Method and apparatus for controlling pulse-width modulation in an electric motor

• US 8,766,572 B2
• Filed: 03/28/2011
• Issued: 07/01/2014
• Est. Priority Date: 03/26/2010
• Status: Active Grant

• Current Assignee: Great Star Tools USA, Inc.
• Original Assignee: Shop-Vac Corporation (Hangzhou Great Star Industrial Company Limited)
• Inventors: Norell, Neil N.
• Primary Examiner(s): LUO, DAVID S
• Application Number:
  US13/073,474
• Publication Number:
  US 20110234131A1
• Time in Patent Office: 1,191 Days
• Field of Search: 318/400.09, 318/400.01, 318/700
• US Class Current: 318/400.09
• CPC Class Codes: A47L 9/0411 driven by electric motor
• CPC Class Codes: A47L 9/0444 for conveying motion by endless flexible members, e.g. belts
• CPC Class Codes: A47L 9/2842 Suction motors or blowers
• CPC Class Codes: A47L 9/2857 User input or output elements for control, e.g. buttons, switches or displays
• CPC Class Codes: A47L 9/2889 Safety or protection devices or systems, e.g. for prevention of motor over-heating or for protection of the user
• CPC Class Codes: H02P 6/085 in a bridge configuration

Abstract

In a method of controlling current in a control circuit of an electric motor, pulse-width modulation (PWM) pulses are applied to a stator of the electric motor, via a plurality of transistors of the control circuit, using a first control mode when a rotational speed of a rotor of the electric motor is within a first range. At least one PWM pulse is applied to the stator, via a subset of the plurality of transistors, using a second control mode when the rotational speed of the rotor is within a second range. When it is determined that the rotational speed of the rotor has changed from being within the second range to being within the first range, additional PWM pulses are applied to the stator such that, for each of the plurality of transistors, a current through the transistor does not exceed a maximum current capacity of the transistor.

Claims

1. A method of controlling pulse-width modulation (PWM) for an electric motor, the method comprising:

applying PWM pulses of a fixed width to a plurality of stator windings of a stator of the electric motor when a rotational speed of the electric motor is below a pre-determined threshold;

applying, to at least one subset of the plurality of stator windings, at least one PWM pulse having a phase advance with respect to the fixed-width PWM pulses when the rotational speed of the electric motor exceeds the pre-determined threshold;

determining that the rotational speed of the electric motor has dropped from being above the pre-determined threshold to being below the pre-determined threshold; and

disabling power to the plurality of stator windings when it is determined that the rotational speed of the electric motor has dropped below the pre-determined threshold.

2. The method of claim 1, wherein disabling power to the plurality of stator windings comprises disabling a first PWM pulse having the fixed width which would otherwise have been applied to a first subset of the plurality of stator windings when the rotational speed of the electric motor dropped below the pre-determined threshold.

3. The method of claim 2, further comprising applying a second PWM pulse having the fixed width to a second subset of the plurality of stator windings after disabling the first fixed-width PWM pulse.

4. The method of claim 3, wherein applying the second fixed-width PWM pulse to the second subset of the plurality of stator windings is performed without making another determination of the rotational speed of the electric motor after it is determined that the rotational speed has dropped below the pre-determined threshold.

5. The method of claim 1, wherein determining that the rotational speed of the electric motor has dropped below the pre-determined threshold comprises:

using an optical sensor communicatively coupled to a rotor of the electric motor to generate a signal in response to rotation of the rotor; and

determining that the rotational speed of the electric motor is below the pre-determined threshold based on the signal from the optical sensor.

6. The method of claim 1, further comprising, for each of the at least one phase-advanced PWM pulse, determining the phase advance based on the rotational speed of the electric motor, a maximum torque of the electric motor at a first operating load, and a maximum torque of the electric motor at a second operating load that is higher than the first operating load.

7. A motor apparatus comprising:

a stator having a plurality of stator poles;

a rotor configured to rotate in response to pulse-width modulation (PWM) pulses applied to the plurality of stator poles; and

a control circuit comprising a plurality of electronic switching mechanisms, the control circuit configured to;

apply PWM pulses to the plurality of stator poles based on a rotational speed of the rotor, via the plurality of electronic switching mechanisms;

determine that the rotational speed of the rotor has dropped below a pre-determined threshold; and

in response to determining that the rotational speed has dropped below the pre-determined threshold, apply additional PWM pulses to the plurality of stator poles such that, for each of the plurality of electronic switching mechanisms, a current through the electronic switching mechanism does not exceed a maximum current capacity of the electronic switching mechanism.

8. The motor apparatus of claim 7, wherein the control circuit is configured to:

disable, in response to determining that the rotational speed has dropped below the pre-determined threshold, a next PWM pulse which would otherwise have been applied to a first subset of the plurality of stator poles adjacent in time to a previous PWM pulse applied to the first subset of the plurality of stator poles; and

apply the additional PWM pulses to the plurality of stator poles after disabling the next PWM pulse which would otherwise have been applied to the first subset of the plurality of stator poles.

9. The motor apparatus of claim 8, wherein the plurality of electronic switching mechanisms comprises a plurality of insulated gate bipolar transistors.

10. The motor apparatus of claim 8, wherein the control circuit is configured to apply PWM pulses of a fixed width to the plurality of stator poles when the rotational speed of the rotor is below the pre-determined threshold and to apply PWM pulses that are phase-advanced with respect to the fixed-width PWM pulses when the rotational speed of the rotor exceeds the pre-determined threshold, wherein the previous PWM pulse applied to the first subset of the plurality of stator poles comprises at least a portion of one of the phase-advanced PWM pulses, and wherein the next PWM pulse which would otherwise have been applied to the first subset of the plurality of stator poles is one of the fixed-width PWM pulses.

11. The motor apparatus of claim 8, wherein the control circuit is further configured to apply at least one of the additional PWM pulses before making a further determination of the rotational speed of the rotor.

12. The motor apparatus of claim 8, wherein the control circuit is further configured to apply a first one of the additional PWM pulses to the first subset of the plurality of stator poles without applying the first additional PWM pulse adjacent in time to the previous PWM pulse applied to the first subset of the plurality of stator poles.

13. The motor apparatus of claim 8, wherein the control circuit is further configured to apply a first one of the additional PWM pulses to a second subset of the plurality of stator poles.

14. The motor apparatus of claim 7, further comprising a sensor communicatively coupled to the control circuit and configured to send a signal to the control circuit in response to rotation of the rotor, wherein the control circuit is further configured to determine the rotational speed of the rotor based on the signal from the sensor.

15. A method of controlling current in a control circuit of an electric motor, the electric motor having a stator and a rotor configured to rotate in response to pulse-width modulation (PWM) pulses applied to the stator, the method comprising:

applying PWM pulses to the stator, via a plurality of transistors of the control circuit, using a first control mode when a rotational speed of the rotor is within a first range;

applying at least one PWM pulse to the stator, via a subset of the plurality of transistors, using a second control mode when the rotational speed of the rotor is within a second range;

determining the rotational speed of the rotor; and

applying, when it is determined that the rotational speed of the rotor has changed from being within the second range to being within the first range, additional PWM pulses to the stator such that, for each of the plurality of transistors, a current through the transistor does not exceed a maximum current capacity of the transistor.

16. The method of claim 15, wherein applying the additional PWM pulses to the stator such that the maximum current capacity is not exceeded comprises:

disabling a first PWM pulse of the first control mode which would otherwise have been applied to the stator adjacent in time to at least a portion of a PWM pulse of the second control mode, when it is determined that the rotational speed of the rotor has changed from being within the second range to being within the first range; and

applying the additional PWM pulses to the stator, using the first control mode, after disabling the first PWM pulse which would otherwise have been applied to the stator.

17. The method of claim 16, wherein applying the additional PWM pulses to the stator further comprises applying at least one of the additional PWM pulses to the stator, using the first control mode, before making a further determination of the rotational speed of the rotor.

18. The method of claim 15, wherein determining the rotational speed of the rotor is performed using a signal received from a sensor communicatively coupled to the rotor, the signal being generated by the sensor in response to rotation of the rotor.

19. The method of claim 18, wherein determining the rotational speed of the rotor is performed each time the signal received from the sensor transitions from a first level to a second level.

20. The method of claim 15, wherein applying PWM pulses to the stator using the first control mode comprises applying PWM pulses of a fixed width to the stator, and wherein applying the at least one PWM pulse to the stator using the second control mode comprises applying, to the stator, at least one PWM pulse having a phase advance with respect to the fixed-width PWM pulses.