Methods and system for motor drive information capture

• US 7,602,132 B2
• Filed: 09/27/2006
• Issued: 10/13/2009
• Est. Priority Date: 09/27/2006
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Davis, Wayne Ronald, Pande, Manish
• Primary Examiner(s): Ro; Bentsu
• Application Number:
  US11/535,675
• Publication Number:
  US 20080074075A1
• Time in Patent Office: 1,112 Days
• Field of Search: 318162-164, 318/558, 318/565, 318/568.24, 318650-654, 318798-812, 388/903, 388/909
• US Class Current: 318/558
• CPC Class Codes: H02P 23/0077 Characterised by the use of a particular software algorithm
• CPC Class Codes: Y10S 388/909 Monitoring means

Abstract

Methods and systems are provided for capturing and saving motor drive information in a non-volatile memory to facilitate troubleshooting and motor fault analysis. The motor drive includes a power conversion system that provides electrical power to an electric motor and a control system providing a control input to the power conversion system, and an information capture system is provided with an information capture component to capture motor drive information and a non-volatile memory component to store the captured information.

Claims

1. A motor drive system for operating an electric motor, the motor drive system comprising:

a power conversion system operative to selectively provide electrical power from a power source to an electric motor according to at least one control input;

a control system providing the control input to the power conversion system for controlling operation of the electric motor; and

an information capture system comprising;

an information capture component operative to capture motor drive information in real time, wherein the captured motor drive information includes at least one of a firmware value from the control system, a firmware state from the control system, control program states from the control system, and breakpoint information from the control system, and

a non-volatile memory component to store the captured information in real time,

wherein the non-volatile memory component is removable from the motor drive system,

wherein the non-volatile memory component is a USB memory key.

2. The motor drive system of claim 1, wherein the power conversion system comprises a switching system with a plurality of switching devices coupled between the power source and the electric motor;

and wherein the control system comprises a motor controller providing a motor controller output for controlling the motor operation according to at least one desired profile or setpoint, and a switch control circuit providing a plurality of switch control signals to control operation of the switching devices of the switching system according to the controller output.

3. The motor drive system of claim 1, wherein the information capture system is operative to capture and store a given amount of motor drive information at least until a trigger event occurs and to thereafter maintain the stored information in the non-volatile memory component.

4. The motor drive system of claim 3, wherein the trigger event is one of a motor drive fault condition, a watchdog timer condition in the control system, and a preconfigured condition in the control system.

5. The motor drive system of claim 3, wherein the control system provides a trigger signal to the information capture component.

6. The motor drive system of claim 1, wherein the captured and stored motor drive information comprises at least one of a feedback value from the power conversion system and a control signal value.

7. The motor drive system of claim 6, wherein the captured and stored motor drive information comprises at least one of a voltage value, a current value, a control input value, a digital I/O value, a firmware value from the control system, and a control system firmware state.

8. The motor drive system of claim 1, wherein the information capture component obtains the motor drive information at least partially from a processor of the control system.

9. The motor drive system of claim 1, wherein the information capture component obtains the motor drive information at least partially from a processor of the control system.

10. The motor drive system of claim 1, wherein the information capture component is a processor of the control system.

11. The motor drive system of claim 1, wherein the information capture component obtains the motor drive information at least partially from an I/O component of the control system.

12. A motor drive system, comprising:

a switching type power conversion system including a plurality of electrical switching devices operative according to switching control signals to convert input electrical power to output electrical power for driving a motor load; and

a switch control system operative to provide the switching control signals to the power conversion system based on at least one control input signal;

a motor control system including;

a motor controller receiving at least one feedback value from the power conversion system and providing the at least one control input signal to the switch control system in order to implement a desired motor operation according to at least one setpoint and the at least one feedback value,

an information capture component operatively coupled with the motor controller and operative to capture feedback values and other motor drive information from the motor controller in real time, the captured motor drive information including at least one of a firmware value from the controller, a firmware state from the controller, control program states from the controller, and breakpoint information from the controller, and

a non-volatile memory component operatively coupled with the information capture component to store the captured motor drive information in real time and removable from the motor drive system to facilitate troubleshooting and analysis of motor faults or motor drive faults, wherein the non-volatile memory component is a USB memory key.