational speed of the motor, a pitch of the UAV, a yaw of the UAV, a roll of the UAV, a pitch of a blade of the propeller, an angle of the motor with respect to the UAV, or an altitude of the UAV.

5. The UAV of claim 1 , wherein the deflection controller is further configured to at least:
determine that the measured distance corresponds to an impact between the propeller and a foreign object; and
wherein the action includes terminating a rotation of the motor.

6. The UAV of claim 1 , further comprising:
a second deflection sensor configured to measure a second distance between the second deflection sensor and the rotor and provide the measured second distance to the deflection controller, wherein the second deflection sensor measures the second distance from a second position that is different than a first position of the deflection sensor.

7. A brushless direct current (DC) motor, comprising:
a base;
a stator affixed to the base and including a plurality of electromagnets;
a rotor having an interior surface and an exterior surface that form a cavity and substantially encompass the stator, the rotor including a plurality of magnets affixed to the interior surface, and the rotor configured to rotate about the stator when a current is applied to the plurality of electromagnets of the stator; and
a deflection sensor configured to measure a distance between the deflection sensor and the rotor during an operation of the brushless DC motor and provide the measured distance.

8. The brushless DC motor of claim 7 , wherein the deflection sensor is positioned within the base such that the measured distance is representative of a distance between a bottom of the rotor and the base.

9. The brushless DC motor of claim 7 , wherein the deflection sensor is positioned within the base such that the measured distance is representative of a distance between a bottom of at least one of the plurality of magnets and the base.

10. The brushless DC motor of claim 7 , wherein the deflection sensor is at least one of a capacitive sensor, an inductive sensor, an ultrasonic sensor, a camera, a Hall effect sensor, or a contact sensor.

11. A computer-implemented method, comprising:
under control of one or more computing systems configured with executable instructions,
receiving from a deflection sensor, a first distance measurement representative of a distance between the deflection sensor and a rotor of a motor of an aerial vehicle, wherein the first distance measurement is obtained during an operation of the motor while the aerial vehicle is aerially navigating according to a flight plan;
determining that the distance measurement exceeds a threshold; and
sending instructions that cause the aerial vehicle to alter a flight characteristic.

12. The computer-implemented method of claim 11 , further comprising:
determining that the distance measurement corresponds to an impact between a propeller rotated by the motor and a foreign object; and
wherein the flight characteristic that is altered is a rotation of the motor, such that the rotation is stopped.

13. The computer-implemented method of claim 11 , further comprising:
receiving from the deflection sensor, a second distance measurement representative of a second distance between the deflection sensor and the rotor of the motor of the aerial vehicle, wherein the second distance measurement is obtained during the operation of the motor while the aerial vehicle is aerially navigating and subsequent to an alteration of the flight characteristic; and
determining that the second distance measurement does not exceed the threshold; and
continuing operation of the aerial vehicle according to the flight plan with the altered flight characteristic.

14. The computer-implemented method of claim 11 , further comprising:
receiving from the deflection sensor, a second distance measurement representative of a second distance between the deflection sensor and the rotor of the motor of the aerial vehicle, wherein the second distance measurement is obtained during the operation of the motor while the aerial vehicle is aerially navigating and subsequent to an alteration of the flight characteristic; and
determining that the second distance measurement exceeds the threshold; and
sending instructions that cause the aerial vehicle to abort the flight plan.

15. The computer-implemented method of claim 11 , wherein the flight characteristic is at least one of a heading of the aerial vehicle, an orientation of the aerial vehicle, a velocity of the aerial vehicle, an acceleration of the aerial vehicle, a speed of the aerial vehicle, a rotational speed of the motor, a pitch of the UAV, a yaw of the UAV, a roll of the UAV, a pitch of a blade of the propeller, an angle of the motor with respect to the UAV, or an altitude of the aerial vehicle.

16. The computer-implemented method of claim 11 , further comprising:
receiving from a second deflection sensor, a second distance measurement representative of a second distance between the second deflection sensor and the rotor of the motor of the aerial vehicle, wherein the second distance measurement is obtained during the operation of the motor while the aerial vehicle is aerially navigating according to the flight plan; and
wherein determining that the distance measurement exceeds a threshold includes determining that at least one of the distance measurement or the second distance measurement exceeds a threshold.

17. The computer-implemented method of claim 16 , wherein the deflection sensor is at a position of approximately zero degree

Assignees

• Amazon Tech Inc

Inventors

• Wilcox Scott Michael
• Yuen Kevin Kwok Leung

Classifications

• B64U2201/10

  autonomous, i.e. by navigating independently from ground or air stations, e.g. by using inertial navigation systems [INS] · CPC title

• B64U2201/00

  UAVs characterised by their flight controls · CPC title

• G05D13/62

  characterised by the use of electric means, e.g. use of a tachometric dynamo, use of a transducer converting an electric value into a displacement {(electric motor control H02P)} · CPC title

• B64C2201/042

  Operations & Transport · mapped topic

• B64C2201/141

  Operations & Transport · mapped topic