Motor controller and methods of monitoring motor status

• US 10,191,482 B1
• Filed: 07/19/2017
• Issued: 01/29/2019
• Est. Priority Date: 07/19/2017
• Status: Active Grant

• Current Assignee: Regal Beloit America, Inc.
• Original Assignee: Regal Beloit America, Inc.
• Inventors: Li, Ming, Becerra, Roger Carlos, Chretien, Ludovic Andre, Beifus, Brian Lee, Stephens, Ryan Keith, Manz, Lester Benjamin, Wagley, John Sheldon
• Primary Examiner(s): Paul, Antony M
• Application Number:
  US15/654,078
• Publication Number:
  US 20190025808A1
• Time in Patent Office: 559 Days
• CPC Class Codes: G01R 31/343 in operation
• CPC Class Codes: G05B 2219/13 Plc programming
• CPC Class Codes: G05B 23/0264 Control of logging system, e.g. decision on which data to store; time-stamping measurements
• CPC Class Codes: H02K 11/33 Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 3/26 consisting of printed conductors
• CPC Class Codes: H02K 3/28 Layout of windings or of connections between windings windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32
• CPC Class Codes: H02K 5/225 Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132
• CPC Class Codes: H02P 1/00 Arrangements for starting electric motors or dynamo-electric converters starting of synchronous motors with electronic commutators except reluctance motors, H02P6/20, H02P6/22; starting dynamo-electric motors rotating step by step H02P8/04; vector control H02P21/00
• CPC Class Codes: H02P 23/0077 Characterised by the use of a particular software algorithm
• CPC Class Codes: H02P 31/00 Arrangements for regulating or controlling electric motors not provided for in groups H02P1/00 - H02P5/00, H02P7/00 or H02P21/00 - H02P29/00

Abstract

A motor controller for controlling an electric motor includes at least one integrated sensor disposed on the electric motor. The least one integrated sensor is configured to collect sensor data associated with a status of the electric motor for a period of time, the period of time beginning at an activation time and extending at least until an installation time. The motor controller may include an energy management system configured to power the at least one integrated sensor for at least a portion of the period of time, and a memory device configured to store the sensor data. The motor controller may include a data management system configured to communicate the sensor data from the at least one integrated sensor to at least one of the memory device and a remote device.

Claims

1. A motor controller for controlling an electric motor, said motor controller comprising:

at least one integrated sensor disposed on the electric motor, said at least one integrated sensor configured to collect sensor data associated with a status of the electric motor for a period of time, the period of time beginning at an activation time and extending at least until an installation time, wherein the activation time is a time at which the energy management system is activated to power said at least one integrated sensor;

an energy management system configured to power said at least one integrated sensor for at least a portion of the period of time; and

a memory device configured to store the sensor data.

2. The motor controller of claim 1 further comprising a data management system configured to communicate the sensor data from said at least one integrated sensor to at least one of said memory device and a remote component in communication with said data management system.

3. A motor controller for controlling an electric motor, said motor controller comprising:

at least one integrated sensor configured to collect sensor data associated with a status of the electric motor for a period of time, the period of time beginning at an activation time and extending at least until an installation time, wherein the activation time is a time at which an energy management system is activated to power said at least one integrated sensor;

a memory device configured to store the sensor data; and

a data management system configured to communicate the sensor data from said at least one integrated sensor to at least one of said memory device and a remote component in communication with said data management system.

4. The motor controller of claim 3, wherein said data management system is activated in response to an interrogation signal from the remote component.

5. The motor controller of claim 3 further comprising an energy management system configured to power said at least one integrated sensor for at least a portion of the period of time.

6. The motor controller of claim 5, wherein said energy management system is further configured to power said data management system for at least a portion of the period of time.

7. The motor controller of claim 3, wherein said data management system comprises an antenna.

8. A method of monitoring a status of an electric motor, said method comprising:

installing at least one integrated sensor in a motor controller configured to control the electric motor;

activating, at an activation time, an energy management system to power the at least one integrated sensor to collect sensor data associated with the status of the electric motor for a period of time, the period of time beginning at the activation time and extending at least until an installation time;

operating the electric motor using an external power source at the installation time, said operating deactivating the energy management system; and

storing the sensor data at a memory device in the motor controller.

9. A motor controller for controlling an electric motor, said motor controller comprising:

at least one integrated sensor disposed on the electric motor, said at least one integrated sensor configured to collect sensor data associated with a status of the electric motor for a period of time, the period of time beginning at an activation time and extending at least until an installation time, wherein the sensor data includes at least one status event and a timestamp respectively associated with each at least one status event;

an energy management system configured to power said at least one integrated sensor for at least a portion of the period of time; and

a memory device configured to store the sensor data.

10. The motor controller of claim 9, wherein the timestamp is relative to the activation time.

11. A motor controller for controlling an electric motor, said motor controller comprising:

at least one integrated sensor disposed on the electric motor, said at least one integrated sensor configured to collect sensor data associated with a status of the electric motor for a period of time, the period of time beginning at an activation time and extending at least until an installation time, wherein said at least one integrated sensor comprises at least one of an accelerometer, a temperature sensor, a humidity sensor, and a location sensor, wherein the sensor data includes at least one status event and a timestamp respectively associated with each at least one status event;

an energy management system configured to power said at least one integrated sensor for at least a portion of the period of time; and

a memory device configured to store the sensor data.

12. The motor controller of claim 11, wherein said at least one integrated sensor comprises said accelerometer, wherein one status event includes an impact event, and wherein the timestamp includes a time at which impact event occurred relative to the activation time.

13. The motor controller of claim 12, wherein the impact event includes an amplitude of an acceleration sensed by said accelerometer when the amplitude is above a threshold.

14. The motor controller of claim 11, wherein said at least one integrated sensor comprises said temperature sensor configured to collect at least one temperature reading when a temperature sensed by said temperature sensor is above a threshold, and wherein the sensor data includes the at least one temperature reading.

15. A motor controller for controlling an electric motor, said motor controller comprising:

at least one integrated sensor disposed on the electric motor, said at least one integrated sensor configured to collect sensor data associated with a status of the electric motor for a period of time, the period of time beginning at an activation time and extending at least until an installation time, wherein said at least one integrated sensor comprises said humidity sensor configured to collect at least one humidity reading when a humidity sensed by said humidity sensor is above a threshold, and wherein the sensor data includes the at least one humidity reading;

an energy management system configured to power said at least one integrated sensor for at least a portion of the period of time; and

a memory device configured to store the sensor data.

16. A motor controller for controlling an electric motor, said motor controller comprising:

at least one integrated sensor disposed on the electric motor, said at least one integrated sensor configured to collect sensor data associated with a status of the electric motor for a period of time, the period of time beginning at an activation time and extending at least until an installation time;

an energy management system configured to power said at least one integrated sensor for at least a portion of the period of time, wherein said energy management system comprises an energy storage component and a control circuit configured to manage energy output from said energy storage component and monitor a lifetime of said energy storage component; and

a memory device configured to store the sensor data.

17. The motor controller of claim 16, wherein said energy management system is configured to power said at least one integrated sensor until the installation time.