U.S. patent number RE35,124 [Application Number 08/156,297] was granted by the patent office on 1995-12-19 for control system, electronically commutated motor system, draft inducer apparatus and method.
This patent grant is currently assigned to General Electric Company. Invention is credited to Mark A. Brattoli, David M. Erdman.
United States Patent |
RE35,124 |
Erdman , et al. |
December 19, 1995 |
Control system, electronically commutated motor system, draft
inducer apparatus and method
Abstract
A control system and method for an electronically commutated
motor having a stationary assembly with a plurality of winding
stages for carrying a motor current in response to application of a
voltage having a magnitude subject to variations, the motor further
having a rotatable assembly. The control system is adapted to
receive control pulses having a duty cycle which is a function of a
desired operating torque or speed for the motor. The control system
and method are responsive to the motor current for generating a
pluse width modulated (PWM) series of pulses having a pulse
repetition rate having a duty cycle which is a function of the duty
cycle of the control pulses. The PWM series of pulses are supplied
to the commutating circuit as a pulsed signal whereby the operating
torque or speed of the motor is a function of the duty cycle of the
control pulses and is substantially independent of variations in
the magnitude of the applied voltage. The control system may be
part of a draft inducer apparatus or method for use with a
combustion chamber having an exhaust outlet including a fan for
moving air through the exhaust outlet and thereby to induce a draft
in the combustion chamber. A pressure sensor connected to the motor
control apparatus may be located within the exhaust outlet.
Inventors: |
Erdman; David M. (Fort Wayne,
IN), Brattoli; Mark A. (Fort Wayne, IN) |
Assignee: |
General Electric Company (Fort
Wayne, IN)
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Family
ID: |
27582439 |
Appl.
No.: |
08/156,297 |
Filed: |
November 23, 1993 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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192249 |
May 10, 1988 |
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15409 |
Feb 17, 1987 |
4743347 |
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463147 |
Feb 2, 1983 |
4654566 |
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412421 |
Aug 27, 1982 |
4449079 |
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141267 |
Apr 17, 1979 |
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77656 |
Sep 21, 1979 |
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802484 |
Jun 1, 1977 |
4169990 |
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729761 |
Oct 5, 1976 |
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482409 |
Jun 24, 1974 |
4005347 |
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482407 |
Jun 24, 1974 |
4015182 |
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Reissue of: |
483329 |
Feb 20, 1990 |
05075608 |
Dec 24, 1991 |
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Current U.S.
Class: |
318/599 |
Current CPC
Class: |
H02P
6/085 (20130101); F23N 3/082 (20130101); F25B
2600/021 (20130101); F23N 2233/04 (20200101) |
Current International
Class: |
F23N
3/08 (20060101); F23N 3/00 (20060101); H02P
6/08 (20060101); H02P 007/29 () |
Field of
Search: |
;318/138,254,439,599
;126/516,517,521,530,533,11R,11A,11D,14A
;323/299,300,301,302,303 |
References Cited
[Referenced By]
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6-17, 6-29. .
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Primary Examiner: Ro; Bentsu
Attorney, Agent or Firm: Krisher, Jr.; Ralph E.
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 07/192,249 filed on
May 10, 1988, now abandoned which is a continuation-in-part of
application Ser. No. 07/015,409 filed Feb. 17, 1987 (now U.S. Pat.
No. 4,743,347) which was a continuation-in-part of application Set.
No. 463,147 filed Feb. 2, 1983 (now U.S. Pat. No. 4,654,566) which
was a continuation-in-part of Ser. No. 412,421 filed Aug. 27, 1982,
(now U.S. Pat. No. 4,449,079) which was a continuation of
application Ser. No. 141,267 filed Apr. 17, 1980 (now abandoned)
which was a continuation-in-part of, application Ser. No. 077,656
filed Sept. 21, 1979 (now abandoned) which was a
continuation-in-part of application Ser. No. 802,484 filed Jun. 1,
1977 (now U.S. Pat. No. 4,169,990) which was a continuation-in-part
of application Ser. No. 729,761 filed Oct. 5, 1976 (now abandoned)
which was a continuation-in-part of application Ser. No. 482,409
filed Jun. 24, 1974 (now U.S. Pat. No. 4,005,347) and of
application Ser. No. 482,407 filed Jun. 24, 1974 (now U.S. Pat. No.
4,015,182). Each of the aforementioned applications and patents are
commonly assigned and are respectively incorporated by reference
herein.
This application is also related to coassigned U.S. Pat. Nos.
4,015,182; 4,162,435; 4,500,821; 4,459,519; 4,528,485 and
4,532,459. The entire disclosures of each of these patents are also
specifically incorporated herein by reference.
Claims
What is claimed is:
1. A control system for an electronically commutated motor having a
stationary assembly with a plurality of winding stages for carrying
a motor current in response to application of a voltage having a
magnitude subject to variations, the motor further having a
rotatable assembly, and which control system is adapted to receive
control pulses having a duty cycle representing a desired operating
torque for the motor, the control system for use with a commutating
circuit for controlling power switching devices for applying the
voltage to one or more of the winding stages at a time having a
duty cycle which is a function of a pulsed signal and for
commutating the winding stages in a preselected sequence to route
the rotatable assembly, the control system comprising:
means responsive to the motor current for generating a pulse width
modulated (PWM) series of pulses .[.having a pulse repetition
rate.]. having a duty cycle which is a function of the duty cycle
of the control pulses, the generating means adapted to supply the
PMW series of pulses to the commutating circuit as the pulsed
signal;
means for comparing the applied voltage to a reference voltage;
and
means, responsive to the means for comparing, for increasing the
duty cycle of the PWM series of pulses as a function of decreases
in the applied voltage and for decreasing the duty cycle of the PWM
series of pulses as a function of increases in the applied voltage
whereby the operating torque of the motor is a function of the duty
cycle of the control pulse and is substantially independent of
variations in the magnitude of the applied voltage.
2. The system of claim 1 wherein said means for comparing comprises
a comparator adapted to compare the applied voltage to an
oscillating voltage signal and to provide a comparator output
signal in response thereto, and a latch, responsive to the
comparator output signal, adapted to inhibit the PWM series of
pulses during the period that the oscillating voltage signal is
greater than the applied voltage.
3. The system of claim 1 further comprising means for generating a
sum of a first voltage having a magnitude which is a function of
the duty cycle of the control pulses and a second voltage having a
magnitude which is a function of the motor current, and means for
inhibiting the PWM series of pulses during the period that the sum
is greater than the reference voltage.
4. The system of claim 1 wherein said means for generating
comprises means for comparing the motor current and a signal
representing the duty cycle of the control pulses and providing an
output signal in response thereto, and means for providing a series
of pulses as the PWM series of pulses, each pulse having a width
which is a function of the output signal of the means for comparing
the motor current.
5. The system of claim 4 wherein said means for comparing the motor
current comprises means for generating a first voltage having a
magnitude which is a function of the duty cycle of the control
pulses, means for generating a second voltage having a magnitude
which is a function of the motor current, means for summing the
first and second voltages, and means for comparing the sum to a
reference voltage to provide an output signal in response thereto
as the PWM series of pulses.
6. The system of claim 5 further comprising means, responsive to
the means for comparing the sum, for selectively inhibiting the PWM
series of pulses during the period that the sum is greater than the
reference voltage.
7. The system of claim 6 wherein said means for comparing the sum
comprises a comparator adapted to compare the sum to the reference
voltage and to provide a comparator output signal in response
thereto, and said means for selectively inhibiting comprises means,
responsive to the comparator output signal, for conducting the PWM
voltage away from said commutating circuit during the period that
the sum is less than the reference voltage.
8. The system of claim 7 wherein said means for generating a first
voltage comprises a dc level converter, said means for generating a
second voltage comprises a motor current shunt, said means for
summing comprises a summer and said means for conducting comprises
a diode.
9. The system, of claim 8 wherein said means for increasing and
decreasing comprises means, responsive to the means for comparing
the applied voltage to a reference voltage, for increasing the duty
cycle of the PWM series of pulses when the applied voltage
decreases and for decreasing the duty cycle of the PWM series of
pulses when the applied voltage increases.
10. The system of claim 9 wherein said means for comparing the
applied voltage to a reference voltage comprises a comparator
adapted to compare the applied voltage to an oscillating voltage
signal and to provide a comparator output signal in response
thereto, and a latch, responsive to the comparator output signal,
adapted to inhibit the PWM series of pulses during the period that
the oscillating voltage signal is greater than the applied
voltage.
11. A control system for an electronically commutated motor having
a stationary assembly with a plurality of winding stages for
carrying a motor current in response to application of a voltage
having a magnitude subject to variations, the motor further having
a rotatable assembly, and which control system is adapted to
receive control pulses having a duty cycle representing a desired
operating torque for the motor, the control system for use with a
commutating circuit for controlling power switching devices for
applying the voltage to one or more of the winding stages at a time
having a duty cycle which is a function of a pulsed signal and for
commutating the winding stages in a preselected sequence to rotate
the rotatable assembly, the control system comprising:
means for generating a pulse width modulated (PWM) series of pulses
having a duty cycle which is a function of the duty cycle of the
control pulses, the generating means adapted to supply the PWM
series of pulses to the commutating circuit as the pulsed
signal;
means for comparing the applied voltage to a reference voltage;
and
means, responsive to the means for comparing, for increasing the
duty cycle of the PWM series of pulses as a function of decreases
in the applied voltage and for decreasing the duty cycle of the PWM
series of pulses as a function of increases in the applied voltage
whereby the operating speed of the motor is a function of the duty
cycle of the control pulses and is substantially independent of
variations in the magnitude of the applied voltage.
12. The system of claim 11 wherein said means for comparing
comprises a comparator adapted to compare the applied voltage to an
oscillating voltage signal and to provide a comparator output
signal in response thereto, and a latch, responsive to the
comparator output signal, adapted to inhibit the PWM series of
pulses during the period that the oscillating voltage signal is
greater than the applied voltage.
13. The system of claim 11 wherein said means for generating
comprises means for comparing an oscillating reference signal and a
signal representing the duty cycle of the control pulses and
providing an output signal in response thereto as the PWM series of
pulses.
14. The system of claim 13 wherein said means for comparing the
applied voltage to a reference voltage comprises means for
generating a first voltage having a magnitude which is a function
of the duty cycle of the control pulses, means for generating a
second voltage having a magnitude which is a function of the
oscillating reference signal, means for comparing the first and
second voltages and generating an output signal representative
thereof as the PWM series of pulses.
15. The system of claim 14 wherein said means for comparing the
first and second voltages comprises a comparator adapted to compare
the magnitudes of the first and second voltages and adapted to
provide a comparator output signal in response thereto.
16. The system of claim 15 wherein said means for generating a
first voltage comprises a dc level converter and said means for
generating a second voltage comprises a motor voltage sensor.
17. The system of claim 11 wherein said means for generating is
responsive to the motor current.
18. The system of claim 17 wherein said means for comparing
comprises a comparator adapted to compare the applied voltage to an
oscillating voltage signal and to provide a comparator output
signal in response thereto, and a latch, responsive to the
comparator output signal, adapted to inhibit the PWM series of
pulses during the period that the oscillating voltage signal is
greater than the applied voltage.
19. The system of claim 18 wherein said means for generating
comprises means for comparing the motor current and a current
reference signal and providing an output signal in response thereto
to inhibit the PWM series of pulses whenever the the motor current
is greater than the current reference signal.
20. The system of claim 19 wherein said means for comparing the
applied voltage to a reference voltage comprises means for
generating a first voltage having a magnitude which is a function
of the current reference signal, means for generating a second
voltage having a magnitude which is a function of the motor
current, means for summing the first and second voltages, means for
comparing the sum to a reference providing an output signal in
response thereto as the PWM series of pulses.
21. The system of claim 20 further comprising means, responsive to
the means for comparing the sum, for inhibiting the PWM series of
pulses during the period that the sum is greater than the reference
voltage.
22. The system of claim 21 wherein said means for comparing the sum
comprises a comparator adapted to compare the sum to the reference
voltage and to provide a comparator output signal in response
thereto, and said means for inhibiting comprises means, responsive
to the comparator output signal, for conducting the PWM series of
pulses away from said commutating circuit during the period that
the sum is less than the reference voltage.
23. The system of claim 22 wherein said means for generating a
first voltage comprises a dc voltage source, said means for
generating a second voltage comprises a motor current shunt, said
means for summing comprises a summer and said means for conducting
comprises a diode.
24. The system of claim 11 further comprising a motor control
apparatus adapted to control the motor by generating the control
pulses having a duty cycle which is a function of a desired
operating torque for the motor and the speed of the motor and
further including means for providing a tachometer signal
representative of the motor speed to the motor control apparatus
whereby the control pulses are a function of the tachometer
signal.
25. The system of claim 11 wherein the control pulses represent a
desired operating torque or speed of the motor; further comprising
means for selecting the motor current or the motor voltage as a
control parameter; and wherein said means for generating is
responsive to the selected motor operating condition.
26. The system of claim 11 further comprising means for generating
a sum of a first voltage having a magnitude which is a function of
the duty cycle of the control pulses and a second voltage having a
magnitude which is a function of the motor current, and means for
inhibiting the PWM series of pulses during the period that the sum
is greater than the reference voltage.
27. A control system for power switching devices of an
electronically commutated motor having a stationary assembly with a
plurality of winding stages for carrying a motor current in
response to application of a voltage having a magnitude subject to
variations, the motor further having rotatable assembly, and which
control system is adapted to receive control pulses having a duty
cycle representing a desired operating torque for the motor, the
control system comprising:
means for controlling the power switching devices to apply a
voltage having a duty cycle which is a function of a pulsed signal
to one or more of the winding stages at a time and for commutating
the winding stages in a preselected sequence to rotate the
rotatable assembly;
means responsive to the motor current for generating a pulse width
modulated (PWM) series of pulses having a duty cycle which is a
function of the duty cycle of the control pulses, the generating
means adapted to supply the PWM series of pulses to the controlling
means as the pulsed signal;
means for comparing the applied voltage to a reference voltage;
and
means, responsive to the means for comparing, for increasing the
duty cycle of the PWM series of pulses as a function of decreases
in the applied voltage and for decreasing the duty cycle of the PWM
series of pulses as a function of increases in the applied voltage
whereby the operating torque of the motor is a function of the duty
cycle of the control pulses and is substantially independent of
variations in the magnitude of the applied voltage.
28. The system of claim 27 wherein said means for generating
comprises means for comparing the motor current and a signal
representing the duty cycle of the control pulses and providing an
output signal in response thereto, and means for providing a series
of pulses as the PWM series of pulses, each pulse having a width
which is a function of the output signal of the means for comparing
the motor current.
29. The system of claim 27 further comprising means for generating
a sum of a first voltage having a magnitude which is a function of
the duty cycle of the control pulses and a second voltage having a
magnitude which is a function of the motor current, and means for
inhibiting the PWM series of pulses during the period that the sum
is greater than the reference voltage.
30. A control system for power switching devices of an
electronically commutated motor having a stationary assembly with a
plurality of winding stages for carrying a motor current in
response to applications of a voltage having a magnitude subject to
variations, the motor further having a rotatable assembly, and
which control system is adapted to receive control pulses having a
duty cycle representing a desired operating speed for the motor,
the control system comprising:
means for controlling the power switching devices to apply a
voltage having a duty cycle which is a function of a pulsed signal
to one or more of the winding stages at a time and for commutating
the winding stages in a preselected sequence to rotate the
rotatable assembly;
means for generating a pulse width modulated (PWM) series of pulses
having a duty cycle which is a function of the duty cycle of the
control pulses, the generating means adapted to supply the PWM
series of pulses to the controlling means as the pulsed signal;
means for comparing the applied voltage to a reference voltage;
and
means, responsive to the means for comparing, for increasing the
duty cycle of the PWM series of pulses as a function of decreases
in the applied voltage and for decreasing the duty cycle of the PWM
series of pulses as a function of increases in the applied voltage
whereby the operating speed of the motor is a function of the duty
cycle of the control pulses and is substantially independent of
variations in the magnitude of the applied voltage.
31. The system of claim 30 wherein said means for generating
comprises means for comparing an oscillating reference signal and a
signal representing the duty cycle of the control pulses and
providing an output signal in response thereto as the PWM series of
pulses.
32. The system of claim 30 wherein said means for generating is
responsive to the motor current.
33. The system of claim 32 wherein said means for generating
comprises means for comparing the motor current and a current
reference signal and providing an output signal in response thereto
to inhibit the PWM series of pulses whenever the the motor current
is greater than the current reference signal.
34. A control system for an electronically commutated motor having
a stationary assembly with a plurality of winding stages for
carrying a motor current in response to application of a voltage
having a magnitude subject to variations, the motor further having
a rotatable assembly, which control system is responsive to a motor
control apparatus adapted to control the motor by generating
control pulses having a duty cycle which is a function of a desired
operating torque for the motor and the speed of the motor, the
control system comprising:
means for applying a voltage having a duty cycle which is a
function of a pulsed signal to one or more of the winding stages at
a time and for commutating the winding stages in a preselected
sequence to rotate the rotatable assembly;
means responsive to the motor current for generating a pulse width
modulated (PWM) series of pulses having a duty cycle which is a
function of the duty cycle of the control pulses, the generating
means adapted to supply the PWM series of pulses to the applying
means as the pulsed signal; and
means for providing a tachometer signal representative of the motor
speed to the motor control apparatus.
35. The system of claim 34 wherein the tachometer signal providing
means comprises an isolator adapted to receive commutation pulses
from said generating means and adapted to provide the tachometer
signal in response to the commutation pulses.
36. The system of claim 35 further including means for varying the
duty cycle of the applied voltage inversely as a function of
variations in the magnitude of the applied voltage.
37. The system of claim 36 wherein said means for varying comprises
means for comparing the applied voltage to a reference voltage, and
means, responsive to the means for comparing, for increasing the
duty cycle of the PWM series of pulses when the applied voltage
decreases and for decreasing the duty cycle of the PWM series of
pulses when the applied voltage increases.
38. The system of claim 37 wherein said means for generating
comprises means for comparing the motor current and a signal
representing the duty cycle of the control pulses and providing an
output signal in response thereto, and means for providing a series
of pulses as the PWM series of pulses, each pulse having a width
which is a function, of the output signal of the means for
comparing the motor current.
39. The system of claim 35 wherein said means for generating
comprises means for comparing the motor current and a signal
representing the duty cycle of the control pulses and providing an
output signal in response thereto, and means for providing a series
of pulses as the PWM series of pulses, each pulse having a width
which is a function of the output signal of the means for
comparing.
40. The system of claim 34 further comprising means for generating
a sum of a first voltage having a magnitude which is a function of
the duty cycle of the control pulses and a second voltage having a
magnitude which is a function of the motor current, and means for
inhibiting the PWM series of pulses during the period that the sum
is greater than a reference voltage.
41. A control system for an electronically commutated motor having
a stationary assembly with a plurality of winding stages for
carrying a motor current in response to application of a voltage
having a magnitude subject to variations, the motor further having
a rotatable assembly, which control system is responsive to a motor
control apparatus adapted to control the motor by generating
control pulses having a duty cycle which is a function of a desired
operating torque for the motor and the speed of the motor, the
control system comprising:
means for applying a voltage having a duty cycle which is a
function of a pulsed signal to one or more of the winding stages at
a time and for commutating the winding stages in a preselected
sequence to rotate the rotatable assembly;
means for varying the duty cycle of the applied voltage as an
inverse function of the magnitude of the applied voltage;
means for generating a pulse width modulated (PWM) series of pulses
having a duty cycle which is a function of the duty cycle of the
control pulses, the generating means adapted to supply the PWM
series of pulses to the applying means as the pulsed signal;
and
means for providing a tachometer signal representative of the motor
speed to the motor control apparatus.
42. The system of claim 41 wherein said means for varying comprises
means for comparing the applied voltage to a reference voltage, and
means, responsive to the means for comparing, for increasing the
duty cycle of the PWM series of pulses when the applied voltage
decreases and for decreasing the duty cycle of the PWM series of
pulses when the applied voltage increases.
43. The system of claim 42 wherein said means for generating
comprises means for comparing an oscillating reference signal and a
signal representing the duty cycle of the control pulses and
providing an output signal in response thereto as the PWM series of
pulses.
44. The system of claim 42 wherein said means for generating is
responsive to the motor current.
45. The system of claim 44 wherein said means for generating
comprises means for comparing the motor current and a current
reference signal and providing an output signal in response thereto
to inhibit the PWM series of pulses whenever the the motor current
is greater than the current reference signal.
46. The system of claim 41 further comprising means for generating
a sum of a first voltage having a magnitude which is a function of
the duty cycle of the control pulses and a second voltage having a
magnitude which is a function of the motor current, and means for
inhibiting the PWM series of pulses during the period that the sum
is greater than a reference voltage.
47. A control system for an electronically commutated motor having
a stationary assembly with a plurality of winding stages for
carrying a motor current and further having a rotatable assembly,
and which control system is adapted to receive control pulses
having a duty cycle representing a desired operating torque or
speed for the motor, the control system being adapted for use with
a commutating circuit for applying a voltage to one or more of the
winding stages at a time in accordance with a pulsed signal and for
commutating the winding stages in a preselected sequence to rotate
the rotatable assembly, the control system comprising:
means for selecting the motor current or the motor voltage as a
control parameter said selecting means, including means for sensing
the motor current and means for providing a reference;
means responsive to the selected motor operating parameter for
generating a pulse width modulated (PWM) series of pulses having a
duty cycle which is a function of the duty cycle of the control
pulses, the generating means adapted to supply the PWM series of
pulses to the commutating circuit as the pulsed signal whereby the
torque of the motor is a function of the duty cycle of the control
pulses when the motor current is selected as the control parameter
and the speed of the motor is a function of the duty cycle of the
control pulses when the motor voltage is selected as the control
parameter.
48. The system of claim 47 wherein said means for generating
comprises means responsive to the motor current for generating a
pulse width modulated (PWM) series of pulses having a duty cycle
which is a function of the duty cycle of the control pulses when
the motor current is selected as the control parameter by said
means for selecting, the generating means adapted to supply the PWM
series of pulses to the commutating circuit as the pulsed signal
whereby the operating torque of the motor is a function of the duty
cycle of the control pulses and is substantially independent of
variations in the magnitude of the applied voltage.
49. The system of claim 47 wherein said means for generating
comprises means for generating a pulse width modulated (PWM) series
of pulses having a duty cycle which is a function of the duty cycle
of the control parameter by said means for selecting, the
generating means adapted to supply the PWM series of pulses to the
commutating circuit as the pulsed signal whereby the operating
speed of the motor is a function of the duty cycle of the control
pulses and is substantially independent of variations in the
magnitude of the applied voltage.
50. The system of claim 47 further comprising means for providing a
tachometer signal representative of the motor speed and wherein
said means for generating is responsive to said means for providing
a tachometer signal to provide the PWM series of pulses having a
duty cycle varying as a function of the tachometer signal.
51. The system of claim 47 wherein said means for selecting
comprises means for switching between said means for sensing the
motor current and said means for providing a reference; and said
means for generating comprises: means for comparing a signal
representative of the duty cycle of the control pulses to a signal
representative of the motor current when said means for switching
is connected to said means for sensing the motor current; and means
for comparing a signal representative of the duty cycle of the
control pulses to an oscillating reference signal when said means
for switching is connected to said means for providing a
reference.
52. The system of claim 51 wherein said means for generating
further comprises means for comparing a reference signal
representative of the maximum motor current to a signal
representative of the motor current when said means for switching
is connected to said means for sensing the motor current.
53. The system of claim 47 wherein said means for generating
comprises means for comparing a signal representative of the duty
cycle of the control pulses to a signal representative of the motor
current when the motor current is selected as the control parameter
by said means for selecting and means for comparing a signal
representative of the duty cycle of the control pulses to an
oscillating reference signal representative of the maximum duty
cycle of the voltage to be applied to the motor when the motor
voltage is selected as the control parameter by said means for
selecting.
54. Draft inducer apparatus for use with a combustion chamber
having an exhaust outlet comprising:
a fan for moving air through the exhaust outlet and thereby to
induce a draft in the combustion chamber;
an electronically commutated motor including a stationary armature
having a core and at least two energizable winding stages arranged
to establish a predetermined number of magnetic poles, and a
permanent magnet rotor coupled to said fan and adapted to rotate in
response to the magnetic poles established by said winding
stages;
means for generating a pulse width modulated (PWM) series of pulses
having a duty cycle representing a desired torque or speed of the
motor;
power switching devices for applying a voltage to one or more of
said winding stages at a time; .[.and.].
means for controlling said power switching devices in accordance
with the PWM series of pulses and commutating said winding stages
in a preselected sequence to rotate said permanent magnet rotor and
said fan; .Iadd.and .Iaddend.
sensor means for sensing pressure within the exhaust outlet, said
means for generating further comprising means connected to said
sensor means for generating the PWM series of pulses with a duty
cycle varying as a function of the sensed pressure.
55. The system of claim 54 wherein said means for generating
comprises means for generating control pulses having a duty cycle
representing a desired operating torque for the motor; means for
varying the duty cycle of the applied voltage inversely as a
function of variations in the magnitude of the applied voltage; and
means responsive to the motor current for generating a pulse width
modulated (PWM) series of pulses having a duty cycle which is a
function of the duty cycle of the control pulses, the generating
means adapted to supply the PWM series of pulses to the power
switching devices as .[.the.]. .Iadd.a .Iaddend.pulsed signal
whereby the operating torque of the motor is a function of the duty
cycle of the control pulses and is substantially independent of
variations in the magnitude of the applied voltage.
56. The system of claim 54 wherein said means for generating
comprises means for generating control pulses having a duty cycle
representing a desired operating speed for the motor; means for
varying the duty cycle of the applied voltage varies inversely as a
function of variations in the magnitude of the applied voltage; and
means for generating a pulse width modulated (PWM) series of pulses
having a duty cycle which is a function of the duty cycle of the
control pulses, the generating means adapted to supply the PWM
series of pulses to the power switching devices as .[.the.].
.Iadd.a .Iaddend.pulsed signal whereby the operating speed of the
motor is a function of the duty cycle of the control pulses and is
substantially independent of variations in the magnitude of the
applied voltage.
57. The system of claim 54 wherein said generating means generates
the PWM series of pulses when the pressure is above a preselected
limit, whereby a draft is induced in the combustion chamber when
the pressure is above the preselected limit.
58. The apparatus of claim 54 further comprising means for
providing a tachometer signal representative of the motor speed and
wherein said means for generating is responsive to said means for
providing a tachometer signal to provide the series of pulses
having a duty cycle varying as a function of the sensed pressure
and the tachometer signal.
59. The system of claim 54 further comprising means for generating
a sum of a first voltage having a magnitude which is a function of
the duty cycle of the control pulses and a second voltage having a
magnitude which is a function of the motor current, and means for
inhibiting the PWM series of pulses during the period that the sum
is greater than a reference voltage.
60. Draft inducer apparatus for use with a combustion chamber
having an exhaust outlet, comprising:
a fan for moving air through the exhaust outlet and thereby to
induce a draft in the combustion chamber;
an electronically commutated motor including a stationary armature
having a core and at least two energizable winding stages arranged
to establish a predetermined number of magnetic poles, and a
permanent magnet .[.motor.]. .Iadd.rotor .Iaddend.coupled to said
fan and adapted to rotate in response to the magnetic poles
established by said winding stages;
means for providing a tachometer signal representative of the motor
speed;
storage means for storing a speed/torque profile of the motor;
means, responsive to said means for providing a tachometer signal
and said storage means, for generating a pulse width modulated
(PWM) series of pulses having a duty cycle varying as a function of
the motor speed/torque profile and the tachometer signal;
power switching devices for applying a voltage to one or more of
said winding stages at a time;
means for controlling said power switching devices in accordance
with the PWM series of pulses and commutating said winding stages
in a preselected sequence to rotate said permanent magnet rotor and
said fan.
61. The apparatus of claim 60 further comprising sensor means for
sensing pressure within the exhaust outlet and wherein said means
for generating comprises means connected to said sensor means for
generating a pulse width modulated (PWM) series of pulses having a
duty cycle varying as a function of the pressure.
62. The system of claim 61 wherein said generating means generates
the PWM series of pulses when the pressure is above a preselected
limit, whereby a draft is induced in the combustion chamber when
the pressure is above the preselected limit.
63. The apparatus of claim 61 wherein said means for generating is
responsive to said means for providing a tachometer signal to
provide the series of pulses having a duty cycle varying as a
function of the pressure and the tachometer signal.
64. The system of claim 60 wherein said means for generating
comprises means for generating control pulses having a duty cycle
representing a desired operating torque for the motor; means for
varying the duty cycle of the applied voltage inversely as a
function of variations in the magnitude of the applied voltage; and
means responsive to the motor current for generating a pulse width
modulated (PWM) series of pulses having a duty cycle which is a
function of the duty cycle of the control pulses, the generating
means adapted to supply the PWM series of pulses to the power
switching devices as the pulsed signal whereby the operating torque
of the motor is a function of the duty cycle of the control pulses
and is substantially independent of variations in the magnitude of
the applied voltage.
65. The system of claim 60 wherein said means for generating
comprises means for generating control pulses having a duty cycle
representing a desired operating speed for the motor; means for
varying the duty cycle of the applied voltage .[.varies.].
inversely as a function of variations in the magnitude of the
applied voltage; and means for generating a pulse width modulated
(PWM) series of pulses having a duty cycle which is a function of
the duty cycle of the control pulses, the generating means adapted
to supply the PWM series of pulses to the power switching devices
as the pulsed signal whereby the operating speed of the motor is a
function of the duty cycle of the control pulses and is
substantially independent of variations in the magnitude of the
applied voltage.
66. The system of claim 60 further comprising means for generating
a sum of a first voltage having a magnitude which is a function of
the duty cycle of the control pulses and a second voltage having a
magnitude which is a function of the motor current, and means for
inhibiting the PWM series of pulses during the period that the sum
is greater than a reference voltage.
67. A control method for an electronically commutated motor having
a stationary assembly with a plurality of winding stages for
carrying a motor current in response to application of a voltage
having a rotatable assembly, and which control method is responsive
to control pulses having a duty cycle representing a desired
operating torque for the motor, the control method for use with a
commutating circuit for controlling power switching devices for
applying the voltage to one or more of the winding stages at a time
having a duty cycle which is a function of a pulsed signal and for
commutating the winding stages in a preselected sequence to rotate
the rotatable assembly, the control method comprising the steps
of:
generating a response to the motor current a pulse width modulated
(PWM) series of pulses .[.having a pulse repetition rat.]. having a
duty cycle which is a function of the duty cycle of the control
pulses, the generating step adapted to supply the PWM series of
pulses to the commutating circuit as the pulsed signal;
comparing the applied voltage to a reference voltage;
increasing the duty cycle of the PWM series of pulses as a function
of decreases in the applied voltage; and
decreasing the duty cycle of the PWM series of pulses as a function
of increases in the applied voltage whereby the operating torque of
the motor is a function of the duty cycle of the control pulses and
is substantially independent of variations in the magnitude of the
applied voltage.
68. A control method for an electronically commutated motor having
a stationary assembly with a plurality of winding stages for
carrying a motor current in response to application of a voltage
having a magnitude subject to variations, the motor further having
a rotatable assembly, and which control method is responsive to
control pulses having a duty cycle representing a desired operating
torque for the motor, the control method for use with a commutating
circuit for controlling power switching devices for applying the
voltage to one or more of the winding stages at a time having a
duty cycle which is a function of a pulsed signal and for
commutating the winding stages in a preselected sequence to rotate
the rotatable assembly, the control method comprising the steps
of:
generating a pulse width modulated (PWM) series of pulses having a
duty cycle which is a function of the duty cycle of the control
pulses, the generating step adapted to supply the PWM series of
pulses to the commutating circuit as the pulsed signal;
comparing the applied voltage to a reference voltage;
increasing the duty cycle of the PWM series of pulses as a function
of decreases in the applied voltage; and
decreasing the duty cycle of the PWM series of pulses as a function
of increases in the applied voltage whereby the operating speed of
the motor is a function of the duty cycle and is substantially
independent of variations in the magnitude of the applied
voltage.
69. A control method for power switching devices of an
electronically commutated motor having a stationary assembly with a
plurality of winding stages for carrying a motor current in
response to application of a voltage having a magnitude subject to
variations, the motor further having a rotatable assembly, and
which control method is responsive to control pulses having a duty
cycle representing a desired operating torque for the motor, the
control method comprising the steps of:
controlling the power switching devices to apply a voltage having a
duty cycle which is a function of a pulsed signal to one or more of
the winding stages at a time;
commutating the winding stages in a preselected sequence to rotate
the rotatable assembly;
generating in response to the motor current a pulse width modulated
(PWM) series of pulses having a duty cycle which is a function of
the duty cycle of the control pulses, the generating step adapted
to supply the PWM series of pulses as the pulsed signal;
comparing the applied voltage to a reference voltage;
increasing the duty cycle of the PWM series of pulses as a function
of decreases in the applied voltage; and
decreasing the duty cycle of the PWM series of pulses as a function
of increases in the applied voltage whereby the operating torque of
the motor is a function of the duty cycle of the control pulses and
is substantially independent of variations in the magnitude of the
applied voltage.
70. A control method for power switching devices of an
electronically commutated motor having a stationary assembly with a
plurality of winding stages for carrying a motor current in
response to application of a voltage having a magnitude subject to
variations, the motor further having a rotatable assembly, and
which control method is responsive to control pulses having a duty
cycle representing a desired operating speed for the motor, the
control method comprising the steps of:
controlling the power switching devices to apply a voltage having a
duty cycle which is a function of a pulsed signal to one or more of
the winding stages at a time;
commutating the winding stages in a preselected sequence to rotate
the rotatable assembly;
generating a pulse width modulated (PWM) series of pulses having a
duty cycle which is a function of the duty cycle of the control
pulses, the generating step adapted to supply the PWM series of
pulses as the pulsed signal;
comparing the applied voltage to a reference voltage;
increasing the duty cycle of the PWM series of pulses as a function
of decreases in the applied voltage; and
decreasing the duty cycle of the PWM series of pulses as a function
of increases in the applied voltage whereby the operating speed of
the motor is a function of the duty cycle of the control pulses and
is substantially independent of variations in the magnitude of the
applied voltage.
71. A control method for an electronically commutated motor having
a stationary assembly with a plurality of winding stages for
carrying a motor current in response to application of a voltage
having a magnitude subject to variations, the motor further having
a rotatable assembly, and which control method is responsive to a
motor control apparatus adapted to control the motor by generating
control pulses having a duty cycle which is a function of a desired
operating torque for the motor and the speed of the motor, the
control method comprising the steps of:
applying a voltage having a duty cycle which is a function of a
pulsed signal to one or more of the winding stages at a time;
storing a speed/torque profile of the motor;
commutating the winding stages in a preselected sequence to rotate
the rotatable assembly;
generating, in response to the motor current and the motor speed, a
pulse width modulated (PWM) series of pulses having a duty cycle
which is a function of the duty cycle of the control pulses, the
generating step adapted to supply the PWM series of pulses as the
pulsed signal;
providing a tachometer signal representative of the motor speed to
the motor control apparatus; and
wherein the generating step is responsive to the storing step and
the providing step for generating the PWM series of pulses with a
duty cycle varying as a function of the motor speed/torque profile
and the tachometer signal.
72. A control method for an electronically commutated motor having
a stationary assembly with a plurality of winding stages for
carrying a motor current in response to application of a voltage
having a magnitude subject to variations, the motor further having
a rotatable assembly, and which control method is responsive to a
motor control apparatus adapted to control the motor by generating
control pulses having a duty cycle which is a function of a desired
operating torque for the motor and the speed of the motor, the
control method comprising the steps of:
applying a voltage having a duty cycle which is a function of a
pulsed signal to one or more of the winding stages at a time;
commutating the winding stages in a preselected sequence to rotate
the rotatable assembly;
varying the duty cycle of the applied voltage as an inverse
function of the magnitude of the applied voltage;
generating a pulse width modulated (PWM) series of pulses having a
duty cycle which is a function of the duty cycle of the control
pulses, the generating step adapted to supply the PWM series of
pulses as the pulsed signal; and
providing a tachometer signal representative of the motor speed to
the motor control apparatus.
73. A control method for an electronically commutated motor having
a stationary assembly with a plurality of winding stages for
carrying a motor current and further having a rotatable assembly,
and which control method is responsive to control pulses having a
duty cycle representing a desired operating torque or speed for the
motor, the control method being adapted for use with a commutating
circuit for applying a voltage to one or more of the winding stages
at a time in accordance with a pulsed signal and for commutating
the winding stages in a preselected sequence to rotate the
rotatable assembly, the control method comprising the steps of:
selecting the motor current or the motor voltage as a control
parameter;
generating in response to the selected motor operating parameter a
pulse width modulated (PWM) series of pulses having a duty cycle
which is a function of the duty cycle of the control pulses, the
generating step adapted to supply the PWM series of pulses to the
commutating circuit as the pulsed signal whereby the torque of the
motor is a function of the duty cycle of the control pulses when
the motor current is selected as the control parameter and the
speed of the motor is a function of the duty cycle of the control
pulses when the motor voltage is selected as the control
parameter.
74. Method of inducing a draft in a combustion chamber having an
exhaust outlet including a fan for moving air through the exhaust
outlet and thereby to induce a draft in the combustion chamber and
an electronically commutated motor including a stationary armature
having a core and at least two energizable winding stages arranged
to establish a predetermined number of magnetic poles, and a
permanent magnet rotor coupled to said fan and adapted to rotate in
response to the magnetic poles established by said winding stages;
said method comprising the steps of:
generating a pulse width modulated (PWM) series of pulses having a
duty cycle representing a desired torque or speed of the motor;
applying a voltage to one or more of said winding stages at a time
by use of power switching devices;
controlling the power switching devices in accordance with the PWM
series of pulses;
commutating said winding stages in a preselected sequence to rotate
said permanent magnet rotor and said fan;
comparing the applied voltage to a reference voltage;
increasing the duty cycle of the PWM series of pulses as a function
of decreases in the applied voltage; and
decreasing the duty cycle of the PWM series of pulses as a function
of increases in the applied voltage.
75. Method of inducing a draft in combustion chamber having an
exhaust outlet including a fan for moving air through the exhaust
outlet and thereby to induce a draft in the combustion chamber and
an electronically commutated motor including a stationary armature
having a core and at least two energizable winding stages arranged
to establish a predetermined number of magnetic poles, and a
permanent magnet rotor coupled to said fan and adapted to rotate in
response to the magnetic poles established by said winding stages;
said method comprising the steps of:
providing a tachometer signal representative of the motor
speed;
storing a speed/torque profile of the motor;
generating a pulse width modulated (PWM) series of pulses having a
duty cycle varying as a function of the motor speed/torque profile
and the tachometer signal;
applying a voltage to one or more of said winding stages at a time
in accordance with the PWM series of pulses; and
commutating said winding stages in a preselected sequence to rotate
said permanent magnet rotor and said fan. .Iadd.
76. A system for driving a rotatable component comprising:
an electronically commutated motor including a stationary armature
having a core and at least two energizable winding stages arranged
to establish a predetermined number of magnetic poles, and a
permanent magnet rotor adapted to be coupled to said rotatable
component and adapted to rotate in response to the magnetic poles
established by said winding stages;
means for providing a tachometer signal representative of the motor
speed;
storage means for storing a speed/torque profile of the motor;
means, responsive to said means for providing a tachometer signal
and said storage means, for generating a pulse width modulated
(PWM) series of pulses having a duty cycle varying as a function of
the motor speed/torque profile and the tachometer signal;
power switching devices for applying a voltage to one or more of
said winding stages at a time; and
means for controlling said power switching devices in accordance
with the PWM series of pulses and commutating said winding stages
in a preselected sequence to rotate said permanent magnet rotor and
said rotatable component..Iaddend. .Iadd.77. The system of claim 76
wherein said means for generating comprises means for generating
control pulses having a duty cycle representing a desired operating
torque for the motor; means for varying the duty cycle of the
applied voltage inversely as a function of variations in the
magnitude of the applied voltage; and means responsive to the motor
current for generating a pulse width modulated (PWM) series of
pulses having a duty cycle which is a function of the duty cycle of
the control pulses, the generating means adapted to supply the PWM
series of pulses to the power switching devices as the pulsed
signal whereby the operating torque of the motor is a function of
the duty cycle of the control pulses and is substantially
independent of variations in the magnitude of the applied
voltage..Iaddend. .Iadd.78. The system of claim 76 wherein said
means for generating comprises means for generating control pulses
having a duty cycle representing a desired operating speed for the
motor; means for varying the duty cycle of the applied voltage
inversely as a function of variations in the magnitude of the
applied voltage; and means for generating a pulse width modulated
(PWM) series of pulses having a duty cycle which is a function of
the duty cycle of the control pulses, the generating means adapted
to supply the PWM series of pulses to the power switching devices
as the pulsed signal whereby the operating speed of the motor is a
function of the duty cycle of the control pulses and is
substantially independent of variations in the magnitude of the
applied voltage..Iaddend. .Iadd.79. The system of claim 76 further
comprising means for generating a sum of a first voltage having a
magnitude which is a function of the duty cycle of the control
pulses and a second voltage having a magnitude which is a function
of the motor current, and means for inhibiting the PWM series of
pulses during the period that the sum is greater than a reference
voltage..Iaddend.
.Iadd. Method of driving a rotatable component by an electronically
commutated motor in response to control pulses having a duty cycle
representing a desired operating torque or speed of the motor, said
motor including a stationary armature having a core and at least
two energizable winding stages arranged to establish a
predetermined number of magnetic poles, and a rotor coupled to said
rotatable component and adapted to rotate in response to the
magnetic poles established by said winding stages; said method
comprising the steps of:
generating a pulse width modulated (PWM) series of pulses having a
duty cycle which is a function of the duty cycle of the control
pulses;
applying a voltage to one or more of said winding stages at a time
by the use of power switching devices;
controlling the power switching devices in accordance with the
series of pulses;
commutating said winding stages in a preselected sequence to rotate
said permanent magnet rotor and said rotatable component;
comparing the applied voltage to a reference voltage;
increasing the duty cycle of the PWM series of pulses as a function
of decreases in the applied voltage; and
decreasing the duty cycle of the PWM series of pulses as a function
of
increases in the applied voltage..Iaddend. .Iadd.81. Method of
driving a rotatable component by an electronically commutated motor
including a stationary armature having a core and at least two
energizable winding stages arranged to establish a predetermined
number of magnetic poles, and a permanent magnet rotor coupled to
said rotatable component and adapted to rotate in response to the
magnetic poles established by said winding stages; said method
comprising the steps of:
providing a tachometer signal representative of the motor
speed;
storing a speed/torque profile of the motor;
generating a pulse width modulated (PWM)series of pulses having a
duty cycle varying as a function of the motor speed/torque profile
and the tachometer signal;
applying a voltage to one or more of said winding stages at a time
in accordance with the PWM series of pulses; and
commutating said winding stages in a preselected sequence to rotate
said permanent magnet rotor and said rotatable component..Iaddend.
Description
FIELD OF THE INVENTION
This invention relates in general to dynamoelectric machines,
control systems and application systems for such machines and to
methods of their control and operation. More particularly, this
invention relates to control systems for an electronically
commutator motor, electronically commutated motor systems, draft
inducer apparatus, and methods of their control and operation.
BACKGROUND OF THE INVENTION
While conventional brush-commutated DC motors may have advantageous
characteristics, including convenience of changing operational
speeds. There may be disadvantages such as brush wear, electrical
loss, noise and radio frequency interference caused by sparking
between the brushes and the segmented commutator, which may limit
the applicability of such brush-commutated DC motors in some fields
such as the furnace blower control field. Electronically commutated
moron, such as brushless DC motors and permanent magnet motors with
electronic commutation, have now been developed and generally are
believed to have the above discussed advantageous characteristics
of the brush-commutated DC motors without many of the disadvantages
thereof while also having other important advantages. Such
electronically commutated motors are disclosed in the David M.
Erdman U.S. Pat. Nos. 4,015,182 and 4,459,519. for instance. These
electronically commutated motors are advantageously employed, for
instance, in various air handling applications such as air
conditioning for cooling and warming.
In a conventional furnace, considerable heat energy is wasted when
it is exhausted to the atmosphere. This makes the overall
efficiency of the system poor considering the BTU content of the
fuel. Efficiency and fuel economy can be greatly improved by
extracting the heat from the furnace exhaust. Natural convection of
the hot exhaust causes it to rise and vent to the atmosphere. In
order to improve efficiency and economy, the heat is extracted from
the exhaust by a heat exchanger in which case additional pressure
is needed to force the cooled exhaust to vent to the atmosphere.
This is accomplished by inducing a draft.
In a draft inducer control system, such as used in high efficiency
furnaces, a variable resistance can be used to vary the speed of a
brush-type fan motor to induce drafts, but this would further
reduce the energy efficiency of the system. While there are some
losses engendered by electronic switching of an electronically
commutated motor, these are negligible compared to brush losses and
rheostat losses in prior art variable speed draft inducer
systems.
Further improvements in control systems, electronically commutated
motor systems, draft inducer apparatus and methods of control and
operation can beneficially contribute to more widespread use of
such motors in various applications including fan control for
inducing drafts in high efficiency furnaces. For example, sudden
changes in resistance to draft and line voltage variations can lead
to reduced drafts or excessive drafts which adversely affect
furnace efficiency and product potentially dangerous backdrafts or
over-drafts. Improvements which achieve increased torque and speed
control would be desirable. Economy of manufacture would also be
enhanced by circuit improvements if they can be made with little
extra cost as part of improved integrated circuit chips. Greater
versatility of response to various control signal conditions and
improved failsafe futures would also be desirable.
SUMMARY OF THE INVENTION
Among the objects of this invention are to provide an improved
control system for an electronically commutated motor, an improved
electronically commutated motor system, improved draft inducer
apparatus and improved methods of control and operation which
overcome at least some of the disadvantageous conditions discussed
above; the provision of an improved control system for an
electronically commutated motor, an improved electronically
commutated motor system, improved draft inducer apparatus and
improved methods of control and operation which substantially
reduce drafts or increase drafts in a high efficiency furnace as a
function of the pressure within the exhaust outlet of the furnace;
the provision of an improved control system for an electronically
commutated motor, an improved electronically commutated motor
system, improved draft inducer apparatus and improved methods of
control and operation which substantially reduce backdrafts and
over-drafts causing inefficient combustion; the provision of an
improved control system for an electronically commutated motor, an
improved electronically commutated motor and system which converts
a duty cycle signal to a corresponding output torque or speed on
the motor; the provision of an improved control system for an
electronically commutated motor, an improved electronically
commutated motor system, improved draft inducer apparatus and
improved methods of control and operation which compensate for line
voltage variations; and the provision of an improved control system
for an electronically commutated motor, an improved electronically
commutated motor system, improved draft inducer apparatus and
improved methods of control and operation which are electrically
efficient, reliable, economical and convenient in use.
Generally, one form of the invention is a control system for an
electronically commutated motor having a stationary assembly with a
plurality of winding stages for carrying a motor current in
response to application of a voltage having a magnitude subject to
variations. The motor further has a rotatable assembly. The control
system is adapted to receive control pulses having a duty cycle
representing a desired operating torque for the motor. The control
system is for use with a commutating circuit for applying the
voltage to one or more of the winding stages at a time having a
duty cycle which is a function of a pulsed signal and for
commutating the winding stages in a preselected sequence to rotate
the rotatable assembly. The control system comprises means for
varying the duty cycle of the applied voltage inversely as a
function of variations in the magnitude of the applied voltage.
Means responsive to the motor current generates a pulse width
modulated (PWM) series of pulses having a pulse repetition rate
having a duty cycle which is a function of the duty cycle of the
control pulses The generating means is adapted to supply the PWM
series of pulses to the commutating circuit as the pulsed signal
whereby the operating torque of the motor is a function of the duty
cycle of the control pulses and is substantially independent of
variations in the magnitude of the applied voltage.
A further form of the invention is a control system for an
electronically commutated motor having a stationary assembly with a
plurality of winding stages for carrying a motor current in
response to application of a voltage having a magnitude subject to
variations, the motor further having a rotatable assembly. The
control system is adapted to receive control pulses having a duty
cycle representing a desired operating torque for the motor. The
control system is for use with a commutating circuit for applying
the voltage to one or more of the winding stages at a time having a
duty cycle which is a function of a pulsed signal and for
commutating the winding stages in a preselected sequence to rotate
the rotatable assembly. The control system comprises means for
varying the duty cycle of the applied voltage inversely as a
function of variations in the magnitude of the applied voltage.
Means generates a pulse width modulated (PWM) series of pulses
having a duty cycle which is a function of the duty cycle of the
control pulses. The generating means is adapted to supply the PWM
series of pulses to the commutating circuit as the pulsed signal
whereby the operating speed of the motor is a function of the first
duty cycle and is substantially independent of variations in the
magnitude of the applied voltage.
A further form of the invention is a control system for an
electronically commutated motor having a stationary assembly with a
plurality of winding stages for carrying a motor current in
response to application of a voltage having a magnitude subject to
variations, the motor Further having a rotatable assembly. The
control system is responsive to a motor control apparatus adapted
to control the motor by generating control pulses having a duty
cycle representing a desired operating torque for the motor. The
control system comprises means for applying a voltage having a duty
cycle which is a function of a pulsed signal to one or more of the
winding stages at a time and for commutating the winding stages in
a preselected sequence to rotate the rotatable assembly. Means
responsive to the motor current generates a pulse width modulated
(PWM) series of pulses having a duty cycle which is a function of
the duty cycle of the control pulses. The generating means is
adapted to supply the PWM series of pulses to the applying means as
the pulsed signal. Means provides a tachometer signal
representative of the motor speed to the motor control apparatus
where by the control pulses are a function of the tachometer
signal.
In another form the invention is a control system for an
electronically commutated motor having a stationary assembly with a
plurality of winding stages for carrying a motor current in
response to application of a voltage having a magnitude subject to
variations, the motor further having a rotatable assembly. The
control system is responsive to a motor control apparatus adapted
to control the motor by generating control pulses having a duty
cycle representing a desired operating torque for the motor. The
control system comprises means for applying a voltage having a duty
cycle which is a function of a pulsed signal to one or more of the
winding stages at a time and for commutating the winding stages in
a preselected sequence to rotate the rotatable assembly. Means
varies the duty cycle of the applied voltage is an inverse function
of the magnitude of the applied voltage. Means generates a pulse
width modulated (PWM) series of pulses having a duty cycle which is
a function of the duty cycle of the control pulses. The generating
means is adapted to supply the PWM series of pulses to the applying
means as the pulsed signal. Means provides a tachometer signal
representative of the motor speed to the motor control apparatus
whereby the control pulses are a function of the tachometer
signal.
In another form the invention is a control system for an
electronically commutated motor having a stationary assembly with a
plurality of winding stages for carrying a motor current and
further having a rotatable assembly. The control system is adapted
to receive control pulses having a duty cycle representing a
desired operating torque or speed for the motor. The control system
for use with a commutating circuit for applying a voltage to one or
more of the winding stages at a time in accordance with a pulsed
signal and for commutating the winding stages in a preselected
sequence to route the rotatable assembly. The control system
comprises means for selecting motor operating conditions including
the motor current and the motor voltage. Means responds to the
selected motor operating conditions for generating a pulse width
modulated (PWM) series of pulses having a duty cycle which is a
function of the duty cycle of the control pulses. The generating
means is adapted to supply the PWM series of pulses to the
commutating circuit as the pulsed signal whereby the torque of the
motor is a function of the duty cycle of the control pulses when
the motor current is selected and the speed of the motor is a
function of the duty cycle of the control pulses when the motor
voltage is selected.
Another form of the invention is a draft inducer apparatus for use
with a combustion chamber having an exhaust outlet and comprises a
fan for moving air through the exhaust outlet and thereby to induce
a draft in the combustion chamber, and an electronically commutated
motor including a stationary armature having a core and at least
two energizable winding stages arranged to establish a
predetermined number of magnetic poles, and a permanent magnet
rotor coupled to the fan and adapted to rotate in response to the
magnetic poles established by the windings. Means generates a pulse
width modulated (PWM) series of pulses having a duty cycle
representing a desired torque or speed of the motor. Means applies
a voltage to one or more of the winding stages at a time in
accordance with the series of pulses and commutates the winding
stages in a preselected sequence to rotate the rotatable assembly
and the fan.
In another form, the invention is a draft inducer apparatus for use
with a combustion chamber having an exhaust outlet and comprising a
fan for moving air through the exhaust outlet and thereby to induce
a draft in the combustion chamber and an electronically commutated
motor including a stationary armature having a core and at least
two energizable winding stages arranged to establish a
predetermined number of magnetic poles, and a permanent magnet
rotor coupled to the fan and adapted to rotate in response to the
magnetic poles established by the windings. Means provides a
tachometer signal representative of the motor speed. Means,
responsive to the tachometer means, generates a pulse width
modulated (PWM) series of pulses having a duty cycle varying as a
function of the tachometer signal, Means applies a voltage to one
or more of the winding stages at a time in accordance with the
series of pulses and commutates the winding stages in a preselected
sequence to route the rotatable assembly and the fan.
The invention comprehends electronically commutated motor systems
and draft inducer apparatus improved to include circuits of the
types described above and other improvements. Also, various methods
of the invention involve steps for accomplishing various aspects of
the control and operation of the circuits described above.
Other objects and features will be in pan apparent and in pan
pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of one embodiment of a draft inducer
apparatus according to the invention having an electronically
commutated motor system including one embodiment of an electronic
torque control according to the invention.
FIG. 1A is a block diagram of one embodiment of a circuit of the
invention for controlling the duty cycle of the applied voltage
inversely as a function of variations in the magnitude of the
applied voltage.
FIG. 2 is a block diagram of one embodiment of a draft inducer
apparatus according to the invention having an electronically
commutated motor system including one embodiment of an electronic
speed control according to the invention.
FIG. 3 is a schematic diagram of one embodiment of a power supply
according to the invention for use as part of an electronic control
for an electronically commutated motor according to the
invention.
FIG. 4 is a schematic diagram of one embodiment of an isolation
circuit according to the invention for use as pan of an electronic
control for an electronically commutated motor according to the
invention.
FIG. 5 is a schematic diagram of one embodiment of an speed and
torque control circuit according to the invention for use as part
of an electronic control for an electronically commutated motor
according to the invention.
FIG. 6 is a schematic diagram of one embodiment of a motor control
integrated circuit and full wave bridge according to the invention
for use as part of an electronic control for an electronically
commutated motor according to the invention.
FIG. 7 is a set of waveform diagrams illustrating the operation of
a draft inducer apparatus having an electronically commutated motor
system including an electronic torque control according to the
invention.
Corresponding reference characters indicate corresponding parts
throughout the several views of the drawings.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates a control system 100 for an electronically
commutated motor 102 having a stationary assembly with a plurality
of winding stages for carrying a motor current in response to
application of a voltage having a magnitude subject to variations,
the motor further having a rotatable assembly (not shown). Control
system 100 is adapted to receive control pulses, such as provided
by microprocessor 104 via line 106, having a duty cycle
representing a desired operating torque for motor 102.
Reference character 108 generally refers to an integrated circuit
(IC) which is generally a universal IC for use as a commutating
circuit in combination with an electronically commutated motor.
Such an IC is described in coassinged U.S. Pat. No. 4,500,821 to
Bitting, et al., incorporated herein by reference, IC 108
constitutes means for applying the voltage to one or more of the
winding stages of motor 102 at a time having a duty cycle which is
a function of a pulsed signal applied to PWM input port 110. IC 108
commutates the winding stages of the motor 102 in a preselected
sequence to rotate the rotatable assembly. IC 108 includes a pulse
width modulated pulse generator (PWM generator) 112 adapted to
provide an oscillating signal, i.e., a PWM series of pulses, having
a duty cycle controlled, a part, by a voltage applied to voltage
oscillator reference (VOSREF) input port 111. In particular, PWM
generator 112 is adapted to generate an oscillating signal having a
duty cycle which is an inverse function of the motor voltage as
sensed by motor voltage sensor 113. As a result, IC 108 constitutes
means for varying the duty cycle of the voltage applied to the
winding stages inversely as a function of variations in the
magnitude of the applied voltage.
The electronic control circuit for IC 108 is generally referred to
by reference character 114 and constitutes means responsive to the
motor current as sensed by motor current sensor 116. Circuit 114
generates the PWM series of pulses to be applied to PWM input port
110 having a duty cycle which is a function of the duty cycle of
the control pulses provided by microprocessor 104 via line 106. As
a result, the operating torque of the motor 102 is a function of
the duty cycle of the control pulses and is independent of
variations in the magnitude of the applied voltage.
Specifically, FIG. 1 illustrates a draft inducer apparatus for use
with combustion chamber 120 having exhaust outlet 122 Fan 124,
preferably positioned within the exhaust outlet 122, moves air
through exhaust outlet 122 and thereby induces a draft in
combustion chamber 120. Electronically commutated motor 102
includes a stationary armature having a core and at least two
energizable winding stages arranged to establish a predetermined
number of magnetic poles (not shown), and a permanent magnet rotor
(not shown) coupled to fan 124 and adapted to rotate in response to
the magnetic poles established by the windings.
Pressure transducer 126, preferably located within exhaust outlet
122 between fan 124 and combustion chamber 120, constitutes sensor
means for sensing the pressure within exhaust outlet 122. It is
contemplated that pressure transducer 126 may be located anywhere
within exhaust outlet 122. Although transducer 126 is shown and
illustrated in FIG. 1 as a pressure transducer located between
motor 102 and combustion chamber 120, transducer 126 may be any
sensor means located between combustion chamber 120 and exhaust
outlet port 128.
Pressure transducer 126 provides a pressure representative signal
via line 130 to microprocessor 104 indicating the pressure within
exhaust outlet 122. Microprocessor 104 evaluates the pressure
representative signal as pan or the procedure it follows to
determine the duty cycle of the PWM series of pulses provided via
line 106. For example, microprocessor 104 may compare the pressure
signal to a desired reference dependent upon the particular cycle
or combustion chamber 120 (e.g., purge cycle, operating cycle or
maximum heat cycle), Three variables determine the operating
parameters of motor 102: the torque or the motor as specified by
the control pulses (due to linearity between duty cycle of control
pulses and the current limiting features of circuit 114), the
pressure specified by pressure transducer 126, and the speed of the
motor as specified by the tachometer signal provided via line 132.
Therefore, microprocessor 104 constitutes means connected to
transducer 126 for generating control pulses via line 106 having a
duty cycle varying as a function of the pressure within exhaust
outlet 122. As a result, IC 108 constitutes means for applying a
voltage to one or more of the winding stages of motor 102 at a time
in accordance with the control pulses generated by microprocessor
104 provided via line 106. IC 108 commutates the winding stages in
a preselected sequence to route the rotatable assembly of motor 102
and ran 124 with a variable torque as a function of the pressure;
e.g., the torque is increased when the pressure within exhaust
outlet 122 is above a preselected limit. As a result, a draft is
induced through exhaust outlet 122 and in the combustion chamber
when the pressure is above the preselected limit. IC 108 also
constitutes means for providing a tachometer signal via line 132
representative of the motor speed. Microprocessor 104 is connected
to the IC 108 via line 132 to receive the tachometer signal and the
series of pulses provided by microprocessor 104 via line 106 has a
duty cycle varying as a function or the pressure and the tachometer
signal.
Electronic control circuit 114 includes DC level converter 134 for
receiving the control pulses provided via line 106 by
microprocessor 104. The control pulses generally have a frequency
in the range of 30-60 hertz. DC level converter 134 converts the
control pulses into a signal having positive voltage which is a
function of the duty cycle or the control pulses. Converter 134
constitutes means for generating a first voltage having a magnitude
which is a function of the duty cycle or the control pulses
provided via line 106. This positive voltage signal is provided to
tint input 136 of summer 138. The other (second) input 140 of
summer 138 is provided with a negative voltage signal which is a
function of the motor current as measured by motor current sensor
116. Summer 138 compares the motor current signal via input 140 to
the signal via input 126 which represents the duty cycle of the
control pulses and provides an output signal (b) in response
thereto The sum of these two voltages is applied to noninverting
input 141 of comparator 142 and compared to a voltage reference
which is provided to inverting input 143 of comparator 142. When
the voltage of the signal applied to input 140 representing the
motor current exceeds in magnitude the voltage signal applied to
input 136 representing the desired duty cycle by an amount which is
greater than the reference voltage applied to input 143 of
comparator 142, the output 144 of comparator 142 is pulled from
high to low (i.e., grounded). This prevents PWM input port 110 from
receiving a reference voltage signal applied through resistor 150
to PWM input 110 via line 118 so that no voltage is applied to the
winding stages for the remainder of the cycle of PWM generator
112.
As the motor current increases as detected by sensor 116, the
corresponding negative voltage provided to input 140 or summer 138
increases in magnitude so that the voltage applied to noninverting
input 141 of comparator 142 is a negative voltage of increasing
magnitude. Sensor 116 constitutes means for generating a second
voltage having a magnitude which is a function of the motor
current. When the magnitude of the voltage applied to noninverting
input 141 of comparator 142 is less than the magnitude of the
reference voltage applied to the inverting input 143, the output
144 of comparator 142 is switched low. As a result, diode 152 is no
longer reverse-biased and provides a path for current from the +9
volt reference applied through resistor 150 to PWM input port via
line 118 which shuts off any signal being provided to PWM input
port 110 by conducting the +9 volt PWM voltage away from 108. As a
result, comparator 141, the +9 volt reference and diode 152
constitute means for providing a series of pulses as the PWM series
of pulses, each pulse having a width which is a function of the
output signal of summer 138. Comparator 141 also constitutes means
for selectively inhibiting +9 volt PWM voltage and for generating
the PWM series of pulses during the period that the sum is greater
than the reference voltage.
By discontinuing application of the +9 volt reference signal being
provided to PWM input port 110, the controlling bridge transistor
(i.e., the transistor of switches A, B and C which is, at that
moment, on and applying a voltage to the motor windings) is turned
off so that no voltage is applied to the windings of motor 102. The
is controlling transistor is latched off for the remainder of the
clock cycle (i.e., one oscillation of PWM generator 112) even
though output 14.4 of comparator 142 may go high during the cycle
and the reference voltage on line 118 is again provided to PWM
input port 110. The controlling transistor does not turn on again
during the remainder of clock oscillator cycle because port 110 of
IC 108 includes a latch (not shown) that is reset by the start of
each oscillator cycle. The latch does not allow the controlling
bridge transistor to become conductive until the end of the clock
cycle even though a +9 V signal may be applied again to PWM input
port 110 before the end of the cycle. In summary, whenever the
reference voltage applied to PWM input port 110 via line 118 is
interrupted by comparator 142, the controlling bridge transistor
which at that point is applying voltage to the motor windings is
turned off (becomes nonconductive) sad is latched off until the end
of the cycle of PWM generator 112 even though the reference voltage
may again be applied to PWM input port 110 via line 118 as a result
of the output of comparator 142 going high before the end of the
cycle. As soon as comparator 142 is switched low and the motor
voltage is discontinued, the motor current decreases considerably
before the end of oscillator cycle. When the latch is reset, the
motor current causes summer input 140 to add less negative voltage
making the summed voltage applied to comparator input 141 greater
than the 317 mv reference applied to comparator input 143. This
results in a signal being applied to input 110. This latching of
the PWM signal is described in U.S. Pat. Nos. 4,642,537
(particularly with respect to FIG. 6A) and 4,654,566 (particularly
with respect to FIG. 13). Both patents are incorporated herein by
reference.
Switches A, B, and C correspond to switches A, B, and C illustrated
in FIG. 4 of U.S. Pat. No. 4,500,821, incorporated herein by
reference. IC 108 corresponds to the motor control IC of that
patent Control and operation of the switches and the IC is
described therein and, particularly, in columns 9, 10 and 11 of the
patent.
In a typical furnace, natural convection of the hot exhaust causes
it to rise and vent to the atmosphere. In order to improve the
efficiency and fuel economy, the heat is extracted from the exhaust
furnace by, for example, by heat exchanger 150. If heat is
extracted from this exhaust, then additional pressure is needed to
force the cooled exhaust to vent to the atmosphere through the
exhaust outlet 122. This is accomplished by inducing a draft such
as by locating fan 114 in the exhaust outlet 122. A positive flue
pressure is developed by fan 124 which forces the furnace exhaust
from combustion chamber 120 through heat exchanger 150 where the
heat is extracted and the cooled exhaust air is then vented via
exhaust outlet 122. The cooled exhaust is provided to the
atmosphere at exhaust outlet port 128. As a result, the exhaust
temperature is low enough where a chimney is no longer needed and
an additional cost savings is provided.
The speed of fan 124 as driven by the rotor of motor 102 regulates
the air flow rate. In high efficiency systems, it is important to
achieve the proper amount of air mixed with fuel (e.g., natural
gas, oil) so that an optimum mum air-fuel mixture is constantly
being burned in combustion chamber 120. To achieve the appropriate
air-fuel mixture, combustion products must be exhausted at an
appropriate rate. Generally, these products do not rise up through
the exhaust outlet 122 because they are cold and create a pressure
in exhaust outlet 122. Pressure transducer 126 monitors the
pressure within exhaust outlet 122 and provides a signal via line
130 to microprocessor 104 representative thereof. Microprocessor
104 generates a series of control pulses via line 106 having a duty
cycle which is a function of the pressure thereby controlling the
duty cycle of motor 102 and the speed of fan 124 in response to the
pressure measured by pressure transducer 126. Depending on the
particular cycle within which the furnace is operating,
microprocessor 104 would compare the signal provided by transducer
126 via line 130 to a reference which would indicate a preselected
pressure limit for the particular cycle. When the signal provided
via line 130 indicates that the pressure within exhaust outlet 122
has exceeded the pressure limit, microprocessor 104 would turn on
or increase the duty cycle of the signal provided via line 106 to
DC level converter 134 in order to increase the torque (or speed)
of fan 124. This would increase the air flow rate through exhaust
outlet 122 so that the pressure within the exhaust outlet 122 would
decrease. When the pressure has decreased to a point below the
pressure limit, microprocessor 104 would provide turn off or reduce
the duty cycle of the signal provided via line 106 to DC level
converter 134 in order to stabilize or decrease the torque (or
speed) of fan 124.
Microprocessor 104 monitors the speed of fan 124 through the
tachometer signal provided via line 132. This permits
microprocessor 104 to increase or decrease the duty cycle of the
signal provided via line 106 depending upon the speed of the fan as
compared to a desired speed. Microprocessor 104, for example, may
include a storage memory programmed with a speed vs. torque profile
so that the relationship between speed and torque would be known
(or could be calculated) permitting microprocessor 104 to
determine, for a given desired torque, the corresponding speed.
Microprocessor 104 constitutes a motor control apparatus adapted to
control the motor by generating control pulses having a duty cycle
which is a function or a desired operating torque (depending on the
furnace cycle) and a function of the speed or the motor.
PWM generator 112 may be internal to IC 108 as illustrated herein
or may be external, discrete components associated with IC 108.
Alternatively, a voltage regulation controller according to the
invention may be employed as part of the control illustrated in
U.S. Pat. No. 4,500,821. For example, in FIG. 10A of that patent
illustrates an oscillator 147 including comparator (COM) 4 which
compares an oscillating (OSC) signal to a 1.8 volt reference (PWM
REF). In order to achieve voltage regulation control according to
the invention, a voltage varying as a function of the line voltage
would be applied to the inverting input or comparator 4 in place of
the 1.8 volt reference.
One embodiment of voltage regulator control (PWM generator) 112 is
illustrated in FIG. 1A. Voltage VDD applied to an oscillator
constituting resistor ROB and capacitor COS generates an
oscillating signal OSC having a sawtooth waveform as illustrated by
reference character 162. This waveform is applied to the
noninverting input of comparator 164. The inverting input of
comparator 164 receives voltage signal VOSREF which is a function
of the line voltage V applied to the motor windings divided by
resistors RO7 and RO9. At some point during the rise time of the
ramp of sawtooth waveform 162, the oscillating signal OSC is
greater .[.that.]. .Iadd.than .Iaddend.voltage signal VOSREF. As a
result, the output of comparator 164 is high which sets latch 166
to provide a high output at Q of latch 166 thereby setting latch
168 so that pulse width modulation is enabled and the output at Q
of latch 168 is high. When the output of latch 166 is high, analog
switch 169 closes and discharges COS. At some point during the fall
time of the sawtooth waveform, the oscillating signal OSC applied
to the inverting input of comparator 170 becomes less than the
internal reference (INTREF) applied to the noninverting input of
comparator 170. As a result, the output of comparator 170 is high
which resets latch 166 forcing it to provide a low output at Q of
latch 166. Therefore. latch 168 is forced to reset by the PWM
signal from comparator 206 so that pulse width modulation is
disabled and the output at Q of latch 168 is held low until latch
168 is set again. In the torque regulation mode. VREF is generally
always higher than OSC so that comparator 206 is always high.
Comparator 164 and divider RO7, RO9 constitutes means for comparing
the applied voltage V to a reference voltage OSC. Latches 166 and
168 constitute means, responsive to comparator 164, and divider
RO7, RO9 for increasing the duty cycle of the PWM series of pulses
when the applied voltage decreases and for decreasing the duty
cycle of the PWM series of pulses when the applied voltage
increases Latches 166 and 168 are responsive to the output signal
of comparator 164 and are adapted to inhibit the PWM series of
pulses during the period that the oscillating voltage signal OSC is
greater than the applied voltage V as sensed by divider RO7,
RO9.
Referring to FIG. 2, the electronic control circuit for IC 108 is
generally referred to by reference character 201 and constitutes
means for generating the PWM series of pulses to be applied to PWM
input port 110 having a duty cycle which is a function of the duty
cycle of the control pulses provided by microprocessor 104 via line
106. As a result, the operating speed of the motor 102 is a
function of the duty cycle of the control pulses provided by
microprocessor 104 via line 106 and is independent of variations in
the magnitude of the applied voltage.
Electronic control circuit 291 includes DC level converter 134 for
receiving the control pulses provided via line 106 by
microprocessor 104. The control pulses would generally have a
frequency in the range of 30-60 hertz. DC level converter 134
converts the control pulses into a signal having a positive voltage
which is a function of the duty cycle of the control pulses. This
positive voltage signal is applied to noninverting input 203 of
comparator 206. Therefore, comparator 206 comprises means for
comparing oscillating reference signal (d) and signal VREF
representing the duty cycle of the control pulses and providing an
output signal (e) in response thereto as the PWM series of pulses.
The inverting input 208 of summer 138 is provided with a positive
voltage signal (d) having a sawtooth waveform (see FIG. 7,
reference character 708) provided by sawtooth generator 243. The
sawtooth waveform (d) is provided to the inverting input 208 of
comparator and compared to the voltage representing the desired
duty cycle which is provided to the noninverting input 203 of
comparator 206. When the voltage of the sawtooth signal exceeds the
threshold voltage signal VREF representing the desired duty cycle,
the output of comparator 206 is pulled from high to low (i.e.,
grounded) and voltage regulation is shut down for the remainder of
the sawtooth oscillation cycle, i.e., when CO8 is discharged. This
interrupts the +9 volt reference voltage provided to PWM input port
110 so that no voltage is applied to the winding stage until the
next oscillator cycle and the voltage applied to input 203 is
greater than the sawtooth voltage signal applied to input 208.
In the voltage regulation mode, as illustrated in FIG. 2, a 634 mv
reference voltage is applied to input 140 of the summer as a
current limiter. This reference voltage is in place of dc level
corresponding to duty cycle applied to input 136 as shown in FIG.
1. When the negative voltage corresponding to the motor current
sensed by sensor 116 added to the 614 mv reference exceeds 330 mv,
output 144 of comparator goes low to interrupt the signal applied
to PWM input port 110 and discontinue application of the applied
voltage to the windings. Therefore, except in a current limiting
condition, the speed of fan 124 driven by motor 102 is regulated in
response to the control pulses provided by microprocessor 106 and,
as in the torque regulation mode of FIG. 1, independent of
variations in the applied voltage.
FIG. 3 illustrates the power supply circuitry of the motor. EMI
filter 302 is provided to minimize switching noise which may be
injected back into the 120 volt AC power being applied to pins 1-3
and 1-4. EMI filter 302 includes common mode inductor LO2 in
parallel with filter capacitors C23, C24, C25 and C26. The EMI
filtered power supply voltage is provided through thermal protector
304 to surge limiter RTO1 and then through diode bridge DO1, DO2,
DO2 and DO4 in parallel with electrolytic capacitor CO1 thereby
generating a 160 volt signal V required to drive the motor. The
diodes and capacitor CO1 function as high voltage DC filter 304.
Overcurrent sensor circuit 306 includes current shunt resistor RO3
which provides shunt voltage S representing the motor current. This
shunt voltage is filtered by capacitor CO2 and resistor RO2. When
the shunt voltage exceeds the desired maximum set by RO3, the base
of transistor QO1 is turned on to generate an overcurrent voltage
signal OC applied to the lockoff port of IC 108 via resistor R17
and capacitor C10 (see FIG.
Low voltage power supply 308 includes transformer TO1 having a
primary connected through thermal protector 304 to applied voltage
V and a secondary in parallel with diode bridge DO5, D22, D23 and
D24 as filtered by capacitor CO3 to drive voltage regulator UOI for
providing a nine volt reference filtered by capacitor CO5 and also
to provide reference voltage VR1 filtered by capacitor CO4 which
represents one diode voltage drop.
FIG. 4 illustrates the isolation circuitry between microprocessor
104 and the speed and torque control circuit 500 and between
microprocessor 104 and the 108. Pin P1-4 is connected to
microprocessor 104 and receives the control pulses generated by
microprocessor 104 having a duty cycle representing the desired
speed or torque of the motor. The control pulses are provided to
light emitting diode 402d of isolator 402 which activates
transistor 402t to generate a representative voltage across
resistor R32 and divided by resistors R35 and R36 so that the
voltage is proportional to the control pulses. The time constant
defined by R35/C18 is on the order of 0.25 seconds to filter
ripples within the 50-200 Hz frequency range. This time constant
can be designed as desired and, preferably is 5 to 10 times the
period of the control pulses. This voltage is connected to the base
of current amplifying transistor (QO2 which has a nine volt
reference signal being applied to its collector. Accordingly, the
emitter of transistor QO2 provides a DC voltage signal between zero
and nine volts representative of the duty cycle between 0 and 100%
of the control pulses provided by microprocessor 104. Jumpers JO1
and J35 provide for a full torque range of 0 to 100%. If a maximum
torque range of less than 100% is desired, jumper JO1 may be
deleted and jumper JO2 inserted. The value of resistor R33 would
then be adjusted to correspond to the desired maximum. If a minimum
starting torque of more than 0 is desired, jumper J35 may be
deleted and jumpers JO3 or may be inserted. The value of resistor
R37 may then be adjusted to correspond to the desired minimum
jumper JO3 would correspond to a preset minimum, such as 50%,
depending, in part, on the values of R35 and R36.
Isolator 404 converts the commutation pulses provided by the COMPUL
output of IC 108 into a tachometer signal to be applied to
microprocessor 104. COMPUL output provides a signal representing
the summation of the commutation pulses provided by ports AT, BT
and CT (or AB, BB and CB) of IC 108. The base of transistor switch
Q15 is biased by a +9 volt signal applied via resistor RO5 and the
collector has a +9 volt reference being applied thereto. The
commutation pulses are added to the biasing voltage to turn switch
transistor Q15 on at each pulse activating LED 404d to turn to the
transistor 404t of isolator 404 which closes the circuit between
pins P1-1 and P1-2. Either of these pins may be provided with a
reference voltage from microprocessor 104 so that the other pin
provides a tachometer signal representative of the speed of the
motor. Isolator 404 constitutes means for providing a tachometer
signal representative of the motor speed to the motor control
apparatus i.e., microprocessor 104.
FIG. 5 illustrates one embodiment of a speed and torque control
circuit generally referred to by reference character 500 including
a selecting circuit 501 for selecting between speed control or
torque control. Control circuit 500 controls the operation of power
switches A,B,C which apply the motor voltage to the motor windings.
This control is accomplished by controlling the signal applied to
PWM input port 110 of IC 108 to control the average voltage applied
to the motor windings. First, the torque regulation mode will be
described followed by the speed regulation mode.
In the torque regulator mode, the motor current is limited to a
fixed level at all speeds where it would normally exceed that level
if full voltage were applied, to provide constant torque. In
particular, a voltage signal is provided to pin P1-2, such as by
microprocessor 104, indicating that torque regulation is desired.
This voltage signal activates isolator 504 which turns off
transistor 506 which causes switches 1 and 2 of switchbank 508 to
close.
This results in a nine volt signal being applied to resistor R10 of
motor voltage control circuit 510. This voltage is divided by
resistor R11, filtered by capacitor C29 and applied to the
noninverting input 512 of comparator 514. In the torque regulation
mode, this voltage signal applied to noninverting input 512 is
always greater than the fixed DC voltage applied to inverting input
516 (described below with regard to the speed regulation mode) so
that the output of comparator 514 is always high. This results in
the application of a +9 volt signal through resistor R12 to PWM
input port 110 of IC 108.
In the torque regulation mode, activation of switch bank 508 also
closes switch 2 which results in the emitter from transistor Q2
(FIG. 4) providing a DC voltage signal to resistor R24 of motor
current control circuit 518. The net voltage on input 520 results
from the voltage across resistor R24 divided by resistors R25 and
R26 minus voltage on shunt resistor RO3. As noted above with regard
to FIG. 4, this DC voltage signal has a magnitude which is a
function of the desired operating torque of the motor. This DC
voltage signal may be filtered by optional capacitor C12 and is
added to a negative voltage signal representing the motor current
provided by shunt S through resistor R25. In particular, the
voltage signal through resistor R25 is a function of the motor
current as sensed by shunt resistor RO3.
The sum of the positive current through resistor R24 and bias
resistor R26 and the negative current through resistor R25 provide
a voltage signal which is filtered by capacitors C13, C15 to
eliminate noise and provided to the noninverting input 520 of
comparator 522. A reference voltage is provided to the inverting
input 524 of comparator 522, This reference voltage is generated by
the nine volts applied to resistor R28 as divided by resistors R27
and R29 and filtered by capacitor C14. When the summed voltage
resulting from the current through R24 minus the shunt current
applied to noninverting input 520 is greater than the reference
voltage applied to inverting input 524, output 526 of the
comparator remains high and the +9 volt signal through resistor R12
is applied to PWM input port 110 of IC 108. In the event that the
summed voltage is less than the reference voltage, output port 526
of comparator 524 goes low and is grounded, As a result, diode DO7
is no longer reverse biased resulting in PWM input port 110 being
disabled (grounded) through comparator 522 and receiving no voltage
signal.
Switchbank 508 constitutes means for selecting the motor current or
the motor voltage as the control parameter. In the torque
regulation mode, motor current control circuit 518 comprises means
responsive to the motor current as the selected operating parameter
for generating a PWM series of pulses. In the speed regulation
mode, motor voltage control circuit 510 comprises means responsive
to the motor voltage as the selected operating parameter for
generating a PWM series of pulses.
Comparator 526 is pan of an automatic on/off circuit which
functions in both the torque and speed regulation modes.
Noninverting input 528 receives the DC voltage signal from the
emitter of transistor Q2 (FIG. 4). This voltage signal represents
the desired operating torque, or speed in the speed regulation
mode. This DC voltage signal is applied through resistor R13,
filtered by capacitor C30 and divided by resistors R14 and R15 so
that it is applied to the noninverting input 528, In contrast,
inverting input 530 receives a voltage signal VR1 generated by the
voltage divider network (FIG. 6) representing one diode voltage
drop. When the divided DC voltage signal from the emitter of
transistor Q2 representing the desired torque (or speed) is above
the divided VR1 reference voltage, output 532 of comparator 526
remains high so that a +9 volt signal is applied through resistor
R16 to the on/off input of IC 108 indicating that the IC should
remain on and activated. In the event that the divided DC voltage
signal representing the desired torque (or speed) falls below the
divided VRI reference voltage, output 532 of comparator 526 goes
low and is grounded thereby grounding the on/off input of IC 108
turning IC 108 off. Accordingly, comparator 526 functions to
prevent operation of IC 108 unless the signal representing desired
torque or speed is greater than a threshold value defined by the
VRI reference voltage
Comparator 532 is pan of a power-on reset circuit. Inverting input
524 receives voltage signal VR2 which represents two diode voltage
drops (1.2 volts) as generated by the voltage divider network (FIG.
63). Noninverting input 536 of comparator 532 is provided with a
reference voltage which is the low voltage supply less the zener
diode voltage drop across DO8. Comparator 532 enables on/off to go
high if the low voltage supply is higher than VR2 added to the
zener diode drop DO8.
Overcurrent voltage OC as filtered by capacitor C10 is applied
through resistor R17 and divided by resistor R18 to the lockoff
input (LOB) of IC 108. When overcurrent transistor switch QO1 (FIG.
3) is activated by an overcurrent condition, the lockoff input is
grounded to disable IC 108 until the motor current falls below the
threshold which deactivates transistor (QO1. For example, when the
motor current equals 1.2 amps, QO1 may be turned on to pull OC low
which prevents a voltage signal through resistor R18 from being
applied to the lockoff input LOB of IC 108 thereby shutting off IC
108 and the voltage applied to drive the motor windings.
Thereafter, the on/off input enables the LOB input to restart
driving the motor windings, i.e., if there is an overcurrent for IC
108 to reset and restart. The voltage applied through R18 pulls the
LOB input back up again (to high) when QO1 is deactivated and the
short it creates is cleared. Resistor R18 also serves an additional
start-up function. When power is first applied to IC 108, inputs
LOB and ON/OFF should go high simultaneously to avoid a logic
indication that there is an overcurrent trip.
In the speed regulation mode, voltage control provides a constant
speed feature in that the average DC voltage applied to the motor
is held constant by switching the current on and off for a fixed
period of time. In particular, isolator 504 is off so that only
switches 3 and 4 of switchbank 508 are closed. Closing switch 3
applies the DC voltage signal representing the desired torque from
the emitter of transistor Q2 to resistor R10 of the motor voltage
control circuit 510. In the speed regulation mode, this DC voltage
is divided by R11, filtered by capacitor C29 and applied to
noninverting input 512. The magnitude of this voltage may not
always be higher than the magnitude voltage applied to inverting
input 516 of comparator 514. In particular, the motor voltage V as
divided by resistors RO7 and RO9, which constitute a motor voltage
sensor, provides the reference voltage for the oscillator
consisting of capacitor CO8 and resistor RO8 which generate an
oscillating signal in combination with internal circuitry of IC
108. This results in a triangular waveform (i.e., a saw-tooth
signal) being applied to the inverting input 516 of comparator 514.
The sawtooth signal will rise to its peak (preferably 4 volts) and
reset upon discharge of capacitor CO8. The sawtooth signal is
compared by comparator 514 to the fixed DC level applied to input
512. When the sawtooth signal representing the motor voltage is
greater than the voltage signal representing the desired speed as
applied to inverting input 512, the output 513 of comparator 514
goes low grounding PWM input port 110 of IC 108 and discontinuing
further voltage application to the motor windings for the remainder
of the oscillating cycle. As long as the DC voltage representing
the desired operating speed is higher than the divided motor
voltage V, the output of comparator 514 remains high so that the
nine volt signal is applied via resistor R12 to PWM input port 110
of IC 108. Output 513 is applied to PWM input 110 of IC 108 to
control application of motor voltage V to the motor windings.
Output 513 will be high during the rise time of the sawtooth signal
(see FIG. 7, reference character 708) and will be low when the ramp
reaches the same value as the fixed DC level applied to input 512.
This provides PWM input 110 with a square wave having a duty cycle
which is a function of the duty cycle of the control pulses.
The oscillator reset (OSCRES) input of IC 108 (FIG. 3 controls the
discharge time of the sawtooth signal as defined by capacitor CO6.
The fixed DC level applied to input 512 is selected so that there
is always a fixed off time, i.e., a period of each cycle of
oscillation during which input 512 is greater than input 516 so
that output 513 is low and no motor voltage V is applied to the
windings. For example, during current limiting when the motor is
running at a desired speed, the current is limited by the back emf
generated in the motor windings. During this period the power
transistors of switches A,B,C should be off to prevent these
devices from being continuously on. A fixed duty cycle, such as
95%, may be selected at which point the current will be turned off
and the duty cycle of the control pulses would be limited to 95%,
This turn off for 5% of the oscillator period limits the maximum
torque.
In the speed regulation mode, switch 4 of switchbank 508 is closed
so that motor current control circuit has a nine volt signal
applied through resistor R24 to the noninverting input 520 of
comparator 522. The current through resistor R24, is summed with
the negative shunt current through resistor R35 to apply a signal
representing the maximum motor current to input 520. This applied
voltage is usually greater than the reference voltage applied to
inverting input 524 so that the output of comparator 522 is always
high. However, in the event that the motor current exceeds a
maximum which is a function of the reference voltage applied to
input such as in the overcurrent condition, the summed voltage
applied to noninverting input 520 may be less than the reference
voltage applied to inverting input 524 so that output 526 is low
thereby grounding PWM input 110. Accordingly, even though control
circuit 500 is in the speed regulation mode, maximum motor current
regulation may occur during speed regulation.
FIG. 6 illustrates the commutation circuitry. Switches 622, 623 and
624 are designed to respond to control signals supplied by IC 108
at pads AT, AB, BB, BT, CT and CB. The initial loners A, B and C
designate the winding stage of motor 102. The second letter "T"
denotes that "on" signals from the pads so designated on IC 108
will produce switch conduction to the 160 volt buss (T for top) in
relation to system ground potential. The second letter "B" denotes
that "on" signals from the pads so designated on the IC 108 will
produce switch conduction to system ground (B for bottom).
The circuit of switch 621, which controls the A winding of the
motor, is shown in FIG. 6. It comprises three bi-polar transistors
Q3, Q4 and Q5 which function to couple the winding A to the motor
voltage V when AT is high. A single FET QO6 functions to couple
that winding terminal to system ground when AB is high. A B and C
are each the same and only switch A is illustrated for
convenience.
Back emf position sensing from each of the windings is provided
through divider network 630 to the back emf sensing input ports VA,
VB and VC of IC 108. Position sensing is accomplished by
integrating the back emf signal of the motor windings once it is
divided down to a low level voltage by resistor network 630. At a
particular volt-see threshold, the appropriate power transistors of
switches A,B,C are gated on and off through a transconductance
amplifier, analog gates and a position counter which are integral
to IC 108 (see U.S. Pat. No. 4,500,821). Reference character 632
refers to an optional high frequency noise filter including
capacitors C19, C20, C21 and C22 and resisters R39, R40 and R41.
Capacitor C9 in conjunction with limiting zener diode DO6 defines
the integration interval of the back emf sensing which, in general,
depends upon number of poles in motor, number of turn is in motor
windings, inductance of motor windings and level of current through
motor winding.
For a complete description of the operation of the switches and IC
108, reference is made to coassigned U.S. Pat. No. 4,500,821,
incorporated herein by reference.
FIG. 7 illustrates various waveforms as labeled in FIGS. 1 and 2.
One oscillation period equals approximately 50 microseconds. This
corresponds to a frequency which is maintained at 20 KHz to avoid
audible noise. As shown by reference character 702, the shunt
current rises to a flat peak value and falls within the 50
microsecond period. The spike at the beginning of each cycle
results from the commutation current necessary to turn off flyback
diodes D15, D18, D21 and FET body diodes. The time between the flat
peak and the end of the 50 microsecond period is off time until the
logic of IC 108 is reset at the end of the oscillation period. If,
in the torque control mode, the motor current never reaches the 0.6
amp peak, pulse width modulation is never turned off. The flat peak
value of the motor current is defined by the value of shunt
resistor R3 (0.5 ohms) and the DC voltage signal provided to
resistor R24 of motor current control circuit 518 from the emitter
of transistor QO2. During each oscillation period, the motor
current provided via sensor 116 varies from a value of
approximately 0.6 raps to 0 amps depending on the point in time
within the period that the motor current exceeds the desired limit
corresponding to the desired torque.
The output (b) of summer 140 in the current regulation mode (FIG.
1) is illustrated by reference character 704 and varies between a
high of 634 millivolts and a low of 317 millivolts depending on the
difference between the sum of the desired motor current provided by
sensor 116 and the desired operating torque as represented by the
dc voltage provided via resistor R24. In the torque regulation
mode, output (b) of summer 140 varies according to the desired
operating torque and the motor current. In the voltage regulation
mode, output (b) varies according to the motor current only because
a constant 634 mv signal is applied to input 136 (see FIG. 2).
In the torque regulation mode, output 144 of comparator 142 varies
between ground and 7.3 volts. This sawtooth wavefore (c) by
referred to by reference character. 706. When the output 142 of
comparator 144 goes low, PWM input port 110 is grounded. When the
output 142 goes high, the voltage applied to PWM input port 110
ramps upward to 7.3 volts in a non-linear manner because of the
time required to charge capacitor C16.
As illustrated by reference character 708, the output (d) of
sawtooth generator 243 which is provided to the inverting input 516
of comparator 514 is defined by resistor RO8 and capacitor CO8 and
varies from a low of 120 millivolts at discharge of capacitor CO8
and ramping upward to a high of 3.62 volts as capacitor CO8
recharges. Reference character 710 illustrates the wavefore at
output 513 of comparator 514 as applied to PWM input port 110 in
the voltage regulation mode. This output vanes between zero and
eight volts and is zero during the portion of the oscillation
period when sawtooth signal 708 is greater than the signal
representing the desired speed as generated by conveyer 134.
Reference character 712 illustrates the waveform at PWM input port
110 in the voltage regulation mode when current limiting by
comparator 142 also occurs during the oscillation periods.
Generally, the voltage regulation occurs during the initial portion
of the oscillation period and dominates until the voltage threshold
is reached and the voltage regulation is shut down or until current
regulation occurs to discharge capacitor C16. Initially, during
oscillation period 714, voltage V is applied to the motor as
voltage regulation begins at point 716. At point 718, current
regulation occurs to discharge capacitor C16. Then, voltage
regulation again takes over as capacitor C16 recharges. Application
of voltage V to the motor is interrupted during zero period 720
when the voltage threshold is reached and voltage regulation is
shut down. During oscillation period 722, voltage regulation occurs
as capacitor recharges. However, at point 72A current regulation
occurs briefly to discharge C16 and for the remainder of period 722
the application of voltage V to the motor is interrupted because
the voltage threshold has been reached. During oscillation period
726, only voltage regulation occurs as capacitor C16 recharges. At
the end of period 726, the voltage regulation shuts down because
the voltage threshold is again reached. During oscillation period
728, voltage regulation occurs until point 730 when current
regulation partially discharges C16. Then, capacitor C16 recharges
under voltage regulation until point 732 when the voltage threshold
is again reached and the voltage regulation is shut down. Reference
characters 734 and 736 indicate points at which current regulation
discharges capacitor C16. Reference characters 738, 740, 742 and
744 indicate zero periods during which the voltage threshold is
reached and the voltage regulation is shut down.
In view of the above, it will be seen that the several objects of
the invention are achieved and other advantageous results
attained.
As various changes could be made in the above constructions without
departing from the scope of the invention, it is intended that all
matter contained in the above description or shown in the
accompanying drawings shall be interpreted as illustrative and not
in a limiting sense.
* * * * *