Systems and methods for driving a compressor with a motor
First Claim
1. A system for driving a rotatable component comprising:
- a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the rotatable assembly being in driving relation to the rotatable component;
a circuit for generating a BEMF signal representative of a back electromotive force (EMF) in the windings, the BEMF signal having first and second polarities representative of position of the rotatable assembly relative to a zero crossing of the back EMF, the first polarity being representative of the position of the rotatable assembly past a position corresponding to the zero crossing and the second polarity being opposite the first polarity;
a control circuit responsive to the BEMF signal for generating a commutation signal, the control circuit including a commutation counter counting at a rate, the commutation counter incrementing its count when the BEMF signal is of the first polarity and decrementing its count when the BEMF signal is of the second polarity, and generating a corresponding commutation signal when the count reaches a commutation delay value; and
power switching devices responsive to the commutation signal for selectively connecting a power supply to the windings in the preselected sequence to produce an electromagnetic field for rotating the rotatable assembly.
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Accused Products
Abstract
A system which drives a compressor of a refrigeration system. The system includes a motor having a stationary assembly and a rotatable assembly. The stationary assembly includes windings adapted to be energized in at least one preselected sequence. The rotatable assembly is in magnetic coupling relation to the stationary assembly and in driving relation to the compressor. The system further includes a circuit for sensing a back electromotive force (EMF) voltage in the windings and for generating a BEMF signal representative thereof. The BEMF signal has first and second polarities representative of position of the rotatable assembly relative to a zero crossing of the sensed back EMF voltage. The first polarity is representative of the position of the rotatable assembly past a position corresponding to the zero crossing and the second polarity is opposite the first polarity. A control circuit responsive to the BEMF signal generates a commutation signal and includes a commutation counter counting at a preset rate. The commutation counter increases its count when the BEMF signal is of the first polarity and decreases its count when the BEMF signal is of the second polarity. The control circuit further generates a corresponding commutation signal when the count reaches a preset value. The system further includes power switching devices responsive to the commutation signal for selectively connecting a power supply to the windings in the preselected sequence to produce an electromagnetic field for rotating the rotatable assembly.
138 Citations
43 Claims
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1. A system for driving a rotatable component comprising:
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a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the rotatable assembly being in driving relation to the rotatable component; a circuit for generating a BEMF signal representative of a back electromotive force (EMF) in the windings, the BEMF signal having first and second polarities representative of position of the rotatable assembly relative to a zero crossing of the back EMF, the first polarity being representative of the position of the rotatable assembly past a position corresponding to the zero crossing and the second polarity being opposite the first polarity; a control circuit responsive to the BEMF signal for generating a commutation signal, the control circuit including a commutation counter counting at a rate, the commutation counter incrementing its count when the BEMF signal is of the first polarity and decrementing its count when the BEMF signal is of the second polarity, and generating a corresponding commutation signal when the count reaches a commutation delay value; and power switching devices responsive to the commutation signal for selectively connecting a power supply to the windings in the preselected sequence to produce an electromagnetic field for rotating the rotatable assembly. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 14)
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12. A system for driving a rotatable component comprising:
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a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the rotatable assembly being in driving relation to the rotatable component; a circuit for generating a BEMF signal representative of a back electromotive force (EMF) in the windings, the BEMF signal having first and second polarities representative of position of the rotatable assembly relative to a zero crossing of the back EMF, the first polarity being representative of the position of the rotatable assembly past a position corresponding to the zero crossing and the second polarity being opposite the first polarity; a control circuit response to the BEMF signal for generating a commutation signal, the control circuit including a commutation counter counting at a rate, the commutation counter increasing its count when the BEMF signal is of the first polarity and decreasing its count when the BEMF signal is of the second polarity, and generating a corresponding commutation signal when the count reaches a commutation delay value, the commutation signal including a series of commutation pulses and the control circuit measuring an interval between commutation pulses; power switching devices responsive to the commutation signal for selectively connecting a power supply to the windings in the preselected sequence to produce an electromagnetic field for rotating the rotatable assembly; a speed regulation circuit for comparing the measured interval to a reference interval, the reference interval corresponding to a desired motor speed, and for generating a difference signal between the compared measured interval and the reference interval defining a speed errors, and a processor for integrating the speed error and for generating an integrated speed error signal in response thereto, the processor including a speed error precounter for accumulating the speed error and altering the integrated speed error signal when the speed error accumulates to, an amount selected from a predefined set of values, the speed regulation circuit including a speed regulation counter responsive to the integrated speed error signal and the difference signal for generating a peak current reference signal, and the speed regulation circuit regulating the current in the windings as a function of the peak current reference signal thereby to regulate the speed of the motor. - View Dependent Claims (13)
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15. A system for driving a rotatable component comprising:
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a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto the stationary assembly including windings adapted to be energized in at least one preselected sequence, the rotatable assembly being in driving relation to the rotatable component; a circuit for generating a BEMF signal representative of a back electromotive force (EMF in the windings, the BEMF signal having first and second polarities representative of position of the rotatable assembly relative to a zero crossing of the back EMF, the first polarity being representative of the position of the rotatable assembly past a position corresponding to the zero crossing and the second polarity being opposite the first polarity; a control circuit responsive to the BEMF signal for generating a commutation signal the control circuit including a commutation counter counting at a rate, the commutation counter increasing its count when the BEMF signal is of the first polarity and decreasing its count when the BEMF signal is of the second polarity, and generating a corresponding commutation signal when the count reaches a commutation delay value; power switching devices responsive to the commutation signal for selectively connecting a power supply to the windings in the preselected sequence to produce an electromagnetic field for rotating the rotatable assembly; a microcomputer in serial communication with the control circuit; and a microcomputer watchdog circuit for resetting the microcomputer when a data signal from the microcomputer is absent for a predetermined interval of time, the microcomputer watchdog circuit generating a reset signal having a predetermined duration for resetting the microcomputer.
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16. A system for driving a rotatable component comprising:
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a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the rotatable assembly being in driving relation to the rotatable component; a circuit for generating a BEMF signal representative of a back electromotive force (EMF) in the windings, said windings having an inductive current producing a field collapse voltage in advance of the back EMF; a control circuit responsive to the BEMF signal for generating a commutation signal; power switching devices responsive to the commutation signal for selectively connecting a power supply to the windings in the preselected sequence to produce an electromagnetic field for rotating the rotatable assembly; and a circuit for inhibiting switching events of the power switching devices in advance of the back EMF during periods when the field collapse voltage is present whereby switching events during field collapse voltage are inhibited when the motor is operating below approximately 1/2 no load speed.
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17. A system for driving a rotatable component comprising:
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a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the rotatable assembly being in driving relation to the rotatable component; a circuit for generating a BEMF signal representative of a back electromotive force (EMF) in the windings; a control circuit responsive to the BEMF signal for generating a commutation signal having a series of commutation pulses and for measuring an interval between commutation pulses; power switching devices responsive to the commutation pulses of the commutation signal for selectively connecting a power supply to the windings in the preselected sequence to produce an electromagnetic field for rotating the rotatable assembly; a speed regulation circuit for comparing the measured interval to a reference interval, the reference interval corresponding to a desired motor speed, and for generating a difference signal between the compared measured interval and the reference interval defining a speed error; a processor for integrating the speed error and for generating an integrated speed error signal in response thereto, the processor including a speed error pre-counter for accumulating the speed error and altering the integrated speed error signal when the speed error accumulates to an amount selected from a predefined set of values; and wherein the speed regulation circuit includes a speed regulation counter responsive to the integrated speed error signal and the difference signal for generating a peak current reference signal, and wherein the speed regulation circuit regulates the current in the windings as a function of the peak current reference signal thereby to regulate the speed of the motor.
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18. A system for driving a rotatable component comprising:
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a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the rotatable assembly being in driving relation to the rotatable component; a circuit for generating a BEMF signal representative of a back electromotive force (EMF) in the windings; a control circuit responsive to the BEMF signal for generating a commutation signal having a series of commutation pulses and for measuring a commutation interval between consecutive commutation pulses; power switching devices responsive to the commutation pulses of the commutation signal for selectively connecting a power supply to the windings in the preselected sequence to produce an electromagnetic field for rotating the rotatable assembly; a current detector circuit for sensing current in each of the windings; and a variable off time circuit for discontinuing for a predetermined period of time power being provided to each of the windings in which the current reaches a peak current reference level for regulating current in the motor, the predetermined period of time selected from a predefined set of values as a function of the measured commutation interval for minimizing losses and for providing smooth torque production.
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19. A refrigeration system comprising:
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a compressor for circulating a refrigerant through an evaporator; a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the rotatable assembly being in driving relation to the compressor; a circuit for generating a BEMF signal representative of a back electromotive force (EMF) in the winding the BEMF signal having first and second polarities representative of position of the rotatable assembly relative to a zero crossing of the back EMF, the first polarity being representative of the position of the rotatable assembly past a position corresponding to the zero crossing and the second polarity being opposite the first polarity; a control circuit responsive to the BEMF signal for generating a commutation signal, the control circuit including a commutation counter counting at a rate, the commutation counter increasing its count when the BEMF signal is of the first polarity and decreasing its count when the BEMF signal is of the second polarity, and generating a corresponding commutation signal when the count reaches a commutation delay value; and power switching devices responsive to the commutation signal for selectively connecting a power supply to the windings in the preselected sequence to produce an electromagnetic field for rotating the rotatable assembly.
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20. A motor comprising:
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a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence; a circuit for generating a BEMF signal representative of a back electromotive force (EMF) in the winding, the BEMF signal having first and second polarities representative of position of the rotatable assembly relative to a zero crossing of the back EMF, the first polarity being representative of the position of the rotatable assembly past a position corresponding to the zero crossing and the second polarity being opposite the first polarity; a control circuit responsive to the BEMF signal for generating a commutation signal, the control circuit including a commutation counter counting at a rate, the commutation counter increasing its count when the BEMF signal is of the first polarity and decreasing its count when the BEMF signal is of the second polarity, and generating a corresponding commutation signal when the count reaches a commutation delay value; and power switching devices responsive to the commutation signal for selectively connecting a power supply to the windings in the preselected sequence to produce an electromagnetic field for rotating the rotatable assembly.
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21. An application specific integrated circuit (ASIC) for use with a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the motor further having power switching devices responsive to a commutation signal for selectively connecting a power supply to the windings in the preselected sequence to produce an electromagnetic field for rotating the rotatable assembly, the ASIC comprising:
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a circuit for generating a BEMF signal representative of a back electromotive force (EMF) in the winding the BEMF signal having first and second polarities representative of position of the rotatable assembly relative to a zero crossing of the back EMF, the first polarity being representative of the position of the rotatable assembly past a position corresponding to the zero crossing and the second polarity being opposite the first polarity; and a control circuit responsive to the BEMF signal for generating the commutation signal, the control circuit including a commutation counter counting at a rate, the commutation counter increasing its count when the BEMF signal is of the first polarity and decreasing its count when the BEMF signal is of the second polarity, and generating a corresponding commutation signal when the count reaches a commutation delay value.
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22. A method of operating a system for driving a rotatable component, the system comprising a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the rotatable assembly being in driving relation to the rotatable component, the method comprising:
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generating a BEMF signal representative of a back electromotive force (EMF) in the windings, the BEMF signal having first and second polarities representative of position of the rotatable assembly relative to a zero crossing of the back EMF, the first polarity being representative of the position of the rotatable assembly past a position corresponding to the zero crossing and the second polarity being opposite the first polarity; generating a commutation signal in response to the BEMF signal; increasing a count of a commutation counter counting at a rate when the BEMF signal is of the first polarity and decreasing the count when the BEMF signal is of the second polarity; generating a corresponding commutation signal when the count reaches a commutation delay value; and selectively connecting a power supply to the windings in the preselected sequence by switching power switching devices in response to the commutation signal to produce an electromagnetic field for rotating the rotatable assembly. - View Dependent Claims (23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36)
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37. A method of operating a system for driving a rotatable component, the system comprising a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the rotatable assembly being in driving relation to the rotatable component, the method comprising:
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generating a BEMF signal representative of a back electromotive force (EMF) in the windings, said windings having an inductive current producing a field collapse voltage in advance of the back EMF; generating a commutation signal in response to the BEMF signal; selectively connecting a power supply to the windings in the preselected sequence by switching power switching devices in response to the commutation signal to produce an electromagnetic field for rotating the rotatable assembly; and inhibiting switching events of the power switching devices in advance of the back EMF during periods when the field collapse voltage is present whereby switching events during field collapse voltage are inhibited when the motor is operating below approximately 1/2 no load speed.
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38. A method of operating a system for driving a rotatable component, the system comprising a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the rotatable assembly being in driving relation to the rotatable component, the method comprising:
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generating a BEMF signal representative of a back electromotive force (EMF) in the windings; generating a commutation signal in response to the BEMF signal, the commutation signal including a series of commutation pulses; measuring an interval between commutation pulses; selectively connecting a power supply to the windings in the preselected sequence by switching power switching devices in response to the commutation signal to produce an electromagnetic field for rotating the rotatable assembly; comparing the measured interval to a reference interval, the reference interval corresponding to a desired motor speed; generating a difference signal between the compared measured interval and the reference interval defining a speed error; integrating the speed error and generating an integrated speed error signal in response thereto; accumulating the speed error; altering the integrated speed error signal when the speed error accumulates to an amount selected from a predefined set of values; and generating a peak current reference signal responsive to the integrated speed error signal and the difference signal, and wherein the current in the windings is regulated as a function of the peak current reference signal thereby to regulate the speed of the motor.
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39. A method of operating a system for driving a rotatable component, the system comprising a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the rotatable assembly being in driving relation to the rotatable component, the method comprising:
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generating a BEMF signal representative of a back electromotive force (EMF) in the windings; generating a commutation signal in response to the BEMF signal, the commutation signal including a series of commutation pulses; measuring a commutation interval between consecutive commutation pulses; selectively connecting a power supply to the windings in the preselected sequence by switching power switching devices in response to the commutation signal to produce an electromagnetic field for rotating the rotatable assembly; sensing current in each of the windings; and discontinuing for a predetermined period of time power being provided to each of the windings in which the current reaches a peak current reference level to regulate current in the motor, the predetermined period of time selected from a predefined set of values as a function of the measured commutation interval for minimizing losses and for providing smooth torque production.
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40. A method of operating a refrigeration system having a compressor for circulating a refrigerant through an evaporator and a motor for driving the compressor, the motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the rotatable assembly being in driving relation to the compressor, the method comprising:
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generating a BEMF signal representative of a back electromotive force (EMF) in the windings, the BEMF signal having first and second polarities representative of position of the rotatable assembly relative to a zero crossing of the back EMF, the first polarity being representative of the position of the rotatable assembly past a position corresponding to the zero crossing and the second polarity being opposite the first polarity; generating a commutation signal in response to the BEMF signal; increasing a count of a conmutation counter counting at a rate when the BEMF signal is of the first polarity and decreasing the count when the BEMF signal is of the second polarity; generating a corresponding commutation signal when the count reaches a commutation delay value; and selectively connecting a power supply to the windings in the preselected sequence by switching power switching devices in response to the commutation signal to produce an electromagnetic field for rotating the rotatable assembly.
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41. A method of operating a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence, the method comprising:
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generating a BEMF signal representative of a back electromotive force (EMF) in the windings, the BEMF signal having first and second polarities representative of position of the rotatable assembly relative to a zero crossing of the back EMF, the first polarity being representative of the position of the rotatable assembly past a position corresponding to the zero crossing and the second polarity being opposite the first polarity; generating a commutation signal in response to the BEMF signal; increasing a count of a commutation counter counting at a rate when the BEMF signal is of the first polarity and decreasing the count when the BEMF signal is of the second polarity; generating a corresponding commutation signal when the count reaches a commutation delay value; and selectively connecting a power supply to the windings in the preselected sequence by switching power switching devices in response to the commutation signal to produce an electromagnetic field for rotating the rotatable assembly.
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42. A method of operating a refrigeration system having a compressor for circulating a refrigerant through an evaporator and a motor for driving the compressor, the motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence during operation of the compressor, the rotatable assembly being in driving relation to the compressor, said system including a refrigerant that is in a gaseous state during compressor operation and that may be in a liquid state during periods when the compressor is not being operated, the method comprising:
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generating a BEMF signal representative of a back electromotive force (EMF) in the windings with a back EMF circuit; disabling the back EMF circuit and generating a sump heat signal; generating first and second commutation signals in response to the sump heat signal and the BEMF signal, respectively, the first commutation signal having a commutation rate corresponding to a motor speed exceeding that at which inertia of the rotatable assembly permits rotation; and supplying electrical energy to at least part of the motor windings in response to the first commutation signal so that heat is generated within such part of the motor windings and so that the rotatable assembly is not caused to commence rotation for a period of time sufficient to cause liquid refrigerant in the compressor to change state to a gaseous state; and thereafter supplying electrical energy to the motor windings in the preselected sequence in response to the second commutation signal thereby causing the rotatable assembly to commence rotation with respect to the stationary assembly.
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43. A refrigeration system comprising:
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a compressor for circulating a refrigerant through an evaporator; a motor having a stationary assembly and a rotatable assembly in magnetic coupling relation thereto, the stationary assembly including windings selectively energized in at least one preselected sequence during operation of the compressor, the rotatable assembly being in driving relation to the compressor; a refrigerant that is in a gaseous state during compressor operation and that may be in a liquid state during periods when the compressor is not being operated; a circuit for generating a BEMF signal representative of a back electromotive force (EMF)in the windings; a sump heat circuit for disabling the back EMF circuit and for generating a sump heat signal; a control circuit responsive to the sump heat signal for generating a first commutation signal and responsive to the BEMF signal for generating a second commutation signals the first commutation having a commutation rate corresponding to a motor speed exceeding that at which inertia of the rotatable assembly permits rotation; and power switching devices responsive to the first commutation signal for selectively connecting a power supply to at least part of the motor windings in a manner that causes heat to be generated within such part of the motor windings and that does not cause the rotatable assembly to commence rotation for a period of time sufficient to cause liquid refrigerant in the compressor to change state to a gaseous state and thereafter responsive to the second commutation signal for selectively connecting the power supply to the motor windings in the preselected sequence and thereby causing the rotatable assembly to commence rotation with respect to the stationary assembly.
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Specification