U.S. patent application number 15/618846 was filed with the patent office on 2018-12-13 for systems and methods for controlling a motor.
The applicant listed for this patent is Regal Beloit America, Inc.. Invention is credited to Malcolm E. Cole, CHRISTOPHER A. MOHALLEY, Bryan J. Stout, Gregory P. Sullivan.
Application Number | 20180356847 15/618846 |
Document ID | / |
Family ID | 64563473 |
Filed Date | 2018-12-13 |
United States Patent
Application |
20180356847 |
Kind Code |
A1 |
MOHALLEY; CHRISTOPHER A. ;
et al. |
December 13, 2018 |
SYSTEMS AND METHODS FOR CONTROLLING A MOTOR
Abstract
An interface module and methods for controlling a motor in a
heating, ventilation, and air conditioning (HVAC) system are
provided. The interface module is configured to determine an
operating mode selected from a plurality of operating modes of the
HVAC system based on at least one signal received from at least one
of a first device and a second device, determine a motor operating
parameter at which to operate the motor based on the determined
operating mode, and control the motor in accordance with the motor
operating parameter.
Inventors: |
MOHALLEY; CHRISTOPHER A.;
(Racine, WI) ; Stout; Bryan J.; (Fort Wayne,
IN) ; Cole; Malcolm E.; (Fort Wayne, IN) ;
Sullivan; Gregory P.; (Fort Wayne, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Regal Beloit America, Inc. |
Beloit |
WI |
US |
|
|
Family ID: |
64563473 |
Appl. No.: |
15/618846 |
Filed: |
June 9, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24F 11/30 20180101;
F24F 11/62 20180101; F24F 11/77 20180101; Y02B 30/70 20130101 |
International
Class: |
G05D 23/19 20060101
G05D023/19; F24F 11/00 20060101 F24F011/00 |
Claims
1. An interface module configured to control a motor in a heating,
ventilation, and air conditioning (HVAC) system, said interface
module configured to: determine an operating mode selected from a
plurality of operating modes of the HVAC system based on at least
one signal received from at least one of a first device and a
second device; determine a motor operating parameter at which to
operate the motor based on the determined operating mode; and
control the motor in accordance with the motor operating
parameter.
2. The interface module of claim 1, wherein to determine the
operating mode of the HVAC system, said interface module is
configured to: continuously monitor an aggregate signal of the
system controller signals and the thermostat signals; and compare
the resulting aggregate signal with stored reference information to
determine the operating mode of the HVAC system.
3. The interface module of claim 1, wherein to determine the
operating mode of the HVAC system, said interface module is
configured to implement an algorithm that, over time, recognizes
and stores as a reference, the first and second device signal
combinations and timing.
4. The interface module of claim 1, wherein to determine the
operating mode of the HVAC system, said interface module is
configured to: capture input data associated with available inputs
for each mode of operation while the HVAC system is exercised
through its modes of operation; and correlate each mode of
operation with respective input data to identify the HVAC system
operating modes.
5. The interface module of claim 1, wherein to determine the
operating mode of the HVAC system, said interface module is
configured to receive and store information for each operating mode
input by a technician.
6. The interface module of claim 1, wherein said interface module
is further configured to implement one of an ON delay and an OFF
delay required by the determined operating mode before transmitting
the control signal to the motor.
7. The interface module of claim 1, wherein the second device is a
system controller, and wherein said interface module is further
configured to provide feedback to be utilized by the HVAC system to
satisfy expectations of the system controller.
8. The interface module of claim 7, wherein said interface module
is further configured to facilitate at least one of enabling,
disabling, and selecting one of a plurality of available motor
output signal types.
9. The interface module of claim 1, wherein to operate the motor,
said interface module is configured to transmit a control signal to
the motor that includes the motor operating parameter.
10. The interface module of claim 1, wherein to control the motor,
said interface module is configured to transmit a pulse width
modulation (PWM) signal that represents the motor operating
parameter.
11. The interface module of claim 10, wherein a duty cycle of the
PWM signal corresponds to a percent of full torque that may be
generated by motor.
12. The interface module of claim 1, wherein to control the motor,
said interface module is configured to transmit a 0 to 10 Vdc
control signal to the motor.
13. The interface module of claim 1, wherein said interface module
comprises a user interface configured to provide information to a
user relating to operation of said interface module, the
information including at least one of system control signals
status, thermostat signals status, system operating mode, motor
torque percent, and delay activity.
14. The interface module of claim 1, wherein said interface module
comprises a user interface configured to provide at least one of
system health diagnostic information and self-test information.
15. The interface module of claim 1, wherein said interface module
comprises a user interface configured to receive operational values
input by a user, the operational values including at least one of
ON delay times, OFF delay times, and duty cycle values.
16. A method of controlling a motor in a heating, ventilation, and
air conditioning (HVAC) system using an interface module, said
method comprising: determining an operating mode selected from a
plurality of operating modes of the HVAC system based on at least
one signal received from at least one of a first device and a
second device; determining a motor operating parameter at which to
operate the motor based on the determined operating mode; and
controlling the motor in accordance with the motor operating
parameter.
17. The method of claim 16, wherein determining the operating mode
of the HVAC system comprises: continuously monitoring an aggregate
signal of the system controller signals and the thermostat signals;
and comparing the resulting aggregate signal with stored reference
information to determine the operating mode of the HVAC system.
18. The method of claim 16, wherein determining the operating mode
of the HVAC system comprises implementing, by the interface module,
an algorithm that, over time, recognizes and stores as a reference,
the first and second device signal combinations and timing.
19. The method of claim 16, wherein controlling the motor comprises
transmitting a pulse width modulation (PWM) signal that represents
the motor operating parameter, wherein a duty cycle of the PWM
signal corresponds to a percent of full torque that may be
generated by motor.
20. The method of claim 16, further comprising: receiving, via a
user interface of the interface module, operational values input by
a user, the operational values including at least one of ON delay
times, OFF delay times, and duty cycle values; and implementing the
operational values prior to operating the motor.
Description
BACKGROUND
[0001] The embodiments described herein relate generally to motors,
and more particularly, to systems and methods for controlling a
motor in a heating, ventilation, air conditioning (HVAC)
system.
[0002] Motors used in HVAC and fluid circulation systems often must
be programmed to operate according to the specific needs of their
systems and may need to be replaced when they do not operate
properly or fail. Typically, the motors are programmed using a
specialized motor programming computer by an Original Equipment
Manufacturers (OEM) at a motor manufacturing facility, at the point
of sale, or at an assembly plant.
[0003] OEMs that utilize configurable/intelligent motors configure
each motor to meet the requirements of the specific product and the
expected application. The functionality of the OEM system is
derived from a combination of the motor's configuration and the
operation of an HVAC system controller. For example, signal
definitions/functions associated with a system controller wiring
harness are determined by the motor's configuration. With each
replacement configurable/intelligent motor needing to be ordered
with the specific OEM system configuration, returning a failed
system to operation may be a time consuming and expensive
process.
BRIEF DESCRIPTION
[0004] In one aspect, an interface module configured to control a
motor in a heating, ventilation, and air conditioning (HVAC) system
is provided. The interface module is configured to determine an
operating mode selected from a plurality of operating modes of the
HVAC system based on at least one signal received from at least one
of a first device and a second device, determine a motor operating
parameter at which to operate the motor based on the determined
operating mode, and control the motor in accordance with the motor
operating parameter.
[0005] In another aspect, a method controlling a motor in a
heating, ventilation, and air conditioning (HVAC) system using an
interface module is provided. The method includes determining an
operating mode selected from a plurality of operating modes of the
HVAC system based on at least one signal received from at least one
of a first device and a second device, determining a motor
operating parameter at which to operate the motor based on the
determined operating mode, and controlling the motor in accordance
with the motor operating parameter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a schematic diagram of an exemplary HVAC system
that includes an interface module for controlling a motor.
[0007] FIG. 2 is a flowchart of an exemplary method of controlling
a motor using the interface module shown in FIG. 1.
DETAILED DESCRIPTION
[0008] FIG. 1 is a schematic diagram of a heating, ventilation, and
air conditioning (HVAC) system 100 that includes an interface
module 102 and a retrofit motor 104. HVAC system 100 also includes
a thermostat 106 and a system controller 108. Interface module 102
is coupled to and configured to receive signals from both
thermostat 106 and system controller 108. Further, interface module
102 is coupled to and configured to transmit signals to motor
104.
[0009] In the exemplary embodiment, motor 104 is an electronically
commutated motor (ECM), which may also be referred to as a
brushless direct current (DC) motor. Motor 104 is utilized as a fan
and/or blower motor in HVAC system 100. Alternatively, motor 104
may be implemented in any other application including, but not
limited to, a fluid (e.g., water, air, etc.) moving system, a clean
room filtering system, a fan filter unit, a variable air volume
system, a refrigeration system, a furnace system, and/or an air
conditioning system. In the exemplary embodiment, HVAC system 100
is retrofit to include motor 104 that replaces an existing ECM or
permanent split capacitor (PSC) motor (hereinafter referred to as
"replaced motor", not shown).
[0010] Thermostat 106 is configured to control a mode in which HVAC
system 100 is operating, for example, a cooling mode, a heating
mode, or a fan only mode, and/or at a first stage or at a second
stage. Thus, in the exemplary embodiment, thermostat 106 includes
plurality of thermostat leads 110 associated with one or more of a
cooling output, a heating output, a fan output, a first stage
output, and a second stage output. However, thermostat 106 is not
limited to these outputs and may include any number of outputs that
enables thermostat 106 to function as described herein. Thermostat
106 generates at least one thermostat signal that is transmitted to
at least one of interface module 102 and system controller 108.
[0011] System controller 108 includes a system controller wiring
harness 112 that was originally coupled to and configured to
transmit instructions to the replaced motor. When interface module
102 is provided during the replacement process, system controller
wiring harness 112 is coupled to and configured to communicate with
interface module 102. For example, system controller 108 relays
signals generated by thermostat 106 to interface module 102. More
specifically, system controller 108 processes the thermostat signal
and generates instructions for operating motor 104 that are
provided to interface module 102. System controller 108 may also
communicate with other input/output devices, such as humidity
control systems, gas burner controls, gas ignition systems, other
motors, safety systems, service systems, and/or combustion blowers.
Accordingly, system controller 108 generates operating instructions
for motor 104 based on signals received from thermostat 106, as
well as signals received from alternative devices coupled to system
controller 108, such as safety systems, ambient sensors, gas
ignition systems, and other HVAC system components.
[0012] Interface module 102 receives signals from at least one of
thermostat 106 and system controller 108. Based on the received
signals, interface module 102 provides motor 104 with control
signals. More specifically, interface module 102 receives signals
from thermostat leads 110, as well as from system controller 108
via system controller wire harness 112, and is configured to
provide motor 104 with a signal that selects a desired motor
control profile.
[0013] In the exemplary embodiment, interface module 102 includes
components mounted to a printed circuit board. More specifically,
in the exemplary embodiment, interface module 102 includes a
processing device 114, a memory device 116, a user interface 118,
and a communication interface 120.
[0014] The term processing device, as used herein, refers to
central processing units, microprocessors, microcontrollers,
reduced instruction set circuits (RISC), application specific
integrated circuits (ASIC), logic circuits, and any other circuit
or processor capable of executing the functions described
herein.
[0015] It should be noted that the embodiments described herein are
not limited to any particular processor for performing the
processing tasks of the invention. The term "processor," as that
term is used herein, is intended to denote any machine capable of
performing the calculations, or computations, necessary to perform
the tasks of the invention. The term "processor" also is intended
to denote any machine that is capable of accepting a structured
input and of processing the input in accordance with prescribed
rules to produce an output. It should also be noted that the phrase
"configured to" as used herein means that the processor is equipped
with a combination of hardware and software for performing the
tasks described herein, as will be understood by those skilled in
the art.
[0016] Communication interface 120 may include an RS-485 connector,
a digital serial interface (DSI) connector, a control wire
reception terminal, and/or any other type of interface that allows
a user, thermostat 106, and/or system controller 108 to provide a
control signal to interface module 102. For example, the control
signal may include a 0-10 volts direct current (VDC) control
signal, a 0-5 VDC control signal, a 4-20 milliampere (mA) control
signal, and/or any other type of control signal that allows
interface module 102 to function as described herein.
[0017] In the exemplary embodiment, interface module 102 also
includes memory device 116. Memory device 116 may be included
within processing device 114, or may be coupled to processing
device 114. In the exemplary embodiment, memory device 116 stores a
plurality of different communications protocols. For example,
processing device 114 may access the communications protocols
stored in memory device 116 in order to translate a signal received
from a user via communication interface 120 into a format that may
be transmitted to motor 104. More specifically, processing device
114 may receive a signal sent using an Ethernet protocol, in which
motor 104 may not be compatible. Processing device 114 translates
the received signal to a communication suitable to be transmitted
to motor 104.
[0018] Interface module 102 includes a user interface 118 that
enables user-interaction with interface module 102 and enables
interface module 102 to provide feedback with regards to its
operation. User interface 118 facilitates configuration (i.e.,
setup) of interface module 102. Original ECM functionality that is
being replicated by interface module 102 is enabled via user
interface 118. User interface 118 further enables selection of
operational values such as "ON" delay times, "OFF" delay times,
duty cycle values, etc.
[0019] User interface 118 includes a plurality of buttons/switches
and a display. The display provides information relating to the
operation of interface module 102 including, but not limited to,
system control signals status, thermostat signals status, system
operating mode, motor torque percent, and/or delay activity. The
display is also configured to provide diagnostic (e.g., system
health) and self-test information.
[0020] Alternatively, interface module 102 may be implemented as a
"black box" void of any buttons/switches or display. In this
implementation, interface module 102 communicates with an
intelligent wireless device (e.g., smartphone, tablet, PDA, etc.,
not shown) using wireless communication (e.g., Wi-Fi, Bluetooth,
RFID, etc.) via communication interface 120. The wireless device
runs/executes an application that provides user interface 118 and
feedback functions.
[0021] Interface module 102 is configured to determine an operating
mode of HVAC system 100 (heat, cool, etc.). When the configuration
of the replaced motor and the operations of system controller 108
are unknown, thermostat signals and the motor control signals from
system controller 108 enable determination of the operating mode of
HVAC system 100. Interface module 102 continuously or periodically
monitors an aggregate signal of the system controller signals and
the thermostat signals, and compares the resulting aggregate signal
with stored reference information to determine the operating mode
of the system.
[0022] In the exemplary embodiment, to acquire the information
necessary for determining the system operating mode, interface
module 102 is configured to "learn" the HVAC system's operation by
implementing a learning algorithm that, over time, enables
interface module 102 to recognize and store as a reference the
system and thermostat signal combinations and timing that are used
to resolve the operating mode of HVAC system 100. In some
embodiments, interface module 102 is configured to discriminate
between discrete and variable speed motor control as well as
recognize a single stage thermostat that is paired with a dual
stage system.
[0023] In another embodiment, the information necessary for
determining the system operating mode is acquired by teaching
interface module 102 to recognize system and thermostat signal
combinations. While exercising HVAC system 100 throughout its
different modes of operation, the installer manually triggers
interface module 102 to capture a "snapshot" of the available
inputs for each mode of operation. Interface module 102 correlates
each mode of operation with a respective snapshot to identify the
system operating modes. A snapshot is a unique combination of
states of individual system and thermostat signals, i.e.,
inputs.
[0024] In yet another embodiment, interface module 102 acquires the
information necessary for determining the system operating mode via
manual configuration of interface module 102 with the appropriate
information by a technician or installer of motor 104.
[0025] Interface module 102 is configured to implement "ON" delays
and "OFF" delays in HVAC systems that allocate this functionality
to motor 104. More specifically, interface module 102 facilitates
enabling/disabling and/or selecting time values for ON delays and
OFF delays for the appropriate system operating modes in order to
complete/replicate the HVAC system performance.
[0026] Interface module 102 is configured to provide feedback to be
utilized by HVAC system 100 to satisfy expectations of system
controller 108. Specifically, interface module 102 facilitates
enabling/disabling and/or selecting one of a plurality of available
motor output signal types. This feature is realized by pairing
interface module 102 with a known retrofit/replacement motor that
provides a fundamental motor output signal that interface module
102 modifies based on its configuration and passes on to system
controller 108.
[0027] Interface module 102 is further configured to control motor
104. In operating motor 104, interface module 102 provides a
control signal to motor 104 based on signals received from
thermostat 106 and system controller 108. In the exemplary
embodiment, motor 104 is a "communicating" ECM motor and interface
module 102 controls motor 104 using commands. For example, the
physical layer of interface module 102 may include serial,
controller area network (CAN), wireless, bus, and/or any other
standard communications interface/protocol. Interface module 102
provides a single control signal that includes an industry
recognized, standard PWM signal to drive motor 104. A duty cycle of
the control signal corresponds to a percent of full torque that may
be generated by motor 104.
[0028] In an alternative embodiment, where motor 104 may need
unique programming, such as field programming, for each system,
interface module 102 is configured to provide a 0 to 10 Vdc control
signal to motor 104.
[0029] Interface module 102 in combination with motor 104 is
configured to affect airflow that assures safe operation of HVAC
system 100. Interface module 102 maintains (e.g., in non-volatile
memory) a duty cycle value for each operating mode of HVAC system
100. Initially, default values are used to operate motor 104.
During installation, a service technician verifies the airflow in
all operating modes to ensure that the temperature rise of fossil
fuel heating systems and the CFM per ton of cooling meet OEM
specifications. Interface module 102 provides a user interface 118
for making adjustments to the stored duty cycle values as
determined by the technician.
[0030] FIG. 2 is a flowchart of an exemplary method 200 of
controlling a motor in a HVAC system using interface module 102
(shown in FIG. 1).
[0031] Initially, method 200 includes determining 202 an operating
mode of a plurality of operating modes of the HVAC system based on
at least one signal received from at least one of a first device
and a second device. In some embodiments, the first device may be a
thermostat and the second device may be a system controller of the
HVAC system. Method 200 also includes determining 204 a motor
operating parameter at which to control the motor based on the
determined operating mode. Method 200 further includes operating
206 the motor in accordance with the motor operating parameter.
[0032] In one embodiment, method 200 may include continuously
monitoring an aggregate signal of the system controller signals and
the thermostat signals, and comparing the resulting aggregate
signal with stored reference information to determine the operating
mode of the HVAC system.
[0033] In another embodiment, to determine the operating mode of
the HVAC system, method 200 may include implementing, by the
interface module, an algorithm that, over time, recognizes and
stores as a reference, the first and second device signal
combinations and timing.
[0034] In another embodiment, wherein to operate the motor, method
200 may include transmitting a pulse width modulation (PWM) signal
that represents the motor operating parameter, wherein a duty cycle
of the PWM signal corresponds to a percent of full torque that may
be generated by motor.
[0035] In another embodiment, method 200 may include receiving, via
a user interface of the interface module, operational values input
by a user, the operational values including at least one of ON
delay times, OFF delay times, and duty cycle values, and
implementing the operational values prior to operating the
motor.
[0036] The embodiments described herein provide an interface module
and methods of controlling a motor. The embodiments facilitate
determining an operating mode of a plurality of operating modes of
the HVAC system based on at least one signal received from at least
one of a first device and a second device, determining a motor
operating parameter at which to operate the motor based on the
determined operating mode, and controlling the motor in accordance
with the motor operating parameter. The interface module
facilitates replacing or retrofitting a failed motor in a HVAC
system with a readily available, stock, retrofit/replacement motor.
The interface module provides a cost-effective solution to
interfacing between HVAC system controllers, thermostats and
replacement motors. Further, the interface module facilitates
returning a failed HVAC system to operation quickly and efficiently
(e.g., in one service call).
[0037] Exemplary embodiments of the interface module and methods of
controlling a motor are described above in detail. The interface
module and methods are not limited to the specific embodiments
described herein, but rather, components of the interface module
and/or steps of the method may be utilized independently and
separately from other components and/or steps described herein. For
example, the control system and methods may also be used in
combination with other motor systems and methods, and are not
limited to practice with only the HVAC system as described herein.
Rather, the exemplary embodiments can be implemented and utilized
in connection with many other system applications or other
support.
[0038] A technical effect of the system described herein includes
at least one of: (a) determining an operating mode of a plurality
of operating modes of the HVAC system based on at least one signal
received from at least one of a first device and a second device;
(b) determining a motor operating parameter at which to operate the
motor based on the determined operating mode; (c) controlling the
motor in accordance with the motor operating parameter; (d)
replacing or retrofitting a failed motor in a HVAC system with a
readily available, stock, retrofit/replacement motor; (e) provides
a cost-effective solution to interfacing between HVAC system
controllers, thermostats and replacement motors; and (f)
facilitates returning a failed HVAC system to operation quickly and
efficiently.
[0039] Although specific features of various embodiments of the
invention may be shown in some drawings and not in others, this is
for convenience only. In accordance with the principles of the
invention, any feature of a drawing may be referenced and/or
claimed in combination with any feature of any other drawing.
[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 layers 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 language of the claims.
* * * * *