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Integrated motor driver/controller with sensorless or sensored commutation

  • US 9,748,882 B1
  • Filed: 03/28/2016
  • Issued: 08/29/2017
  • Est. Priority Date: 03/28/2016
  • Status: Active Grant
First Claim
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1. A motor controller configured to control any designated one of at least three different types of electronically commutated motors (ECMs), the motor controller comprising:

  • a controller area network (CAN) connection;

    a switching assembly configured to control current flow through a phase A stator coil of an ECM, a phase B stator coil of the ECM, and a phase C stator coil of the ECM;

    a phase B current sensor configured to measure current flowing through the phase B stator coil;

    a phase C current sensor configured to measure current flowing through the phase C stator coil;

    rotor orientation signal inputs including;

    one or more Hall sensor inputs configured to receive output generated by Hall sensors responsive to the ECM including the one or more Hall sensors configured to sense orientation of a rotor of the ECM; and

    one or more encoder inputs configured to receive output generated by one or more encoders responsive to the ECM including the one or more encoders configured to sense orientation of the rotor; and

    a control unit operatively coupled with the CAN connection, the rotor orientation signal inputs, the phase B current sensor, the phase C current sensor, and the switching assembly, the control unit being configured to;

    receive D and Q axis current commands via the CAN connection;

    receive data designating one of at least three different types of ECMs via the CAN connection and store the designated ECM type in memory, the at least three different types of ECMs including a) an ECM that includes one or more Hall sensors configured to sense rotor orientation, b) an ECM that includes one or more encoders configured to sense rotor orientation, and c) an ECM that does not include any sensors configured to sense rotor orientation; and

    control the switching assembly to operate the ECM in accordance with the D and Q axis current commands using rotor orientation estimated based on at least one of a) the output generated by the one or more Hall sensors, b) the output generated by the one or more encoders, or c) outputs from the phase B current sensor and the phase C current sensor.

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