Controller for AC induction motors

• US 5,592,062 A
• Filed: 03/08/1994
• Issued: 01/07/1997
• Est. Priority Date: 03/08/1994
• Status: Expired due to Term

• Current Assignee: DGB Technologies, Inc.
• Original Assignee: Daniel G. Bach
• Inventors: Bach, Daniel G.
• Primary Examiner(s): Wysocki, Jonathan
• Application Number:
  US08/207,588
• Time in Patent Office: 1,036 Days
• Field of Search: 318/798-815, 318/727, 318/772, 363/92, 363/132, 363/40, 363/41, 363/56, 363/58, 363/59, 363/60, 363/89, 363/97, 363/131
• US Class Current: 318/805
• CPC Class Codes: H02P 25/14 Universal motors H02P25/12 takes precedence

Abstract

A controller for use with AC induction motors utilizes a microcontroller in conjunction with a triac to control the duty cycle of the AC power applied to the motor. A voltage sensing circuit provides signals to the microcontroller. The microcontroller is also coupled to the gate of a triac. The microcontroller automatically selects the appropriate parameters for most efficient motor operation based upon the motor power factor as determined by the time at which the voltage across the motor crosses zero and the voltage at the triac gate crosses zero.

Claims

1. A controller for an AC induction motor coupled to an AC power source, said controller comprising:

a circuit for providing a voltage signal in phase with voltage applied to said motor from said AC power source;

a triac coupled between said motor and said AC power source, said triac having a gate and being switchable from a non-conductive state to a conductive state in response to a control signal applied to said gate, said triac remaining in said conductive state until current flowing through said triac becomes zero; and

a microcontroller coupled to said circuit and to said gate, and responsive to said voltage signal and the voltage at said gate of said triac during at least the time that said motor is to be operated after an initial start period for determining a time during each AC cycle that said triac is rendered conductive to couple said AC power source to said motor and to generate said control signal in accordance with said time.

2. A controller in accordance with claim 1, wherein said microcontroller comprises:

an analog to digital convertor receiving said voltage signal and said gate voltage and converting each to corresponding digital signals; and

a microprocessor operating in response to said digital signals to determine a motor power factor and to generate said control signal.

3. A controller in accordance with claim 2 wherein:

said microcontroller is operative when said motor power factor is within a predetermined range to generate said control signal to cause said triac to be continuously in said conductive state.

4. A controller in accordance with claim 3 wherein said predetermined range is indicative of a load having a substantial resistive component.

5. A controller in accordance with claim 1 wherein:

said microcontroller is further operative such that when said voltage signal and said gate voltage have a predetermined relationship, said microcontroller generates said control signal to cause said triac to continuously be in said conductive state.

6. A controller in accordance with claim 1 wherein:

said microcontroller is operative such that when said motor is started, said microcontroller generates said control signal to cause said triac to be switched to said conductive state for a first predetermined time period such that AC power is initially applied to said motor at a first predetermined level.

7. A controller in accordance with claim 6 wherein:

said microcontroller is further operative such that the duration of time that said triac is in said conductive state is increased in subsequent AC cycles from said first predetermined time period in a predetermined manner.

8. A controller in accordance with claim 1 wherein:

said microcontroller is operative in response to parameters indicative of the size of said motor to generate said control signals.

9. A controller for an AC induction motor coupled to an AC power source, comprising:

a circuit coupled to said motor to provide a voltage signal indicating when AC voltage applied to said motor crosses zero;

a triac coupled between said motor and said AC power source, said triac having a gate and being switchable from a non-conductive state to a conductive state in response to a control signal applied to said gate, said triac remaining in said conductive state until current flowing through said triac goes to zero whereupon said triac switches to said nonconductive state; and

a microcontroller connected to said circuit and to said gate of said triac for monitoring said voltage signal and said gate voltage, said microcontroller generating said control signals at least during the time that said motor is operated after an initial start up period such that the duration of time during each AC cycle that the triac connects power to said motor is varied in inverse proportion to the difference in phase between said gate voltage and said voltage signal.

10. A controller in accordance with claim 9 wherein:

said microcontroller determines the power line frequency of said AC power source from said voltage signal said controller automatically adjusting timing of said control signals in accordance with said frequency.

11. Apparatus comprising:

an AC induction motor;

a controller for said motor, said controller comprising;

a triac coupled between said motor and an AC power source, said triac having a gate and being switchable from a non-conductive state to a conductive state in response to a control signal at a gate terminal;

a circuit for providing a voltage signal indicative of when the voltage applaud to said motor crosses zero; and

a microcontroller coupled to said circuit and to said gate to receive said voltage signal and the voltage at said gate, and coupled to said gate for supplying said control signal thereto during at least the time said motor is operated after an initial start up period such that the duration of time during each AC cycle that said triac is in said conductive state is varied in accordance with a predetermined relationship between said voltage signal and said gate voltage.