Methods and systems for recording operating information of an electric motor

• US 10,447,193 B2
• Filed: 08/23/2018
• Issued: 10/15/2019
• Est. Priority Date: 03/09/2007
• Status: Expired due to Fees

• Current Assignee: Regal Beloit America, Inc. (Regal Rexnord Corp.)
• Original Assignee: Regal Beloit America, Inc. (Regal Rexnord Corp.)
• Inventors: Beifus, Brian L., Selking, Paul Nathanael, Gurudasani, Vijay Dayaldas, Koller, Michael R.
• Primary Examiner(s): Paul, Antony M
• Application Number:
  US16/110,229
• Publication Number:
  US 20180367081A1
• Time in Patent Office: 418 Days
• Field of Search: 318565, 31840021, 3185681, 31840001, 31840012, 31840032, 318727, 318782, 318783, 318799, 318515, 318543, 31840022, 318490, 318700, 388904, 388909, 388934, 361 22, 361 23, 361 56, 361 88, 361 90, 361 911, 361111, 361272, 361534, 361 30, 363 5605, 363 5608, 363 5607, 363 5612
• CPC Class Codes: G05B 2219/23193 Memory stores lifetime, different settings, configurations of controlled device
• CPC Class Codes: G05B 2219/24053 Diagnostic of controlled machine
• CPC Class Codes: G05B 2219/24067 Processor stores variables, events and date in eeprom, for external monitor
• CPC Class Codes: G05B 23/0264 Control of logging system, e.g. decision on which data to store; time-stamping measurements
• CPC Class Codes: H02P 29/02 Providing protection against overload without automatic interruption of supply protection against faults of stepper motors H02P8/36
• CPC Class Codes: H02P 29/024 Detecting a fault condition, e.g. short circuit, locked rotor, open circuit or loss of load
• CPC Class Codes: H02P 29/0241 the fault being an overvoltage
• CPC Class Codes: H02P 6/06 Arrangements for speed regulation of a single motor wherein the motor speed is measured and compared with a given physical value so as to adjust the motor speed
• CPC Class Codes: H02P 6/34 Modelling or simulation for control purposes

Abstract

A unit for recording operating information of an electronically commutated motor (ECM) is described. The unit includes a system controller communicatively coupled to an ECM. The system controller includes a processing device configured to control the unit. The unit also includes a memory device communicatively coupled to the system controller. The memory device is configured to receive and store ECM operating information provided by the processing device.

Claims

1. A system comprising:

a motor controller communicatively coupled to an electric motor, said motor controller comprising;

a processing device configured to;

control the electric motor;

collect operating information from the electric motor during operation of the electric motor;

temporarily store the operating information; and

identify a motor controller failure; and

a memory device communicatively coupled to said processing device, said memory device configured to receive and store the operating information collected during operation of the electric motor upon said processing device identifying the motor controller failure; and

a computing device communicatively coupled to said motor controller, said computing device configured to communicate with said motor controller to receive the stored operating information for display to a user.

2. The system according to claim 1, wherein said motor controller further comprises a communications interface operable to process communications between said processing device and said computing device.

3. The system according to claim 2, wherein said communications interface comprises a wireless transceiver operable to transmit and receive wireless communications to and from said computing device.

4. The system according to claim 2, wherein said communications interface comprises a data connector operable to receive a cable connected to said computing device such that a direct physical connection is formed.

5. The system according to claim 2, wherein said communications interface comprises a network connector operable to communicatively couple said motor controller to a network.

6. The system according to claim 1, wherein when said processing device identifies a motor controller failure, said memory device is further configured to receive and store the operating information for a predefined time period prior to the motor controller failure.

7. The system according to claim 1, wherein said memory device is further configured to store at least one of motor controller parameter information, electric motor information, and external system controller information for use by a successive motor controller after the motor controller failure is identified.

8. The system according to claim 1, wherein said motor controller further comprises a voltage protection circuit coupled to said memory device, said voltage protection circuit configured to prevent high-voltage damage to said memory device.

9. The system according to claim 8, wherein said voltage protection circuit comprises one or more signal diodes that limit a terminal voltage at said memory device to a predefined voltage.

10. The system according to claim 1, wherein the operating information comprises at least one of production process information, scratch-pad information, a total length of time said electric motor receives power, a total length of time said electric motor has run, a total length of time said electric motor has operated in a cutback region, a total length of time said electric motor has operated with a temperature above a thermal limit setting, a total number of cycles said electric motor has completed, a high operating temperature, a low operating temperature, a final operating torque level, a final operating bus voltage, a last operating speed, a last module temperature, a count of fault events, a count of reset cycles, a count of oscillator stop events, and a count of stall events.

11. The system according to claim 1, wherein said processing device is further configured to:

overwrite the stored operating information at least once; and

upon identifying the motor controller failure, suspend overwriting of the stored operating information.

12. The system according to claim 11, wherein said processing device is further configured to periodically overwrite the stored operating information.

19. The method according to claim 11, further comprising:

overwriting, by the processing device, the stored operating information at least once; and

upon identifying the motor controller failure, suspend overwriting of the stored operating information.

20. The method according to claim 19 wherein overwriting the stored operating information at least once comprises periodically overwriting the stored operating information.

13. A method of recording operating information of a motor, said method comprising:

collecting, by a processing device of a motor controller communicatively coupled to the motor, operating information of the motor during motor operation;

temporarily storing, by the processing device, the operating information;

identifying, by the processing device, a motor controller failure;

storing, by a memory device communicatively coupled to the processing device, the operating information collected by the processing device upon the identifying of the motor controller failure; and

transmitting, by the processing device, the operating information to a computing device communicatively coupled to the motor controller for display to a user.

14. The method according to claim 13, wherein transmitting the operating information comprises wirelessly transmitting the operating information to the computing device.

15. The method according to claim 13, further comprising receiving and storing, by the memory device, the operating information for a predefined time period prior to the motor controller failure.

16. The method according to claim 13, further comprising storing, by the memory device, at least one of motor controller parameter information, electric motor information, and external system controller information for use by a successive motor controller after the motor controller failure is identified.

17. The method according to claim 13, further comprising preventing high-voltage damage to the memory device using a voltage protection circuit coupled to the memory device.

18. The method according to claim 13, further comprising storing, by the memory device, identification and tracking information for one or more additional electric motors that have been coupled to the motor controller.