Systems and methods for sensing a line powering an electric motor

• US 10,008,968 B2
• Filed: 01/29/2015
• Issued: 06/26/2018
• Est. Priority Date: 01/29/2015
• Status: Active Grant

• Current Assignee: Regal Beloit America, Inc. (Regal Rexnord Corp.)
• Original Assignee: Regal Beloit America, Inc. (Regal Rexnord Corp.)
• Inventors: Nardin, Steven Albert, Koller, Michael R.
• Primary Examiner(s): Santana, Eduardo Colon
• Assistant Examiner(s): Mustafa, Iftekhar
• Application Number:
  US14/609,040
• Publication Number:
  US 20160226422A1
• Time in Patent Office: 1,244 Days
• Field of Search: 3184003, 31840038, 31856816, 318787, 31840024, 318708, 307104, 307413
• CPC Class Codes: H02P 27/06 using dc to ac converters or inverters H02P27/05 takes precedence

Abstract

A system includes an electric motor controller configured to be coupled to an electric motor is provided. The controller includes a first power input, a second power input, and a third power input, each of the first, second, and third power inputs are configured to receive power from an alternating current (AC) power source. The controller also includes a microcontroller configured to generate a radio frequency (RF) signal in each of the first, second, and third power inputs. The controller further includes an RF based line sensing device configured to sense which one of said first, second, and third power inputs has received power from the AC power source based on the RF signal.

Claims

1. An electric motor controller configured to be coupled to an electric motor, said controller comprising:

a first power input connector, a second power input connector, and a third power input connector, each of said first, second, and third power input connectors configured to receive power from an alternating current (AC) power source, wherein only one of said first, second, and third power input connectors is energized at a time;

a radio frequency (RF) based line sensing device coupled to at least said first and second power input connectors and configured to generate a sensing device signal when one of said at least said first and second power input connectors is energized by the AC power source, wherein the sensing device signal is based on an RF signal generated in said first, second, and third power input connectors; and

a microcontroller configured to;

generate the RF signal in said first, second, and third power input connectors while one of said first, second, and third power input connectors is energized; and

determine which of said first, second, and third power input connectors is energized based at least in part on whether the sensing device signal is received by said microcontroller.

2. A controller in accordance with claim 1, wherein said microcontroller is configured to toggle an oscillator above a predetermined rate of speed such that the RF signal appears to be conducted through said first, second, and third power input connectors.

3. A controller in accordance with claim 2, wherein said oscillator comprises one of dedicated hardware located within said microcontroller and motor windings of the electric motor.

4. A controller in accordance with claim 2, wherein said RF based line sensing device comprises a first sensor coupled to said first power input connector and a second sensor coupled to said second power input connector.

5. A controller in accordance with claim 4, wherein one of said first and second sensors is configured to output a voltage level when the one of said first and second sensors is energized.

6. A controller in accordance with claim 4, wherein said third power input connector is sensorless, said microcontroller determines that said third power input connector is energized when the RF signal is produced and no signal is sensed by said first and second sensors.

7. A controller in accordance with claim 1, wherein said microcontroller is configured to:

operate the electric motor at a lowest speed when power is received;

monitor harmonics existing on said first, second, and third power input connectors, the harmonics internally generated by the electric motor; and

sense which of said first, second, and third power input connectors is energized based on the monitored harmonics.

8. A controller in accordance with claim 1, wherein said RF based line sensing device further comprises an RF generator coupled to said first, second, and third power input connectors, wherein each of said first, second, and third power input connectors has a different frequency and an energized one of said first, second, and third power input connectors excites said RF generator.

9. A controller in accordance with claim 8, wherein said microcontroller further comprises a receiver configured to detect the frequency being generated and determine which power input connector is energized.

10. A controller in accordance with claim 1, further comprising:

a rectifier for rectifying the power received from the AC power source to a direct current (DC) power; and

an inverter for inverting the rectified power to three-phase power for operating the electric motor.

11. A method of sensing a line powering an electric motor, said method comprising:

providing a first power input connector, a second power input connector, and a third power input connector, each of the first, second, and third power input connectors configured to receive power from an alternating current (AC) power source, wherein only one of the first, second, and third power input connectors is energized at a time;

generating, by a microcontroller, a radio frequency (RF) signal in each of the first, second, and third power input connectors while one of said first, second, and third power input connectors is energized;

generating, using a RF based line sensing device coupled to at least the first and second power input connectors, a sensing device signal when one of the at least first and second power input connectors is energized by the AC power source, wherein the sensing device is based on the RF signal generated in the first, second, and third power input connectors; and

determining, by the microcontroller, which one of the first, second, and third power input connectors is energized based at least in part on whether the sensing device signal is received by the microcontroller.

12. A method in accordance with claim 11, further comprising toggling an oscillator above a predetermined rate of speed such that the RF signal appears to be conducted through the first, second, and third power input connectors.

13. A method in accordance with claim 11, wherein sensing which one of the first, second, and third power input connectors has received power from the AC power source further comprises:

providing a first sensor coupled to the first power connector and a second sensor coupled to the second power connector; and

outputting, by one of the first and second sensors, a voltage level when the one of the first and second sensors is energized.

14. A method in accordance with claim 13, further comprising:

providing a sensorless third power input connector; and

determining that the third power input connector is energized when the RF signal is generated and no signal is sensed by the first and second sensors.

15. A method in accordance with claim 11, further comprising:

operating the electric motor at a lowest speed when power is received;

monitoring harmonics existing on said first, second, and third power input connectors, the harmonics internally generated by the electric motor; and

sensing the energized power input connector based on the monitored harmonics.

16. An electric motor controller configured to be coupled to an electric motor, said controller comprising:

a first power input connector, a second power input connector, and a third power input connector, each of said first, second, and third power input connectors configured to receive power from an alternating current (AC) power source, wherein only one of said first, second, and third power input connectors is energized at a time;

a radio frequency (RF) based line sensing device configured to generate a signal based on harmonics measured on at least one of said first, second, and third power input connectors; and

a microcontroller configured to;

operate the electric motor at a lowest speed when power is received on at least one of said first, second, and third power input connectors;

receive the signal from said RF based line sensing device including measured harmonics on at least one of said first, second, and third power input connectors, the harmonics internally generated by the electric motor; and

determine which of said first, second, and third power input connectors is energized based on the measured harmonics.

17. An electric motor controller configured to be coupled to an electric motor, said controller comprising:

a first power input connector, a second power input connector, and a third power input connector, each of said first, second, and third power connectors configured to receive power from an alternating current (AC) power source;

a radio frequency (RF) based line sensing device coupled to said first and second power input connectors and configured to generate a signal when one of said first and second power input connectors is energized by the AC power source based on an RF signal generated in said first, second, and third power input connectors, wherein said RF based line sensing device comprises a first sensor coupled to said first power input connector and a second sensor coupled to said second power input connector; and

a microcontroller configured to;

toggle an oscillator above a predetermined rate of speed such that the RF signal appears to be conducted through said first, second, and third power input connectors to generate the RF signal in said first, second, and third power input connectors; and

determine which of said first, second, and third power input connectors is energized based at least in part on whether the signal is received from said RF based line sensing device.