Methods and systems for recording operating information of an electric motor

• US 8,269,448 B2
• Filed: 01/15/2010
• Issued: 09/18/2012
• Est. Priority Date: 03/09/2007
• Status: Active Grant

• Current Assignee: Regal Beloit America, Inc.
• Original Assignee: RBC Manufacturing Corp. (Regal Rexnord Corp.)
• Inventors: Beifus, Brian L., Selking, Paul Nathanael, Koller, Michael R., Gurudasani, Vijay Dayaldas
• Primary Examiner(s): Benson, Walter
• Assistant Examiner(s): Paul, Antony M
• Application Number:
  US12/688,443
• Publication Number:
  US 20100117584A1
• Time in Patent Office: 977 Days
• Field of Search: 318/400.21, 318/400.22, 318/783, 318/490, 327/180, 327/321, 327/312, 360/323, 257/173, 368/141, 363/56.11, 361/23, 361/1, 361/20, 361/272, 361/534, 361/93.1, 738/62, 320/134, 369/275.5, 369/53.21, 700/21, 700/79, 700/292, 711/E12.102
• US Class Current: 318/490
• CPC Class Codes: G05B 2219/23193 Memory stores lifetime, different settings, configurations of controlled device
• CPC Class Codes: G05B 2219/24053 Diagnostic of controlled machine
• CPC Class Codes: G05B 2219/24067 Processor stores variables, events and date in eeprom, for external monitor
• CPC Class Codes: G05B 23/0264 Control of logging system, e.g. decision on which data to store; time-stamping measurements
• CPC Class Codes: H02P 29/02 Providing protection against overload without automatic interruption of supply protection against faults of stepper motors H02P8/36
• CPC Class Codes: H02P 29/024 Detecting a fault condition, e.g. short circuit, locked rotor, open circuit or loss of load
• CPC Class Codes: H02P 29/0241 the fault being an overvoltage
• CPC Class Codes: H02P 6/06 Arrangements for speed regulation of a single motor wherein the motor speed is measured and compared with a given physical value so as to adjust the motor speed
• CPC Class Codes: H02P 6/34 Modelling or simulation for control purposes

Abstract

A unit for recording operating information of an electronically commutated motor (ECM) is described. The unit includes a system controller communicatively coupled to an ECM. The system controller includes a processing device configured to control the unit. The unit also includes a memory device communicatively coupled to the system controller. The memory device is configured to receive and store ECM operating information provided by the processing device.

Claims

1. A unit for recording operating information of an electric motor, said unit comprising:

a motor controller communicatively coupled to an electric motor, said motor controller comprising a processing device configured to control said unit, collect operating data from an electric motor, and identify at least one of a motor failure and a motor controller failure;

a protective circuit communicatively coupled to said processing device; and

a memory device communicatively coupled to said protective circuit, said memory device configured to receive and store motor operating information after at least one of a motor failure, a motor controller failure, and a user provided power-down instruction, the operating information provided by said processing device via said protective circuit, said protective circuit configured to limit a voltage applied to said memory device.

2. A unit according to claim 1 wherein said memory device comprises a communications interface configured to allow a user to access the contents of said memory device.

3. A unit according to claim 1 wherein said memory device comprises a non-volatile memory.

4. A unit according to claim 1 wherein said processing device comprises a random access memory (RAM) configured to temporarily store the motor operating information.

5. A unit according to claim 1 wherein said memory device comprises at least one of an erasable programmable read-only memory and a flash memory.

6. A unit according to claim 1 wherein said processing device comprises an internal memory device.

7. A unit according to claim 1 wherein the motor operating information comprises at least one of production process information, scratch-pad information, a total length of time said electric motor receives power, a total length of time said electric motor has run, a total length of time said electric motor has operated in a cutback region, a total length of time said electric motor has operated with a temperature above a thermal limit setting, a total number of cycles said electric motor has completed, a high operating temperature, a low operating temperature, a final operating torque level, a final operating bus voltage, a last operating speed, a last module temperature, a count of fault events, a count of reset cycles, a count of oscillator stop events, and a count of stall events.

8. A unit according to claim 1 wherein said electric motor comprises an electronically commutated motor (ECM).

9. A unit according to claim 1 wherein said processing device is communicatively coupled to a system controller, said memory device further configured to store system controller information for use by a successive system controller.

10. A method for providing a system to record operating information of an electric motor, said method comprising:

configuring a processing device to collect operating data from an electric motor;

configuring the processing device to identify at least one of a motor failure and a motor controller failure;

configuring a memory device to receive and store the operating data after at least one of a motor failure, a motor controller failure, and a user provided power-down instruction;

positioning a protective circuit between the processing device and the memory device; and

configuring the protective circuit to limit voltages applied to the memory device.

11. A method according to claim 10 further comprising configuring the processing device to temporarily store the operating data in a random access memory (RAM).

12. A method according to claim 11 further comprising configuring the processing device to transfer the operating data stored in the RAM to the memory device.

13. A method according to claim 10 further comprising configuring the memory device to survive at least one of a motor failure and a motor controller failure.

14. A method according to claim 10 wherein the electric motor comprises an electronically commutated motor (ECM).

15. A method according to claim 10 further comprising:

communicatively coupling a system controller to the processing device; and

configuring the memory device to receive and store system controller information for use by a successor system controller upon replacement of the system controller.

16. A motor system comprising:

an electric motor;

a motor controller communicatively coupled to said electric motor, said motor controller comprising a processing device configured to control operation of said electric motor, collect operating data from the electric motor, and identify at least one of a motor failure and a motor controller failure;

a protective circuit communicatively coupled to said processing device; and

a memory device communicatively coupled to said protective circuit, said memory device configured to receive, from said processing device via said protective circuit, and store the operating information collected by said processing device after at least one of a motor failure, a motor controller failure, and a user provided power-down instruction, the operating information, said protective circuit configured to limit a voltage applied to said memory device.

17. A system according to claim 16 wherein said memory device comprises a communications interface configured to allow a user to access the contents of said memory device.

18. A system according to claim 16 wherein said memory device is further configured to prevent at least one of loss of information and corruption of information stored by said memory device.

19. A system according to claim 16 wherein said processing device comprises a random access memory (RAM) configured to temporarily store the operating information.

20. A system according to claim 16 wherein said processing device comprises an internal memory device.

21. A system according to claim 16 wherein said memory device comprises at least one of an erasable programmable read-only memory and a flash memory.

22. A system according to claim 16 wherein the operating information comprises at least one of production process information, scratch-pad information, a total length of time said electric motor receives power, a total length of time said electric motor has run, a total length of time said electric motor has operated in a cutback region, a total length of time said electric motor has operated with a temperature above a thermal limit setting, a total number of cycles said electric motor has completed, a high operating temperature, a low operating temperature, a final operating torque level, a final operating bus voltage, a last operating speed, a last module temperature, a count of fault events, a count of reset cycles, a count of oscillator stop events, and a count of stall events.

23. A system according to claim 16 wherein said electric motor comprises an electronically commutated motor (ECM).

24. A system according to claim 16 further comprising a system controller communicatively coupled to said processing device, said memory device further configured to store system controller information for use by a successor system controller upon replacement of said system controller.

25. A method for recording operating information of an electric motor, said method comprising:

storing system controller data;

collecting operating data from an electric motor;

identifying at least one of a motor failure and a motor controller failure;

storing the electric motor operating data after identifying at least one of a motor failure and a motor controller failure;

providing the stored electric motor operating data and the stored system controller data to a replacement system controller; and

protecting the stored electric motor operating data and the stored system controller data from corruption caused by the at least one of a motor failure and a motor controller failure.