Drive circuit and method for an electric actuator with spring return

• US 6,249,100 B1
• Filed: 07/31/1997
• Issued: 06/19/2001
• Est. Priority Date: 07/31/1997
• Status: Expired due to Term

• Current Assignee: Honeywell Incorporated (Honeywell International Inc.)
• Original Assignee: Honeywell International Inc.
• Inventors: Lange, Christopher M.
• Primary Examiner(s): IP, SHIK LUEN PAUL
• Application Number:
  US08/904,005
• Time in Patent Office: 1,419 Days
• Field of Search: 318/254, 318/471, 318/811, 318/455, 318/466, 318/472, 318/160-180, 318/430-480, 318/600-640, 363/41
• US Class Current: 318/471
• CPC Class Codes: G05B 19/404 characterised by control arrangements for compensation, e.g. for backlash, overshoot, tool offset, tool wear, temperature, machine construction errors, load, inertia G05B19/19, G05B19/41 take precedence
• CPC Class Codes: G05B 2219/41127 Compensation for temperature variations of servo
• CPC Class Codes: G05B 2219/41251 Servo with spring, resilient, elastic element, twist
• CPC Class Codes: G05B 2219/42237 Pwm pulse width modulation, pulse to position modulation ppm

Abstract

A spring return rotary actuator incorporating a DC brush commutated electric motor and a pulse width modulation drive circuit which reduces the voltage at which current is supplied to the motor once a rotation sensor senses that the actuator output shaft has stalled. The drive circuit also includes a temperature responsive feature which increases the voltage at which current is supplied to the motor in the event a sensed temperature exceeds a temperature limit.

Claims

1. A drive circuit for an actuator having an output shaft, a spring coupled to the shaft operable to bias the shaft for rotation toward a rest position, and an electric motor coupled to the shaft and energizable by electric current at at least a predetermined average voltage to rotate the shaft against the bias of the spring away from the rest position, the spring being operable to return the shaft to the rest position when the motor is not energized, the drive circuit comprising:

input means for providing current at at least the predetermined average voltage when it is desired to rotate the shaft away from the rest position;

a rotation sensor operable to produce a first signal indicative of whether or not the actuator output shaft is rotating; and

a modulation circuit operable in response to both current received from said input means and the first signal indicating rotation of the actuator output shaft to supply current at a first average voltage adequate to energize the electric motor to continue to rotate the output shaft away from the rest position against the bias of the spring, and operable in response to current received from said input means to supply current at a second average voltage less than the first average voltage, but sufficient to hold the actuator output shaft in position against the bias of the spring when the first signal indicates that the actuator output shaft has stalled.

2. The drive circuit of claim 1 wherein said modulation circuit is operable to pulse width modulate the current received from said input means, said current being pulse width modulated at a first duty cycle to rotate the output shaft away from the rest position, and at a second duty cycle less than the first duty cycle when the first signal indicates that the actuator output shaft has stalled.

3. The drive circuit of claim 1 for energizing a DC electric motor wherein said input means provides unidirectional current.

4. The drive circuit of claim 3 wherein the first duty cycle is greater than 50% and the second duty cycle is less than 50%.

5. The drive circuit of claim 4 wherein said rotation sensor is implemented with a Hall effect device.

6. The drive circuit of claim 1 wherein:

a temperature sensor is included, said temperature sensor being operable to supply a second signal to said modulation circuit in response to having sensed a temperature above a predetermined temperature limit; and

said modulation circuit is operable to supply current at a third average voltage greater than the first average voltage for energizing the electric motor in response to supply of the second signal by said temperature sensor.

7. The drive circuit of claim 6 wherein said modulation circuit is operable to pulse width modulate the current received from the input means, the current being pulse width modulated at a first duty cycle to rotate the actuator output shaft away from the rest position when said temperature sensor has not sensed a temperature above the predetermined temperature limit, the current being pulse width modulated at a second duty cycle less than the first duty cycle when the first signal indicates that the actuator output shaft has stalled, and the current being pulse width modulated at a third duty cycle greater than the first duty cycle to rotate the actuator output shaft away from the rest position cycle in response to said temperature sensor having sensed a temperature above the predetermined temperature limit.

8. The drive circuit of claim 7 wherein said first duty cycle is between 50% and 95%, said second duty cycle is less than 50%, and said third duty cycle is greater than 95%.

9. The drive circuit of claim 8 for energizing a DC electric motor wherein said input means provides unidirectional current.

10. The drive circuit of claim 9 wherein said rotation sensor is implemented with a Hall effect device.

11. A method of energizing an actuator system in which an output shaft is rotated away from a rest position by an electric motor and is returned to the rest by biasing means operable to rotate the shaft when the motor is not energized, the method comprising the steps of:

supplying electric current to the motor when rotation of the output shaft away from its rest position is desired;

sensing whether or not the shaft is rotating;

controlling the average voltage at which current is supplied to the motor to a first level sufficient to sustain rotation of the shaft against the urging of the biasing means if the shaft is rotating; and

controlling the average voltage at which current is supplied to the motor to a second level less than the first level, but sufficient to hold the shaft in position against the urging of the biasing means if the shaft has stalled.

12. The method of claim 11 wherein the steps of controlling the average voltages at which currents are supplied to the motor comprise pulse width modulating said currents.

13. The method of claim 12 wherein the electric motor is a DC electric motor and the electric current supplied to the motor is unidirectional electric current.

14. The method of claim 13 wherein the first and second average voltage levels are produced by pulse width modulating the currents supplied to the motor at duty cycles of greater than 50% and less than 50% respectively.

15. The method of claim 11 including the further steps of:

sensing a temperature affecting the actuator system; and

controlling the average voltage at which current is supplied to the motor at a third level greater than the first level if the shaft is not stalled and sensed temperature exceeds a predetermined temperature limit.

16. The method of claim 15 wherein the steps of controlling the average voltages at which currents are supplied to the motor comprise pulse width modulating said currents.

17. An electrically energizable actuator system comprising:

an output member mounted for rotation about an axis;

a biasing element coupled to said output member operable to urge said output member to rotate in a first direction;

an electric motor coupled to said output member operable to rotate said output member in a second direction opposite the first direction against the urging of said biasing element when energized with electric current at at least a first average voltage;

conductors for supplying electric current from a source of electric current at at least the first average voltage;

a rotation sensor operable to produce a first signal indicative of whether or not said output member is rotating; and

a control circuit connected to receive current supplied by said conductors and the first signal from said rotation sensor and to supply energization current to said electric motor, said control circuit being operable to control the voltage at which current is supplied to said electric motor to at least the first average voltage when receiving both current from said conductors and the first signal from said rotation sensor indicates that said output member is rotating, said control circuit further being operable to control the voltage at which current is supplied to said electric motor to a second average voltage less than the first average voltage, but sufficient to hold said output member in position against the urging of said biasing element when receiving both current from said conductors and the first signal from said rotation sensor indicates that said output member has stalled.

18. The electrically energizable actuator system of claim 17 wherein:

said electric motor is a DC electric motor; and

the electric current supplied by said conductors from the source of electric current is unidirectional electric current.

19. The electrically energizable actuator system of claim 18 wherein said electric motor is a DC brush commutated electric motor.

20. The electrically energizable actuator system of claim 19 wherein said control circuit is a modulation circuit operable to pulse width modulate the current supplied to said electric motor at a first duty cycle when the first signal indicates that said output member is rotating, and at a second duty cycle less than the first duty cycle when the first signal indicates that said output member has stalled.

21. The electrically energizable actuator system of claim 20:

further including a temperature sensor operable to produce a second signal indicative of whether or not a sensed temperature has exceeded a predetermined temperature limit; and

wherein said modulation circuit is operable to pulse width modulate the current supplied to said electric motor at a third duty cycle greater than the first duty cycle when the second signal indicates that the sensed temperature has exceeded the predetermined temperature limit.

22. The electrically energizable actuator system of claim 21 wherein said modulation circuit includes an oscillator having a feedback path whose characteristics are modified in response to the first signal from said rotation sensor and the second signal from said temperature sensor.

23. The electrically energizable actuator system of claim 22 wherein said rotation sensor comprises:

a pulse generator operable to produce an electrical pulse train in response to rotation of said output member;

a storage circuit connected to said pulse generator for storing a voltage whose magnitude is dependent on whether or not said pulse generator is producing an electrical pulse train; and

a comparitor for comparing the voltage stored by said storage circuit with a threshold voltage to produce the first signal of said rotation sensor.

24. The electrically energizable actuator system of claim 23 wherein said pulse generator includes a Hall effect switch.

25. The electrically energizable actuator system of claim 24 wherein said temperature sensor includes a temperature responsive fusible link which, when intact, supplies a predetermined reference voltage to said modulation circuit.

26. The electrically energizable actuator system of claim 25 further including a start-up circuit operable to cause said modulation circuit to supply current to said electric motor at at least the first average voltage upon initial supplying of current by said conductors and continuing for a time interval sufficient to permit said output member to commence rotation.

27. In an actuator system of the type including an output shaft rotatable between a rest position and a limiting stop position, a spring biasing the output shaft toward the rest position, and a motor which, when energerized with electric current at at least a first average voltage, is operable to rotate the output shaft against the bias of the spring toward the limiting stop position, an improved circuit for supply energization to the motor, comprising:

a supply circuit for selectively supplying electric current to energize the motor;

a rotation sensor for producing a rotation signal indicative of whether the output shaft is rotating; and

a modulation circuit operable to vary the average voltage at which electric current is supplied to the motor by said supply circuit in response to the rotation signal produced by said rotation sensor, the average voltage being sufficient to sustain rotation of the output shaft against the bias of the spring if the rotation signal indicates rotation of the shaft, the average voltage being reduced, but sufficient to hold the output shaft in position against the bias of the spring, if the rotation signal indicates that rotation of the output shaft has ceased.

28. The actuator system of claim 27 further including a temperature sensor connected to said modulation circuit and operable when sensing a temperature above a predetermined temperature limit to cause said modulation circuit to increase the average voltage at which electric current is supplied to the motor.

29. The actuator system of claim 28 further including a startup circuit operable to cause said modulation circuit to supply electric current to the motor at an average voltage sufficient to sustain rotation of the output shaft upon initiation of the supply of current by said supply circuit, and continuing for a time interval sufficient to permit the output shaft to commence rotation.