Generic motor control system

• US 7,646,155 B2
• Filed: 06/23/2005
• Issued: 01/12/2010
• Est. Priority Date: 04/30/2003
• Status: Expired due to Fees

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Leh, Jason K, Forster, Michael K, Crowell, Brian R, Brotto, Daniele C, Vanko, John C, Woods, Samuel G
• Primary Examiner(s): Ro; Bentsu
• Assistant Examiner(s): GLASS, ERICK DAVID
• Application Number:
  US11/159,948
• Publication Number:
  US 20050237011A1
• Time in Patent Office: 1,664 Days
• Field of Search: 318/34, 318/53, 318/255
• US Class Current: 318/53
• CPC Class Codes: H02P 25/14 Universal motors H02P25/12 takes precedence
• CPC Class Codes: H02P 29/00 Arrangements for regulating or controlling electric motors, appropriate for both AC and DC motors arrangements for starting electric motors H02P1/00; arrangements for stopping or slowing electric motors H02P3/00; control of motors that can be connected to two or more different electric power supplies H02P4/00; regulating or controlling the speed or torque of two or more electric motors H02P5/00; vector control H02P21/00
• CPC Class Codes: H02P 29/40 Regulating or controlling the amount of current drawn or delivered by the motor for controlling the mechanical load
• CPC Class Codes: Y10S 388/937 Hand tool

Abstract

A method for controlling the operation of a motor utilizing a generic motor control module. The method includes sampling at least one motor operating criterion during operation of the motor and executing a generic control algorithm at a predetermined periodic interval. Execution of the algorithm provides a firing angle, duty cycle, or other suitable control function solution for an electronic valve for each periodic interval, thereby controlling the behavior of the motor. Additionally, the method includes firing the electronic valve at the calculated timing during each periodic interval such that the motor functions in accordance with desired motor operational parameters.

Claims

1. A motor control module adapted to universally control any of a plurality of motors utilized in a plurality of differing implementations, said motor control module comprising:

a first memory device adapted to store a generic control algorithm and at least one programmable variable utilized during execution of the generic control algorithm;

a second memory device adapted to store at least one programmable constant that represents a function parameter relating to a specific functionality of a specific, selected motor used in a specific, selected motor application; and

a processor adapted to execute the generic control algorithm implementing the variable and the constant to transform the generic control algorithm from a non-tool-specific format into a tool-specific format specifically suited for controlling the specific, selected motor used in the specific, selected motor application;

wherein the at least one programmable constant comprises at least one of;

a non-motor function parameter relating to the specific application of the specific, selected motor;

a motor function parameter relating to an operational parameter of the specific, selected motor used in the specific application;

at least one look-up table utilized as a transfer function accessible during execution of the generic control algorithm, the look-up table comprising a plurality of predetermined timing solutions for controlling a flow of current through the specific, selected motor; and

wherein the timing solution comprises a firing angle solution for controlling the operation of an electronic valve configured to control the flow of current through the specific, selected motor.

2. The control module of claim 1, wherein the second memory device is further adapted to store a state diagram for enabling and disabling the non-motor function parameter.

3. The control module of claim 1, wherein the timing solution comprises a duty cycle solution for controlling the operation of an electronic valve configured to control the flow of a DC current through the specific, selected motor.

4. The control module of claim 1, wherein the variables comprise motor operating criterion that are periodically sampled during operation of the specific, selected motor, the specific, selected motor operating criterion comprising at least one of:

a trigger position;

a closed loop dial;

an open loop dial;

a current flow through the specific, selected motor;

a voltage across the specific, selected motor; and

a speed of the specific, selected motor.

5. A method for controlling a motor utilizing a universal control module, said method comprising:

storing a generic control algorithm in the universal control module, the generic control algorithm including at least one programmable constant;

electrically connecting the universal control module to a selected one of a plurality of different motors;

executing the generic control algorithm incorporating the programmable constant to;

transform the generic control algorithm from a non-application-specific format into an application-specific format specifically suited for controlling the selected motor used in a specific, selected motor application; and

generate a timing solution for controlling a flow of current through the selected motor so that operation of the selected motor is tailored in accordance with performance parameters of a specific, selected application of the selected motor;

wherein the constant comprises at least one of;

a non-motor function parameter relating to the specific, selected application of the selected motor; and

a motor function parameter relating to an operational parameter of the selected motor used in the specific, selected application;

operating an electronic valve in accordance with the timing solution to control the flow of current through the selected motor; and

wherein the plurality of motors comprises at least one of;

a plurality of different motors having at least one of a different size, a different operational rating and a different type, and the motors are adaptable for use in a plurality of differing motor application requiring differing motor performance parameters; and

a plurality of substantially similar motors adaptable for use in a plurality of differing motor application requiring differing motor performance parameters.

6. The method of claim 5, wherein the universal control module includes:

a non-volatile non-alterable memory device having stored therein the generic control algorithm and the motor function parameters; and

a non-volatile alterable memory device having stored therein the non-motor function parameters.

7. The method of claim 5, wherein:

executing the generic control algorithm comprises utilizing at least one look-up table as a transfer function accessible during execution of the generic control algorithm, and

the content of the look-up table comprises a plurality of predetermined timing solutions.

8. The method of claim 5, wherein the method further comprises enabling the soft-coded non-motor function parameter utilizing a state diagram stored in the control module.

9. The method of claim 5, wherein executing the generic control algorithm comprises:

sampling at least one motor operating criterion during operation of the selected motor, the selected motor operating criterion being representative of a pertinent motor input; and

utilizing the selected motor operation criterion as an input to the generic control algorithm during execution of the generic control algorithm.

10. The method of claim 5, wherein:

the selected motor comprises an AC motor; and

executing the generic control algorithm comprises generating a firing angle to control an electronic valve that controls the flow of current through the AC motor so that operation of the AC motor is tailored in accordance with performance parameters of the specific application.

11. The method of claim 5, wherein:

the selected motor comprises a DC motor; and

executing the generic control algorithm comprises generating a duty cycle to control an electronic valve that controls the flow of current through the DC motor so that operation of the DC motor is tailored in accordance with performance parameters of the specific application.

12. A method for controlling a motor utilizing a universal control module, said method comprising:

storing a generic control algorithm in the universal control module, the generic control algorithm including at least one programmable constant;

electrically connecting the universal control module to a selected one of a plurality of different motors;

executing the generic control algorithm incorporating the programmable constant to;

transform the generic control algorithm from a non-application-specific format into an application-specific format specifically suited for controlling the selected motor used in a specific, selected motor application; and

generate a timing solution for controlling a flow of current through the selected motor so that operation of the selected motor is tailored in accordance with performance parameters of a specific, selected application of the motor;

wherein the constant comprises at least one of;

a non-motor function parameter relating to the specific application of the selected motor; and

a motor function parameter relating to an operational parameter of the selected motor used in the specific application;

operating an electronic valve in accordance with the timing solution to control the flow of current through the selected motor; and

wherein executing the generic control algorithm includes;

sampling at least one motor operating criterion during operation of the selected motor, the selected motor operating criterion being representative of a pertinent motor input; and

utilizing the selected motor operation criterion as an input to the generic control algorithm during execution of the generic control algorithm.

13. The method of claim 12, wherein the universal control module includes:

a non-volatile non-alterable memory device having stored therein the generic control algorithm and the motor function parameters; and

a non-volatile alterable memory device having stored therein the non-motor function parameters.

14. The method of claim 12, wherein:

executing the generic control algorithm comprises utilizing at least one look-up table as a transfer function accessible during execution of the generic control algorithm, and

the content of the look-up table comprises a plurality of predetermined timing solutions.

15. The method of claim 12, wherein the method further comprises enabling the soft-coded non-motor function parameter utilizing a state diagram stored in the universal control module.

16. The method of claim 12, wherein:

the selected motor comprises an AC motor; and

executing the generic control algorithm comprises generating a firing angle to control an electronic valve that controls the flow of current through the AC motor so that operation of the AC motor is tailored in accordance with performance parameters of the specific application.

17. The method of claim 12, wherein:

the selected motor comprises a DC motor; and

executing the generic control algorithm comprises generating a duty cycle to control an electronic valve that controls the flow of current through the DC motor so that operation of the DC motor is tailored in accordance with performance parameters of the specific application.