Portable motor drive system

• US 10,003,293 B2
• Filed: 03/15/2013
• Issued: 06/19/2018
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Andrew John Bartlik, Jr., Charles Thomas Mclees
• Original Assignee: Jr., Charles Thomas Mclees
• Inventors: Bartlik, Andrew John, McLees, Jr., Charles Thomas
• Primary Examiner(s): Ro, Bentsu
• Assistant Examiner(s): JOSEPH, DEVON A
• Application Number:
  US13/841,766
• Publication Number:
  US 20140265946A1
• Time in Patent Office: 1,922 Days
• Field of Search: 318701, 318802, 320116, 324429
• CPC Class Codes: H02P 23/0004 Control strategies in general, e.g. linear type, e.g. P, PI, PID, using robust control
• CPC Class Codes: H02P 27/04 using variable-frequency supply voltage, e.g. inverter or converter supply voltage

Abstract

Systems and methods for driving a motor are provided. One implementation of a drive system comprises a user interface, a variable speed drive, and a controller. The user interface enables a user to select an operating frequency set point and an operating voltage set point. The operating frequency set point is selected from a range of frequency set points and the operating voltage set point is selected from a range of voltage set points. The variable speed drive is configured to drive a motor at the selected operating frequency set point and selected operating voltage set point. The controller is configured to receive input from the user interface and control the operating frequency and operating voltage of the variable speed drive.

Claims

1. A drive system for operating a valve in an emergency situation, the drive system comprising:

a portable housing;

a user interface configured to receive at least one user input;

a memory configured to store at least one operating frequency and at least one operating voltage for driving a valve motor of a valve, the valve motor and valve external to the portable housing;

a controller disposed within the portable housing, the controller configured to receive the at least one user input from the user interface and retrieve the at least one operating frequency and at least one operating voltage from the memory based on the received at least one user input;

a variable speed drive disposed within the portable housing, the variable speed drive configured to drive the valve motor for operating the valve, wherein the controller is configured to control the variable speed drive to drive the valve motor at the at least one operating frequency and at least one operating voltage, and

a power supply disposed within the portable housing, the power supply providing power to the variable speed drive, wherein the power supply is a hybrid system including a battery pack having a high energy-to-weight ratio and at least one capacitor having a high power-to-weight ratio, wherein the battery pack is configured to supply power at a first power level and the at least one capacitor is configured to supply power at a second power level,

wherein the controller is configured to control the power supply to supply power to the variable speed drive to drive the valve motor for operating the valve.

2. The drive system of claim 1, wherein the controller is contained in the variable speed drive.

3. The drive system of claim 1, wherein the controller is further configured to monitor the output current of the variable speed drive to determine torque imposed on the valve.

4. The drive system of claim 3, wherein the controller is configured to control the power supply to shut off power to the variable speed drive when a predetermined output current, indicative of a desired torque, is detected.

5. The drive system of claim 4, wherein the power supply shuts off power without the assistance of a torque switch.

6. The drive system of claim 1, wherein the controller is further configured to maintain the variable speed drive at the at least one operating frequency and at least one operating voltage until a forward stroke set point or reverse stroke set point of the valve motor is reached.

7. The drive system of claim 1, wherein the controller is further configured to control the variable speed drive to seat or unseat the valve during an intentional hammer blow mode, wherein the valve motor includes a rotor and the valve includes a drive, the rotor engaging the drive to turn the valve, and during the intentional hammer blow mode the controller selectively controls the operating frequency and operating voltage that the variable speed drive drives the valve motor with to cause the rotor of the valve motor to accelerate toward and impact the drive of the valve from an unloaded position one or more times.

8. The drive system of claim 1, wherein the power supply includes a plurality of capacitors that are charged by the battery pack during a charging mode.

9. The drive system of claim 8, further comprising:

a pre-charge contact configured to switchably couple the battery pack to the plurality of capacitors during the charging mode; and

a capacitor switching contact configured to switchably couple the plurality of capacitors to the variable speed drive during a seating/unseating mode.

10. The drive system of claim 9, further comprising a current sensing device configured to switchably uncouple the plurality of capacitors from the variable speed drive when an increase in current is detected during the seating/unseating mode.

11. The drive system of claim 8, wherein the battery pack is configured to charge the capacitors when the capacitors are in parallel, and wherein the capacitors are configured to provide power to the variable speed drive when the capacitors are in series.

12. The drive system of claim 11, further comprising:

a first set of switches configured to connect the capacitors in parallel when the capacitors are being charged;

a second set of switches configured to connect the capacitors in series when the capacitors provide power to the variable speed drive.

13. The drive system of claim 1, wherein the user interface receives at least one second user input associated with at least one second operating frequency and at least one second operating voltage and the controller is configured to control the variable speed drive to drive the valve motor at the at least one second operating frequency and at least one second operating voltage based on the at least one second user input.

14. The drive system of claim 1, wherein the controller is configured to control the power supply to supply power to the variable speed drive at the first power level to operate the selected valve during normal operation and to control the power supply to supply power to the variable speed drive at the second power level to seat or unseat the selected valve, the second power level being higher than the first power level.

15. The drive system of claim 1, wherein the battery pack supplies power at the first power level for a longer time than the at least one capacitor supplies power at the second power level.

16. The drive system of claim 1, wherein the portable housing comprises a first module that houses the user interface, controller, and variable speed drive and a second module that houses the power supply.

17. The drive system of claim 1, wherein the valve is designed to operate with a torque switch, and wherein the at least one operating frequency and at least one operating voltage corresponds to preprogrammed torque limits of the valve to enable the variable speed drive to operate the valve without a torque switch.

18. The drive system of claim 1, wherein the at least one operating frequency and at least one operating voltage are reduced with respect to conventional operating levels to prevent damage to the selected valve.

19. The drive system of claim 1, wherein the drive system is configured to be utilized as a temporary motor control device during an emergency situation when conventional motor controller systems are inoperable, and wherein the weight of the drive system enables a human to handle the drive system for temporary replacement of the inoperable motor controller systems.

20. A drive system for operating a valve in an emergency situation, the drive system comprising:

a portable housing;

a user interface at least partially disposed within the portable housing, the user interface enabling a user to select a valve from a plurality of valves, each of the plurality of valves being external to the portable housing and configured to control the flow of a fluid;

a memory configured to store respective operating frequencies and operating voltages corresponding to each of the plurality of valves;

a controller disposed within the portable housing, the controller configured to receive input from the user interface regarding a selected valve, the controller further configured to retrieve an operating frequency and an operating voltage corresponding to the selected valve from the memory based on the received input; and

a variable speed drive disposed within the portable housing, the variable speed drive configured to drive a valve motor for operating the selected valve, the valve motor external to the portable housing, wherein the controller is configured to control the variable speed drive to drive the valve motor at the operating frequency and operating voltage of the selected valve;

a power supply disposed within the portable housing, the power supply providing power to the variable speed drive, wherein the power supply is a hybrid system including a battery pack having a high energy-to-weight ratio and at least one capacitor having a high power-to-weight ratio, wherein the battery pack is configured to supply power at a first power level and the at least one capacitor is configured to supply power at a second power level,

wherein the controller is configured to control the power supply to supply power to the variable speed drive to drive the valve motor for operating the valve.