Spikeless motor starting circuit

• US 5,017,853 A
• Filed: 02/27/1990
• Issued: 05/21/1991
• Est. Priority Date: 02/27/1990
• Status: Expired due to Term

• Current Assignee: Rexnord Corporation
• Original Assignee: Rexnord Corporation
• Inventors: Chmiel, Steven F.
• Primary Examiner(s): Shoop, Jr., William M.
• Assistant Examiner(s): Cabeca, John W.
• Application Number:
  US07/485,952
• Time in Patent Office: 448 Days
• Field of Search: 318/751, 318/752, 318/778, 318/779, 318/780, 318/781, 318/785, 318/786, 318/787, 318/792, 318/793, 318/794, 318/795, 318/796, 318/817
• US Class Current: 318/786
• CPC Class Codes: H02P 1/445 by using additional capacitors switched at start up

Abstract

A capacitor-start capacitor-run single phase AC induction motor control starting circuit is provided which minimizes first cycle current spiking magnitude, and also minimizes cycle to cycle current spiking magnitude, without a choke or inductor in the loop containing the run capacitor, start capacitor and start switch. The first cycle current spiking problem is solved by controlling when the start switch may be turned on at initiation of the starting mode in relation to the AC cycle, to permit turn-on of the start switch only within a known or predictable range of voltage differential between the run and start capacitors. The cycle to cycle current spiking problem is solved by proper phasing of gate current, and supplying gate current to the start switch in phase with the voltage across the run capacitor and out of phase with the current through the series connected start switch and start capacitor.

Claims

1. In a capacitor-start capacitor-run single phase AC induction motor having a main winding and an auxiliary winding both connected to an AC power source, a run capacitor for providing a phase shifted field for starting and running torque, a start capacitor for providing a phase shifted field for starting torque, a start switch for automatically connecting and disconnecting said start capacitor to and from said AC source in starting and running modes, respectively, said run capacitor and said start capacitor being connected in parallel in said starting mode such that during the first cycle of said AC source upon initiation of said starting mode there is an equalization of capacitor voltages and an exchange of current between said run and start capacitors resulting in current flow through a loop including said run and start capacitors and said start switch, which current flow may reach a high peak current spike if there is a large magnitude voltage differential between said run and start capacitors, an inhibit switch responsive to said magnitude of said voltage differential between said run and start capacitors and preventing said start switch from connecting said start capacitor to said AC source until said magnitude drops below a given maximum level, to reduce said first cycle current spike, and reduce damage to and extend the life of said start switch and said start capacitor.

2. The invention according to claim 1 wherein said start switch comprises a semiconductor power switch conductive during said starting mode and nonconductive during said running mode, said power switch having a gate circuit for controlling conduction of said power switch, said inhibit switch comprises a light responsive element in said gate circuit, said gate circuit being connected through said light responsive element to said loop containing said run and start capacitors to derive gate current therefrom for gating said power switch as controlled by said light responsive element, a control circuit providing starting and running mode signals and including a light emitting element optically coupled to said light responsive element for supplying light thereto such that conduction of said light responsive element is controlled by said light emitting element when the voltage across said light responsive element is below a predetermined value, and such that when the voltage across said light responsive element is above said predetermined value said light responsive element prevents gate current flow to said power switch to prevent conduction of said power switch and prevent connection of said start capacitor to said AC source regardless of the condition of said light emitting element.

3. The invention according to claim 2 wherein each of said run capacitor, said start capacitor, and said light responsive element has first and second terminals, said second terminals of said run and start capacitors are coupled to each other at a common node, said second terminal of said light responsive element is coupled to said first terminal of said start capacitor, said first terminal of said light responsive element is coupled to said first terminal of said run capacitor, to sense voltage differential between said run and start capacitors.

4. The invention according to claim 3 comprising a first resistor connecting said second terminal of said light responsive element to said first terminal of said start capacitor, and a second resistor connecting said second terminal of said light responsive element to said second terminal of said start capacitor.

5. The invention according to claim 3 wherein said first terminal of said start capacitor is coupled through a voltage divider to said second terminal of said light responsive element, said voltage divider comprising first and second resistors each having first and second terminals, said first terminal of said first resistor being connected to said first terminal of said start capacitor, said second terminal of said first resistor and said first terminal of said second resistor being connected to each other at a second node, which second node is connected to said second terminal of said light responsive element, said second terminal of said second resistor being connected to said first mentioned node common to said second terminals of said run and start capacitors, said power switch has a first main terminal connected to said first terminal of said run capacitor, said power switch has a second main terminal connected to a third node between said first terminal of said start capacitor and said first terminal of said first resistor, said power switch has a gate terminal connected to said first terminal of said light responsive element.

6. In a capacitor-start capacitor-run single phase AC induction motor having a main winding and an auxiliary winding both connected to an AC power source, a run capacitor for providing a phase shifted field for starting and running torque, a start capacitor for providing a phase shifted field for starting torque, a start switch for automatically connecting and disconnecting said start capacitor to and from said AC source in starting and running modes, respectively, said run capacitor and said start capacitor being connected in parallel in said starting mode, said start switch comprising a semiconductor power switch connected in series with said start capacitor and being conductive during said starting mode and nonconductive during said running mode, said power switch having a gate circuit for controlling conduction thereof, the voltage across said run capacitor during said starting mode being in phase with the voltage across said start capacitor, the current through said series connected power switch and start capacitor being out of phase with said voltage across said run capacitor, said power switch in said starting mode requiring triggering into conduction by gate current from said gate circuit during each half cycle of said AC source following a zero-crossing of current through said series connected power switch and start capacitor, means supplying gate current to said gate circuit in phase with said voltage across said run capacitor and out of phase with said current through said series connected power switch and start capacitor.

7. The invention according to claim 6 wherein said gate current supplying means supplies substantially maximum gate current to said gate circuit at said zero-crossing of current through said series connected power switch and start capacitor, to minimize turn-on delay of said power switch following said zero-crossing, to minimize the magnitude of cycle to cycle current spikes and di/dt stress of said power switch and said start capacitor.

8. The invention according to claim 7 wherein said gate current supply means comprises a circuit connection between said run capacitor and said gate circuit and supplying said gate current from the voltage across said run capacitor such that said gate current is in phase with said voltage across said run capacitor.

9. The invention according to claim 8 wherein each of said run capacitor and said start capacitor has first and second terminals, said power switch has first and second main terminals and a gate terminal, said second terminals of said run and start capacitors are coupled to each other at a common node, said circuit connection of said gate current supplying means comprises a resistor connected between said gate circuit and said common node.

10. The invention according to claim 8 wherein each of said run capacitor and said start capacitor has first and second terminals, said power switch has first and second main terminals and a gate terminal, and comprising first and second resistors each having first and second terminals, said second terminals of said run and start capacitors are connected to each other at a common first node, said first terminal of said run capacitor is connected to said first main terminal of said power switch, said first terminal of said start capacitor is connected to said second main terminal of said power switch, said second terminal of said second resistor is connected to said first node common to said second terminals of said run and start capacitors, said first terminal of said second resistor is connected to said second terminal of said first resistor at a second node which is connected to said gate circuit, said first terminal of said first resistor is connected to a third node between said first terminal of said start capacitor and said second main terminal of said power switch.

11. In a capacitor-start capacitor-run single phase AC induction motor having a main winding and an auxiliary winding both connectable to an AC power source, a run capacitor for providing a phase shifted field for starting and running torque, a start capacitor for providing a phase shifted field for starting torque, a start switch for automatically connecting and disconnecting said start capacitor to and from said AC source in starting and running modes, respectively, said run capacitor and said start capacitor being connected in parallel in said starting mode such that during the first cycle of said AC source upon initiation of said starting mode there is an equalization of capacitor voltages and an exchange of current between said run and start capacitors resulting in current flow through a loop including said run and start capacitors and said start switch, which current flow may reach a high peak current spike if there is a large magnitude voltage differential between said run and start capacitors, an inhibit switch responsive to said magnitude of said voltage differential between said run and start capacitors and preventing said start switch from connecting said start capacitor to said AC source until said magnitude drops below a given maximum level, to reduce said first cycle current spike, and reduce damage to and extend the life of said start switch and said start capacitor, said start switch comprising a semiconductor power switch connected in series with said start capacitor and being conductive during said starting mode and nonconductive during said running mode, said power switch having a gate circuit for controlling conduction thereof, the voltage across said run capacitor during said starting mode being in phase with the voltage across said start capacitor, the current through said series connected power switch and start capacitor being out of phase with said voltage across said run capacitor, said power switch in said starting mode requiring triggering into conduction by gate current from said gate circuit during each half cycle of said AC source following a zero-crossing of current through said series connected power switch and start capacitor, means supplying gate current to said gate circuit in phase with said voltage across said run capacitor and out of phase with said current through said series connected power switch and start capacitor.

12. The invention according to claim 11 wherein said gate current supplying means supplies substantially maximum gate current to said gate circuit at said zero-crossing of current through said series connected power switch and start capacitor, to minimize turn-on delay of said power switch following said zero-crossing, to minimize the magnitude of cycle to cycle current spikes and di/dt stress of said power switch and said start capacitor.

13. The invention according to claim 11 wherein said gate current supply means comprises a circuit connection between said run capacitor and said gate circuit and supplying said gate current from the voltage across said run capacitor such that said gate current is in phase with said voltage across said run capacitor.

14. The invention according to claim 13 wherein said inhibit switch comprises a light responsive element in said gate circuit, said gate circuit being connected through said light responsive element to said loop containing said run and start capacitors to derive gate current therefrom for gating said power switch as controlled by said light responsive element, a control circuit providing starting and running mode signals and including a light emitting element optically coupled to said light responsive element for supplying light thereto such that conduction of said light responsive element is controlled by said light emitting element when the voltage across said light responsive element is below a predetermined value, and such that when the voltage across said light responsive element is above said predetermined value said light responsive element prevents gate current flow to said power switch to prevent conduction of said power switch and prevent connection of said start capacitor to said AC source regardless of the condition of said light emitting element.

15. The invention according to claim 14 where each of said run capacitor, said start capacitor, and said light responsive element has first and second terminals, said second terminals of said run and start capacitors are coupled to each other at a common node, said second terminal of said light responsive element is coupled to said first terminal of said start capacitor, said first terminal of said light responsive element is coupled to said first terminal of said run capacitor, to sense voltage differential between said run and start capacitors.

16. The invention according to claim 15 comprising first and second resistors each having first and second terminals, said power switch has first and second main terminals, said first terminal of said run capacitor is connected to said first main terminal of said power switch, said first terminal of said start capacitor is connected to said first terminal of said first resistor, said second terminal of said first resistor is connected to said first terminal of said second resistor at a second node which is connected to said second terminal of said light responsive element, said second terminal of said second resistor is connected to said first node common to said second terminals of said run and start capacitors, said second main terminal of said power switch is connected to a third node between said first terminal of said start capacitor and said first terminal of said first resistor.