System and method for bypassing a motor drive

• US 7,081,735 B1
• Filed: 09/16/2003
• Issued: 07/25/2006
• Est. Priority Date: 09/16/2003
• Status: Expired due to Fees

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Bruski, Gary P., Malkowski, Chester Jr., Heberlein, G. Erich Jr.
• Primary Examiner(s): Fletcher, Marlon T.
• Assistant Examiner(s): MCCLOUD, RENATA D
• Application Number:
  US10/663,229
• Time in Patent Office: 1,043 Days
• Field of Search: 318805-807, 318/811, 318/254, 318/780, 363/51, 363/64, 363/131, 363/132, 363/153, 363/98, 290/38, 322/10, 322/61
• US Class Current: 318/807
• CPC Class Codes: H02P 25/18 with arrangements for switching the windings, e.g. with mechanical switches or relays
• CPC Class Codes: H02P 27/08 with pulse width modulation

Abstract

A motor control system comprising a plurality of motor controllers and a power source adapted to drive an electric motor. The motor control system comprises a switch that is selectively operable between at least a first position and a second position. In the first position, the power source is coupled to a first controller to provide the power to drive the electric motor. In the second position, the power source is coupled to a second controller to provide the power to drive the electric motor. The switch also electrically isolates the input and the output of the first controller from the power source when the manual bypass switch is positioned in the second position.

Claims

1. A motor control system for an electric motor, comprising:

a bypass switch comprising;

a first set of contacts electrically coupled in series between a power source and an input of a variable frequency drive;

a second set of contacts electrically coupled in series between an output of the variable frequency drive and a load;

an operator having a first position and a second position, wherein the first set of contacts and the second set of contact are closed when operator is oriented in the first position and the first set of contacts and the second set of contacts are open when the operator is oriented in the second position;

a bypass contactor having a set of bypass contacts, wherein the set of bypass contacts is electrically coupled in parallel with the first set of contacts and the second set of contacts between the power source and the load; and

the switch being configured to energize the bypass contactor and thereby close the set of bypass contacts when the first and second sets of contacts are open.

2. The system as recited in claim 1, wherein the operator is adapted to be selectively manually positioned in each of the first and second positions.

3. The system as recited in claim 1, further comprising a set of auxiliary contacts electrically coupled in series with the bypass contactor, the set of auxiliary contacts being adapted to open the set of bypass contacts when the first and second sets of contacts are closed.

4. The system as recited in claim 3, wherein the manual bypass switch is adapted to open the set of auxiliary contacts to de-energize the bypass contactor and open the third set of contacts before the first set of contacts and the second set of contacts are closed.

5. The system as recited in claim 1, comprising a disconnect adapted to control power to the motor controller from a source, wherein the first set of contacts is electrically coupled in series with the disconnect.

6. The system as recited in claim 1, comprising a terminal adapted to receive a conductor electrically coupled to the motor, wherein the second set of contacts and set of bypass contacts are electrically coupled to the terminal.

7. The system as recited in claim 1, comprising the variable frequency drive.

8. A motor control system, comprising:

a variable frequency drive adapted to produce a variable frequency output to control the speed of a motor, the variable frequency drive comprising;

an input to enable power from an external power source to be coupled to the variable frequency drive; and

an output to enable the variable frequency drive to be coupled to the motor; and

an electrical system operable to selectively couple the motor to the output of the variable frequency drive and the external power source, the electrical system being adapted to electrically isolate the input and the output of the variable frequency drive from the external power source when the motor is coupled to the external power source;

wherein the electrical system comprises a manual bypass switch and a bypass contactor;

the bypass contactor having at least one set of contacts electrically connected in parallel with the variable frequency drive and electrically connected in series between the external power source and the motor; and

wherein the manual bypass switch has a first set of contacts electrically connected in series to the input of the variable frequency drive and a second set of contacts electrically connected in series to the output of the variable frequency drive.

9. The system as recited in claim 8, wherein the manual bypass switch comprises a double-break switch having an operator, wherein the first and second sets of contacts are closed when the operator is positioned in a first position and open when the operator is positioned in a second position.

10. The system as recited in claim 9, wherein the manual bypass switch comprises at least one auxiliary contact electrically connected in series with the bypass contactor, the auxiliary contact being a early-break contact.

11. The system as recited in claim 8, wherein the variable frequency drive is located in a first compartment of an enclosure and the manual bypass switch and bypass contactor is located within a second compartment of the enclosure.

12. The system as recited in claim 8, wherein the external power source is an electrical bus of a motor control center.

13. The system as recited in claim 8, wherein the electrical system is operable to provide a control signal to the variable frequency drive to establish a desired variable frequency output.

14. The system as recited in claim 13, wherein the electrical system is coupled to an external communication system to enable the desired variable frequency output to be established remotely via the external communication system.

15. A motor control system, comprising:

a variable frequency drive adapted to produce a variable frequency output to control the speed of a motor;

a bypass switch having first and second sets of contacts for electrically coupling the variable frequency drive to a external power source and to the motor, and a set of auxiliary contacts;

a bypass contactor having a set of bypass contacts, the bypass contactor configured to be energized by the auxiliary contacts to electrically coupled the motor to the external power source such that the bypass contacts are electrically parallel to the variable frequency drive.

16. The motor control system of claim 15, wherein the bypass contactor is in series with the auxiliary set of contacts of the bypass switch.

18. The motor control system of claim 15, wherein the first and second set of contacts open before the auxiliary set of contacts cause the closure of the bypass contactor.

19. The motor control system of claim 15, comprising a control relay coupled to the bypass contactor for enabling the bypass contactor.

20. The motor control system of claim 19, wherein contacts of the control relay are coupled in series with the bypass contactor and the control relay is energized upon starting the motor.

17. The motor control system of 15, wherein the bypass switch has a first position and a second position;

the first position enabling the variable frequency drive; and

the second position isolating the variable frequency drive.

21. A system comprising:

a motor drive operable to drive an electric motor;

a bypass contactor electrically in parallel with the motor drive;

a motor control system comprising a manual bypass switch selectively operable to couple the motor drive between a power source and the electric motor, wherein the manual bypass switch is operable to electrically isolate the motor drive from the power source and from the motor, and to close the bypass contactor to couple the motor directly to the power source; and

a set of contacts electrically coupled in series with the bypass contactor for opening the contactor before the motor drive is recoupled between the power source and the motor.