High-temperature brushless DC motor controller

• US 9,654,035 B1
• Filed: 09/30/2014
• Issued: 05/16/2017
• Est. Priority Date: 09/30/2014
• Status: Active Grant

• Current Assignee: National Technology & Engineering Solutions Of Sandia LLC (Honeywell International Inc.)
• Original Assignee: Sandia Corporation (Martin Marietta Corporation)
• Inventors: Cieslewski, Crzegorz, Lindblom, Scott C., Maldonado, Frank J., Eckert, Michael Nathan
• Primary Examiner(s): Duda, Rina
• Application Number:
  US14/502,821
• Time in Patent Office: 959 Days
• Field of Search: 318599, 318811, 318459, 318500, 318461, 318797, 318801
• CPC Class Codes: H02M 7/48 using discharge tubes with control electrode or semiconductor devices with control electrode
• CPC Class Codes: H02P 27/08 with pulse width modulation
• CPC Class Codes: H02P 6/085 in a bridge configuration

Abstract

A motor control system for deployment in high temperature environments includes a controller; a first half-bridge circuit that includes a first high-side switching element and a first low-side switching element; a second half-bridge circuit that includes a second high-side switching element and a second low-side switching element; and a third half-bridge circuit that includes a third high-side switching element and a third; low-side switching element. The motor controller is arranged to apply a pulse width modulation (PWM) scheme to switch the first half-bridge circuit, second half-bridge circuit, and third half-bridge circuit to power a motor.

Claims

1. A motor controller for deployment in high temperature environments, comprising:

a first half-bridge circuit comprising a first high-side switching element and a first low-side switching element;

a second half-bridge circuit comprising a second high-side switching element and a second low-side switching element;

a third half-bridge circuit comprising a third high-side switching element and a third;

low-side switching element;

wherein the controller is arranged to apply a pulse width modulation (PWM) scheme to switch the first half-bridge circuit, second half-bridge circuit, and third half-bridge circuit to power a motor; and

wherein the controller is configured to detect a stall condition of the motor in response to a voltage feedback signal; and

to stop commutation of the motor in response to detecting the stall condition; and

a charge pump to provide a control voltage to the controller that is greater than a rated power supply voltage (VCC) for operation of the high-side switching element.

2. The motor controller of claim 1, wherein the controller is configured to implement a constant speed algorithm, the constant speed algorithm configured to commute the motor at a predetermined rotational speed.

3. The motor controller of claim 1, wherein the controller is configured to switch the first half-bridge circuit, the second half-bridge circuit and the third half-bridge circuit in a predetermined sequence to provide a current sufficient to ensure a predetermined torque output.

4. The motor controller of claim 3, wherein the controller is configured to switch the first half-bridge circuit, the second half-bridge circuit and the third half-bridge circuit in a predetermined sequence to slowly increase a motor speed to a constant operating speed.

5. The motor controller of claim 1, further comprising an analog-to-digital converter (ADC), wherein the ADC provides a voltage feedback signal to the controller, and the controller adjusts an output power to the motor in response to the voltage feedback signal.

6. The motor controller of claim 1, wherein the controller dynamically adjusts a PWM duty cycle to increase or decrease a torque generated by the motor.

7. The motor controller of claim 2, wherein the constant speed algorithm determines a remedial commutation sequence to apply to the motor in response to the voltage feedback signal.

8. The motor controller of claim 7, wherein the voltage feedback signal is processed by the controller to determine if the stall condition exists, and in response to determining that the stall condition exists, the controller stops commutation of the motor.

9. The motor controller of claim 1, wherein the motor comprises a Brushless DC motor.

10. The motor controller of claim 1, wherein the controller comprises a field programmable array.

11. The motor controller of claim 1, wherein at least one of the switching elements comprises a silicon-on-insulator (SOI) metal-oxide-semiconductor field-effect transistor (MOSFET) transistor.

12. A tool comprising:

a housing;

a protrusion pivotally attached to the housing;

a motor and a controller disposed within the housing; and

a coupling connected between the motor and protrusion;

wherein the protrusion is pivoted away from the housing in response to operation of the motor; and

wherein the controller comprises;

a first half-bridge circuit comprising a first high-side switching element and a first low-side switching element;

a second half-bridge circuit comprising a second high-side switching element and a second low-side switching element; and

a third half-bridge circuit comprising a third high-side switching element and a third;

low-side switching element;

wherein the controller is arranged to apply a pulse width modulation (PWM) scheme to switch the first half-bridge circuit, second half-bridge circuit, and third half-bridge circuit to power the motor; and

wherein the controller is configured to detect a stall condition of the motor in response to a voltage feedback signal; and

to stop commutation of the motor in response to detecting the stall condition; and

a charge pump to provide a control voltage to the controller that is greater than a rated power supply voltage (VCC) for operation of the high-side switching element.

13. The tool of claim 12, wherein the protrusion is pivoted away from the housing in response to operation of the motor by rotation of the coupling in response to rotation of the motor.

14. The tool of claim 12, wherein the controller is configured to implement a constant speed algorithm, the constant speed algorithm configured to commute the motor at a predetermined rotational speed.

15. The tool of claim 12, wherein the controller is configured to switch the first half-bridge circuit, the second half-bridge circuit and the third half-bridge circuit in a predetermined sequence to provide a current sufficient to ensure a predetermined torque output.

16. The tool of claim 15, wherein the controller is configured to switch the first half-bridge circuit, the second half-bridge circuit and the third half-bridge circuit in a predetermined sequence to slowly increase a motor speed to a constant operating speed.

17. The tool of claim 12, further comprising an analog-to-digital converter, wherein the analog-to-digital converter provides the voltage feedback signal to the controller, and the controller adjusts an output power to the motor in response to the voltage feedback signal.

18. The tool of claim 12, wherein the motor comprises a brushless DC motor.

19. The tool of claim 12, wherein the controller comprises a field programmable array.