Motor drive system and method

• US 10,090,878 B2
• Filed: 08/28/2014
• Issued: 10/02/2018
• Est. Priority Date: 09/05/2013
• Status: Active Grant

• Current Assignee: Franklin Electric Company Incorporated (EBW, Inc.)
• Original Assignee: Franklin Electric Company Incorporated (EBW, Inc.)
• Inventors: Emshwiller, Greg A., Halsey, Richard J., Hawkins, Christopher J., Lynn, Douglas C., Smith, Robert C., Waite, Ross E., Spreen, James H.
• Primary Examiner(s): Duda, Rina
• Assistant Examiner(s): Joseph, Devon
• Application Number:
  US14/916,995
• Publication Number:
  US 20160197640A1
• Time in Patent Office: 1,496 Days
• Field of Search: 318727
• CPC Class Codes: G08C 17/02 using a radio link
• CPC Class Codes: H02P 25/02 characterised by the kind of motor
• CPC Class Codes: H04B 1/40 Circuits

Abstract

A system and a method for driving an electrical motor with a drive unit including a wireless transceiver. A user may wirelessly couple a user input device with the transceiver, and use a drive application to, optionally, update configuration information including drive control parameters, update application logic residing in the drive unit, and/or upload performance parameters.

Claims

1. A system comprising:

a drive unit adapted to drive a motor coupled to a load, the drive unit including a processing device, a wireless transceiver, and a non-transitory machine readable medium having embedded therein processing instructions configured to perform a method when executed by the processing device, the drive unit further comprising a main board and an expendable external signal input board removably connected to the main board, the expendable external signal input board including a signal conductor and a primary surge protection device configured to ground the signal conductor upon detection of a voltage of the signal conductor exceeding a predetermined voltage to protect the main board, the method including;

receiving a selection, with a drive application installed in a portable user device, of a configuration information including a motor identifier and a system application;

wirelessly receiving, by the wireless transceiver, the configuration information; and

configuring, by the processing device, the drive unit based on the configuration information.

2. A system as in claim 1, the method further comprising operating the motor, determining performance parameters, comparing the performance parameters to control parameters associated with the system application and the motor identifier, and verifying a correct configuration of the drive unit based on the comparing.

8. A system as in claim 1, wherein the drive unit includes life extension logic configured to control at least one of a cooling apparatus and a power consumption of the drive unit to maintain a temperature of the drive unit within a preselected temperature range.

9. A system as in claim 8, wherein the life extension logic includes a fold-back algorithm configured to cause the processing device to fold-back a speed of the motor to reduce power consumption.

10. A system as in claim 1, wherein the drive unit is configurable in two or more operating modes including one of a life extension mode and an efficiency mode, wherein the configuration information includes an operating mode selection to configure the drive unit in one of the operating modes.

3. A system comprising:

a drive unit adapted to drive a motor coupled to a load, the drive unit including;

a main board; and

an expendable external signal input board removably connected to the main board, the expendable external signal input board including a signal conductor and a primary surge protection device configured to ground the signal conductor upon detection of a voltage of the signal conductor exceeding a predetermined voltage to protect the main board.

4. A system as in claim 3, the main board including a protected ground trace, the expendable external signal input board including an expendable ground trace removably connected to the protected ground trace and configured to cease conducting current flowing from the grounded signal conductor before the current damages the protected ground trace.

5. A system as in claim 4, the protected ground trace having a current capacity that exceeds a current capacity of the expendable ground trace.

6. A system as in claim 3, the primary surge protection device comprising a gas discharge tube.

7. A system as in claim 3, the main board further comprising application logic and a flux fringing filter adjacent the application logic, the flux fringing filter comprising three open-core inductors arranged in a triangular topology to cancel stray flux, with the cores of the open-core inductors extending substantially perpendicularly from the main board.

11. A method for controlling a motor coupled to a load for use in an application, the method comprising:

driving the motor with a drive unit including a wireless transceiver and a processing device;

receiving a selection, with a drive application installed in a portable user device, of a configuration information including a motor identifier and a system application;

by the wireless transceiver, wirelessly receiving the selection of the configuration information including the system application and the motor identifier, wherein the system application includes predetermined procedures to drive the motor according to the application; and

by the processing device, configuring the drive unit based on the configuration information.

12. A method as in claim 11, further comprising:

downloading a logic update into a user input device;

downloading the logic update from the user input device to the drive unit; and

updating an application logic of the drive unit with the logic update.

13. A method as in claim 11, the configuration information including drive control parameters, further comprising updating application logic of the drive unit with the drive control parameters.

14. A method as in claim 11, further comprising:

operating the motor, determining performance parameters, comparing the performance parameters to control parameters associated with the system application and the motor identifier, and verifying a correct configuration of the drive unit based on the comparing.

15. A method as in claim 11, further comprising controlling at least one of a cooling apparatus and a power consumption to maintain a temperature of the drive unit within a preselected temperature range.

16. A method as in claim 15, wherein controlling power consumption comprises, by the processing device, folding-back a speed of the motor to reduce power consumption if the temperature exceeds the preselected temperature range.

22. The method of claim 11, wherein the application is selected from a water pressure control application, a water level control application, a deliquification application, a water irrigation application, a waste water treatment application, a well extraction application, a coal bed methane extraction application, or a coal seam gas well extraction application.

17. A method comprising:

driving a motor coupled to a load with a drive unit including a wireless transceiver and a processing device;

receiving a selection, with a drive application installed in a portable user device, of a configuration information including a motor identifier and a system application;

by the wireless transceiver, wirelessly receiving the configuration information; and

by the processing device, configuring the drive unit based on the configuration information, wherein the drive unit comprises a main board and an expendable external signal input board including a primary surge protection device, the method further comprising;

upon sensing a voltage of an input signal greater than a predetermined voltage, the primary surge protection device grounding the input signal;

determining that the expendable ground trace is damaged; and

replacing the expendable external signal input board without replacing the main board.

18. A method as in claim 17, wherein the main board has a protected ground trace having a current capacity and the expendable external signal input board includes an expendable ground trace having a current capacity which is less than the current capacity of the protected ground trace.

19. A system configurable for use in an application of a motor coupled to a load, the system comprising:

a drive unit adapted to drive the motor, the drive unit including a processing device, a wireless transceiver, and a non-transitory machine readable medium having embedded therein processing instructions configured to perform a method when executed by the processing device, the method including;

receiving a selection, with a drive application installed in a portable user device, of a configuration information including a motor identifier and a system application;

by the wireless transceiver, wirelessly receiving the configuration information, wherein the system application includes predetermined procedures to drive the motor according to the system application; and

by the processing device, configuring the drive unit based on the system application and the motor identifier.

20. The system of claim 19, the method further comprising operating the motor, determining performance parameters, comparing the performance parameters to control parameters associated with the system application and the motor identifier, and verifying a correct configuration of the drive unit based on the comparing.

21. The system of claim 19, wherein the application is selected from a water pressure control application, a water level control application, a deliquification application, a water irrigation application, a waste water treatment application, a well extraction application, a coal bed methane extraction application, or a coal seam gas well extraction application.