Apparatus for accommodating inductive flyback in pulsed motor windings

• US 4,574,225 A
• Filed: 08/06/1984
• Issued: 03/04/1986
• Est. Priority Date: 08/06/1984
• Status: Expired due to Fees

• Current Assignee: Pacific Scientific Company Incorporated (Regal Rexnord Corp.)
• Original Assignee: Pacific Scientific Company Incorporated (Regal Rexnord Corp.)
• Inventors: Pershall, Arthur A., Holling, George H.
• Primary Examiner(s): Shoop, Jr., William M.
• Assistant Examiner(s): Ro, Bentsu
• Application Number:
  US06/637,850
• Time in Patent Office: 575 Days
• Field of Search: 318/138, 318/254, 318/254 A, 318/439, 318/685, 318/696, 318/345 R, 318/345 C, 318/345 CA, 318/345 AB, 318/345 B, 318/345 D, 318/345 G, 318/701
• US Class Current: 318/400.26
• CPC Class Codes: H02P 6/12 Monitoring commutation; Providing indication of commutation failure

Abstract

Control circuits for operating electric motors of the class having windings pulsed in sequence and a magnetic field, the class being exemplified by brushless d.c. motors. Improved apparatus is provided for accommodating flyback action when excitation current through any one of the windings is interrupted by the opening of a switch device (e.g., on-off controlled transistor), whether that device be a sequence power switch or a main switch having a common series relation to all of the power switches and operated with an adjustable duty cycle so as to permit adjustment of motor speed and torque. The flyback apparatus, as here disclosed, provides low loss flyback current paths so as to return inductively stored energy back into the winding when its excitation is interrupted, thereby to enhance motor efficiency while eliminating high open circuit voltages across the switching devices. Negative torque which might be created in the flyback circuits as a result of back e.m.f. in a winding is precluded by threshold circuit elements or by timed control of the conductive and non-conductive states of the flyback current paths.

Claims

1. In a d.c. motor having a magnetic field multipole rotor and plurality of stator phase windings with switching means to sequentially connect the windings to a d.c. voltage source as the rotor turns through successive angular regions, a flyback circuit associated with at least one of said windings and comprising, in combination

(a) means constituting a normally non-conductive current flow path in parallel with the winding, said means including an element which, when enabled, makes said path conductive with substantally negligible opposition to current flow,

(b) means responsive to the voltage across said winding for setting said element into an enabled state when said voltage (i) is of the polarity created by inductive flyback action and (ii) exceeds a predetermined threshold magnitude, and

(c) means for restoring said element to its disabled state, after it has been enabled, when current flow therethrough falls essentially to a predetermined low value.

2. The combination set out in claim 1 further characterized in that said predetermined low value is zero.

3. The combination set out in claim 1 further characterized in that said predetermined threshold magnitude is greater than the largest amplitude of back e.m.f. induced in the winding during operation of the motor within the range of speeds for which it is designed and specified.

4. The combination set out in claim 1 further characterized in that said means (b) includes a sensing circuit connected across the winding to sense the winding voltage, said sensing circuit including, in series,

(1) a unidirectionally conductive device poled to prevent sensing circuit current when the winding voltage is of a polarity opposite to that created by inductive flyback,

(2) means creating a bias voltage which opposes forward current flow through said unidirectionally conductive device, and

(3) means responsive to current flow through said device (1) and said means (2) for producing a signal which sets said element into an enabled state.

5. The combination defined by claim 4 wherein said unidirectionally conductive device (1) is a diode,

said means (2) is a Zener diode poled oppositely to said diode, and

said means (3) is a circuit element which produces a voltage drop thereacross as a result of current flow therethrough, said voltage drop constituting said signal.

6. The combination set forth in claim 1 further characterized in that said element is a normally non-conductive electrical device capable of being triggered into an enabled, conductive state in response to a momentary triggering pulse and which reverts automatically to a disabled, non-conductive state when current flow therethrough falls essentially to zero;

said element thereby including and constituting said means (c).

7. The combination set forth in claim 6 further characterized in that said element is a silicon controlled rectifier (SCR).

8. The combination set forth in claim 1 further characterized in that

said means (a) is a TSCO device,

said means (b) is a series combination of a diode, a Zener diode, and a resistance connected across the winding, with a coupling from said resistance to trigger said TSCO, and

said means (c) is constituted by said TSCO device.

9. The combination set forth in claim 8 wherein said TSCO device is an SCR.

10. A flyback accommodating circuit for use in association with a stator winding of a d.c. motor having a multiple magnetic field rotor and a plurality of stator windings, each stator winding having switch means for periodically applying thereto a d.c. source voltage, said flyback circuit comprising, in combination

(a) a normally disabled, non-conductive element connected across the winding, said element when enabled being conductive with substantially negligible opposition to current flow,

(b) means responsive to the voltage across the winding for setting said element into an enabled state when such voltage (i) is of the polarity created by inductive flyback action and (ii) exceeds a predetermined threshold magnitude, and

(c) means for restoring said element to its disabled state, after it has been enabled, when current flow therethrough falls essentially to a predetermined low value.

11. The combination set out in claim 10 further characterized in that said predetermined low value is zero.

12. The combination set out in claim 10 further characterized in that said predetermined threshold magnitude is greater than the largest amplitude of back e.m.f. induced in the winding during operation of the motor within the range of speeds for which it is designed and specified.

13. The combination set out in claim 10 further characterized in that said means (b) includes a sensing circuit connected across the winding to sense the winding voltage, said sensing circuit including in series

(1) a unidirectionally conductive device poled to prevent sensing circuit current when the winding voltage is of a polarity opposite to that created by inductive flyback,

(2) means creating a bias voltage which opposes forward current flow through said unidirectionally conductive device, and

(3) means responsive to current flow through said device (1) and said means (2) for producing a signal which sets said element into an enabled state.

14. The combination defined by claim 13 wherein

said unidirectionally conductive device (1) is a diode,

said means (2) is a Zener diode poled oppositely to said diode, and

said means (3) is a circuit element which produces a voltage drop thereacross as a result of current flow therethrough, said voltage drop constituting said signal.

15. The combination set forth claim 10 further characterized in that said element is a normally non-conductive electrical device capable of being triggered into an enabled, conductive state in response to a momentary triggering pulse and which reverts automatically to a disabled, non-conductive state when current flow therethrough falls essentially to zero;

said element thereby including and constituting said means (c).

16. The combination set forth in claim 15 further characterized in that said element is a silicon controlled rectifier (SCR).

17. The combination set forth in claim 10 further characterized in that

said element (a) is a TSCO device,

said means (b) is a series combination of a diode, a Zener diode, and a resistance connected across the winding, with a coupling from said resistance to trigger said TSCO, and

said means (c) is constituted by said TSCO device.

18. The combination set forth in claim 17 wherein said TSCO device is an SCR.

19. In a d.c. motor having a permanent magnetic field rotor and a plurality of stator windings, with switch means for connecting said windings in sequence to a d.c. source voltage as the rotor turns through successive angular regions, the improvement in flyback accommodation which comprises, in association with each given winding

(a) a TSCO device connected in parallel with the given winding,

(b) a sensing circuit connected across the given winding to sense the winding voltage, said sensing circuit including in series

(1) a unidirectionally conductive device poled to prevent sensing circuit current when the winding voltage is of a polarity opposite to that created by inductive flyback,

(2) means creating a bias voltage which opposes forward current flow through said unidirectionally conductive device, and

(3) means responsive to current flow through said unidirectionally conductive device (1) and said means (2) for producing and applying a triggering signal to said TSCO device when the voltage across the given winding (i) is of the polarity created by flyback action and (ii) exceeds in magnitude said bias voltage.

20. The improvement defined in claim 19 further characterized in that said means (2) creates a bias voltage which is at least greater in magnitude that the peak amplitude of the back e.m.f. induced in the given winding during normal usage of the motor within the intended range of operating speeds.

21. The improvement defined in claim 19 wherein said TSCO device is an SCR.

22. The improvement defined in claim 19 wherein said means (2) is a Zener diode.

23. The improvement defined in claim 19 wherein said means (3) is a resistance.

24. In a control circuit for a d.c. motor having a multipole magnetic field rotor and a plurality of stator phase windings, the combination comprising

(a) a plurality of power switches, each respectively in series with one of said phase windings to form a series leg,

(b) a main switch,

(c) means connecting said series legs in a parallel array, and the parallel array in series with said main switch between first and second terminals adapted for connection to a d.c. voltage source,

(d) control means for closing said power switches in staggered sequence as the rotor turns through successive angular regions,

(e) control means for closing and opening said main switch with a selected duty cycle and at a frequency which is greater than the frequency at which said power switches are closed, and

(f) a plurality of flyback accommodating circuits each respectively associated with one of said windings, each of said flyback circuits including

(f1) means constituting a normally non-conductive current flow path in parallel with the winding, said means including an element which, when enabled, makes said path conductive with substantially negligible opposition to current flow,

(f2) means responsive to voltage across said winding for setting said element into an enabled state when such voltage (i) is of the polarity created by inductive flyback action and (ii) exceeds a predetermined threshold magnitude, and

(f3) means for restoring said element to its disabled state, after it has been enabled, when current flow therethrough falls essentially to a predetermined low value

whereby said element carries flyback current and returns energy to the winding after current flow through the winding from the d.c. voltage source is interrupted by the opening of either the main switch or the associated power switch.

25. The combination set forth in claim 24 further characterized by and including a diode connected across said parallel array and poled to conduct flyback current through any of said windings when curent flow through a given winding from the d.c. voltage source is interrupted by the opening of the main switch, said element thus conducting flyback current when interruption occurs due to opening of the power switch associated with the given winding.

26. The combination set out in claim 24 further characterized in that said predetermined low value is zero.

27. The combination set out in claim 24 characterized in that said predetermined threshold magnitude for said means (f2) is greater than the largest amplitude of back e.m.f. induced in said winding during operation of the motor within the range of speeds for which it is designed and specified.

28. The combination set out in claim 24 further characterized in that said means (f2) includes a sensing circuit connected across the winding to sense the winding voltage, said sensing circuit including, in series,

(1) a unidirectionally conductive device poled to prevent sensing circuit current when the winding voltage is of a polarity opposite to that created by inductive flyback,

(2) means creating a bias voltage which opposes forward current flow through said unidirectionally conductive device, and

(3) means responsive to current flow through said device (1) and said means (2) for producing a signal which sets said element into an enabled state.

29. The combination defined by claim 28 wherein said unidirectionally conductive device (1) is a diode,

said means (2) is a Zener diode poled oppositely to said diode, and

said means (3) is a circuit element which produces a voltage drop thereacross as a result of current flow therethrough, said voltage drop constituting said signal.

30. The combination set forth in claim 24 further characterized in that said element is a normally non-conductive electrical device capable of being triggered into an enabled, conductive state in response to a momentary triggering pulse and which reverts automatically to a disabled, non-conductive state when current flow therethrough falls essentially to zero;

said element thereby including and constituting said means (f3).

31. The combination set forth in claim 30 further characterized in that said element is a silicon controlled rectifier (SCR).

32. The combination set forth in claim 24 further characterized in that

said means (f1) is a TSCO device,

said means (f2) is a series combination of a diode, a Zener diode, and a resistance connected across the winding, with a coupling from said resistance to trigger said TSCO, and

said means (f3) is constituted by said TSCO device.

33. The combination set forth in claim 32 wherein said TSCO device is an SCR.