Serial backplane for medium voltage motor drive system

• US 7,705,553 B2
• Filed: 09/10/2007
• Issued: 04/27/2010
• Est. Priority Date: 09/10/2007
• 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: Worrall, Stephen
• Primary Examiner(s): Duda; Rina I
• Application Number:
  US11/852,583
• Publication Number:
  US 20090066282A1
• Time in Patent Office: 960 Days
• Field of Search: 318/625, 318/46, 318/51, 318/798, 318/800, 318/802
• US Class Current: 318/625
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 7/1432 specially adapted for power drive units or power converters
• CPC Class Codes: H05K 7/14325 for cabinets or racks
• CPC Class Codes: H05K 7/1457 Power distribution arrangements

Abstract

A hybrid backplane uses multiple, parallel serial communication channels to provide flexibility and robustness in a motor drive control requiring high-speed data communication for the real-time control of motor waveforms.

Claims

1. A motor drive system controlling power semiconductor devices to provide controlled power to an electric motor, the motor drive system comprising:

a rack having a housing with a backplane, the housing providing slots holding modules removably held within the rack so that releasable electrical connectors on a rear face of the modules abut a mating electrical connector on the backplane;

a set of modules including;

at least one drive control module receiving command signals to provide gating signals for the control of the power semiconductor devices; and

at least two gate modules receiving gating signals and providing semiconductor drive signals to the power semiconductor devices;

wherein the backplane provides a set of separate serial communication channels communicating between the modules, each serial communication channel independently transferring multi-bit data words as sequential single bits;

wherein the separate serial communication channels include at least one serial communication channel communicating among multiple drive control modules and gate modules to direct gating signals between specific modules according to at least one address contained in transmitted data; and

whereby drive control modules and gate control modules may be reconfigured without rewiring.

2. The motor drive system of claim 1 wherein the power semiconductors are part of devices selected from the group consisting of:

at least one rectifier and at least one inverter.

3. The motor drive system of claim 1 wherein the separate communication channels include at least one serial communication channel dedicated to one pair of modules.

4. The motor drive system of claim 1 wherein at least one serial communication channel is full-duplex.

5. The motor drive system of claim 1 wherein at least one serial communication channel provides a transfer rate in excess of two Gbit per second.

6. The motor drive system of claim 1 wherein the set of modules further includes:

at least one communication module receiving command signals from a programmable logic controller;

at least two drive control modules; and

wherein the serial communication channels provide a full mesh interconnect among the communication module and the drive control modules.

7. The motor drive system of claim 1 wherein the set of modules further includes a data drive recorder recording data describing operation of the motor drive system.

8. The motor drive system of claim 1 wherein the separate serial communication channels include at least one shared serial communication channel communicating with multiple modules to direct data to specific modules according to at least one address contained in transmitted data, and at least one dedicated serial communication channel dedicated to a pair of modules;

wherein the separate serial communication channels communicate among the control modules and the shared communication channel communicates among the control modules and the gate modules.

9. The motor drive system of claim 1 wherein modules further include input/output modules accepting feedback signals from outside the rack.

10. The motor drive system of claim 1 wherein the serial communication channels are selected from the group consisting of Fiber Channel, Gbit Ethernet, XAUI, Infiniband, and Aurora.

11. The motor drive system of claim 1 wherein the serial communication channels use low voltage differential signaling.

12. The motor drive system of claim 1 wherein the control modules include a computer executing stored software allowing the control modules to receive commands to change the gate modules to which they are connected by changing addressing on a serial communication network.

13. The motor drive system of claim 1 wherein the control modules include a computer executing stored software allowing the control modules to assume a function of a failed control module.

14. The motor drive system of claim 1 wherein the separate serial communication channels include at least two serial communication channels communicating among multiple drive control modules and gate modules to direct gating signals between specific modules according to at least one address contained in transmitted data.

15. A method of controlling power semiconductor devices to provide controlled power to an electric motor in a motor drive system including:

a rack having a housing with a backplane, the housing providing slots holding modules removably held within the rack so that releasable electrical connectors on a rear face of the modules abut a mating electrical connector on the backplane

a set of modules including;

at least one drive control module receiving command signals to provide gating signals for the control of the power semiconductor devices; and

at least one gate module receiving gating signals and providing semiconductor drive signals to the power semiconductor devices;

wherein the backplane provides a set of separate serial communication channels communicating between the modules, each serial communication channel independently transferring multi-bit data words as sequential single bits;

wherein the separate serial communication channels include at least one serial communication channel communicating among multiple drive control modules and at least one gate module to direct gating signals between specific modules according to at least one address contained in transmitted data;

wherein the method comprises the steps of;

(1) communicating among drive control modules and the gate control modules using different serial communication channels; and

(2) reconfiguring the communication of gating signals among drive control modules and gate modules by changing addresses contained in the transmitted data.

16. The method of claim 15 wherein the control modules receive commands to change the gate modules to which they are connected by changing addressing of messages on a serial communication channel.

17. The method of claim 15 wherein the control modules assume the function of a failed control module by communicating over the dedicated serial communication channels and the backup gate driver module shared communication channel.

18. The method of claim 15 wherein the separate serial communication channels include at least two serial communication channels communicating among multiple drive control modules and gate modules to direct gating signals between specific modules according to at least one address contained in transmitted data.