Hybrid drive circuit for variable speed induction motor

• US 9,800,188 B2
• Filed: 09/15/2015
• Issued: 10/24/2017
• Est. Priority Date: 09/15/2015
• Status: Active Grant

• Current Assignee: Regal Beloit America, Inc.
• Original Assignee: Regal Beloit America, Inc.
• Inventors: Chretien, Ludovic Andre, Becerra, Roger Carlos
• Primary Examiner(s): Ip, Paul
• Application Number:
  US14/854,757
• Publication Number:
  US 20170077857A1
• Time in Patent Office: 770 Days
• Field of Search: 318772, 318785, 318786, 318794, 318798, 318807
• CPC Class Codes: H02P 1/426 by using a specially adapted frequency converter
• CPC Class Codes: H02P 1/44 by phase-splitting with a capacitor
• CPC Class Codes: H02P 23/0086 specially adapted for high speeds, e.g. above nominal speed
• CPC Class Codes: H02P 23/02 specially adapted for optimising the efficiency at low load
• CPC Class Codes: H02P 23/28 Controlling the motor by varying the switching frequency of switches connected to a DC supply and the motor phases
• CPC Class Codes: H02P 25/04 Single phase motors, e.g. capacitor motors
• CPC Class Codes: H02P 27/08 with pulse width modulation

Abstract

Hybrid motor drive circuits configured to drive a motor are provided herein. A hybrid motor drive circuit includes an inverter coupled to the motor and configured to drive the motor when a motor commanded frequency is not within a predetermined range of line input power frequencies. The hybrid motor drive circuit also includes a first switch device configured to couple line input power to an output of the inverter when the motor commanded frequency is within the predetermined range of line input power frequencies.

Claims

1. A motor drive circuit configured to drive a motor, said motor drive circuit comprising:

a three-phase inverter coupled to the motor and configured to generate a two-phase AC output voltage to drive the motor when a motor commanded frequency is not within a predetermined range of line input power frequencies, said three-phase inverter comprising;

a first phase output coupled to a main winding of the motor;

a second phase output coupled to the main winding and a start winding of the motor; and

a third phase output coupled to a capacitor that is coupled to the start winding; and

a first switch device configured to couple line input power to an output of the inverter to drive the motor using the line input power when the motor commanded frequency is within the predetermined range of line input power frequencies.

2. The motor drive circuit of claim 1, further comprising a power converter configured to convert alternating current (AC) line input power to direct current (DC) power, the AC line input power received from a power source at an input terminal.

3. The motor drive circuit of claim 1, wherein:

said first phase output is coupled to a first side of the main winding;

said second phase output is coupled to a second side of the main winding and a first side of the start winding; and

said third phase output is coupled to the capacitor that is series-coupled to a second side of the start winding.

4. The motor drive circuit of claim 3, further comprising a second switch device configured to enable the capacitor of the motor when the first switch device couples the line input power to the output of the three-phase inverter.

5. The motor drive circuit of claim 1, further comprising:

the start winding comprising an input coupled to the second phase output of the three-phase inverter and an output coupled to a third phase output of the three-phase inverter; and

the capacitor comprising an input coupled to the third phase output of the three-phase inverter and an output.

6. The motor drive circuit of claim 1, further comprising a controller configured to control operation of the first switch device.

7. The motor drive circuit of claim 1, further configured to drive at least one of a compressor, a condenser fan, and an indoor blower motor.

8. The motor drive circuit of claim 1, further configured to drive a compressor motor and at least one of a reversing valve and an expansion valve in a cooling and heat pump application.

9. The motor drive circuit of claim 1, further configured to use a drive circuit to increase efficiency when the motor commanded frequency is not within the predetermined range of line input power frequencies.

10. The motor drive circuit of claim 1, further configured to operate directly from the line input power to eliminate or mitigate electronic drive losses and increase efficiency over at least a portion of the operating range of the motor.

11. The motor drive circuit of claim 1, wherein the motor is a permanent split capacitor motor.

12. The motor drive circuit of claim 1, wherein the motor is a first motor, said motor drive circuit is further configured to operate at least one of a second motor and a third motor.

13. A motor drive circuit configured to drive a motor, said motor drive circuit comprising:

a power converter configured to convert alternating current (AC) line input power to direct current (DC) power, the AC line input power received from a power source at an input terminal;

a DC link electrically coupled to the rectifier, the DC-link comprising a low-capacitance capacitor having a capacitance less than 100 μ

F;

a three-phase inverter coupled downstream from the DC-link and configured to generate a two-phase AC output voltage to drive the motor, said three-phase inverter comprising;

a first phase output coupled to a main winding of the motor;

a second phase output coupled to the main winding and a start winding of the motor; and

a third phase output coupled to a capacitor that is coupled to the start winding; and

a controller configured to;

operate a switch device configured to bypass a capacitor of the motor when a motor commanded frequency is not within a predetermined range of line input power frequencies; and

synchronize two phases of the three-phase inverter to apply an output voltage to the motor that is substantially equivalent to line input voltage when the motor commanded frequency is within the predetermined range of line input power frequencies.

14. The motor drive circuit of claim 13, wherein:

the first phase output is coupled to a first side of the main winding;

the second phase output is coupled to a second side of the main winding and a first side of the start winding; and

the third phase output is coupled to the capacitor that is series-coupled to a second side of the start winding.

15. The motor drive circuit of claim 13, wherein the controller is further configured to implement two-phase switching for variable speed control of the motor.

16. The motor drive circuit of claim 13, wherein the controller is further configured to synchronize the three-phase inverter output to operate at substantially twice the frequency of the line input power.

17. A motor drive circuit configured to drive a motor, said motor drive circuit comprising:

a bi-directional power converter configured to realize bidirectional power transfer of AC line input power received from a power source and regenerated power from the motor;

a three-phase inverter coupled downstream from the bi-directional power converter and configured to generate a two-phase AC output voltage to drive the motor, said three-phase inverter comprising;

a first phase output coupled to a main winding of the motor;

a second phase output coupled to the main winding and a start winding of the motor; and

a third phase output coupled to a capacitor that is coupled to the start winding; and

a controller configured to;

synchronize multiple outputs of the inverter by providing two inverter phases with the same command; and

enable regeneration of power from the motor to the power source when instantaneous power of the motor becomes negative.

18. The motor drive circuit of claim 17, further comprising a DC link electrically coupled to the bi-directional power converter, the DC-link comprising a low-capacitance capacitor having a capacitance less than 100 μ

F.

19. The motor drive circuit of claim 17, wherein the controller is further configured to control active front end operation of the bi-directional power converter and two-phase synchronization of the inverter when the motor commanded frequency is within the predetermined range of line input power frequencies.