Controller for a motor and a method of controlling the motor

• US 20080095639A1
• Filed: 10/13/2006
• Published: 04/24/2008
• Est. Priority Date: 10/13/2006
• Status: Abandoned Application

• Current Assignee: Regal Beloit America, Inc. (Regal Rexnord Corp.)
• Original Assignee: A. O. Smith Corporation
• Inventors: Richardson, Howard, Bartos, Ronald P., Branecky, Brian Thomas
• Application Number:
  US11/549,499
• Publication Number:
  US 20080095639A1
• Time in Patent Office: Days
• US Class Current: 417/44.11
• CPC Class Codes: F04D 15/00 Control, e.g. regulation, of pumps, pumping installations or systems
• CPC Class Codes: F04D 15/0055 Rotors with adjustable blades
• CPC Class Codes: F04D 15/0066 by changing the speed, e.g. of the driving engine
• CPC Class Codes: F04D 15/0236 Lack of liquid level being detected by analysing the parameters of the electric drive, e.g. current or power consumption

Abstract

A pumping apparatus for a jetted-fluid system includes a pump having an inlet connectable to the drain, and an outlet connectable to the return. The pump is adapted to receive the fluid from the drain and jet fluid through the return. The pumping apparatus includes a motor coupled to the pump to operate the pump, a sensor connectable to the power source and configured to generate a signal having a relation to a parameter of the motor, and a switch coupled to the motor and configured to control at least a characteristic of the motor. The pumping apparatus also includes a microcontroller coupled to the sensor and the switch. The microcontroller is configured to generate a derivative value based on the signal, and to control the motor based on the derivative value.

Claims

1. A pumping apparatus for a jetted-fluid system comprising a vessel for holding a fluid, a drain, and a return, the pumping apparatus being connectable to a power source and comprising:

a pump including an inlet connectable to the drain, and an outlet connectable to the return, the pump adapted to receive the fluid from the drain and jet fluid through the return;

a motor coupled to the pump to operate the pump;

a sensor connectable to the power source and configured to generate a signal having a relation to a parameter of the motor;

a switch coupled to the motor and configured to control at least a characteristic of the motor; and

a microcontroller coupled to the sensor and the switch, the microcontroller configured to generate a derivative value based on the signal, and to control the motor based on the derivative value.

2. The pumping apparatus of claim 1, wherein the microcontroller is configured to calculate a value indicative of the parameter, and to generate the derivative value based on the value.

3. The pumping apparatus of claim 1, wherein the sensor includes a voltage sensor configured to generate a first signal having a relation to a voltage applied to the motor, and a current sensor configured to generate a second signal having a relation to a current applied to the motor, and wherein the microcontroller is configured to generate the derivative value based on the first signal and the second signal.

4. The pumping apparatus of claim 1, wherein the sensor includes a voltage sensor and a current sensor, the parameter includes a motor input power, and the derivative value includes a derivative value of the motor input power.

5. The pumping apparatus of claim 4 wherein the microcontroller is configured to determine the motor input power based on signals from the voltage and current sensors, and to determine the derivative value based on the motor input power.

6. The pumping apparatus of claim 1, wherein the parameter includes a motor torque, and the derivative value includes a derivative value of the motor torque.

7. The pumping apparatus of claim 1, wherein the parameter includes a motor power factor, and the derivative value includes a derivative value of the motor power factor.

8. The pumping apparatus of claim 1, wherein the microcontroller is further configured to monitor the derivative value,

determine whether the monitored derivative value indicates an undesired flow of fluid through the pump, and

control the motor to cease operation of the pump when the determination indicates an undesired flow of fluid through the pump and zero or more other conditions exist.

9. A pumping apparatus for a jetted-fluid system comprising a vessel for holding a fluid, a drain, and a return, the pumping apparatus being connectable to a power source and comprising:

a pump including an inlet connectable to the drain, and an outlet connectable to the return, the pump adapted to receive the fluid from the drain and jet fluid through the return;

a motor coupled to the pump to operate the pump;

a sensor coupled to the motor and configured to generate a signal having a relation to a power of the motor;

a switch coupled to the motor and configured to control at least a characteristic of the motor; and

a microcontroller coupled to the sensor and the relay circuit, the microcontroller configured to generate a derivative value of a parameter based on the signal, and to control the motor based on the derivative value.

10. The pumping apparatus of claim 9, wherein the microcontroller is configured to calculate a value indicative of the parameter, and to generate the derivative value based on the value.

11. The pumping apparatus of claim 9, wherein the sensor includes a voltage sensor configured to generate a first signal having a relation to a voltage applied to the motor, and a current sensor configured to generate a second signal having a relation to a current applied to the motor, and wherein the microcontroller is configured to generate the derivative value based on the first signal and the second signal.

12. The pumping apparatus of claim 9, wherein the sensor includes a voltage sensor and a current sensor, the parameter includes a motor input power, and the derivative value includes a derivative value of the motor input power.

13. The pumping apparatus of claim 12 wherein the microcontroller is configured to determine the motor input power based on signals from the voltage and current sensors, and to determine the derivative value based on the motor input power.

14. The pumping apparatus of claim 9, wherein the microcontroller is further configured to monitor the derivative value,

determine whether the monitored derivative value indicates an undesired flow of fluid through the pump, and

control the motor to cease operation of the pump when the determination indicates an undesired flow of fluid through the pump and zero or more other conditions exist.

15. A method of controlling a motor operating a pumping apparatus of a fluid-pumping application, the pumping apparatus comprising a pump having an inlet to receive a fluid and an outlet to exhaust the fluid, and the motor coupled to the pump to operate the pump, the method comprising:

sensing a motor current;

sensing a motor voltage;

obtaining a derivative value of the motor power based on the sensed voltage and the sensed current;

determining whether the derivative value indicates a condition of the pump; and

controlling the motor to operate the pump based on the condition of the pump.

16. The method of claim 15, further comprising obtaining a power value of the motor power based on the sensed voltage and the sensed current.

17. The method of claim 15, wherein the condition of the pump is an undesired flow of fluid through the pump.

18. The method of claim 15, wherein the pumping apparatus further comprises a voltage sensor and a current sensor, wherein sensing a motor voltage comprises sensing a voltage applied to the motor with the voltage sensor, and wherein sensing a motor current comprises sensing a current through the motor with the current sensor.

19. A pumping apparatus for a jetted-fluid system comprising a vessel for holding a fluid, a drain, and a return, the pumping apparatus being connectable to a power source and comprising:

a pump including an inlet connectable to the drain, and an outlet connectable to the return, the pump adapted to receive the fluid from the drain and jet fluid through the return;

a motor coupled to the pump to operate the pump;

a sensor connectable to the power source and configured to generate a signal having a relation to a parameter of the motor;

a switch coupled to the motor and configured to control at least a characteristic of the motor; and

a derivative device coupled to the sensor and the switch, the derivative device configured to generate a derivative value based on the signal to control the motor based on the derivative value.

20. The pumping apparatus of claim 20, wherein the derivative device includes an operational amplifier circuit.

21. The pumping apparatus of claim 20, wherein the sensor includes a voltage sensor configured to generate a first signal having a relation to a voltage applied to the motor, and a current sensor configured to generate a second signal having a relation to a current applied to the motor, and wherein the derivative device is configured to generate the derivative value based on the first signal and the second signal.

22. The pumping apparatus of claim 20, wherein the sensor includes a voltage sensor and a current sensor, the parameter includes a motor input power, and the derivative value includes a derivative value of the motor input power.

23. The pumping apparatus of claim 20, wherein the parameter includes a motor torque, and the derivative value includes a derivative value of the motor torque.

24. The pumping apparatus of claim 20, wherein the parameter includes a motor power factor, and the derivative value includes a derivative value of the motor power factor.

25. A pumping apparatus for a jetted-fluid system comprising a vessel for holding a fluid, a drain, and a return, the pumping apparatus being connectable to a power source and comprising:

a pump comprising an inlet connectable to the drain, and an outlet connectable to the return, the pump adapted to receive the fluid from the drain and jet fluid through the return;

a motor coupled to the pump to operate the pump;

a sensor configured to generate a signal having a relation to a parameter of the motor;

a switch coupled to the motor and configured to control a characteristic of the motor; and

a microcontroller coupled to the sensor and the switch, the microcontroller configured to generate a value based on the signal, the value having a relation to the motor torque, and to control the motor based on the value.

26. The pumping apparatus of claim 25, wherein the sensor is connectable to the power source.

27. The pumping apparatus of claim 25, wherein the sensor is coupled to the motor.

28. The pumping apparatus of claim 25, wherein the sensor includes a current sensor configured to generate a signal related to the current of the motor.

29. The pumping apparatus of claim 26, and further comprising a second sensor configured to generate a signal indicative of the speed of the motor.

30. The pumping apparatus of claim 26, wherein the microcontroller is further configured to determine the speed of the motor, and wherein the value has a further relation to the speed of the motor.

31. The pumping apparatus of claim 27, wherein the microcontroller is further configured to determine a relationship between the speed of the motor and the signal related to the current of the motor to calculate the value.

32. The pumping apparatus of claim 25, wherein the microcontroller is further configured to monitor the value,

determine whether the monitored value indicates an undesired flow of fluid through the pump, and

control the motor to cease operation of the pump when the determination indicates an undesired flow of fluid through the pump and zero or more other conditions exist.

33. A method of controlling a motor operating a pumping apparatus of a jetted fluid system comprising a vessel for holding a fluid, a drain, and a return, the pumping apparatus comprising a pump having an inlet connectable to the drain, and an outlet connectable to the return, the pump adapted to receive the fluid from the drain and jet fluid through the return, and the motor coupled to the pump to operate the pump, the method comprising:

controlling the motor to operate the pump;

sensing a current of the motor;

calculating a torque of the motor based on the sensed current;

determining whether the torque indicates a condition of the pump; and

further controlling the motor to operate the pump based on the condition of the pump.

34. The method of claim 33, wherein monitoring the operation of the pump further comprises

sensing a voltage applied to the motor;

determining a speed value related to the motor; and

wherein the calculating a torque is further based on the speed value.

35. The method of claim 33, further comprising

sensing a speed of the motor;

and

wherein the calculating a torque is further based on the sensed speed.

36. The method of claim 33, further comprising

calculating a value indicative of input power to the motor;

and

determining a linear relationship between the torque and the input power to the motor.