U.S. patent application number 13/925431 was filed with the patent office on 2013-10-31 for systems and methods for controlling operation of a motor.
The applicant listed for this patent is Regal Beloit America, Inc.. Invention is credited to Brian L. Beifus, Vijay D. Gurudasani, Michael R. Koller, Thaylen Leany, Edward Yager, Steve Zavodny.
Application Number | 20130289779 13/925431 |
Document ID | / |
Family ID | 42197026 |
Filed Date | 2013-10-31 |
United States Patent
Application |
20130289779 |
Kind Code |
A1 |
Leany; Thaylen ; et
al. |
October 31, 2013 |
SYSTEMS AND METHODS FOR CONTROLLING OPERATION OF A MOTOR
Abstract
A method for editing a motor profile is described. The method
includes receiving a stored motor profile selection via a user
interface, wherein a stored motor profile associated with the
stored motor profile selection includes a speed instruction that
corresponds to at least one of a pumping amplitude and a pumping
time. The method also includes receiving user inputs via the user
interface. The user inputs include instructions relating to an edit
of the selected motor profile. The method further includes storing
the edited motor profile.
Inventors: |
Leany; Thaylen; (Fort Wayne,
IN) ; Zavodny; Steve; (Fort Wayne, IN) ;
Gurudasani; Vijay D.; (Vadodara, IN) ; Beifus; Brian
L.; (Fort Wayne, IN) ; Koller; Michael R.;
(Columbia City, IN) ; Yager; Edward; (Fort Wayne,
IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Regal Beloit America, Inc. |
Beloit |
WI |
US |
|
|
Family ID: |
42197026 |
Appl. No.: |
13/925431 |
Filed: |
June 24, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12323250 |
Nov 25, 2008 |
8473110 |
|
|
13925431 |
|
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Current U.S.
Class: |
700/282 |
Current CPC
Class: |
H02P 2207/01 20130101;
G05D 7/0617 20130101; H02P 23/0077 20130101; H02P 23/0027 20130101;
H02P 2207/05 20130101; H02P 23/20 20160201 |
Class at
Publication: |
700/282 |
International
Class: |
G05D 7/06 20060101
G05D007/06 |
Claims
1. A method for editing a motor profile, said method comprising:
receiving a stored motor profile selection via a user interface,
wherein a stored motor profile associated with the stored motor
profile selection includes a speed instruction that corresponds to
at least one of a pumping amplitude and a pumping time; receiving
user inputs via the user interface, the user inputs including
instructions relating to an edit of the selected motor profile; and
storing the edited motor profile.
2. A method in accordance with claim 1, wherein receiving the
stored motor profile selection via the user interface comprises
receiving a user selection of motor control instructions comprising
a time-varying motor speed instruction that corresponds to at least
one of a pumping amplitude and a pumping time.
3. A method in accordance with claim 1 wherein receiving the user
inputs via the user interface is based at least on one of a minimum
flow rate and a temperature selected.
4. A method in accordance with claim 3, wherein the pumping time
comprises a pre-determined period of time.
5. A method in accordance with claim 1, wherein receiving user
inputs via the user interface comprises receiving user inputs to at
least one of: increase the pumping amplitude of all motor profile
amplitudes by a user defined amount, reduce the pumping amplitude
of all motor profile amplitudes by a user defined amount, and
increase/decrease the length of the motor profile.
6. A method in accordance with claim 1, wherein the stored motor
profile comprises a pre-determined time period.
7. A method for end user operation of a variable speed motor,
wherein operation of the variable speed motor is controlled based
on at least one stored motor profile, said method comprising:
accessing a stored motor profile using a control system input
device, wherein the stored motor profile includes at least one of
an output torque instruction and a speed instruction that
corresponds to at least one of a pumping amplitude and a pumping
time; editing the stored motor profile using the control system
input device; storing the edited motor profile; providing the
edited motor profile to the variable speed motor; and varying at
least one of an output torque and a speed of the variable speed
motor in accordance with the edited motor profile.
8. A method in accordance with claim 7, wherein operating the
variable speed motor in accordance with the edited motor profile
comprises changing operation of the variable speed motor at a
pre-determined time.
9. A method in accordance with claim 7, wherein editing the stored
motor profile comprises at least one of: increasing the pumping
amplitude of all motor profile amplitudes by a user defined amount
and reducing the pumping amplitude of all motor profile amplitudes
by a user defined amount.
10. A method in accordance with claim 7, wherein varying at least
one of the output torque and the speed of the variable speed motor
is based on maintaining a minimum flow rate.
11. A method in accordance with claim 7, wherein varying at least
one of the output torque and the speed of the variable speed motor
is based on a temperature selected.
12. A method in accordance with claim 7, further comprising scaling
the edited motor profile over time.
13. A motor control system comprising: a processing device; a
memory device coupled to said processing device and configured to
store a catalog of motor profiles that includes at least one motor
profile, wherein the at least one motor profile includes a speed
instruction that corresponds to at least one of a pumping amplitude
and a pumping time; and an input device coupled to said processing
device and configured to provide said processing device with motor
profile editing instructions from a user, wherein said processing
device is configured to edit the motor profile based on at least
the motor profile editing instruction, provide the edited motor
profile to a variable speed motor and store the edited motor
profile in said memory device.
14. A motor control system in accordance with claim 13, wherein
said processing device is configured to provide the edited motor
profile to the variable speed motor installed in a refrigeration
product.
15. A motor control system in accordance with claim 13, wherein
said processing device is configured to scale the edited motor
profile over time during operation of the variable speed motor.
16. A motor control system in accordance with claim 13, wherein
said processor device is configured to scale the pumping amplitude
over time.
17. A motor control system in accordance with claim 13, wherein
said processor device is configured to add an offset value to the
motor profile.
18. A motor control system in accordance with claim 17, wherein
said said pumping amplitude, said pumping time and said offset
value are user defined.
19. A motor control system in accordance with claim 13, wherein
said pumping time is a pre-determined time.
20. A motor control system in accordance with claim 13, wherein
said motor profile editing instructions comprise at least one of:
increase the pumping amplitude of all motor profile amplitudes by a
user defined amount, reduce the pumping amplitude of all motor
profile amplitudes by a user defined amount, increase/decrease the
pumping amplitude of an individual motor profile section,
increase/decrease the length of the motor profile,
increase/decrease the length or duration of an individual motor
profile section, and repeat one or more sections of the motor
profile.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. non-provisional continuation
application of and claiming priority to U.S. patent application
Ser. No. 12/323,250 filed on Nov. 25, 2008, which is hereby
incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The field of the invention relates generally to controlling
operation of a variable speed motor, and more specifically to
selection of and editing of stored motor profiles during use of the
motor.
[0003] Spas and hot tubs are generally used for relaxation and
other therapeutic purposes. A basin or tub structure holds a supply
of water. Typically, a spa or hot tub includes a circulation pump
as part of a water circulation and heating system. The pump, in
combination with a pump motor, facilitates filtering and heating of
the water by removing water from the tub structure, through a
filter and/or heater, and returning the water into the tub
structure. The water is generally returned to an interior of the
tub structure through a plurality of water jets or nozzles. The
water jets facilitate providing a pressurized flow of water into
the tub structure. The spa may also include a plurality of main
pumps to increase the pressure of the return water flow, and/or to
provide a pulsating flow of water.
[0004] In some known spas, along with adjusting a temperature of
the water in the tub, a user can input a length of time that the
pressurized return flow of water is pumped into the tub. The user
may also be able to select a high or low level of pulsating flow.
However, limitations in the capabilities of motors typically used
in spa and hot tub applications, along with control system
limitations, prevent further customization of spa operation while
maintaining efficient operation of the pump motors.
BRIEF DESCRIPTION OF THE INVENTION
[0005] In one aspect, a method for editing a motor profile is
described. The method includes receiving a stored motor profile
selection via a user interface, wherein a stored motor profile
associated with the stored motor profile selection includes a speed
instruction that corresponds to at least one of a pumping amplitude
and a pumping time. The method also includes receiving user inputs
via the user interface. The user inputs include instructions
relating to an edit of the selected motor profile. The method
further includes storing the edited motor profile.
[0006] In another aspect, a method for end user operation of a
variable speed motor is provided. The operation of the variable
speed motor is controlled based on at least one stored motor
profile. The method includes accessing a stored motor profile using
a control system input device, wherein the stored motor profile
includes at least one of an output torque instruction and a speed
instruction that corresponds to at least one of a pumping amplitude
and a pumping time. The method also includes editing the stored
motor profile using the control system input device and storing the
edited motor profile. The edited motor profile is provided to the
variable speed motor. The method further includes varying at least
one of an output torque and a speed of the variable speed motor in
accordance with the edited motor profile.
[0007] In yet another aspect, a motor control system is provided.
The motor control system includes a processing device and a memory
device coupled to said processing device. The memory device is
configured to store a catalog of motor profiles that includes at
least one motor profile, wherein the at least one motor profile
includes a speed instruction that corresponds to at least one of a
pumping amplitude and a pumping time. The motor control system also
includes an input device coupled to said processing device and
configured to provide said processing device with motor profile
editing instructions from a user. The processing device is
configured to edit the motor profile based on at least the motor
profile editing instruction, provide the edited motor profile to a
variable speed motor and store the edited motor profile in the
memory device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a block diagram of one embodiment of a motor
control system.
[0009] FIG. 2 is a block diagram of an alternative embodiment of
the motor control system shown in FIG. 1.
[0010] FIG. 3 is an exemplary embodiment of a specific application
for the motor control systems shown in FIGS. 1 and 2.
[0011] FIG. 4 is a graph illustrating an example of a motor
profile.
[0012] FIG. 5 is an illustration of an embodiment of the input
device and the display device of the motor control system shown in
FIG. 1.
[0013] FIG. 6 is an illustration of an alternative embodiment of
the input device and the display device of the motor control system
shown in FIG. 1.
[0014] FIG. 7 is an illustration of another alternative embodiment
of the input device and the display device of the motor control
system shown in FIG. 1.
[0015] FIG. 8 is a flow chart of an exemplary method for
controlling operation of a motor.
[0016] FIG. 9 is a flow chart of an exemplary method for
controlling operation of a motor.
DETAILED DESCRIPTION OF THE INVENTION
[0017] FIG. 1 is a block diagram of an exemplary embodiment of a
motor control system 100. In the exemplary embodiment, motor
control system 100 controls operation of a motor 110. In some
embodiments, motor 110 is a variable speed motor, for example, a
brushless direct current (DC) motor, also referred to herein as an
electronically commutated motor (ECM). However, motor 110 may be
any other type of variable speed motor that facilitates operation
of system 100 as described herein.
[0018] In the exemplary embodiment, system 100 includes a motor
controller 120. In the exemplary embodiment, motor controller 120
includes a processing device 124, a memory device 126, and a motor
drive circuit 128. Processing device 124 is communicatively coupled
to memory device 126 and is configured to execute a program stored
in memory device 126. In the exemplary embodiment, motor drive
circuit 128 is configured to provide power to motor 110 based on
instructions from processing device 124. In some examples, memory
device 126 is an electrically erasable programmable read-only
memory (EEPROM). In other examples, memory device 126 is an onboard
flash memory device included within processing device 124. In other
examples, memory device 126 is a ferromagnetic device, an electron
spin device, and/or a backed-up random access memory (RAM). In
still other examples, memory device 126 is any type of non-volatile
memory device, internal or external to processing device 124, that
enables motor controller 120 to function as described herein. As
used herein, processing device 124 is not limited to just those
integrated circuits referred to in the art as a processing device,
but broadly refers to: a processor, a microprocessor, a digital
signal processor, a controller, a microcontroller, a programmable
logic controller, an application specific integrated circuit, and
other programmable circuits.
[0019] In the exemplary embodiment, system 100 also includes a
display device 140 and an input device 142, both coupled to motor
controller 120, and more specifically, to processing device 124.
Although illustrated as separate devices, display device 140 and
input device 142 may be included within a single component. Display
device 140 and input device 142 may be coupled to motor controller
120 through interfaces 144 and 146, respectively. However, display
device 140 and input device 142 may be coupled to motor controller
120 through a single, bidirectional wire interface, or using a
wireless interface (not shown in FIG. 1). Display device 140 and
input device 142 are described further below.
[0020] In the exemplary embodiment, motor controller 120 is
configured to regulate electric power provided to motor 110 in
accordance with motor profiles stored in memory device 126. In the
exemplary embodiment, memory device 126 stores a plurality of
different motor profiles. A listing or description of the plurality
of motor profiles is referred to herein as a catalog of motor
profiles stored in memory device 126. Motor controller 120
facilitates a user selecting one of the motor profiles stored in
memory device 126. For example, motor controller 120 receives an
input from input device 142, interprets the input, and sends a
corresponding command to motor 110, display device 140, and/or
memory device 126. The command may include selecting one of the
motor profiles stored in memory device 126 for execution by
processing device 124. Motor controller 120 may also send a signal
to display device 140, the signal facilitating viewing of the
catalog of motor profiles stored in memory device 126.
[0021] In some embodiments, motor controller 120 also includes a
communications port/jack 150 configured to couple motor controller
120 to an external source, for example, an external computing
device 152. In an exemplary embodiment, external computing device
152 is a personal computer (PC) that is configured to facilitate
modification of the catalog of stored motor profiles. For example,
computing device 152 may allow a user to download new motor
profiles from a web site and transfer the new profiles to system
100 for storage in memory device 126, and eventual execution by
processing device 124. In other examples, computing device 152 may
include software that facilitates user customization of the stored
motor profiles. In further examples, computing device 152 may
facilitate updating of other software included in system 100 and/or
troubleshooting of problems encountered by system 100.
[0022] FIG. 2 is a block diagram of an alternative embodiment of
motor control system 160. In the alternative embodiment, motor
control system 160 includes a system controller 162. In some
embodiments, system controller 162 includes a processor 164 and a
memory device 166. In the alternative embodiment, some of the
functions of motor controller 120, described with respect to FIG.
1, are performed by system controller 162. For example, processor
164 may receive input signals from input device 142, interpret the
input signal, and send a corresponding command to motor controller
120. Motor controller 120 may then supply motor 110 with control
signals corresponding to the command provided by processor 164.
Motor controller 120 may also return a motor profile catalog from
memory device 126 to system controller 162 upon receipt of a motor
profile catalog request from system controller 162. System
controller 162 may also communicate through communications
port/jack 150 with external computing device 152. Components that
are common in both motor control systems 100 and 160 are identified
using the same reference numerals.
[0023] FIG. 3 is an exemplary embodiment of a specific application
for motor control system 100 (shown in FIG. 1). FIG. 3 illustrates
motor 110 coupled to motor control system 100, in addition to a
pump 168. As described above, in a spa/hot tub application, motor
110 and pump 168 may provide return water to an interior of a tub
structure (not shown in FIG. 3). Components illustrated in FIG. 3
that are also illustrated in FIG. 1 are identified with
corresponding reference numerals.
[0024] FIG. 4 is a graph illustrating an exemplary motor profile
170. In the example embodiment of a spa/hot tub, motor 110 drives
pump 168 (shown in FIG. 3), delivering water flow having an
amplitude and a pulse frequency in accordance with a motor profile,
for example, motor profile 170. In other words, motor profile 170
represents instructions that are sent to motor 110 to drive pump
168 at a predetermined amplitude and pulse frequency. To facilitate
driving of pump 168 at a predetermined amplitude and pulse
frequency, an output torque and/or a speed of motor 110 is
automatically varied versus time according to motor profile 170.
Motor profile 170 includes a list of commands stored in, for
example, memory device 126 (shown in FIG. 1). For example, in a
specific embodiment, motor profile 170 includes motor control
instructions for a thirty minute period of time. A first section
180 of motor profile 170 instructs motor 110 to operate pump 168 at
80% of a maximum pumping amplitude and at 20% of a maximum pulsing
frequency for five minutes. A second section 182 of motor profile
170 then instructs motor 110 to operate pump 168 at 50% of the
maximum pumping amplitude and at 90% of the maximum pulsing
frequency for seven minutes. A third section 184 of motor profile
170 then instructs motor 110 to operate pump 168 at 90% of the
maximum pumping amplitude and at 90% of the maximum pulsing
frequency for eight minutes. A fourth section 186 of motor profile
170 then instructs motor 110 to operate pump 168 at 50% of the
maximum pumping amplitude and at 60% of the maximum pulsing
frequency for ten minutes. After the fourth section is complete,
motor profile 170 is also complete. Although described above as
including four sections lasting a total of thirty minutes, motor
profile 170 may have any number of sections and control operation
of motor 110 over any length of time.
[0025] FIG. 5 is an illustration of an exemplary embodiment of an
input/display device 200. In the exemplary embodiment,
input/display device 200 includes a display device, for example,
display device 140 (shown in FIG. 1). In the exemplary embodiment,
input/display device 200 also includes an input device, for
example, input device 142 (shown in FIG. 1). In the exemplary
embodiment, display device 140 includes a liquid crystal display
(LCD) type screen, however, display device 140 may include any type
of display that facilitates operation of input/display device 200
as described herein. In the exemplary embodiment, input device 142
includes multiple selection buttons, for example, UP buttons 210
and 212, DOWN buttons 214 and 218, a LEFT button 220, a RIGHT
button 222, an ENTER button 224, and a PROFILE SELECT button 226.
In the exemplary embodiment, buttons 210, 212, 214, 218, 220, 222,
224, and 226 facilitate navigating through screens displayed on
display device 140, and entering user selections. Input device 142
facilitates allowing a user to view the motor profiles stored in
memory device 126. When a user would like to view a list of
available motor profiles, input device sends a catalog request to
processor 124, processor 124 interprets the request and sends the
catalog request to memory device 126. Memory device 126 returns the
motor profile catalog to processor 124, which then provides the
catalog to display device 140 for viewing by the user. The list may
include pre-stored motor profiles, as well as user edited motor
profiles.
[0026] FIG. 6 is an illustration of an alternative embodiment of
input/display device 200 (shown in FIG. 5), input/display device
230. In the alternative embodiment, rather than buttons 210, 212,
214, 218, 220, 222, 224, and 226 (shown in FIG. 5), input device
142 of input/display device 230 includes selection buttons 240 and
242, and a selection jog dial 246. Selection buttons 240 and 242,
and selection jog dial 246 also facilitate navigating through
screens displayed on display device 140, and entering user
selections. In some embodiments, selection jog dial 246 may provide
a push-to-select function that either replaces or supplements one
of buttons 240 and 242. For example, selection jog dial 246 may be
rotated to move through a plurality of menu items, and may be
pushed to select one of the menu items.
[0027] FIG. 7 is an illustration of a further alternative
embodiment of input/display device 200 (shown in FIG. 5),
input/display device 250. In the second alternative embodiment,
input/display device 250 includes a touch screen display device
260. Touch screen display device 260 combines the functions of
display device 140 (shown in FIG. 1) and input device 142 (shown in
FIG. 1). More specifically, touch screen display device 260
facilitates displaying input options to a user as well as
displaying motor profiles to select and/or view. FIG. 7 illustrates
a sample display 270 that may be provided by touch screen display
device 260. Sample display 270 provides a user with sections of
display device 260 that correspond to a SELECT PROFILE input 272, a
MODIFY PROFILE input 274, a DEFINE PROFILE input 276, and a
SETTINGS input 278. Touch screen display device 260 provides an
input signal to a motor controller, for example, motor controller
120 (shown in FIG. 1), when a user touches the section
corresponding to one of inputs 272, 274, 276, and 278. In the
example illustrated in FIG. 7, sample screen-shot 270 also provides
a user with a display of one of the motor profiles 290 stored in a
memory device, for example, memory device 126 (shown in FIG.
1).
[0028] FIG. 8 is a flow chart 300 of an exemplary method 310 for
editing a motor profile. More specifically, method 310 facilitates
editing a motor profile, for example motor profile 170 (shown in
FIG. 4) for use by a brushless DC motor, for example motor 110
(shown in FIG. 1). In the exemplary embodiment, method 310 includes
receiving 320 a stored motor profile selection via a user
interface, for example, input/display device 200 (shown in FIG. 5).
In the exemplary embodiment of a spa/hot tub, the stored motor
profile includes amplitude and frequency information, which when
provided to, for example, motor drive circuit 128 and/or motor 110
(shown in FIG. 1), facilitate operating motor 110 in accordance
with a selected motor profile, for example, motor profile 170
(shown in FIG. 4).
[0029] In the exemplary embodiment, method 310 also includes
displaying 330 the selected motor profile via the user interface,
for example, input/display device 200 (shown in FIG. 5). Displaying
330 may include providing a list of motor profile names on display
device 140 (shown in FIG. 5), providing a list of numbers on
display device 140 (shown in FIG. 5) that correspond to numbers of
stored motor profiles, or providing a graphical view, for example
motor profile 290 (shown in FIG. 7), of each motor profile. In the
exemplary embodiment, input/display device 200 (shown in FIG. 5) is
configured to facilitate user selection of a motor profile and
facilitate editing of the motor profile. For example, input device
142 (shown in FIG. 5) is configured to provide user inputs to motor
controller 120, and motor controller 120 is configured to receive
user inputs from input device 142 and interpret the user inputs.
The user inputs may correspond to a motor profile selection and/or
motor profile editing instructions.
[0030] In the exemplary embodiment, method 310 also includes
receiving 332 user inputs via the user interface. In the exemplary
embodiment, the user inputs include instructions relating to an
edit of the selected motor profile. Method 310 also includes
storing 334 the edited motor profile. Storing 334 the edited motor
profile may include storing the edited motor profile as a new motor
profile in, for example, memory device 126 (shown in FIG. 1).
Storing 334 may also include replacing the selected motor profile
with the edited motor profile.
[0031] As described above, in the example of a spa/hot tub, motor
110 (shown in FIG. 3) may be instructed to drive pump 168 (shown in
FIG. 3) to pump water into the tub structure at predetermined
amplitudes and at predetermined pulsing frequencies, for
predetermined periods of time. The instructions are summarized in a
motor profile. For example, sample motor profile 170 (shown in FIG.
4), includes four sections of different amplitude and pulsing
frequencies. Input device 142 facilitates a user selecting a motor
profile and editing/modifying the motor profile. Editing the motor
profile may include, but is not limited to, increasing the
amplitude of all motor profile amplitudes by a user defined amount,
reducing the amplitude of all motor profile amplitudes by a user
defined amount, increasing/decreasing the amplitude of an
individual motor profile section, increasing/decreasing the length
of the motor profile, increasing/decreasing the length of an
individual motor profile section, increasing/decreasing the pulsing
frequencies of all motor profile pulsing frequencies by a user
defined amount, reducing the pulsing frequencies of all motor
profile pulsing frequencies by a user defined amount,
increasing/decreasing the pulsing frequency of an individual motor
profile section, or repeating one or more sections of the motor
profile. Editing the motor profile facilitates a customized
experience for the user.
[0032] FIG. 9 is a flow chart 400 of an exemplary method 410 for
end user operation of a variable speed motor. In the exemplary
embodiment, the end user operation of the variable speed motor, for
example, motor 110 (shown in FIG. 1), is controlled based on at
least one stored motor profile, for example, motor profile 170
(shown in FIG. 4). In the exemplary embodiment, method 410 includes
accessing 420 a stored motor profile using a control system input
device, for example input/display device 200 (shown in FIG. 5). In
the example continued herein of a spa/hot tub, stored motor profile
170 (shown in FIG. 4) for motor 110 (shown in FIG. 1) may be
accessed 420 through input/display device 200 (shown in FIG. 5) by
a user. In the exemplary embodiment, method 410 also includes
editing 422 the stored motor profile using input/display device
200.
[0033] In the exemplary embodiment, method 410 also includes
providing 424 the edited motor profile to motor 110 and operating
426 the motor in accordance with the edited motor profile. In some
embodiments, the edited motor profile is stored in a memory device,
for example, memory device 126 (shown in FIG. 1). In some
embodiments, operating 426 the variable speed motor in accordance
with the edited motor profile comprises editing the motor profile
during operation of the variable speed motor, wherein the motor
responds to the edited motor profile substantially
instantaneously.
[0034] Described herein are exemplary systems and methods for
controlling operation of a motor. More specifically, the systems
and methods described herein enable a user to select and edit motor
profiles that control operation of the motor. In the example of a
spa/hot tub, the systems and methods described herein allow a user
to select a motor profile, as well as to edit the motor profile,
while using the spa/hot tub. The systems and methods described
herein allow storage and user access to multiple motor profiles,
and more specifically, to a plurality of editable motor
profiles.
[0035] The systems and methods described herein facilitate
efficient and economical control of a motor. The systems and
methods described herein also facilitate efficient and economical
operation of an application that includes a variable speed motor.
For example, a spa/hot tub that includes an ECM and the control
system described herein facilitates increased motor efficiency and
reduced heating of the motor throughout a motor profile when
compared to, for example, an induction motor.
[0036] Exemplary embodiments of systems and methods are described
and/or illustrated herein in detail. The systems and methods are
not limited to the specific embodiments described herein, but
rather, components of each system, as well as steps of each method,
may be utilized independently and separately from other components
and steps described herein. Each component, and each method step,
can also be used in combination with other components and/or method
steps. More specifically, although described herein with respect to
a spa/hot tub application, the systems and methods described herein
are not limited to spa/hot tub applications. For example, the
systems and methods described herein may be included in commercial
refrigeration products, as well as other refrigeration/heating,
ventilation, and air conditioning systems. In a specific example,
motor profiles are stored that facilitate efficient operation of
commercial refrigeration products by changing motor operation at
predetermined times, for example, at predetermined times of the
year. In another example, motor profiles vary the speed/torque of a
motor, such that a specific speed/torque is not set once and never
varied.
[0037] As described herein, in certain embodiments, the output
torque and/or speed of a variable speed motor is automatically
varied versus time according to a preset motor profile, implemented
through a microcontroller based variable speed control by accessing
a list of commands stored in an internal/external non-volatile
memory. Automatically varying the torque and/or speed of the
variable speed motor provides at least the following benefits:
allowing a user to store multiple desired motor profiles in the
memory, allowing the stored motor profiles to be identified with a
name-tag, allowing a system controller to request a catalog of
stored profiles, allowing a user to select a desired profile for
execution and having the motor's microcontroller execute that
profile, and during profile execution, allowing the user to
dynamically scale the entire profile over time, dynamically scale
the pulse amplitude, and also dynamically offset the pulse for an
altered profile execution. The user may also have multiple repeats
of any section of the executed profile.
[0038] More specifically, for spa/hot tub applications, users may
view the available profiles in the form of a catalog so that, with
reference to the available categories of profiles, the user can
switch from one profile to another. In some embodiments, the
catalog request is provided by the system controller to the motor
controller and the motor controller provides a list of available
profiles to the system controller by reading the motor's memory.
Furthermore, the systems and methods described herein facilitate
customizing the selected profile as per individual user comfort. In
other words, the user can dynamically scale the entire profile over
time to have a faster/slower pulse, and/or a higher/lower pulse
amplitude. In some embodiments, a requirement to maintain a minimum
flow rate may be satisfied by adding an offset value to the pulse
profile. The offset value would prevent a user from reducing pump
flow below a recommended level, for example, below a level
recommended that corresponds to a heating temperature selected. The
offset, amplitude scale, and time scale may be user defined and
vary dynamically as per individual comfort level requests sent to
the motor from the system controller.
[0039] When introducing elements/components/etc. of the methods and
apparatus described and/or illustrated herein, the articles "a",
"an", "the", and "said" are intended to mean that there are one or
more of the element(s)/component(s)/etc. The terms "comprising",
"including", and "having" are intended to be inclusive and mean
that there may be additional element(s)/component(s)/etc. other
than the listed element(s)/component(s)/etc.
[0040] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal languages of the claims.
* * * * *