WO2002052712A1 - Efficiency maximizing motor controller and method - Google Patents

Efficiency maximizing motor controller and method Download PDF

Info

Publication number
WO2002052712A1
WO2002052712A1 PCT/US2001/049214 US0149214W WO02052712A1 WO 2002052712 A1 WO2002052712 A1 WO 2002052712A1 US 0149214 W US0149214 W US 0149214W WO 02052712 A1 WO02052712 A1 WO 02052712A1
Authority
WO
WIPO (PCT)
Prior art keywords
current
induction motor
dsp
electrical communication
motor
Prior art date
Application number
PCT/US2001/049214
Other languages
French (fr)
Inventor
John Lumsden
Melvin L. Kanar
Original Assignee
John Lumsden
Kanar Melvin L
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by John Lumsden, Kanar Melvin L filed Critical John Lumsden
Publication of WO2002052712A1 publication Critical patent/WO2002052712A1/en

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P27/00—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage
    • H02P27/02—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using supply voltage with constant frequency and variable amplitude

Definitions

  • This invention relates to control of electrical current for efficiency increase and protective powering of electrical motors.
  • Potential for increase in efficiency of electrical motors by regulation of current for their operation has resulted in a variety of motor-electric controllers for its accomplishment. None, however, computes on a microsecond basis the motor-loading needs of electrical motors for electrical current and, accordingly, optimizes the electrical current supplied for predetermined rotational speeds of the motors and, in addition, provide operational analyses and fault protection against hazzards to motors and to rotationally coupled devices in a manner taught by this invention.
  • Objects of patentable novelty and utility taught by this invention are to provide an efficiency-maximizing motor controller and method which: provides soft starts of motors for eliminating extra power consumption, for decreasing motor wear and for decreasing wear of devices coupled to the motors from full-power, fast startups of motors; provides consumption of bare minimum amounts of electrical power for selectively no-load and part-load operation of motors at design motor speeds in order to save up to seventy percent of.
  • This invention accomplishes these and other objectives with an efficiency- maximizing motor controller and method in which an induction motor has a digital signal processor (DSP) that calculates and optimizes supply of current for existent motor loading from a mains voltage through a current-control element.
  • the current-control element can include a standard triac, a field-effect transistor, an insulated gate bipolar transistor, a 3 quadrant triac or other select control element.
  • An induction motor rotating unloaded is predominately an inductor . In this state, the only work being done is to overcome frictional losses and inertial kinetic energy necessary to maintain rotation. Being largely inductive in this state, current lags voltage by nearly ninety degrees. As the motor is loaded increasingly, a phase difference of current lag diminishes. This is a change in phase angle from near ninety degrees to an angle approaching zero degrees of current lag, Accurately computed with artificial intelligence, this change in phase angle is an accurate measure of motor load for which current is required for operation at an optimum rotation
  • This invention uses this and other motor characteristics to calculate optimum firing angles, firing durations and firing current .
  • dynamically adaptive triacs in order to achieve motor horsepower adaptively to its work loading at the optimum rotational speed.
  • Digital calculation and motor-control feedback of this and other motor parameters in millionths of seconds with this invention provide motor-current optimization for all motor-use conditions. Calculation of motor-load requirement for current and supply of that current are effectively simultaneous.
  • FIG. 1 is a block diagram of the efficiency-maximization motor controller
  • FIG. 2 is an electrical diagram of an analog signal conditioner phase "A" ;
  • FIG. 3 is an electrical diagram of a second amplifier stage for the FIG. 2 signal conditioner;
  • FIG.4 is an electrical diagram of a second capacitor for the FIG.2 ground virtual circuit
  • FIG. 5 is an electrical diagram of an analog signal conditioner phase "B"
  • FIG. 6 is an electrical diagram of a second amplifier stage for the FIG. 5 signal conditioner
  • FIG.7 is an electrical diagram of a second capacitor for the FIG. 5 ground virtual circuit
  • FIG. 8 is an electrical diagram of an analog signal conditioner phase "C" ;
  • FIG. 9 is an electrical diagram of a second amplifier stage for the FIG. 8 signal conditioner;
  • FIG. 10 is an electrical diagram of a second capacitor for the FIG. 2 signal conditioner
  • FIG. 11 is a shrunk diagram of a digital signal processor (DSP);
  • FIG. 11A is an un-shrunk diagram of a top-left portion of the FIG. 11 shrunk diagram;
  • FIG. 11B is an un-shrunk diagram of a top-right portion of the FIG. 11 shrunk diagram
  • FIG. 11C is an un-shrunk diagram of a bottom-left portion of the FIG. 11 shrunk diagram
  • FIG. 11D is an un-shrunk diagram of a bottom-right portion of the FIG. 11 shrunk diagram
  • FIG. 12 is an electrical diagram of a double header assembly for the DSP
  • FIG. 13 is an electrical diagram of a single header assembly for the DSP
  • FIG. 14 is an electrical diagram of a jumper assembly for the DSP
  • FIG. 15 is an electrical diagram of an activity indicator for an activity LED for the DSP
  • FIG. 16 is an electrical diagram of a ground for the DSP
  • FIG. 17 is an electrical diagram of a time clock-out switch for the DSP
  • FIG. 18 is an electrical diagram of a communications port for the debugger and programing port
  • FIG. 19 is an electrical diagram of a triac three-phase driver for a motor triac
  • FIGS. 20-24 are electrical diagrams of power-connection elements for a single-phase triac
  • FIG. 25 is an electrical diagram of an IGBT three-phase driver
  • FIG. 26 is an electrical diagram of an IGBT single-phase connection
  • FIGS. 27-28 are electrical diagrams of communications connections to the outside world for use on personal computers
  • FIG. 29 is an electrical diagram of a main PSU
  • FIG. 30 is an electrical diagram of a power conditioner
  • FIGS. 31-32 are electrical diagrams of an ISO-PSU;
  • FIG. 33 is an electrical diagram of three-phase IGBT power module;
  • FIG. 34 is an electrical diagram of three-phase IGBT power connection;
  • FIG. 35 is an electrical diagram of three-phase triac power module.
  • U1C amplifier 48. current transformer Reference is made first to FIG. 1. Electrical power for an induction motor 1 from a main power supply 2 is applied through a shunt resistor 3 in a mains neutral 4 line and through a predetermined control element 5 in a mains line 6 in electrical communication with the power supply 2.
  • the predetermined control element 5 can be selected from a class of control elements that include a triac, a field-effect transistor (FET), an insulated gate bipolar transistor (IGBT) device, an SCR, and a 3 quadrant triac.
  • a voltage analog-to-digital (A/D) converter 7 is in electrical communication intermediate the power supply 2 and a digital signal processor (DSP) 8 with mains voltage being applied to the voltage A/D converter 7. Output of Hie voltage A/D converter 7 is applied to the DSP 8 for voltage measurement.
  • DSP digital signal processor
  • a volts zero-crossing detector 9 is in electrical communication intermediate the power supply 2 and the digital signal processor (DSP) 8 with mains voltage being applied to the volts zero-crossing detector 9. Output of the volts zero- crossing detector 9 is applied to the DSP 8 for phase-angle measurement of volts.
  • a current A/D converter 10 is in electrical communication intermediate the power supply 2 and the digital signal processor (DSP) 8 with current to drive the induction motor 1 being monitored by the shunt resistor 3 and with the current being applied to the current A/D converter 10 through the shunt resistor 3. Output of the current A/D converter 10 is applied to the DSP 8 for current measurement.
  • a current zero-crossing detector 11 is in electrical communication intermediate the power supply 2 and the digital signal processor (DSP) 8 with the current being applied to the current zero-crossing detector 11 through the shunt resistor 3. Output of the current zero-crossing detector 11 is applied to the DSP 8 for time and phase-angle measurements of current relative to voltage.
  • DSP digital signal processor
  • the DSP 8. is a micro-controller having architecture to compute predetermined parameters of the induction motor 1 selectively and for controlling current for the induction motor 1 in response to the predetermined parameters.
  • An optoelectronically (opto) isolated driver 12 is in electrical communication intermediate the DSP 8 and the control element 5.
  • a switching controller 13 is in electrical communication intermediate the opto isolated driver 12 and the control element 5.
  • a control attachment 14 is in control communication intermediate the DSP and a class of control connectors 15 or connector ports that include serial connectors RS232, serial connectors RS485, Control Area Network (CAN), ethernet, Universal Serial Bus (USB), TCPIP, MODBUS, MODBUS+ , wireless, fiber optics, custom utility connectors, and a manual control switch for motor- current-optimization selectively.
  • the predetermined parameters of the induction motor 1 that the DSP 8 has computer architecture to compute for controlling current for the induction motor 1 include (a) energy savings resulting from predeterminedly selected motor uses; (b) motor soft-start requirements for current to prevent its predeterminedly fast starting; (c) motor stop requirements for current to prevent its predeterminedly fast stopping; (d) motor random-start requirements for current to provide optimum current for its predeterminedly random starting; (e) motor remote-start requirements for current to provide optimum current for its predeterminedly remote starting; (f) motor intranet and internet networking requirements for current to provide optimum current for its predetermined intranet and internet networking; (g) comprehensive monitoring of a selection of the induction motor's 1 electrical parameters that include harmonic content, RMS current, power output, watts consumed, VARs, cycle frequency, phase angle, firing angle, PWM, zero-crossing point, and power being saved by predetermined application of the efficiency-maximization motor controller; (h) automatic logging of usage and downtime of the induction motor; (i) a running total
  • a potential divider connected to power supply 2A as shown is used to reduce the 120/240 volts to about 1 volt RMS for voltage measurement.
  • the potential divides comprise the resistor group 19, R5+R7 with R4 as a trim, together with Rl 1 , which provides the division.
  • the divided voltage is applied through C2 18 for DC offset isolation to the unity gain follower UIB 16.
  • the output of UIB 16 symmetrical around the split + 3.3V is applied to the DSP for voltage measurement.
  • the same signal is applied to U2A which is a comparator with a threshold at the split rail potential (zero volts for the AC voltage present there).
  • R8 and R10 provide Hysteresis by applying a small amount of positive feedback.
  • the current input uses a shunt resistor R17 3 to reduce costs.
  • the shunt is differentially connected to U1D 20 via C6 & C7 for DC isolation to the unity gain differential stage.
  • the output of U1D 20 is connected to the inverting amplifier UIC 22 whose gain can be altered by selection of R16 to match the shunt to different power rated models.
  • the output of UIC 22 is applied to the DSP for current measurement.
  • U2B 23 is a comparator with a threshold at the split rail potential (zero volts for the AC current, represented as a voltage present there).
  • R13 and R12 provide Hysteresis by applying a small amount of positive feedback.
  • Voltage and current transformers are used instead of the resistive potential divider network used with one phase power supply 2A as described previously.
  • a voltage transformer 47 is connected to the circuitry via power supply 2B, Rll serves as the load on the transformer, and the transformer ratio together with Rll presents the correct voltage level through C2 18 to UIB 16. Similar circuitry is used for the other two phases as shown in FIGS. 5 and 8. Similarly for three phase three current transformers are used together with a "burden resistor" in place of the shunt.
  • a current transformer is connected to power supply 2B with the primary in series with each motor phase.
  • the UID op-amp 20 is in electrical communication with a UIC amplifier 22 and a U2B collector 23 with output to communicate current zero crossing 24 which is shown as IA ZERO CROSS, to the DSP 8 which is shown in FIGS. 1 and 11-18.
  • AC current is read as a voltage across the series motor shunt resistor 3 that is shown as R17. This is done by use of the differentially connected op-amp UID 20 in a classic configuration to avoid any "ground loop" conditions created by common impedance coupling. Connection to the shunt resistor 3 is accomplished in a Kelvin configuration where separate monitoring connections are made to the shunt resistor 3 as shown. Differential signals are passed to the op-amp UID 20 via R14, R21, R18 and R21. Two capacitors, C6 and C7, are used to isolate the DC component on op-amp inputs.
  • the differential UID op- amp 20, together with the second UIC amplifier 22 stage, has sufficient gain to raise the small voltage derived from the shunt resistor 3 to a level appropriate for accurate analog-to-digital conversion within a range consistent with the induction motor 1 requirements.
  • This signal is taken from the output of the second-stage amplifier. Simultaneously, this buffered output is applied to U2B comparator 23 which senses the zero-crossing point 24 accurately. Hysteresis is used to speed up the edge of the current zero-crossing detector 24 to further enhance accuracy.
  • the output is taken from the open collector output of the U2B comparator 23 and passed to a zero-cross input of the DSP 8. DC isolation is required at both the voltage and current inputs with use of single-supply op-amps and comparators. In order to enable bi-polar signals to pass, the operating point is offset to half of the supply voltage in a "virtual ground" circuit.
  • the DSP 8 is used to process data rapidly for virtually every aspect of the efficiency-maximization motor controller . It runs at thirty MHz and is capable of performing thirty million instructions per second (30 MIPS). Independently, it handles all of the A/D conversions, PWM generation and the timing necessary to make determinations of the period between zero-crossing points. This processor performs all calculations within each and every half cycle period of 8.33 milli-seconds. Simultaneously, the DSP 8 monitors temperature of the motor, reads start/stop switches, monitors all supply voltages, performs all communications, and outputs appropriate drive signals to the TRIAC or the IGBT/MOS-FET, monitors RPM and temperature. Further, the DSP 8 supports "in-system programming" background de-bugging, and an activity LED.
  • triac controller 30 has an opto-isolated driver, optol 31, which is an opto-triac that is driven by a Schmitt inverter U13A.
  • Triac drive inverted from the DSP 8, shown in FIGS. 1 and 11-18, turns on the LED of the optol 31 which, in turn, switches on the internal photo-sensitive triac controller 30 which turns on a main triac Q7 32 as shown in FIG. 20.
  • Resistor R125 33 and capacitor C80 34 form a snubber network and a transorb device D49 absorbs and clamps any transients to a magnitude which is harmless to the triac Q7 32.
  • an IGBT controller 35 has a first opto isolator U25 36 and a second opto isolator U26 37 that are driven by U8A 38 and U8B 39, which in turn drive IGBT device Q8 40 and IGTB device Q9 41.
  • Each device is controlled independently by the DSP 8, allowing full control of firing angle. Unlike the triac, this gives full control over the reactive portion of the current Q9 which reduces substantially to the problems associated with power factor (PF) .
  • PF power factor
  • FIGS. 27-28 a communications example is shown for a simple RS232 serial port which can be connected to a computer to display all monitor and control functions.
  • the DSP 8 can support a plurality of control connectors that include but are not limited to (a) Serial Communications RS232; (b) Serial Communications RS845; (c) CAN (Control Area Network); (d) Ethernet; (e) USB (Universal Serial Bus); (f) TCPIP (stack for internet and intranet communications); (g) Modbus; and (h) Modbus-K
  • main +5V power is provided by an "off-line" switching regulator.
  • the +5V is accurately maintained by a feedback loop comprising U23 42, U24 43 and reference D48 44.
  • U24 43 is an opto isolator.
  • U9 45 is a linear low-drop-out regulator which provides +3.3 V for the DSP 8 and other active circuitry.
  • Various +3.3V feeds are derived from the main feed, each of which includes LC filtering as appropriate for needs on the circuit blocks.
  • a bead inductor L2 46 provides isolation of digital noise from the analog ground system. When IGBT devices are employed, two additional, small, isolated supplies are required. These are similar to the offline regulator, except that three + 18V are produced.
  • a use method for optimization of electrical current supplied to the induction motor 1 has the following steps .
  • a no-load phase angle of lag of voltage by current is predetermined for rotating the induction motor 1 at a predetermined operational speed of rotation without motor-load resistance in excess of the motor-load resistance inherent to the induction motor 1 separately from and independently of motor loading that is applied to an output shaft of the induction motor 1 for output work.
  • the part-load increase of current required is directed to the induction motor 1 from the power supply 2.
  • efficiency-maximization motor controller As described, with the DSP 8 having computer architecture to compute for the system's predetermined parameters of the induction motor 1, and with a control attachment 14 that is in control communication intermediate the DSP 8 and a predetermined class of control connectors 15 as diagramed in FIG. 1, at least one of the electrical parameters is entered into the efficiency-maximization motor controller for an objective of operation of the induction motor 1 through a selected control connector 15.
  • a new and useful efficiency-maximization motor controller and method having been described, all such foreseeable modifications, adaptations, substitutions of equivalents, mathematical possibilities of combinations of parts, pluralities of parts, applications and forms thereof as described by the following claims and not precluded by prior art are included in this invention.

Abstract

An efficency-maximization motor controller that includes a use method has power conveyance to an induction motor (1) with a digital signal processor (DSP) (8) that calculates and optimizes supply of current for existent motor loading from a power supply (2) and mains voltage through a control element (5). The control element can include a standard triac, a field-effect transistor, an insulated gate bipolar transistor, a 3 quadrant triac or other select control element. Digital calculation and motor-control feedback of current requirments for motor loading and other motor parameters are calcualted in millionths of seconds to provide motor-current optimization for all motor-use conditions. Calculations of motor-load requirment for current and supply of that current are effectively simultaneous.

Description

EFFICIENCY MAXIMIZING MOTOR CONTROLLER AND METHOD
BACKGROUND OF THE INVENTION This invention relates to control of electrical current for efficiency increase and protective powering of electrical motors. Potential for increase in efficiency of electrical motors by regulation of current for their operation has resulted in a variety of motor-electric controllers for its accomplishment. None, however, computes on a microsecond basis the motor-loading needs of electrical motors for electrical current and, accordingly, optimizes the electrical current supplied for predetermined rotational speeds of the motors and, in addition, provide operational analyses and fault protection against hazzards to motors and to rotationally coupled devices in a manner taught by this invention.
Examples of most-closely related known but yet different motor-electric controllers are described in the following patent documents . U.S. Patent Number 5,249, 118, issued to Smith on Sep. 28, 1993, described input control of current for a rotational-speed controller that also controlled rate of increase and decrease of rotational speed for computer-controlled machinery. It is representative of a plurality of patents and prior art that relate to control of speed with control of input current in contrast to Applicants' invention for optimization-control of current for predetermined rotational speed of motors. In the Smith patent, as in other variable-speed motors, current to the motors is not optimized at the variable speeds in a manner taught by this invention. Logic, methods and features for accomplishing speed control differ accordingly from the current-optimization control for predetermined speed described by Applicants. Current control for economizing power of motors at operational speeds by control of input current with yet different logic, methods and features are described in the following patent documents. U.S. Patent Number 4,864,212, issued to Parker on Sep. 5, 1989, described a sine wave power source connected through a triac to a control system with a gate electrode which is energized by a train (sequence) of sawtooth-shaped control signals having a repetition rate which is twice the frequency of the sine wave power source for providing short bursts of energy to decrease total power input for low power requirements at low fixed rates for variable rates of low-speed operation. U.S. Patent Number 4,636,702, issued to Hedges on Jan. 13, 1987, described a sample transformer operative to generate a voltage pulse related to inrush-current parameters for control of portions of sine waves of power input to stator windings for diminishing electrical current to a motor during low loading. It is limited further to a "manually settable means" for selecting a maximum value of motor torque during start mode of operation. U.S. Patent Number 4,382,223, issued to Hedges on May 3, 1983, and an improvement thereof, U.S. Patent Number 4,414,499 issued to Hedges on Nov. 8, 1983, described use of a small AC generator coupled to a rotor of an electric motor to produce a signal for controlling a sine wave modifier to regulate current to the motor in accordance with load requirements . The load requirements were determined by a difference between an optimal RPM for the motor and an RPM indicated by the small AC generator. U.S. Patent Number 4,341,984, issued to Parker, et al. on Jul. 27, 1982, is based on a frequency controller to produce at least two output frequencies for different speeds of operation of a motor. Other U.S. patents issued to Parker and/or Hedges, have employed variations of those indicated above. SUMMARY OF THE INVENTION Objects of patentable novelty and utility taught by this invention are to provide an efficiency-maximizing motor controller and method which: provides soft starts of motors for eliminating extra power consumption, for decreasing motor wear and for decreasing wear of devices coupled to the motors from full-power, fast startups of motors; provides consumption of bare minimum amounts of electrical power for selectively no-load and part-load operation of motors at design motor speeds in order to save up to seventy percent of. electrical power required for full-load operation; provides motor-parameter off-switching and selective on- switching for fault protection against power surges, power deficiencies, motor stalling, overload, excessive heat or cold and other extraneous problems; provides analyses of motor-operation factors and efficiencies; decreases motor power use and costs; decreases world need and consumption of electrical power; and can be used on both single-phase and three-phase motors and on nearly all sizes of motors for nearly all consumer and industrial applications of motors.
This invention accomplishes these and other objectives with an efficiency- maximizing motor controller and method in which an induction motor has a digital signal processor (DSP) that calculates and optimizes supply of current for existent motor loading from a mains voltage through a current-control element. The current-control element can include a standard triac, a field-effect transistor, an insulated gate bipolar transistor, a 3 quadrant triac or other select control element. An induction motor rotating unloaded is predominately an inductor . In this state, the only work being done is to overcome frictional losses and inertial kinetic energy necessary to maintain rotation. Being largely inductive in this state, current lags voltage by nearly ninety degrees. As the motor is loaded increasingly, a phase difference of current lag diminishes. This is a change in phase angle from near ninety degrees to an angle approaching zero degrees of current lag, Accurately computed with artificial intelligence, this change in phase angle is an accurate measure of motor load for which current is required for operation at an optimum rotational speed.
This invention uses this and other motor characteristics to calculate optimum firing angles, firing durations and firing current . for dynamically adaptive triacs in order to achieve motor horsepower adaptively to its work loading at the optimum rotational speed. Digital calculation and motor-control feedback of this and other motor parameters in millionths of seconds with this invention provide motor-current optimization for all motor-use conditions. Calculation of motor-load requirement for current and supply of that current are effectively simultaneous.
The above and other objects, features and advantages of the present invention should become even more readily apparent to those skilled in the art upon a reading of the following detailed description in conjunction with the drawings wherein there is shown and described illustrative embodiments of the invention. BRIEF DESCRIPTION OF DRAWINGS This invention is described by appended claims in relation to description of a preferred embodiment with reference to the following drawings which are explained briefly as follows: FIG. 1 is a block diagram of the efficiency-maximization motor controller;
FIG. 2 is an electrical diagram of an analog signal conditioner phase "A" ; FIG. 3 is an electrical diagram of a second amplifier stage for the FIG. 2 signal conditioner;
FIG.4 is an electrical diagram of a second capacitor for the FIG.2 ground virtual circuit;
FIG. 5 is an electrical diagram of an analog signal conditioner phase "B"; FIG. 6 is an electrical diagram of a second amplifier stage for the FIG. 5 signal conditioner;
FIG.7 is an electrical diagram of a second capacitor for the FIG. 5 ground virtual circuit;
FIG. 8 is an electrical diagram of an analog signal conditioner phase "C" ; FIG. 9 is an electrical diagram of a second amplifier stage for the FIG. 8 signal conditioner;
FIG. 10 is an electrical diagram of a second capacitor for the FIG. 2 signal conditioner;
FIG. 11 is a shrunk diagram of a digital signal processor (DSP); FIG. 11A is an un-shrunk diagram of a top-left portion of the FIG. 11 shrunk diagram;
FIG. 11B is an un-shrunk diagram of a top-right portion of the FIG. 11 shrunk diagram; FIG. 11C is an un-shrunk diagram of a bottom-left portion of the FIG. 11 shrunk diagram;
FIG. 11D is an un-shrunk diagram of a bottom-right portion of the FIG. 11 shrunk diagram; FIG. 12 is an electrical diagram of a double header assembly for the DSP;
FIG. 13 is an electrical diagram of a single header assembly for the DSP;
FIG. 14 is an electrical diagram of a jumper assembly for the DSP;
FIG. 15 is an electrical diagram of an activity indicator for an activity LED for the DSP; FIG. 16 is an electrical diagram of a ground for the DSP;
FIG. 17 is an electrical diagram of a time clock-out switch for the DSP;
FIG. 18 is an electrical diagram of a communications port for the debugger and programing port;
FIG. 19 is an electrical diagram of a triac three-phase driver for a motor triac;
FIGS. 20-24 are electrical diagrams of power-connection elements for a single-phase triac;
FIG. 25 is an electrical diagram of an IGBT three-phase driver;
FIG. 26 is an electrical diagram of an IGBT single-phase connection; FIGS. 27-28 are electrical diagrams of communications connections to the outside world for use on personal computers;
FIG. 29 is an electrical diagram of a main PSU;
FIG. 30 is an electrical diagram of a power conditioner;
FIGS. 31-32 are electrical diagrams of an ISO-PSU; FIG. 33 is an electrical diagram of three-phase IGBT power module; FIG. 34 is an electrical diagram of three-phase IGBT power connection; and
FIG. 35 is an electrical diagram of three-phase triac power module.
DESCRIPTION OF PREFERRED EMBODIMENT
Listed numerically below with reference to the drawings are terms used to describe features of this invention. These terms and numbers assigned to them designate the same features throughout this description.
1. Induction motor 23. U2B comparator
2. Power supply 24. Zero crossing detector
2A. single phase power supply 25. U1A 2B. additional two phase power 26. R3 supply 27. R6
3. Shunt resistor 28. Rail splitter
4. Mains neutral 29. C19
5. Control element 30. Triac controller
6. Mains line 31. Optol
7. Voltage A/D converter 32. Triac Q7
8. DSP 33. Resistor R125
9. Volts zero-crossing detector 34. Capacitor C80
10. Current A/D converter 35. IGBT controller
11. Current zero-crossing 36. First opto isolator U25 detector 37. Second opto isolator U26
12. Opto isolated driver 38. U8A
13. Switching controller 39. U8B
14. Control attachment 40. IGBT device Q8
15. Control connectors 41. IGBT device Q9
16. U1B unity gain follower 42. U23
17. Alternator network 43. U24
18. Capacitor C2 44. D48
19. Resistors 45. U9
20. U1D op-amp 46. Bead inductor L2
21. Capacitors 47. voltage transformer
22. U1C amplifier 48. current transformer Reference is made first to FIG. 1. Electrical power for an induction motor 1 from a main power supply 2 is applied through a shunt resistor 3 in a mains neutral 4 line and through a predetermined control element 5 in a mains line 6 in electrical communication with the power supply 2. The predetermined control element 5 can be selected from a class of control elements that include a triac, a field-effect transistor (FET), an insulated gate bipolar transistor (IGBT) device, an SCR, and a 3 quadrant triac.
A voltage analog-to-digital (A/D) converter 7 is in electrical communication intermediate the power supply 2 and a digital signal processor (DSP) 8 with mains voltage being applied to the voltage A/D converter 7. Output of Hie voltage A/D converter 7 is applied to the DSP 8 for voltage measurement.
A volts zero-crossing detector 9 is in electrical communication intermediate the power supply 2 and the digital signal processor (DSP) 8 with mains voltage being applied to the volts zero-crossing detector 9. Output of the volts zero- crossing detector 9 is applied to the DSP 8 for phase-angle measurement of volts. A current A/D converter 10 is in electrical communication intermediate the power supply 2 and the digital signal processor (DSP) 8 with current to drive the induction motor 1 being monitored by the shunt resistor 3 and with the current being applied to the current A/D converter 10 through the shunt resistor 3. Output of the current A/D converter 10 is applied to the DSP 8 for current measurement.
A current zero-crossing detector 11 is in electrical communication intermediate the power supply 2 and the digital signal processor (DSP) 8 with the current being applied to the current zero-crossing detector 11 through the shunt resistor 3. Output of the current zero-crossing detector 11 is applied to the DSP 8 for time and phase-angle measurements of current relative to voltage.
The DSP 8. is a micro-controller having architecture to compute predetermined parameters of the induction motor 1 selectively and for controlling current for the induction motor 1 in response to the predetermined parameters. An optoelectronically (opto) isolated driver 12 is in electrical communication intermediate the DSP 8 and the control element 5.
A switching controller 13 is in electrical communication intermediate the opto isolated driver 12 and the control element 5. A control attachment 14 is in control communication intermediate the DSP and a class of control connectors 15 or connector ports that include serial connectors RS232, serial connectors RS485, Control Area Network (CAN), ethernet, Universal Serial Bus (USB), TCPIP, MODBUS, MODBUS+ , wireless, fiber optics, custom utility connectors, and a manual control switch for motor- current-optimization selectively.
The predetermined parameters of the induction motor 1 that the DSP 8 has computer architecture to compute for controlling current for the induction motor 1 include (a) energy savings resulting from predeterminedly selected motor uses; (b) motor soft-start requirements for current to prevent its predeterminedly fast starting; (c) motor stop requirements for current to prevent its predeterminedly fast stopping; (d) motor random-start requirements for current to provide optimum current for its predeterminedly random starting; (e) motor remote-start requirements for current to provide optimum current for its predeterminedly remote starting; (f) motor intranet and internet networking requirements for current to provide optimum current for its predetermined intranet and internet networking; (g) comprehensive monitoring of a selection of the induction motor's 1 electrical parameters that include harmonic content, RMS current, power output, watts consumed, VARs, cycle frequency, phase angle, firing angle, PWM, zero-crossing point, and power being saved by predetermined application of the efficiency-maximization motor controller; (h) automatic logging of usage and downtime of the induction motor; (i) a running total of energy savings from predetermined use of the efficiency-maximization motor controller; and (j) monitoring the induction motor 1 against overload, stalling, loss of phase, over- , voltage, under voltage, over-current, under-current, detrimental temperature, low RPM and DC offset. Referring to FIG. 2, when configured for single phase, and to reduce costs, a potential divider, connected to power supply 2A as shown is used to reduce the 120/240 volts to about 1 volt RMS for voltage measurement. The potential divides comprise the resistor group 19, R5+R7 with R4 as a trim, together with Rl 1 , which provides the division. The divided voltage is applied through C2 18 for DC offset isolation to the unity gain follower UIB 16. The output of UIB 16 symmetrical around the split + 3.3V is applied to the DSP for voltage measurement. The same signal is applied to U2A which is a comparator with a threshold at the split rail potential (zero volts for the AC voltage present there). R8 and R10 provide Hysteresis by applying a small amount of positive feedback.
Likewise, the current input uses a shunt resistor R17 3 to reduce costs. The shunt is differentially connected to U1D 20 via C6 & C7 for DC isolation to the unity gain differential stage. The output of U1D 20 is connected to the inverting amplifier UIC 22 whose gain can be altered by selection of R16 to match the shunt to different power rated models. The output of UIC 22 is applied to the DSP for current measurement. The same signal is applied to U2B 23 which is a comparator with a threshold at the split rail potential (zero volts for the AC current, represented as a voltage present there). R13 and R12 provide Hysteresis by applying a small amount of positive feedback.
When configured for three phase power with additional two phase power supply input 2B all inputs need to be isolated. Voltage and current transformers are used instead of the resistive potential divider network used with one phase power supply 2A as described previously. A voltage transformer 47 is connected to the circuitry via power supply 2B, Rll serves as the load on the transformer, and the transformer ratio together with Rll presents the correct voltage level through C2 18 to UIB 16. Similar circuitry is used for the other two phases as shown in FIGS. 5 and 8. Similarly for three phase three current transformers are used together with a "burden resistor" in place of the shunt. A current transformer is connected to power supply 2B with the primary in series with each motor phase. In single phase the shunt is in series with the motor neutral for current measurement, impossible in three phase without isolated A/D converters or Isolation amplifiers, the transformers are much less expensive. Monitoring the split rail voltage and also the 3.3 volt rail in the DSP removes completely any inaccuracies associated with the divider chain to U1A 25, the rail splitter.
The UID op-amp 20 is in electrical communication with a UIC amplifier 22 and a U2B collector 23 with output to communicate current zero crossing 24 which is shown as IA ZERO CROSS, to the DSP 8 which is shown in FIGS. 1 and 11-18.
AC current is read as a voltage across the series motor shunt resistor 3 that is shown as R17. This is done by use of the differentially connected op-amp UID 20 in a classic configuration to avoid any "ground loop" conditions created by common impedance coupling. Connection to the shunt resistor 3 is accomplished in a Kelvin configuration where separate monitoring connections are made to the shunt resistor 3 as shown. Differential signals are passed to the op-amp UID 20 via R14, R21, R18 and R21. Two capacitors, C6 and C7, are used to isolate the DC component on op-amp inputs. The differential UID op- amp 20, together with the second UIC amplifier 22 stage, has sufficient gain to raise the small voltage derived from the shunt resistor 3 to a level appropriate for accurate analog-to-digital conversion within a range consistent with the induction motor 1 requirements.
This signal is taken from the output of the second-stage amplifier. Simultaneously, this buffered output is applied to U2B comparator 23 which senses the zero-crossing point 24 accurately. Hysteresis is used to speed up the edge of the current zero-crossing detector 24 to further enhance accuracy. The output is taken from the open collector output of the U2B comparator 23 and passed to a zero-cross input of the DSP 8. DC isolation is required at both the voltage and current inputs with use of single-supply op-amps and comparators. In order to enable bi-polar signals to pass, the operating point is offset to half of the supply voltage in a "virtual ground" circuit. This topology is achieved by use of Ul A 25 which has R3 26 and R6 27 arranged as a rail splitter, split rail 28, and decoupled by Cl 29. This arrangement gives the virtual ground or split rail extremely low impedance which is at the same AC potential as the analog ground.
Referring to FIGS. 1 and 11-18, the DSP 8 is used to process data rapidly for virtually every aspect of the efficiency-maximization motor controller . It runs at thirty MHz and is capable of performing thirty million instructions per second (30 MIPS). Independently, it handles all of the A/D conversions, PWM generation and the timing necessary to make determinations of the period between zero-crossing points. This processor performs all calculations within each and every half cycle period of 8.33 milli-seconds. Simultaneously, the DSP 8 monitors temperature of the motor, reads start/stop switches, monitors all supply voltages, performs all communications, and outputs appropriate drive signals to the TRIAC or the IGBT/MOS-FET, monitors RPM and temperature. Further, the DSP 8 supports "in-system programming" background de-bugging, and an activity LED.
Referring to FIGS. 19-24, triac controller 30 has an opto-isolated driver, optol 31, which is an opto-triac that is driven by a Schmitt inverter U13A. Triac drive, inverted from the DSP 8, shown in FIGS. 1 and 11-18, turns on the LED of the optol 31 which, in turn, switches on the internal photo-sensitive triac controller 30 which turns on a main triac Q7 32 as shown in FIG. 20. Resistor R125 33 and capacitor C80 34 form a snubber network and a transorb device D49 absorbs and clamps any transients to a magnitude which is harmless to the triac Q7 32.
Referring to FIGS. 25-26, an IGBT controller 35 has a first opto isolator U25 36 and a second opto isolator U26 37 that are driven by U8A 38 and U8B 39, which in turn drive IGBT device Q8 40 and IGTB device Q9 41. Each device is controlled independently by the DSP 8, allowing full control of firing angle. Unlike the triac, this gives full control over the reactive portion of the current Q9 which reduces substantially to the problems associated with power factor (PF) . Unlike the triac which stays on until current has ceased to flow, the IGBT controller 35 can be turned on or off at will. Since the IGBT controller's 35 on cycle is PWM modulated, complete control of rise time, amplitude, and duration are available . This provides much improvement of RFI/EMG, harmonic content and reactive power factor (PF) for part-power operation. Referring to FIGS. 27-28, a communications example is shown for a simple RS232 serial port which can be connected to a computer to display all monitor and control functions. Similarly the DSP 8 can support a plurality of control connectors that include but are not limited to (a) Serial Communications RS232; (b) Serial Communications RS845; (c) CAN (Control Area Network); (d) Ethernet; (e) USB (Universal Serial Bus); (f) TCPIP (stack for internet and intranet communications); (g) Modbus; and (h) Modbus-K
Referring to FIGS. 29-32, for power supply units, main +5V power is provided by an "off-line" switching regulator. The +5V is accurately maintained by a feedback loop comprising U23 42, U24 43 and reference D48 44. U24 43 is an opto isolator. U9 45 is a linear low-drop-out regulator which provides +3.3 V for the DSP 8 and other active circuitry. Various +3.3V feeds are derived from the main feed, each of which includes LC filtering as appropriate for needs on the circuit blocks. A bead inductor L2 46 provides isolation of digital noise from the analog ground system. When IGBT devices are employed, two additional, small, isolated supplies are required. These are similar to the offline regulator, except that three + 18V are produced. In the case of the single- phase embodiment with IGBT Mosfets, only two outputs are required. When triacs are employed, no isolated voltages are required. A use method for optimization of electrical current supplied to the induction motor 1 has the following steps . For the efficiency-maximization motor controller, a no-load phase angle of lag of voltage by current is predetermined for rotating the induction motor 1 at a predetermined operational speed of rotation without motor-load resistance in excess of the motor-load resistance inherent to the induction motor 1 separately from and independently of motor loading that is applied to an output shaft of the induction motor 1 for output work. Current required for rotating the induction motor 1 under a predetermined full load and having a predetermined full-load phase angle of lag of voltage by current for rotating the induction motor 1 maximumly loaded at the predetermined operational speed is predetermined. With the efficiency-maximization motor controller is calculated any part- load phase angle of the lag of voltage by current for rotating the induction motor 1 at the predetermined operational speed of rotation with any added motor-load resistance from any part-loading that is applied to the induction motor 1. Calculated also with the efficiency-maximization motor controller is any part-load increase of current required for any part-loading of the induction motor 1 as a part-load percent of a difference between the no-load phase angle and the full- load phase angle.
Then with the efficiency-maximization motor controller, the part-load increase of current required is directed to the induction motor 1 from the power supply 2.
Using the efficiency-maximization motor controller as described, with the DSP 8 having computer architecture to compute for the system's predetermined parameters of the induction motor 1, and with a control attachment 14 that is in control communication intermediate the DSP 8 and a predetermined class of control connectors 15 as diagramed in FIG. 1, at least one of the electrical parameters is entered into the efficiency-maximization motor controller for an objective of operation of the induction motor 1 through a selected control connector 15. A new and useful efficiency-maximization motor controller and method having been described, all such foreseeable modifications, adaptations, substitutions of equivalents, mathematical possibilities of combinations of parts, pluralities of parts, applications and forms thereof as described by the following claims and not precluded by prior art are included in this invention.

Claims

CLAIMS What is claimed is: 1. An efficiency-maximizing motor controller comprising: an induction-motor power conveyance with which mains voltage from a power supply is in electrical communication for power to be applied to the induction motor through a shunt resistor in a mains neutral line and a predetermined control element in a mains line in electrical communication with the power supply; the predetermined control element being selected from a class of control elements that include a triac, a field-effect transistor (FET), an insulated gate bipolar transistor device (IGBT), an SCR and a 3 quadrant triac; a voltage analog-to-digital (A/D) converter in electrical communication intermediate the power supply and a digital signal processor (DSP); mains voltage being in electrical communication to be applied to the voltage A/D converter; output of the voltage A/D converter being in electrical communication to be applied to the DSP for voltage measurement; a volts zero-crossing detector in electrical communication intermediate the power supply and the DSP; mains voltage being in electrical communication to be applied to the volts zero-crossing detector; output of the volts zero-crossing detector being in electrical communication to be applied to the DSP for time and phase-angle measurements of volts; a current A/D converter in electrical communication intermediate the power supply and the DSP; current to drive the induction motor being in electrical communication to be monitored by the shunt resistor; the current being in electrical communication to be applied to the current A/D converter through the shunt resistor; output of the current A/D converter being in electrical communication to be applied to the DSP for current measurement; a current zero-crossing detector in electrical communication intermediate the power supply and the DSP; mains current being in electrical communication to be applied to the current zero-crossing detector through the shunt resistor; output of the current zero-crossing detector being in electrical communication to be applied to the DSP for time and phase-angle measurements of current; the DSP having computer architecture to compute predetermined parameters of the induction motor selectively; the DSP being a micro-controller for controlling current for the induction motor in predetermined response to the predetermined parameters of the induction motor; an optoelectronically (opto) isolated driver in electrical communication intermediate the DSP and the control element; and a switching controller in electrical communication intermediate the opto isolated driver and the control element.
2. The efficiency-maximization motor controller of claim 1 and further comprising: a control attachment in control communication intermediate the DSP and a class of control connectors that includes serial connectors RS232, serial connectors RS485 , Control Area Network (CAN) , ethernet, Universal Serial Bus (USB), TCPIP, MODBUS, MODBUS + , wireless, fiber optics, custom utility communications, and a manual control switch for motor-current-optimization selectively.
3. The efficiency-maximization motor controller of claim 1 wherein: the predetermined parameters of the induction motor that the DSP has computer architecture to compute for controlling current for the induction motor include energy savings resulting from predeterminedly selected uses of the efficiency-maximization motor controller.
4. The efficiency-maximization motor controller of claim 1 wherein: the predetermined parameters of the induction motor that the DSP has computer architecture to compute for controlling current for the induction motor include the induction motor's soft-start requirement for current to prevent its predeterminedly fast starting.
5. The efficiency-maximization motor controller of claim 1 wherein: the predetermined parameters of the induction motor that the DSP has computer architecture to compute for controlling current for the induction motor include the induction motor's soft-stop requirement for current to prevent its predeterminedly fast stopping.
6. The efficiency-maximization motor controller of claim 1 wherein: the predetermined parameters of the induction motor that the DSP has computer architecture to compute for controlling current for the induction motor include the induction motor's random-start requirement for current to provide optimum current for its predeterminedly random starting.
7. The efficiency-maximization motor controller of claim 1 wherein: the predetermined parameters of the induction motor that the DSP has computer architecture to compute for controlling current for the induction motor include the induction motor's remote-start requirement for current to provide optimum current for its predeterminedly remote starting.
8. The efficiency-maximization motor controller of claim 1 wherein: the predetermined parameters of the induction motor that the DSP has computer architecture to compute for controlling current for the induction motor include the induction motor' s intranet and internet networking requirements for current to provide optimum current for its predetermined intranet and internet networking.
9. The efficiency-maximization motor controller of claim 1 wherein: the predetermined parameters of the induction motor that the DSP has computer architecture to compute for controlling current for the induction motor include comprehensive monitoring of a selection of the induction motor's electrical parameters that include harmonic content, RMS volts, RMS current, power output, watts consumed, VARs, cycle frequency, phase angle, firing angle, PWM, zero-crossing point, and power being in electrical communication to be saved by predetermined application of the efficiency-maximization motor controller.
10. The efficiency-maximization motor controller of claim 1 wherein: the predetermined parameters of the induction motor that the DSP has computer architecture to compute for controlling current for the induction motor include automatic logging of usage and downtime of the induction motor.
11. The efficiency-maximization motor controller of claim 1 wherein: the predetermined parameters of the induction motor that the DSP has computer architecture to compute for controlling current for the induction motor include a running total of energy savings from predetermined use of the efficiency-maximization motor controller.
12. The efficiency-maximization motor controller of claim 1 wherein: the predetermined parameters of the induction motor that the DSP has computer architecture to compute for controlling current for the induction motor include monitoring the induction motor predeterminedly for its comprehensive safeguard and protection of the induction motor against overload, stalling, loss of phase, over-voltage, under-voltage, over-current, under-current, detrimental temperature, low RPM, and DC offset.
13. The efficiency-maximization motor controller of claim 1 wherein: the mains line and the mains neutral line are in electrical communication with a UIB op-amp through an alternator network and through a C2 capacitor to isolate any DC component present in a non-inverting input; the alternator network includes a plurality of predetermined resistors ; the UIB op-amp is in electrical communication with a U2A comparator to sense voltage zero crossing with predetermined accuracy for communication to the DSP; the mains line and the mains neutral line are in electrical communication with a UID op-amp through the shunt resistor to read AC current as a voltage across the shunt resistor; a plurality of predetermined resistors and capacitors are positioned in the electrical communication of the mains line and the mains neutral line to isolate DC component; and the U 1 D op-amp is in electrical commumcation with a U 1 C amplifier and a U2B collector output to communicate current zero crossing to the DSP.
14. Efficiency-maximizing motor controller comprising: an induction-motor power conveyance with which mains voltage from a power supply is in electrical communication for power to be applied to the induction motor through a shunt resistor in a mains neutral line and a predetermined control element in a mains line in electrical communication with the power supply; the predetermined control element being selected from a class of control elements that include a triac, a field-effect transistor (FET), an insulated gate bipolar transistor device (IGBT), an SCR and a 3 quadrant triac; a voltage analog-to-digital (A/D) converter in electrical communication intermediate the power supply and a digital signal processor (DSP); mains voltage being in electrical communication to be applied to the voltage A/D converter; output of the voltage A/D converter being in electrical communication to be applied to the DSP for voltage measurement; a volts zero-crossing detector in electrical communication intermediate the power supply and the DSP; mains voltage being in electrical communication to be applied to the volts zero-crossing detector; output of the volts zero-crossing detector being in electrical communication to be applied to the DSP for time and phase-angle measurements of volts; a current A/D converter in electrical communication intermediate the power supply and the DSP; current to drive the induction motor being in electrical communication to be monitored by the shunt resistor; the current being in electrical communication to be applied to the current A/D converter through the shunt resistor; output of the current A/D converter being in electrical commumcation to be applied to the DSP for current measurement; a current zero-crossing detector in electrical commumcation intermediate the power supply and the DSP; mains current being in electrical communication to be applied to the current zero-crossing detector through the shunt resistor; output of the current zero-crossing detector being in electrical communication to be applied to the DSP for time and phase-angle measurements of current; the DSP having computer architecture to compute predetermined parameters of the induction motor selectively; the DSP being a micro-controller for controlling current for the induction motor in predetermined response to the predetermined parameters of the induction motor; an optoelectronically (opto) isolated driver in electrical communication intermediate the DSP and the control element; a switching controller in electrical communication intermediate the opto isolated driver and the control element; a control attachment in control communication intermediate the DSP and a class of control connectors that includes serial connectors RS232, serial connectors RS485 , Control Area Network (CAN) , ethernet, Universal Serial Bus (USB), TCPIP, MODBUS, MODBUS+, wireless, fiber optics, custom utility communications, and a manual control switch for motor-current-optimization selectively; and the predetermined parameters of the induction motor that the DSP has computer architecture to compute for controlling current for the induction motor include at least two of the following: (a) energy savings resulting from predeterminedly selective uses of the efficiency-maximization motor controller, (b) the induction motor' s soft-start requirement for current to prevent its predeterminedly fast starting, (c) the induction motor's soft-stop requirement for current to prevent its predeterminedly fast stopping, (d) the induction motor's random-start requirement for current to provide optimum current for its predeterminedly random starting, (e) the induction motor's remote-start requirement for current to provide optimum current for its predeterminedly remote starting, (f) the induction motor's intranet and internet networking requirement for current to provide optimum current for its predetermined intranet and internet networking, (g) comprehensive monitoring of a selection of the induction motor's electrical parameters that include harmonic content, RMS volts. RMS current, power output, watts consumed, VARs, cycle frequency, phase angle, firing angle, PWM, zero- crossing point, and power being in electrical communication to be saved by predetermined application of the efficiency-maximization motor controller, (h) automatic logging of usage and downtime of the induction motor, (i) a running total of energy savings from predetermined use of the efficiency-maximization motor controller, and (j) monitoring the induction motor predeterminedly for its comprehensive safeguard and protection of the induction motor against overload, stalling, loss of phase, over-voltage, under- 86 voltage, over-current, under-current, detrimental temperature, low
87 RPM, and DC offset.
1 15. The efficiency-maximization motor controller of claim 14 wherein:
2 the mains line and the mains neutral line are in electrical
3 commumcation with a UIB op-amp through an alternator network and through
4 a C2 capacitor to isolate any DC component present in a non-inverting input;
5 the alternator network includes a plurality of predetermined resistors ;
6 the UIB op-amp is in electrical communication with a U2A
7 comparator to sense voltage zero crossing with predetermined accuracy for
8 communication to the DSP;
9 the mains line and the mains neutral line are in electrical
10 communication with a UID op-amp through the shunt resistor to read AC current
11 as a voltage across the shunt resistor;
12 a plurality of predetermined resistors and capacitors are positioned
13 in the electrical communication of the mains line and the mains neutral line to
14 isolate DC component; and
15 the U 1 D op-amp is in electrical commumcation with a U 1 C amplifier
16 and a U2B collector output to communicate current zero crossing to the DSP.
1 16. A use method comprising the following steps for maximizing
2 efficiency of the induction motor with the efficiency-maximization motor
3 controller:
4 predetermining a no-load phase angle of lag of voltage by current for
5 rotating the induction motor at a predetermined operational speed of rotation
6 without motor-load resistance in excess of the motor-load resistance inherent to the induction motor separately from motor loading that is applied to an output shaft of the induction motor; predetermining the current required for rotating the induction motor under a predetermined full load and having a predetermined full-load phase angle of the lag of voltage by current for rotating the induction motor maximumly loaded at the predetermined operational speed; with the efficiency-maximization motor controller, calculating any part-load phase angle of the lag of voltage by current for rotating the induction motor at the predetermined operational speed of rotation with any added motor- load resistance from any part-loading that is applied to the induction motor; and with the efficiency-maximization motor controller, calculating any part-load increase of current required for any part-loading of the induction motor as a part-load percent of a difference between the no-load phase angle and the full-load phase angle.
17. The use method claim 16 wherein the efficiency-maximization motor controller includes: an induction-motor power conveyance with which mains voltage from a power supply is in electrical communication for power to be applied to the induction motor through a shunt resistor in a mains neutral line and a predetermined control element in a mains line in electrical communication with the power supply; the predetermined control element being selected from a class of control elements that include a triac, a field-effect transistor (FET), an insulated gate bipolar transistor device (IGBT), an SCR and a 3 quadrant triac; a voltage analog-to-digital (A/D) converter in electrical communication intermediate the power supply and a digital signal processor (DSP); mains voltage being in electrical commumcation to be applied to the voltage A/D converter; output of the voltage A/D converter being in electrical communication to be applied to the DSP for voltage measurement; a volts zero-crossing detector in electrical communication intermediate the power supply and the DSP; mains voltage being in electrical communication to be applied to the volts zero-crossing detector; output of the volts zero-crossing detector being in electrical communication to be applied to the DSP for time and phase-angle measurements of volts; a current A/D converter in electrical commumcation intermediate the power supply and the DSP; current to drive the induction motor being in electrical communication to be monitored by the shunt resistor; the current being in electrical communication to be applied to the current A/D converter through the shunt resistor; output of the current A/D converter being in electrical commumcation to be applied to the DSP for current measurement; a current zero-crossing detector in electrical communication intermediate the power supply and the DSP; mains current being in electrical communication to be applied to the current zero-crossing detector through the shunt resistor; output of the current zero-crossing detector being in electrical communication to be applied to the DSP for time and phase-angle measurements of current; the DSP having computer architecture to compute predetermined parameters of the induction motor selectively; the DSP being a micro-controller for controlling current for the induction motor in predetermined response to the predetermined parameters of the induction motor; an optoelectronically (opto) isolated driver in electrical communication intermediate the DSP and the control element; and a switching controller in electrical communication intermediate the opto isolated driver and the control element; and the use method comprises the additional step of directing the part- load increase of current required to the induction motor from a power supply.
18. A use method having the following steps for using efficiency- maximizing motor controller comprising: an induction motor to which mains voltage from an in electrical commumcation for being applied through a shunt resistor in an mains neutral line and a predetermined control element in an mains line in electrical communication with the power supply; the predetermined control element being selected from a class of control elements that include a triac, a field-effect transistor (FET), an insulated gate bipolar transistor device (IGBT), an SCR and a 3 quadrant triac; a voltage analog-to-digital (A/D) converter in electrical communication intermediate the power supply and a digital signal processor (DSP); mains voltage being in electrical communication to be applied to the voltage A/D converter; output of the voltage A/D converter being in electrical communication to be applied to the DSP for voltage measurement; a volts zero-crossing detector in electrical communication intermediate the power supply and the DSP; mains voltage being in electrical communication to be applied to the volts zero-crossing detector; output of the volts zero-crossing detector being in electrical communication to be applied to the DSP for time and phase-angle measurements of volts; a current A/D converter in electrical commumcation intermediate the power supply and the DSP; current to drive the induction motor being in electrical commumcation to be monitored by the shunt resistor; the current being in electrical commumcation to be applied to the current A/D converter through the shunt resistor; output of the current A/D converter being in electrical communication to be applied to the DSP for current measurement; a current zero-crossing detector in electrical communication intermediate the power supply and the DSP; mains current being in electrical communication to be applied to the current zero-crossing detector through the shunt resistor; output of the current zero-crossing detector being in electrical communication to be applied to the DSP for time and phase-angle measurements of current; the DSP having computer architecture to compute predetermined parameters of the induction motor selectively; the DSP being a micro-controller for controlling current for the induction motor in predetermined response to the predetermined parameters of the induction motor; an optoelectronically (opto) isolated driver in electrical communication intermediate the DSP and the control element; a switching controller in electrical commumcation intermediate the opto isolated driver and the control element; a control attachment in control communication intermediate the DSP and a class of control connectors that includes serial connectors RS232, serial connectors RS485 , Control Area Network (CAN) , ethernet, Universal Serial Bus (USB), TCPIP, MODBUS, MODBUS + , wireless, fiber optics, custom utility communications, and a manual control switch for motor-current-optimization selectively; and the predetermined parameters of the induction motor that the DSP has computer architecture to compute for controlling current for the induction motor include at least two of the following: (a) energy savings resulting from predeterminedly selective uses of the efficiency-maximization motor controller, (b) the induction motor's soft-start requirement for current to prevent its predeterminedly fast starting, (c) the induction motor's soft-stop requirement for current to prevent its predeterminedly fast stopping, (d) the induction motor's random-start requirement for current to provide optimum current for its predeterminedly random starting, (e) the induction motor's remote-start requirement for current to provide optimum current for its predeterminedly remote starting, (f) the induction motor's intranet and internet networking requirement for current to provide optimum current for its predetermined intranet and internet networking, (g) comprehensive monitoring of a selection of the induction motor's electrical parameters that include harmonic content, RMS volts. RMS current, power output, watts consumed, VARs, cycle frequency, phase angle, firing angle, PWM, zero- crossing point, and power being in electrical commumcation to be saved by predetermined application of the efficiency-maximization motor controller, (h) automatic logging of usage and downtime of the induction motor, (i) a running total of energy savings from predetermined use of the efficiency-maximization motor controller, and (j) monitoring the induction motor predeterminedly for its comprehensive safeguard and protection of the induction motor against overload, stalling, loss of phase, over-voltage, under- 86 voltage, over-current, under-current, detrimental temperature, low
87 RPM, and DC offset;
88 entering at least one electrical parameter into the efficiency-
89 maximization motor controller for an objective of operation of the induction
90 motor; and
91 operating the induction motor in accordance with the objective of
92 operation.
1 19. The use method of claim 18 wherein:
2 the electrical parameter is entered into the efficiency-maximization
3 motor controller through a select control attachment that is in control
4 communication intermediate the DSP.
1 20. The efficiency-maximizing motor controller of claim 1 further
2 comprising:
3 the predetermined control element contains a plurality of IGBTs to
4 provide power factor correction and improvement.
PCT/US2001/049214 2000-12-26 2001-12-21 Efficiency maximizing motor controller and method WO2002052712A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US09/748,773 US6489742B2 (en) 2000-12-26 2000-12-26 Efficiency maximizing motor controller and method
US09/748,773 2000-12-26

Publications (1)

Publication Number Publication Date
WO2002052712A1 true WO2002052712A1 (en) 2002-07-04

Family

ID=25010859

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2001/049214 WO2002052712A1 (en) 2000-12-26 2001-12-21 Efficiency maximizing motor controller and method

Country Status (2)

Country Link
US (1) US6489742B2 (en)
WO (1) WO2002052712A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004019706A1 (en) * 2002-08-27 2004-03-11 Fmc Technologies, Inc. Juice extractor having soft start motor control

Families Citing this family (55)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6801005B2 (en) * 2001-10-26 2004-10-05 Load Logic, Inc. Method and apparatus for controlling three-phase power
US20030206386A1 (en) * 2002-05-01 2003-11-06 Hill Christopher Lawrence Power supply isolation during motor spinup
US6646849B1 (en) * 2002-05-24 2003-11-11 Long Well Electronics Corp. Digital power inverter and method of controlling the same
US6862538B2 (en) * 2002-07-23 2005-03-01 Reliance Electric Technologies, Llc. Induction motor module and motor incorporating same
US7414377B2 (en) * 2002-09-23 2008-08-19 Siemens Energy & Automation, Inc. System and method for automatic current limit control
US6895809B2 (en) * 2002-12-31 2005-05-24 Spx Corporation Method and apparatus for testing a motor
US7196491B2 (en) * 2003-02-12 2007-03-27 Siemens Energy & Automation, Inc. System and method for stall detection of a motor
US7268505B2 (en) * 2003-09-12 2007-09-11 A. O. Smith Corporation Electric machine and method of operating the electric machine
US7102324B2 (en) * 2003-09-12 2006-09-05 A.O. Smith Corporation Fixed speed drive
US7327118B2 (en) * 2003-09-12 2008-02-05 A. O. Smith Corporation Electric machine and method of operating the electric machine
CA2443206A1 (en) * 2003-09-23 2005-03-23 Ignis Innovation Inc. Amoled display backplanes - pixel driver circuits, array architecture, and external compensation
US7184902B2 (en) * 2003-09-30 2007-02-27 Reliance Electric Technologies, Llc Motor parameter estimation method and apparatus
US7178436B2 (en) * 2003-11-07 2007-02-20 United States Steel Corporation Method of cutting carbon and alloy steel
US7196295B2 (en) * 2003-11-21 2007-03-27 Watlow Electric Manufacturing Company Two-wire layered heater system
KR20050111204A (en) * 2004-05-21 2005-11-24 엘지전자 주식회사 Method for power factor compensation of inverter control circuit
US7102323B2 (en) * 2004-11-30 2006-09-05 Honeywell International Inc. High power density/limited DC link voltage synchronous motor drive
US20090206818A1 (en) * 2005-01-03 2009-08-20 Horan Michael J Ac voltage regulation system and method
US7295651B2 (en) * 2005-06-30 2007-11-13 General Electric Company Stationary computed tomography system and method
US7768221B2 (en) * 2006-06-02 2010-08-03 Power Efficiency Corporation Method, system, and apparatus for controlling an electric motor
GB0625942D0 (en) * 2006-12-27 2007-02-07 Nokia Corp Switched mode power supply for a transmitter
US8010318B2 (en) * 2007-06-04 2011-08-30 Eaton Corporation System and method to determine electric motor efficiency nonintrusively
US8085009B2 (en) * 2007-08-13 2011-12-27 The Powerwise Group, Inc. IGBT/FET-based energy savings device for reducing a predetermined amount of voltage using pulse width modulation
US20110182094A1 (en) * 2007-08-13 2011-07-28 The Powerwise Group, Inc. System and method to manage power usage
US8619443B2 (en) 2010-09-29 2013-12-31 The Powerwise Group, Inc. System and method to boost voltage
US8120307B2 (en) * 2007-08-24 2012-02-21 The Powerwise Group, Inc. System and method for providing constant loading in AC power applications
US8085010B2 (en) * 2007-08-24 2011-12-27 The Powerwise Group, Inc. TRIAC/SCR-based energy savings device for reducing a predetermined amount of voltage using pulse width modulation
US8810190B2 (en) * 2007-09-14 2014-08-19 The Powerwise Group, Inc. Motor controller system and method for maximizing energy savings
US8698447B2 (en) 2007-09-14 2014-04-15 The Powerwise Group, Inc. Energy saving system and method for devices with rotating or reciprocating masses
KR100810651B1 (en) 2007-11-09 2008-03-06 삼화디에스피주식회사 Multi-functional motor protection relay capable of monitoring electric power
RU2360354C1 (en) * 2007-12-04 2009-06-27 Олег Анатольевич Буглаев Ac electronic motor
US8749936B2 (en) * 2007-12-06 2014-06-10 Freescale Semiconductor, Inc. Semiconductor device and apparatus including semiconductor device
US8004255B2 (en) 2008-08-07 2011-08-23 The Powerwise Group, Inc. Power supply for IGBT/FET drivers
US8698446B2 (en) * 2009-09-08 2014-04-15 The Powerwise Group, Inc. Method to save energy for devices with rotating or reciprocating masses
KR101816058B1 (en) * 2009-09-08 2018-01-08 더 파워와이즈 그룹, 인코포레이티드 Energy saving system and method for devices with rotating or reciprocating masses
US8638059B2 (en) 2010-08-11 2014-01-28 Dayton-Phoenix Group, Inc. Control for multi-phase induction motor
CN102004221A (en) * 2010-08-26 2011-04-06 沈阳工业大学 Reciprocal energy feeding test device for actuating mechanism of dual linear induction motors
US8996142B2 (en) * 2010-12-22 2015-03-31 Aktiebolaget Skf Alignment software process management
US8816830B2 (en) * 2011-08-19 2014-08-26 Legendaire Technology Co., Ltd. Motor control system and the method of controlling motor
CN102437799B (en) * 2011-10-21 2013-12-04 福州大学 Method for realizing digital signal processor (DSP) control over intermediate frequency single-phase generator inverter
US8937448B2 (en) 2011-11-21 2015-01-20 Baker Hughes Incorporated Systems and methods for downhole power factor correction
FR2984641B1 (en) * 2011-12-15 2014-06-13 Eutelsat Sa TRANSMITTING / RECEIVING RADIO SIGNAL INSTALLATION
US9281770B2 (en) * 2012-01-27 2016-03-08 Ingersoll-Rand Company Precision-fastening handheld cordless power tools
US8988030B2 (en) * 2012-11-13 2015-03-24 Schlumberger Technology Corporation Power control for electrical applications over long cables
BR102013003829A2 (en) * 2013-02-19 2014-11-04 Whirlpool Sa WASHER ELECTRIC MOTOR DRIVING METHOD
US10148155B2 (en) 2013-12-04 2018-12-04 Barrett Technology, Llc Method and apparatus for connecting an ultracompact, high-performance motor controller to an ultracompact, high-performance brushless DC motor
KR101938220B1 (en) * 2014-01-27 2019-01-14 엘에스산전 주식회사 Analog current output module
US9578702B2 (en) * 2014-05-09 2017-02-21 Osram Sylvania Inc. Synchronized PWM-dimming with random phase
CN104533383A (en) * 2014-12-18 2015-04-22 宝鸡石油机械有限责任公司 Local and remote control panel of soft starter of hydraulic pressure station
DE112016006552T5 (en) * 2016-03-07 2018-12-20 Danfoss Power Electronics A/S Method and device for characterizing a three-phase asynchronous motor
EP3330722A1 (en) * 2016-12-01 2018-06-06 Siemens Aktiengesellschaft Method and circuit for diagnosing a thyristor load current based on the gate current
WO2019111145A1 (en) * 2017-12-06 2019-06-13 Thekke Peedikayil Kunjimon Electronically controlled high efficiency induction motor
US10461537B2 (en) * 2017-12-19 2019-10-29 Eurotherm Limited Method to drive a power control device connected to unbalanced three-phase loads when no neutral reference is available in an alternative electrical network
KR102036578B1 (en) * 2018-05-09 2019-10-25 엘에스산전 주식회사 Apparatus for detecting output phase open in inverter
JP7116338B2 (en) * 2020-12-24 2022-08-10 ダイキン工業株式会社 Information takeover system, second substrate, air conditioner, and information takeover method
US20230165430A1 (en) * 2021-11-30 2023-06-01 Haier Us Appliance Solutions, Inc. Dishwashing appliance with decision making via sensor circuit

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5737762A (en) * 1993-12-08 1998-04-07 Kabushiki Kaisha Toshiba Data recording/reproducing system capable of processing servo process program at high speed
US6175465B1 (en) * 1997-12-26 2001-01-16 Kabushiki Kaisha Toshiba Head positioning control system for use in a disk storage drive

Family Cites Families (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4190793A (en) 1977-10-06 1980-02-26 Louis W. Parker Energy economizer for induction motors
US4382223A (en) 1978-06-21 1983-05-03 Louis W. Parker Voltage and frequency-controlled AC wave modifier
US4242625A (en) 1979-05-04 1980-12-30 Louis W. Parker Energy economizer for polyphase induction motors
US4341984A (en) 1980-05-15 1982-07-27 Louis W. Parker Electronic commutation for direct current electric motors
US4297628A (en) 1980-07-03 1981-10-27 Louis W. Parker Energy economizer for induction motors
US4414499A (en) 1981-10-14 1983-11-08 Dr. Louis W. Parker Motor protecting improved energy economizer for induction motors
US4636702A (en) 1984-08-09 1987-01-13 Louis W. Parker Energy economizer controlled-current start and protection for induction motors
US4864212A (en) 1989-02-03 1989-09-05 Parker Louis W Energy economizing AC power system
US5249118A (en) 1991-09-03 1993-09-28 Golden Gate Microsystems Incorporated Fully adaptive velocity tracking drive control positioning system
US5754732A (en) 1995-06-07 1998-05-19 Kollmorgen Corporation Distributed power supply for high frequency PWM motor controller with IGBT switching transistors
US5612605A (en) 1995-09-22 1997-03-18 Allen-Bradley Company, Inc. Auto boost for voltage/frequency motor controller
US5841641A (en) 1996-05-01 1998-11-24 Compaq Computer Corporation Protected zero-crossing detection using switching transistor's on-resistance
US5796194A (en) 1996-07-15 1998-08-18 General Electric Company Quadrature axis winding for sensorless rotor angular position control of single phase permanent magnet motor
US5723966A (en) 1996-08-23 1998-03-03 Current Technology, Inc. System and method for increasing the efficiency of alternating current induction motors
JPH10313600A (en) 1997-05-09 1998-11-24 Matsushita Electric Ind Co Ltd Motor control device
US5978547A (en) 1998-04-20 1999-11-02 K-Tron Technologies, Inc. High-turndown DC motor controller and method

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5737762A (en) * 1993-12-08 1998-04-07 Kabushiki Kaisha Toshiba Data recording/reproducing system capable of processing servo process program at high speed
US6175465B1 (en) * 1997-12-26 2001-01-16 Kabushiki Kaisha Toshiba Head positioning control system for use in a disk storage drive

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004019706A1 (en) * 2002-08-27 2004-03-11 Fmc Technologies, Inc. Juice extractor having soft start motor control

Also Published As

Publication number Publication date
US6489742B2 (en) 2002-12-03
US20020079859A1 (en) 2002-06-27

Similar Documents

Publication Publication Date Title
US6489742B2 (en) Efficiency maximizing motor controller and method
US7170261B2 (en) Generator with dual cycloconverter for 120/240 VAC operation
US6954004B2 (en) Doubly fed induction machine
CN101204003A (en) Power conversion control device, power conversion control method, and power conversion control program
WO2008133878A1 (en) Zero crossing detection for an electric power generation system
CN110086390B (en) Power generation equipment for providing double-level voltage and movable generator set
CN105846728B (en) A kind of intelligent AC regulating fan method for controlling number of revolution
CN110086388B (en) Power generation equipment running off grid and voltage frequency control method thereof
RU2361357C2 (en) Device for controlling asynchronous engine in vehicles
CN110086389B (en) Power generation equipment and movable generator set running off grid
Gandhi et al. Simulation of PWM inverter for VFD application Using MATLAB
RU2695795C1 (en) Connection method of asynchronous motor to ac sinusoidal voltage network by means of ac voltage regulator
CN213125884U (en) Single-phase AC speed-regulating current controller without electrolytic capacitor
Babu et al. A novel grid interface for wind-driven grid-connected induction generators
US11916497B2 (en) Variable-speed drive for single-phase asynchronous motors
CN114336689B (en) Control method and system of high-voltage three-phase load unbalance compensation device
CN108448973A (en) Brushless double feed independent power generating device and system
CN2249990Y (en) Non-static frequency converting stepless speed regulator
Eskander et al. Comparison between two inverter topologies for application in industrial drives
Singh et al. An adjustable speed PMBLDCM drive for air conditioner using PFC Zeta converter
SU764084A1 (en) Method for frequency controlling rotary speed of ac electric motor
Shanmugam et al. Implementation, Simulation of Four Switch Converter Permanent Magnet Brushless DC Motor Drive for Industrial Applications
Shanmugam et al. Design and Implementation of Low Cost Four Switch Inverter for Brushless Motor Drive with Active Power Factor Correction
PL307273A1 (en) Rotary induction-type electric power generator adapted to be driven by prime mover
Krischan et al. Low cost speed control for single phase induction motors-comparing different approaches with regard to efficiency

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EE ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NO NZ PL PT RO RU SD SE SG SI SK SL TJ TM TR TT TZ UA UG UZ VN YU ZA ZW

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): GH GM KE LS MW MZ SD SL SZ TZ UG ZM ZW AM AZ BY KG KZ MD RU TJ TM AT BE CH CY DE DK ES FI FR GB GR IE IT LU MC NL PT SE TR BF BJ CF CG CI CM GA GN GQ GW ML MR NE SN TD TG

121 Ep: the epo has been informed by wipo that ep was designated in this application
REG Reference to national code

Ref country code: DE

Ref legal event code: 8642

122 Ep: pct application non-entry in european phase
NENP Non-entry into the national phase

Ref country code: JP

WWW Wipo information: withdrawn in national office

Country of ref document: JP