Motor controller and related method

• US 8,796,966 B2
• Filed: 05/12/2010
• Issued: 08/05/2014
• Est. Priority Date: 05/12/2009
• Status: Active Grant

• Current Assignee: Raymond John Peto
• Original Assignee: Raymond John Peto
• Inventors: Peto, Raymond John
• Primary Examiner(s): Ip, Paul
• Application Number:
  US13/138,966
• Publication Number:
  US 20120086382A1
• Time in Patent Office: 1,546 Days
• Field of Search: 318/400.2, 318/400.3, 318/400.29, 318/729, 318/811, 318/362, 318/400.19, 318/254.2, 318/438, 363/35, 363/41
• US Class Current: 318/400.19
• CPC Class Codes: H02M 1/0006 Arrangements for supplying an adequate voltage to the control circuit of converters
• CPC Class Codes: H02M 1/4225 using a non-isolated boost converter
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: H02P 23/26 Power factor control [PFC]
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

The present invention relates to a motor controller and related method. The invention is particularly well suited for use with an alternating current (AC) induction motor. Previously motor controllers did not take into account the combined effect a control circuit and controlled motor, had upon a mains supply and more particularly their separate and combined effect upon the power factor of an alternating current. The invention solves this problem by providing a motor controller which modifies an input current to an alternating current (AC) motor. The motor controller comprises: a power input rectifier; a low voltage power supply; a variable output voltage circuit for adjusting a drive output voltage circuit; and a control circuit arranged to control the variable output voltage circuit and to provide timed waveforms to the drive output voltage circuit.

Claims

1. A motor controller to modify an input current to an alternating current (AC) motor, said motor controller comprising:

a variable voltage output circuit adapted to be connected to an input power supply, to provide impedance conversion to said input power supply so that a controlled current is drawn from said input power supply,

a drive voltage output circuit comprising half bridges with top and bottom transistors configured to operate as a single or a multi-phase power supply for said motor, each half bridge including a slew rate limiting capacitor connected to a junction of top and corresponding bottom transistors, an output of said drive voltage output circuit being connected to at least one winding of said motor in parallel with said slew rate limiting capacitors, so that said slew rate limiting capacitors apply a slew rate limited wave voltage to said motor to enhance lossless switching of said drive voltage output circuit; and

a control circuit arranged to control an output voltage of said variable voltage output circuit, and to control a frequency of an output signal of said drive voltage output circuit;

wherein said variable voltage output circuit provides a variable voltage between a minimum and a maximum, across a capacitor and a terminal to an input of said drive voltage output circuit.

2. A motor controller according to claim 1, wherein:

said variable voltage output circuit further provides a power factor corrected input current waveform.

3. A motor controller according to claim 1, wherein:

said drive voltage output circuit comprises a switching device; and

said variable voltage output circuit comprises a power supply and a transistor in series with a first input of said power supply and a first contact of said terminal to isolate said switching device from said power supply.

4. A motor controller according to claim 3, wherein:

a first input of said power supply is connected to a drain of said transistor, and a gate of said transistor is connected to one terminal of a bulk storage capacitor, and a second terminal of said bulk storage capacitor is connected to said power supply, so that said drive voltage output circuit and said switching device are isolated from said input power supply.

5. A motor controller according to claim 4, wherein said variable voltage output circuit comprises:

a dynamic reservoir having two windings on one coil assembly and a capacitor connected to a drain of a transistor, a diode, and a transformer comprising a first coil with a first coil input and a first coil output and a second coil with a second coil input and a second coil output;

wherein a first input of said power supply is connected to said first coil input and a second input of said power supply is connected to said second coil input, and said first coil output is connected to a drain of said transistor, and a sink of said transistor is connected to a cathode of said diode, and said second coil output is connected to an anode of said diode.

6. A motor controller according to claim 4, further comprising:

a pulse width modulator (PWM) that operates to switch a transistor and thereby control a ramp up of voltage on said bulk storage capacitor from ground level to a desired level.

7. A motor controller according to claim 1, wherein:

said drive voltage output circuit is arranged to switch voltage at an adjustable repetition rate in synchronism with a variable voltage provided to said at least one winding of said motor.

8. A motor controller according to claim 1, further comprising:

means for modifying an input of said variable voltage output circuit, so that a near unity power factor is presented to said power supply.

9. A motor controller according to claim 1, wherein said drive voltage output circuit is arranged to apply, in use, a voltage waveform to said motor from a group comprising:

sine waves,

square waves,

saw tooth waves,

variants and combinations of the aforesaid waves.

10. A motor controller according to claim 1, having a single or multi-phase controller arranged to switch an input current to ground level for a predetermined and variable time duration.

11. A motor controller according to claim 1, further comprising:

means for providing harmonic information to provide an indication of a power factor.

12. A motor controller according to claim 1, wherein:

said motor is adapted to operate in a regenerative mode.