Electronic motor load sensing device

• US 5,473,497 A
• Filed: 02/05/1993
• Issued: 12/05/1995
• Est. Priority Date: 02/05/1993
• Status: Expired due to Term

• Current Assignee: Franklin Electric Company Incorporated (EBW, Inc.)
• Original Assignee: Franklin Electric Company Incorporated (EBW, Inc.)
• Inventors: Beatty, James A.
• Primary Examiner(s): Hoff, Marc S.
• Assistant Examiner(s): JACKSON, STEPHEN W
• Application Number:
  US08/014,327
• Time in Patent Office: 1,033 Days
• Field of Search: 361/23, 361/28, 361/29, 361/30, 361/31, 361/79, 361/90, 361/94, 361/33
• US Class Current: 361/23
• CPC Class Codes: H02H 3/42 responsive to product of voltage and current
• CPC Class Codes: H02H 7/0827 responsive to underload or no-load, e.g. pump-off control circuits for pump motors
• CPC Class Codes: H02H 7/0833 for electric motors with control arrangements

Abstract

A device for measuring energy delivered by a motor to a load is adapted to be connected to the motor which is coupled to the load and connected to a power source through first and second power supply lines. The device includes a line voltage sensing circuit for sensing the voltage across the power supply lines, a line current sensing circuit for sensing the current flowing through the motor and a pulse width modulator which modulates the sensed voltage to produce a pulse width modulated first electrical signal. The device also includes a first switch, responsive to the pulse width modulated first electrical signal which modulates an output of the line current sensing circuit to produce a power waveform and an integrator which integrates the power waveform to produce an output signal indicative of the energy delivered by the motor to the load. The device further includes a switch controller which compares the output signal to a first reference signal to detect the existence of an overload condition and which compares the output signal to a second reference signal to detect the existence of an underload condition. The switch controller opens a second switch to disconnect the motor from the power source in response to either an overload condition or an underload condition.

Claims

1. A device adapted to be connected to a motor which is coupled to a load for measuring energy delivered by the motor to the load, wherein the motor is adapted to be connected between first and second power supply lines connected to a power source, the device comprising:

developing means for developing first and second electrical signals indicative of first and second parameters of power delivered to the load;

pulse width modulating means for pulse width modulating the first electrical signal to produce a pulse width modulated first electrical signal;

modulating means responsive to the pulse width modulated first electrical signal for modulating the second electrical signal to produce a power waveform; and

producing means responsive to the power waveform for producing an output signal indicative of the energy delivered by the motor to the load.

2. The device of claim 1, further comprising controlling means responsive to the output signal for controlling the power delivered to the motor.

3. The device of claim 2, wherein the controlling means includes first detecting means for detecting an overload condition or an underload condition and means responsive to the first detecting means and coupled to one of the lines for disconnecting the motor from the power source when an overload condition or an underload condition is detected.

4. The device of claim 3, wherein the producing means includes integrating means for integrating the power waveform.

5. The device of claim 4, wherein the first electrical signal has a plurality of positive half-cycles and negative half-cycles and wherein the integrating means includes second detecting means for detecting the plurality of positive half-cycles or negative half-cycles and an integrator for integrating the power waveform during the plurality of positive half-cycles or negative half-cycles.

6. The device of claim 5, wherein the integrating means includes means for combining the integrated power waveforms during consecutive positive half-cycles or negative half-cycles.

7. The device of claim 5, wherein the modulating means includes a switch which alternatively connects the second electrical signal to the integrating means and disconnects the second electrical signal from the integrating means in response to the pulse width modulated first electrical signal.

8. The device of claim 7, wherein the developing means includes a voltage sensor and a current sensor, and wherein the first electrical signal comprises a voltage signal and the second electrical signal comprises a current signal.

9. The device of claim 8, wherein the integrating means includes means for resetting the output signal after a predetermined number of cycles of the first electrical signal.

10. The device of claim 2, further including a phase shifting means connected between the developing means and the modulating means for phase shifting one of the first or the second electrical signals.

11. The device of claim 10, wherein the phase shifting means delays the one of the first or the second electrical signals in phase up to approximately ten electrical degrees.

12. The device of claim 10, wherein the phase shifting means delays the one of the first or the second electrical signals in phase approximately ten electrical degrees.

13. A protection system adapted to be connected to an electric motor and first and second power supply lines, the lines being connectable to an AC power source which supplies a line voltage and a line current, the system comprising:

line voltage sensing means adapted to be connected to the lines for sensing the voltage therebetween to produce a voltage signal;

line current sensing means adapted to be connected to one of the power supply lines for sensing the current flowing therein to produce a current signal;

pulse width modulating means for pulse width modulating one of the voltage or the current signals to produce a pulse width modulated signal;

modulating means responsive to the pulse width modulated signal for modulating the other of the voltage or current signals to produce a modulated waveform;

integrating means for integrating the modulated waveform to produce an energy signal;

detecting means responsive to the energy signal for detecting the existence of an overload or an underload condition; and

disconnecting means responsive to the detecting means for disconnecting the AC power source from the electric motor in response to an overload condition or an underload condition.

14. The protection system of claim 13, further comprising phase shifting means for shifting the phase of one of the current signal or the voltage signal.

15. The protection system of claim 14, wherein the phase shifting means shifts the phase of the one of the current signal or the voltage signal approximately ten electrical degrees.

16. The protection system of claim 14, wherein the phase shifting means shifts the phase of the one of the current signal or the voltage signal up to approximately ten electrical degrees.

17. The protection system of claim 13, wherein the detecting means compares the energy signal to first reference signal and to a second reference signal to determine the existence of an overload condition or an underload condition, respectively.

18. The protection system of claim 17, wherein the voltage signal has positive half-cycles and negative half-cycles and wherein the integrating means includes further means for integrating the modulated current signal during a plurality of consecutive positive half-cycles or negative half-cycles.

19. The protection system of claim 17, wherein the voltage signal has positive half-cycles and negative half-cycles and wherein the integrating means includes further means for integrating the modulated current signal during at least one of the positive half-cycles or negative half-cycles.

20. The protection system of claim 19, wherein the disconnecting means includes a switch which is coupled to one of the power supply lines and is capable of interrupting the supply of power from the power source.

21. A method for controlling a motor connected to a load, wherein the motor is also connected to a power source through first and second power supply lines, the method comprising the steps of:

developing first and second electrical signals indicative of first and second parameters of power delivered to the motor;

pulse width modulating the first electrical signal to produce a pulse width modulated first electrical signal;

modulating the second electrical signal in response to the pulse width modulated first electrical signal to produce a power waveform; and

producing an output signal from the power waveform wherein the output signal is indicative of the energy delivered by the motor to the load.

22. The method of claim 21, further including the step of controlling the power delivered to the motor in response to the output signal.

23. The method of claim 22, wherein the step of controlling includes the steps of detecting an overload condition or an underload condition and disconnecting the power source from the motor when an overload condition or an underload condition occurs.

24. The method of claim 23, wherein the step of developing includes the steps of sensing the voltage developed across the motor and sensing the current flowing through the motor, and wherein the first electrical signal comprises a voltage signal and the second electrical signal comprises a current signal.

25. The method of claim 21, further including the step of phase shifting one of the first or the second electrical signals prior to the step of modulating.

26. The method of claim 25, wherein the step of phase shifting the one of the first or the second electrical signals prior to the step of modulating comprises the step of phase shifting the one of the first or the second electrical signals up to approximately ten electrical degrees.

27. The method of claim 25, wherein the step of phase shifting the one of the first or the second electrical signals prior to the step of modulating comprises the step of phase shifting the one of the first or the second electrical signals approximately ten electrical degrees.

28. A method for controlling a motor connected to a load, wherein the motor is also connected to a power source through first and second power supply lines, the method comprising the steps of:

developing first and second electrical signals indicative of first and second parameters of power delivered to the motor;

pulse width modulating the first electrical signal to produce a pulse width modulated first electrical signal;

modulating the second electrical signal in response to the pulse width modulated first electrical signal to produce a power waveform; and

producing an output signal from the power waveform wherein the output signal is indicative of the energy delivered by the motor to the load; and

further including the steps of providing power for a short duration of time when a switch interrupts power flow through one of the power supply lines, producing a further signal indicative of the number of times within a predetermined amount of time that the switch has consecutively interrupted and re-enabled the flow of power through the power supply lines within the short duration of time and controlling the power delivered to the motor in response to the further signal to prevent rapid cycling of the motor.

29. A device adapted to be connected to a motor which is coupled to a load for measuring energy delivered by the motor to the load and further adapted to be connected to a switch which alternatively disconnects the device from and reconnects the device to a power source, wherein the motor is adapted to be connected between first and second power supply lines connected to the power source, the device comprising:

developing means for developing first and second electrical signals indicative of first and second parameters of power delivered to the load;

pulse width modulating means for pulse width modulating the first electrical signal to produce a pulse width modulated first electrical signal;

modulating means responsive to the pulse width modulated first electrical signal for modulating the second electrical signal to produce a power waveform;

producing means responsive to the power waveform for producing an output signal indicative of the energy delivered by the motor to the load;

controlling means responsive to the output signal for controlling the power delivered to the motor; and

means for preventing rapid cycling of the motor including means for providing power for a short duration of time when the switch disconnects the device from the power source and means for indicating the number of times within a predetermined amount of time that the switch has disconnected the device from and reconnected the device to the power source within the short duration of time;

wherein the controlling means is further responsive to the indicating means to disconnect the power source from the motor when the power source has been disconnected from and reconnected to the device a present number of times during the predetermined amount of time.

30. The device of claim 29, wherein the indicating means includes a memory which stores an indication of the number of times the switch has disconnected the device from and reconnected the device to the power source in the predetermined amount of time and wherein the providing means includes a capacitor which stores energy when the power source is connected to the device and which delivers energy to the indicating means for the short duration of time when the power source is disconnected from the device.

31. A motor protection device adapted to be connected between a motor and a switch which disconnects a power source from the motor protection device in response to a first condition and which reconnects the power source to the motor protection device in response to a second condition, wherein the motor protection device is adapted to prevent rapid cycling of the motor, the motor protection device comprising;

means for providing power for a short duration of time when the power source is disconnected from the motor protection device;

means for storing a signal indicative of the number of times within a predetermined amount of time that the power source is both disconnected from the motor protection device and reconnected to the motor protection device within an amount of time equal to the short duration of time; and

means response to the signal for disconnecting the motor from the power source when the power source has been disconnected from and reconnected to the motor protection device a preset number of times during the predetermined amount of time.

32. The improvement of claim 31 wherein the storing means includes a memory and wherein the providing means includes a capacitor which stores energy when the power source is connected to the motor protection device and which delivers energy to the storing means for the short duration of time when the power source is disconnected from the motor protection device.

33. A device for measuring the torque delivered by a motor to a load, comprising:

first measuring means for measuring a first parameter of power across the motor to develop a first signal;

second measuring means for measuring a second parameter of power across the motor to develop a second signal;

a pulse width modulator responsive to the first signal for producing a pulse width modulated signal;

a modulator responsive to the second signal and to the pulse width modulated signal for modulating the second signal; and

a phase shifter connected between either the first measuring means and the pulse width modulator or the second measuring means and the modulator for phase shifting one of the first or second signals.

34. The torque measuring device of claim 33, wherein the phase shifter phase shifts one of the first and the second signals up to approximately ten electrical degrees.

35. The torque measuring device of claim 33, wherein the phase shifter phase shifts one of the first and the second signals approximately ten electrical degrees.