Systems for heating, ventilation, and air conditioning applications

• US 9,657,960 B2
• Filed: 11/09/2015
• Issued: 05/23/2017
• Est. Priority Date: 08/08/2008
• Status: Active Grant

• Current Assignee: Regal Beloit America, Inc. (Regal Rexnord Corp.)
• Original Assignee: Regal Beloit America, Inc. (Regal Rexnord Corp.)
• Inventors: Barry, Andrew C., Knollman, Andrew M., Koller, Michael R., Beifus, Brian L., Becerra, Roger Carlos, Nardin, Steven A.
• Primary Examiner(s): Glass, Erick
• Application Number:
  US14/936,054
• Publication Number:
  US 20160061479A1
• Time in Patent Office: 561 Days
• Field of Search: 31840009
• CPC Class Codes: F04D 27/001 Testing thereof; Determination or simulation of flow characteristics; Stall or surge detection, e.g. condition monitoring
• CPC Class Codes: F04D 27/004 by varying driving speed
• CPC Class Codes: F24F 11/30 for purposes related to the operation of the system, e.g. for safety or monitoring
• CPC Class Codes: F24F 11/62 characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values
• CPC Class Codes: F24F 11/67 Switching between heating and cooling modes
• CPC Class Codes: F24F 11/74 for controlling air flow rate or air velocity
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: F24F 2110/00 Control inputs relating to air properties
• CPC Class Codes: F24F 2110/10 Temperature
• CPC Class Codes: G05D 23/19 characterised by the use of electric means G05D23/1393 takes precedence
• CPC Class Codes: G05D 23/1917 using digital means
• 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: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

A motor control system for heating, ventilation, and air conditioning (HVAC) applications is described. The motor control system includes a thermostat and an electronically commutated motor (ECM) coupled to the thermostat. The ECM is configured to retrofit an existing non-ECM electric motor included in an HVAC application and to operate in one of a plurality of HVAC modes. The HVAC modes include at least one of a heating mode, a cooling mode, and a continuous fan mode. The HVAC mode is determined based at least partially on outputs provided by the thermostat.

Claims

1. A motor control system for heating, ventilation, and air conditioning (HVAC) applications, said motor control system comprising:

a motor;

control circuitry coupled to said motor, said control circuitry configured to determine a motor operating profile at which the motor operates based on a selected mode of operation; and

an interface module coupled to said control circuitry, said interface module configured to be electronically connected to a first device and a second device and further configured to provide said control circuitry with the selected mode of operation based on at least one of a first voltage signal received from the first device and a second voltage signal received from the second device, wherein the second voltage signal is different than the first voltage signal.

2. The motor control system in accordance with claim 1, wherein one of said first device and said second device is a thermostat.

3. The motor control system in accordance with claim 1, wherein one of said first device and second device is a system controller.

4. The motor control system in accordance with claim 1, wherein the motor operating profile comprises a motor speed selected based on at least one of the first voltage signal and the second voltage signal.

5. The motor control system in accordance with claim 1, wherein the control circuitry is configured to enable a service technician to at least one of create and edit the motor operating profile at a field location.

6. The motor control system in accordance with claim 1, further comprising a set of diodes positioned between the first device and said motor, said set of diodes configured to prevent a short circuit.

7. The motor control system in accordance with claim 1, wherein said motor, said control circuitry, and said interface module are included within a single housing.

8. The motor control system in accordance with claim 1, wherein the interface module is integrated into said control circuitry.

9. The motor control system in accordance with claim 1, wherein said interface module comprises a plurality of optically isolated relays.

10. The motor control system in accordance with claim 1, wherein said interface module comprises a plurality of differently colored light-emitting diodes configured for use in troubleshooting said interface module.

11. The motor control system in accordance with claim 1, wherein said interface module comprises at least one resistor that enables said interface module to operate while being supplied with one of two different power supply voltage levels.

12. The motor control system in accordance with claim 1, wherein said interface module is coupled to a power supply and is configured to sense a power supply voltage level from said power supply.

13. A motor control system for heating, ventilation, and air conditioning (HVAC) applications, said motor control system comprising:

a motor;

control circuitry coupled to said motor, said control circuitry configured to determine a motor operating profile at which the motor operates based on a selected mode of operation; and

an interface module coupled to said control circuitry, said interface module configured to be electronically connected to a first device and a second device and further configured to provide said control circuitry with the selected mode of operation based on at least one of a first voltage signal received from the first device and a second voltage signal received from the second device, wherein said interface module is configured to receive the first voltage signal wirelessly.

14. A motor control system for heating, ventilation, and air conditioning (HVAC) applications, said motor control system comprising:

a motor;

control circuitry coupled to said motor, said control circuitry configured to determine a motor operating profile at which the motor operates based on a selected mode of operation; and

an interface module coupled to said control circuitry, said interface module configured to be electronically connected to a first device and a second device and further configured to provide said control circuitry with the selected mode of operation based on at least one of a first voltage signal received from the first device and a second voltage signal received from the second device,

wherein the motor operating profile is selected from among a plurality of motor operating profiles included in a table of predefined motor operating profiles based on the at least one of the first voltage signal and the second voltage signal, wherein the plurality of motor operating profiles are calculated to substantially match an airflow produced by said motor to an airflow produced by a different motor.

15. The motor control system in accordance with claim 14, wherein the plurality of motor operating profiles are configured such that said motor does not operate at a constant speed or a constant torque, and said motor operates to produce an airflow that is substantially equivalent to an airflow produced by a different motor replaced by said motor.

16. A motor control system for heating, ventilation, and air conditioning (HVAC) applications, said motor control system comprising:

a motor;

control circuitry coupled to said motor, said control circuitry configured to determine a motor operating profile at which the motor operates based on a selected mode of operation; and

an interface module coupled to said control circuitry, said interface module configured to be electronically connected to a first device and a second device and further configured to provide said control circuitry with the selected mode of operation based on at least one of a first voltage signal received from the first device and a second voltage signal received from the second device, wherein said interface module is configured to select one of a heating mode, a cooling mode, and a continuous fan mode as the selected mode of operation, wherein the motor operating profile for the continuous fan mode comprises a lower torque and a lower speed than the heating mode and the cooling mode.