Method and apparatus for quiet variable motor speed control

• US 7,330,004 B2
• Filed: 06/06/2006
• Issued: 02/12/2008
• Est. Priority Date: 06/06/2005
• Status: Active Grant

• Current Assignee: Lutron Technology Company LLC
• Original Assignee: Lutron Electronics Company Incorporated (Lutron Electronics)
• Inventors: Steiner, James P, DeJonge, Stuart, Dobbins, Aaron, Wu, Chen Ming
• Primary Examiner(s): Donovan; Lincoln
• Assistant Examiner(s): BRANDT, MICHAEL J
• Application Number:
  US11/447,728
• Publication Number:
  US 20060273751A1
• Time in Patent Office: 616 Days
• Field of Search: 318/244, 318/245
• US Class Current: 318/244
• CPC Class Codes: H02P 25/04 Single phase motors, e.g. capacitor motors
• CPC Class Codes: H02P 25/14 Universal motors H02P25/12 takes precedence
• CPC Class Codes: H02P 27/16 using ac to ac converters without intermediate conversion to dc H02P27/05 takes precedence
• CPC Class Codes: H02P 29/50 Reduction of harmonics
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

An apparatus for controlling the speed of an AC motor comprising a switch adapted to be coupled in parallel with power terminals for the AC motor; a capacitor coupled in series with the parallel combination of the switch and the motor; the capacitor adapted to provide an AC supply voltage from an AC source to the parallel circuit comprising the motor and the switch; and a control circuit for controlling the conduction time of the switch in order to vary the speed of the motor. The switch is preferably pulse-width modulated at a frequency twice the line frequency of the AC supply voltage, and the switch is turned on when the voltage across the AC motor is zero volts. The apparatus is operable to provide for continuously variable control of the motor speed while minimizing acoustic noise in the motor.

Claims

1. An apparatus for controlling the speed of an AC motor to be driven from an AC supply voltage from an AC source, comprising:

a first series capacitor adapted to be coupled in series electrical connection between the AC source and the AC motor;

a shunt switch adapted to be coupled in shunt electrical connection across the AC motor, the switch having a control input; and

a control circuit coupled to the control input for controlling the conduction time of the shunt switch;

whereby the motor speed is controllable in dependence upon the conduction time of the shunt switch and wherein the control circuit causes the shunt switch to become conductive when the voltage across the motor is approximately zero volts.

2. The apparatus of claim 1, wherein the control circuit is operable to generate a pulse-width modulated signal for controlling the conduction time of the shunt switch, the pulse-width modulated signal having a variable duty cycle for varying the motor speed.

3. The apparatus of claim 2, wherein the variable duty cycle is continuously variable.

4. The apparatus of claim 2, wherein the variable duty cycle is discretely variable.

5. The apparatus of claim 2, wherein the control circuit is operable when starting up the motor to open the shunt switch for a predetermined period of time before controlling the shunt switch with the pulse-width modulated signal.

6. The apparatus of claim 2, further comprising:

a bypass switch coupled in parallel electrical connection across the first series capacitor to bypass the first series capacitor to achieve substantially full speed operation of the motor;

wherein the control circuit is operable when starting up the motor to close the bypass switch for a predetermined period of time before opening the bypass switch and controlling the shunt switch with the pulse-width modulated signal.

7. The apparatus of claim 6, further comprising:

a first series switch coupled in series electrical connection with the first series capacitor, the first series switch having a control input, the first series switch and the first series capacitor coupled parallel to the bypass switch;

a second series capacitor adapted to be coupled in series electrical connection between the AC source and the AC motor; and

a second series switch coupled in series electrical connection with the second series capacitor, the second series switch having a control input, the second series switch and the second series capacitor coupled parallel to the first series switch and the first series capacitor;

wherein the control circuit is operable to maintain the shunt switch non-conductive while discretely controlling the first series switch and the second series switch, such that the motor speed is discretely controllable in dependence upon the conduction states of the first series switch and the second series switch.

8. The apparatus of claim 7, further wherein the control circuit is operable to control the shunt switch with a pulse-width modulated signal when a desired motor speed is above a predetermined threshold and to discretely control the first series switch and the second series switch when the desired motor speed is below the predetermined threshold.

9. The apparatus of claim 1, wherein the control circuit controls the conduction time of the shunt switch at a frequency dependent on the line frequency of the AC supply voltage.

10. The apparatus of claim 9, wherein the control circuit controls the conduction time of the shunt switch at a frequency that is twice the line frequency of the AC supply voltage.

11. The apparatus of claim 1, further comprising:

a motor voltage monitoring circuit adapted to be coupled to the motor for monitoring a voltage across the motor;

the motor voltage monitoring circuit having an output coupled to the control circuit.

12. The apparatus of claim 1, wherein the shunt switch comprises a semiconductor device.

13. The apparatus of claim 12, wherein the semiconductor device comprises two field-effect transistors in anti-serial connection.

14. The apparatus of claim 12, wherein the semiconductor device comprises a field-effect transistor in a rectifier bridge.

15. The apparatus of claim 1, further comprising a bypass switch coupled in parallel electrical connection across the first series capacitor to bypass the first series capacitor to achieve substantially full speed operation of the motor.

16. The apparatus of claim 15, wherein the bypass switch comprises a semiconductor device.

17. The apparatus of claim 1, further comprising:

a shunt capacitor adapted to be coupled in shunt electrical connection across the AC motor.

18. A method for controlling the speed of an AC motor driven from an AC supply voltage from an AC source, comprising the steps of:

coupling a first capacitor in series electrical connection between the AC source and the AC motor;

coupling a shunt switch in shunt electrical connection across the AC motor, the shunt switch having a control input for controlling the conduction time of the shunt switch; and

controlling the conduction time of the shunt switch to vary the speed of the motor;

whereby the motor speed is controllable in dependence upon the conduction time of the shunt switch and wherein the step of controlling causes the shunt switch to become conductive when the voltage across the motor is approximately zero volts.

19. The method of claim 18, wherein the step of controlling comprises generating a pulse-width modulated signal for controlling the conduction time of the shunt switch, the pulse-width modulated signal having a variable duty cycle for varying the motor speed.

20. The method of claim 19, wherein the variable duty cycle is continuously variable.

21. The method of claim 19, wherein the variable duty cycle is discretely variable.

22. The method of claim 19, further comprising the steps of:

opening the shunt switch for a predetermined amount of time when starting up the motor to achieve maximum speed operation of the motor; and

controlling the shunt switch with the pulse-width modulated signal after the predetermined amount of time has elapsed.

23. The method of claim 19, further comprising the steps of:

coupling a bypass switch in parallel electrical connection with the first capacitor;

closing the bypass switch for a predetermined amount of time when starting up the motor to bypass the first capacitor to achieve substantially full speed operation of the motor;

opening the bypass switch after the predetermined amount of time has elapsed; and

controlling the shunt switch with the pulse-width modulated signal after the predetermined amount of time has elapsed.

24. The method of claim 19, further comprising the steps of:

coupling a first series switch in series electrical connection with the first capacitor, the first series switch having a control input, the first series switch and the first capacitor coupled parallel to the bypass switch;

coupling a second capacitor in series electrical connection between the AC source and the AC motor; and

coupling a second series switch in series electrical connection with the second capacitor, the second series switch having a control input, the second series switch and the second capacitor coupled parallel to the first series switch and the capacitor; and

discretely controlling the first and second series switches while maintaining the shunt switch non-conductive;

whereby the motor speed is discretely controllable in dependence upon the conduction states of the first and second series switches.

25. The method of claim 24, further comprising the steps of:

controlling the shunt switch with a pulse-width modulated signal when a desired motor speed is above a predetermined threshold; and

discretely controlling the first and second series switches when the desired motor speed is below the predetermined threshold.

26. The method of claim 18, wherein the step of controlling comprises controlling the conduction time of the shunt switch at a frequency dependent on the line frequency of the AC supply voltage.

27. The method of claim 26, wherein the step of controlling comprises controlling the conduction time of the shunt switch at a frequency that is twice the line frequency of the AC supply voltage.

28. The method of claim 18, wherein the step of controlling comprises monitoring a voltage across the motor.

29. The method of claim 18, wherein the shunt switch comprises a semiconductor device.

30. The method of claim 29, wherein the semiconductor device comprises two field-effect transistors in anti-serial connection.

31. The method of claim 29, wherein the semiconductor device comprises a field-effect transistor in a rectifier bridge.

32. The method of claim 18, further comprising the steps of:

coupling a bypass switch in parallel electrical connection with the first capacitor; and

closing the bypass switch to bypass the first capacitor to achieve substantially full speed operation of the motor.

33. The method of claim 32, wherein the bypass switch comprises a semiconductor device.

34. The method of claim 18, further comprising the step of:

coupling a second capacitor in shunt electrical connection across the AC motor.