Portable motor drive system

• US 10,476,422 B2
• Filed: 06/18/2018
• Issued: 11/12/2019
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Andrew John Bartlik, Jr., Charles Thomas Mclees
• Original Assignee: Andrew John Bartlik, Jr., Charles Thomas Mclees
• Inventors: Bartlik, Andrew John, McLees, Jr., Charles Thomas
• Primary Examiner(s): Dhakal, Bickey
• Assistant Examiner(s): Joseph, Devon A
• Application Number:
  US16/011,180
• Publication Number:
  US 20180302016A1
• Time in Patent Office: 512 Days
• 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, the drive system comprising:

a controller;

a variable speed drive configured to drive a valve motor, the controller is configured to control the variable speed drive to selectively drive the valve motor at an operating frequency and an operating voltage to spin a rotor of the valve motor such that the rotor engages the valve to operate the valve;

wherein, the valve motor and valve are configured such that the rotor can spin from an unloaded position a predetermined number of degrees without engaging the valve, the unloaded position being a position where the rotor is not engaging the valve;

wherein, during a hammer blow mode, the controller selectively controls the variable speed drive to cause the rotor of the valve motor to spin in a first direction until a predetermined condition is satisfied and an unloaded position is achieved, and, after the predetermined condition is satisfied, the controller controls the variable speed drive to cause the rotor to accelerate in a second direction to create an impact when the rotor engages the valve and to start the valve moving; and

a power supply for providing power to the variable speed drive.

2. The drive system of claim 1, wherein the predetermined condition is satisfied if the controller senses an increase in current outputted by the variable speed drive.

3. The drive system of claim 1, wherein the predetermined condition is satisfied after the controller instructs the variable speed drive to spin the rotor a predetermined number of revolutions in the first direction.

4. 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 and 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, such that the assistance of a torque switch is not required.

5. 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 a 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 a second power level to seat or unseat the selected valve, the second power level being higher than the first power level.

6. The drive system of claim 1, wherein the valve is designed to operate with a torque switch and the controller is configured to limit the voltage outputted by the variable speed drive to limit the torque imposed on the valve without the use of a torque switch.

7. The drive system of claim 1, wherein, during the hammer blow mode, the controller selectively controls the variable speed drive to cause the rotor to engage and impact the valve from an unloaded position multiple times.

8. The drive system of claim 1, wherein, during the hammer blow mode, the controller monitors the angular speed of the rotor as the rotor accelerates in the second direction and, if the angular speed reaches a set point, the controller controls the variable speed drive to stop accelerating the rotor and maintain the angular speed.

14. The drive system of claim 3, wherein the at least one capacitor includes a plurality of capacitors and the battery is configured to charge the plurality of 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.

15. The drive system of claim 14, wherein the power supply includes a first set of switches configured to connect the plurality of capacitors in parallel when the plurality of capacitors are being charged and a second set of switches configured to connect the plurality of capacitors in series when the plurality of capacitors provide power to the variable speed drive.

9. A drive system for operating a valve, the drive system comprising:

a controller;

a variable speed drive configured to drive a valve motor, wherein the controller is configured to control the variable speed drive to drive the valve motor at an operating frequency and an operating voltage for operating the valve;

a power supply including a battery and at least one capacitor, the controller configured to selectively control the battery and the at least one capacitor for supplying power to the variable speed drive, wherein the battery is configured to provide a first level of power, the first level of power being less than a second level of power required to operate the valve throughout a valve stroke, such that the weight of the power supply is reduced with respect to a second power supply including a second battery configured to provide the second level of power; and

a portable housing, wherein the controller, the variable speed drive, and the power supply are disposed within the portable housing.

10. The drive system of claim 9, wherein the battery has a high energy-to-weight-ratio and the at least one capacitor has a high power-to-weight ratio and the battery is configured to supply power at the level of power and the at least one capacitor is configured to supply power at a third level of power.

11. The drive system of claim 10, wherein the controller is configured to control the power supply to supply power to the variable speed drive at the first level of power 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 level of power to seat or unseat the selected valve, the second level of power being higher than the first level of power.

12. The drive system of claim 9, wherein the power supply is configured such that only the at least one capacitor is used to supply power to the variable speed drive for operating the valve and the battery is used to charge the at least one capacitor.

13. The drive system of claim 9, wherein the power supply includes a pre-charge circuit configured to charge the at least one capacitor from the battery.

16. The drive system of claim 9, wherein, during an initial operation of the variable speed drive, the battery is used to power the variable speed drive and, thereafter, the at least one capacitor is switched in to power the variable speed drive instead of the battery based on one of a detected increase in current and a detected decrease in voltage.

17. The drive system of claim 16, wherein, while the at least one capacitor is switched in to power the variable speed drive, if the voltage of the at least one capacitor drops, the battery is configured to contribute to the available current used to power the variable speed drive.

18. The drive system of claim 9, wherein the first level of power is the power required to stroke the valve when a valve disc of the valve is not in contact with a seat of the valve and the at least one capacitor is configured to provide a third level of power required to torque the valve closed.

19. The drive system of claim 18, wherein the controller is further configured to maintain the variable speed drive at the operative frequency and operative voltage until a forward stroke set point or reverse stroke set point of the valve motor is reached.

20. A drive system for operating a valve, the drive system comprising:

a controller;

a variable speed drive configured to drive a valve motor, the controller is configured to control the variable speed drive to selectively drive the valve motor at an operating frequency and an operating voltage to spin a set of ears of the valve motor such that the set of ears of the valve motor engage a set of ears of the valve for operating the valve;

wherein, the valve motor and valve are configured such that the set of ears of the valve motor can spin from an unloaded position a predetermined number of degrees without engaging the set of ears of the valve, the unloaded position being a position where the set of ears of the valve motor are not engaging the set of ears of the valve;

wherein, during a hammer blow mode, the controller selectively controls the variable speed drive to cause the set of ears of the valve motor to spin in a first direction until a predetermined condition is satisfied and an unloaded position is achieved, and, after the predetermined condition is satisfied, the controller controls the variable speed drive to cause the set of ears of the valve motor to accelerate in a forward direction until the set of ears of the valve motor impact the set of ears of the valve to start the valve moving; and

a power supply for providing power to the variable speed drive.