Systems and method for wirelessly communicating with electric motors

• US 10,006,462 B2
• Filed: 09/18/2013
• Issued: 06/26/2018
• Est. Priority Date: 09/18/2012
• Status: Active Grant

• Current Assignee: Regal Beloit America, Inc.
• Original Assignee: Regal Beloit America, Inc.
• Inventors: Becerra, Roger Carlos, Beifus, Brian L.
• Primary Examiner(s): Wang, Quan-Zhen
• Assistant Examiner(s): Foxx, Chico A
• Application Number:
  US14/029,997
• Publication Number:
  US 20140079564A1
• Time in Patent Office: 1,742 Days
• Field of Search: None
• CPC Class Codes: F04D 13/0693 Details or arrangements of the wiring
• CPC Class Codes: F04D 15/0066 by changing the speed, e.g. of the driving engine
• CPC Class Codes: F24F 11/56 Remote control
• CPC Class Codes: F24F 11/74 for controlling air flow rate or air velocity

Abstract

An electric motor communication system for use with a fluid moving system is provided. The electric motor communication system includes an electric motor including a wireless communication device configured to transmit and receive wireless signals, and a processing device coupled to the wireless communication device and configured to control the electric motor based at least in part on wireless signals received at the wireless communication device. The electric motor communication system further includes at least one external device configured to communicate wirelessly with the electric motor.

Claims

1. An electric motor communication system for use with a heating, ventilation and air conditioning (HVAC) system, said electric motor communication system comprising:

an electric motor assembly comprising;

an electric motor including a plurality of winding stages housed within a motor housing; and

a motor controller coupled to the motor housing, said motor controller comprising;

an enclosure mounted to the motor housing;

a wireless communication device comprising a wireless antenna positioned within said enclosure, said wireless antenna configured to transmit wireless signals from said electric motor including performance data associated with operation of said electric motor and failure data associated with a failure of said electric motor to at least one external device in response to a request from the at least one external device, said wireless antenna configured to receive wireless signals for said electric motor, the received wireless signals including at least a control signal corresponding to updated operating parameters to be applied by said motor controller to operate said electric motor;

a processing device coupled to said wireless communication device and configured to control said electric motor based at least in part on the updated operating parameters received at said wireless communication device; and

a daughterboard mounted on a printed circuit board (PCB) internally within said enclosure of said motor controller and configured to secure said wireless communication device and said processing device on said PCB within said motor controller and to communicatively couple said wireless communication device and said processing device; and

the at least one external device configured to communicate wirelessly with said electric motor assembly to provide the control signal including the updated operating parameters and receive at least one of the performance data and failure data transmitted by said wireless communication device via said wireless antenna based upon the request.

2. An electric motor communication system in accordance with claim 1, wherein said at least one external device is a system controller configured to transmit wireless signals that include at least one of configuration data for said electric motor and control commands for said electric motor.

3. An electric motor communication system in accordance with claim 2, wherein said system controller is a HVAC system controller.

4. An electric motor communication system in accordance with claim 1, wherein said at least one external device is a diagnostic tool configured to wirelessly collect diagnostic information from said electric motor.

5. An electric motor communication system in accordance with claim 1, wherein said at least one external device is a thermostat including a plurality of user-selectable modes and configured to transmit wireless signals to said electric motor that cause said electric motor to operate in accordance with a selected mode of the plurality of user-selectable modes.

6. An electric motor communication system in accordance with claim 1, wherein said at least one external device is a sensor configured to wirelessly transmit sensor measurements to said electric motor.

7. An electric motor communication system in accordance with claim 6, wherein said sensor is at least one of a CO/NO_X sensor, a CO₂ sensor, a vibration sensor, a temperature sensor, a diagnostic sensor, an indoor air quality (IAQ) sensor, and a sensor that measures at least one operating parameter of said electric motor.

8. An electric motor communication system in accordance with claim 1, wherein said at least one external device is a database server configured to wirelessly receive and store information from said electric motor.

9. An electric motor communication system in accordance with claim 1, wherein said wireless communication device comprises a radio frequency identification (RFID) chip, and wherein said at least one external device is an RFID reader.

10. An electric motor communication system in accordance with claim 9, wherein said RFID reader is configured to update configuration data stored on said RFID chip by wirelessly transmitting updated configuration data to said RFID chip.

11. An electric motor communication system in accordance with claim 1, wherein said motor controller further comprises:

a motor control connector defined through an outer shell of said motor controller; and

at least one of an RFID chip and an RFID antenna coupled to said motor control connector.

12. An electric motor for use in a heating, ventilation and air conditioning (HVAC) system, said electric motor comprising:

a motor housing configured to house a plurality of winding stages; and

a motor controller coupled to said motor housing, said motor controller comprising;

an enclosure mounted to the motor housing;

a wireless communication device comprising a wireless antenna positioned within said enclosure, said wireless antenna configured to transmit wireless signals from said electric motor including performance data associated with operation of said electric motor and failure data associated with a failure of said electric motor to at least one external device in response to a request from the at least one external device, said wireless antenna configured to receive wireless signals for said electric motor from said at least one external device, the received wireless signals including at least a control signal corresponding to updated operating parameters to be applied by said motor controller to operate said electric motor;

a processing device coupled to said wireless communication device and configured to control said electric motor based at least in part on the updated operating parameters received at said wireless communication device; and

a daughterboard mounted on a printed circuit board (PCB) internally within said enclosure of said motor controller and configured to secure said wireless communication device and said processing device on said PCB within said motor controller and to communicatively couple said wireless communication device and said processing device.

13. An electric motor in accordance with claim 12, wherein the at least one external device comprises at least one of a system controller, a thermostat, a diagnostic tool, a database server, and a sensor.

14. An electric motor in accordance with claim 12, wherein said wireless communication device is a radio frequency identification (RFID) chip configured to communicate wirelessly with an RFID reader.

15. An electric motor in accordance with claim 14 wherein said daughterboard is coupled to a controller of said electric motor.

16. An electric motor in accordance with claim 12, further comprising a substantially transparent holder, wherein said substantially transparent holder facilitates maintaining a connection between said daughterboard and said processing device.

17. A method of operating an electric motor in a heating, ventilation and air conditioning (HVAC) system, said method comprising:

communicatively coupling the electric motor to at least one external device, the electric motor including a motor housing and a motor controller coupled to the motor housing, the motor controller including an enclosure mounted to the motor housing, a wireless communication device including a wireless antenna positioned within the enclosure, a processing device, and a daughterboard, the daughterboard mounted on a printed circuit board (PCB) internally within the enclosure of the motor controller and configured to secure the wireless communication device and the processing device on the PCB;

transmitting, by the wireless communication device via the wireless antenna, wireless signals from the electric motor to the at least one external device, the transmitted wireless signals including performance data associated with operation of the electric motor and failure data associated with a failure of the electric motor in response to a request from the at least one external device;

receiving, at the wireless communication device via the wireless antenna, wireless signals from the at least one external device, the wireless communication device communicatively coupled to the processing device by the daughterboard, the received wireless signals, from the at least one external device, including at least a control signal corresponding to updated operating parameters to be applied by the motor controller to operate the electric motor; and

controlling, using the processing device, the electric motor based at least in part on the received updated operating parameters.

18. A method in accordance with claim 17, wherein receiving wireless signals from the at least one external device comprises receiving wireless signals from a system controller.

19. A method in accordance with claim 17, wherein receiving wireless signals from the at least external device comprises receiving wireless signals from a thermostat that includes a plurality of user-selectable modes and wherein the wireless signals specify a selected mode of the plurality of user-selectable modes.

20. A method in accordance with claim 17, wherein receiving wireless signals comprises receiving wireless signals that include configuration data for the electric motor.