Method and means for detecting motor rotation

• US 9,825,563 B2
• Filed: 09/21/2015
• Issued: 11/21/2017
• Est. Priority Date: 09/19/2014
• Status: Active Grant

• Current Assignee: Flow Control LLC (Xylem, Inc.)
• Original Assignee: Flow Control LLC (Xylem, Inc.)
• Inventors: Estrada, Jesus, Patel, Akshaykumar
• Primary Examiner(s): Leykin, Rita
• Application Number:
  US14/860,202
• Publication Number:
  US 20160099666A1
• Time in Patent Office: 792 Days
• Field of Search: 31840004, 31840001, 318700, 318727, 31840038, 31840024, 310 81, 310DIG 6, 31015632, 31015653, 310179, 310 63, 310 68 R, 310 71, 417354, 4174101
• CPC Class Codes: F04B 2203/0203 Magnetic flux
• CPC Class Codes: F04B 43/02 having plate-like flexible members, e.g. diaphragms F04B43/14 takes precedence
• CPC Class Codes: H02K 1/17 Stator cores with permanent magnets
• CPC Class Codes: H02K 11/215 Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements
• CPC Class Codes: H02P 6/16 Circuit arrangements for detecting position
• CPC Class Codes: H02P 6/17 and for generating speed information

Abstract

Apparatus features a microcontroller configured to: receive signaling containing information about a measured change of a magnetic field created by a magnetic circuit driving a motor; and determine corresponding signaling containing information about the speed of rotation of the motor, based upon the signaling received. The microcontroller provides control signaling containing information to control the operation of the motor, including where the motor control is used to control the flow of fluids from a pump. A Hall Effect Sensor is used to sense the magnetic flux and provide the signaling in the form of a feedback signal for implementing motor control. The motor housing has a slot, the Hall Effect sensor is mounted external the motor housing over the slot, and a ferromagnetic bridge is arranged over the Hall Effect sensor to close the magnetic circuit and cause more flux to go through the Hall Effect sensor.

Claims

1. Apparatus comprising:

a signal processor, microcontroller or signal processing module configured at least to;

receive signaling containing information about a measured change of a magnetic field created by a magnetic circuit driving a motor, the magnetic circuit having some combination of a stator, a rotor, and a motor housing, including where the stator and the rotor comprises permanents magnets and ferromagnetic core, or including where the stator is a wound stator, or where the motor is an AC or DC motor;

determine corresponding signaling containing information about the speed of rotation of the motor, based upon the signaling received; and

a Hall Effect Sensor mounted externally to the motor housing and configured to sense some part of the magnetic field that leaves the motor housing, including being mounted on an external surface of the motor housing, the motor housing being configured or formed with a slot therein that is cut into the motor housing to allow configured, mounted or placed in relation to the slot to detect the magnetic flux leakage passing through the slot in the motor housing.

2. Apparatus according to claim 1, wherein the signal processor, microcontroller or signal processing module is configured to provide the corresponding signaling as control signaling containing information to control the operation of the motor, including where the motor control is used to control the flow of fluids from a pump.

3. Apparatus according to claim 2, wherein

the apparatus comprises a control circuit that includes the signal processor, microcontroller or signal processing module in combination with the Hall Effect Sensor in a feedback loop;

and

the Hall Effect Sensor is configured to sense the measured change of the magnetic field created by the magnetic circuit driving the motor and provide the signaling containing information about the measured change.

4. Apparatus according to claim 2, wherein

the apparatus comprises a pump configured to respond to the corresponding signaling and pump the fluid to be pumped, including where the pump is a piston or diaphragm pump.

5. Apparatus according to claim 1, wherein the Hall Effect Sensor is configured to sense magnetic flux and provide the signaling in the form of a feedback signal for implementing motor control.

6. Apparatus according to claim 1, wherein the apparatus comprises a pump having the motor and also having a control system configured with the signal processor, microcontroller or signal processing module for controlling the operation of the pump for controlling the dispensing of the flow of fluids from the pump.

7. Apparatus according to claim 1, wherein the signal processor, microcontroller or signal processing module is configured to determine the position of the ferromagnetic core by detecting the measured change of the magnetic field.

8. Apparatus according to claim 1, wherein the magnetic circuit comprises a ferromagnetic bridge built above the Hall Effect sensor to close the magnetic circuit and cause more flux to go through the Hall Effect sensor contained between the ferromagnetic bridge and the motor housing.

9. Apparatus according to claim 8, wherein the ferromagnetic bridge is configured above the Hall Effect sensor, including being mounted on the motor housing above the Hall Effect sensor.

10. Apparatus comprising:

a signal processor, microcontroller or signal processing module configured at least to;

receive signaling containing information about a measured change of a magnetic field created by a magnetic circuit driving a motor, the magnetic circuit having some combination of a stator, a rotor, and a motor housing, including where the stator and the rotor comprises permanents magnets and ferromagnetic core, or including where the stator is a wound stator, or where the motor is an AC or DC motor;

determine corresponding signaling containing information about the speed of rotation of the motor, based upon the signaling received;

wherein the motor housing is configured with a cut or slot formed therein that produces a leak in the magnetic field, and the apparatus comprises a Hall Effect Sensor configured in relation to the cut or slot to sense the leak in the magnetic field.

11. Apparatus according to claim 10, wherein the signal processor, microcontroller or signal processing module is configured to provide the corresponding signaling as control signaling containing information to control the operation of the motor, including where the motor control is used to control the flow of fluids from a pump.

12. Apparatus comprising:

a signal processor, microcontroller or signal processing module configured at least to;

receive signaling containing information about a measured change of a magnetic field created by a magnetic circuit driving a motor, the magnetic circuit having some combination of a stator, a rotor, and a motor housing, ferromagnetic core, or including where the stator is a wound stator, or where the motor is an AC or DC motor;

determine corresponding signaling containing information about the speed of rotation of the motor, based upon the signaling received; and

a Hall Effect Sensor mounted externally to the motor housing and configured to sense some part of the magnetic field that leaves the motor housing, including being mounted on an external surface of the motor housing;

the magnetic circuit having a ferromagnetic bridge built above the Hall Effect sensor to close the magnetic circuit and cause more flux to go through the Hall Effect sensor contained between the ferromagnetic bridge and the motor housing.

13. Apparatus comprising:

a signal processor, microcontroller or signal processing module configured at least to;

receive signaling containing information about a measured change of a magnetic field created by a magnetic circuit driving a motor, the magnetic circuit having some combination of a stator, a rotor, and a motor housing, including where the stator and the rotor comprises permanents magnets and ferromagnetic core, or including where the stator is a wound stator, or where the motor is an AC or DC motor; and

determine corresponding signaling containing information about the speed of rotation of the motor, based upon the signaling received;

wherein the motor housing is configured or formed with a hole therein, and the apparatus comprises a Hall Effect sensor that is mounted internally inside the motor, including through the hole.

14. Apparatus according to claim 13, wherein the apparatus comprises a mounting assembly arranged in relation to the permanent magnets and the ferromagnetic core, and the Hall Effect sensor is mounted to some part of the mounting assembly.

15. Apparatus according to claim 13, wherein the random noise acquired by the signal from the Hall Effect sensor is minimized due to the motor housing acting as a protective shield, and the signal strength is maximized due to the proximity of the Hall Effect sensor with components creating the signal.

16. Apparatus according to claim 13, wherein the signal processor, microcontroller or signal processing module is configured to provide the corresponding signaling as control signaling containing information to control the operation of the motor, including where the motor control is used to control the flow of fluids from a pump.

17. A method comprising:

receiving with a signal processor, microcontroller or signal processing module signaling containing information about a measured change of a magnetic field created by a magnetic circuit driving a motor, the magnetic circuit having some combination of a stator, a rotor, and a motor housing, including where the stator and the rotor comprises permanents magnets and ferromagnetic core, or including where the stator is a wound stator, or where the motor is an AC or DC motor;

determining with the signal processor, microcontroller or signal processing module corresponding signaling containing information about the speed of rotation of the motor, based upon the signaling received;

mounting externally a Hall Effect Sensor to the motor housing that is configured to sense some part of the magnetic field that leaves the motor housing, including being mounted on an external surface of the motor housing;

configuring or forming in the motor housing a slot that is cut into the motor housing to allow magnetic flux leakage through the motor housing; and

configuring, mounting or placing the Hall Effect sensor in relation to the slot to detect the magnetic flux leakage passing through the slot in the motor housing.

18. A method according to claim 17, wherein the method comprises providing with the signal processor, microcontroller or signal processing module the corresponding signaling as control signaling containing information to control the operation of the motor, including where the motor control is used to control the flow of fluids from a pump.

19. A method comprising:

receiving with a signal processor, microcontroller or signal processing module signaling containing information about a measured change of a magnetic field created by a magnetic circuit driving a motor, the magnetic circuit having some combination of a stator, a rotor, and a motor housing, including where the stator and the rotor comprises permanents magnets and ferromagnetic core, or including where the stator is a wound stator, or where the motor is an AC or DC motor;

determining with the signal processor, microcontroller or signal processing module corresponding signaling containing information about the speed of rotation of the motor, based upon the signaling received;

configuring the motor housing with a cut or slot formed therein that produces a leak in the magnetic field; and

configuring a Hall Effect Sensor in relation to the cut or slot to sense the leak in the magnetic field.

20. A method according to claim 19, wherein the method comprises providing with the signal processor, microcontroller or signal processing module the corresponding signaling as control signaling containing information to control the operation of the motor, including where the motor control is used to control the flow of fluids from a pump.

21. A method comprising:

receiving with a signal processor, microcontroller or signal processing module signaling containing information about a measured change of a magnetic field created by a magnetic circuit driving a motor, the magnetic circuit having some combination of a stator, a rotor, and a motor housing, including where the stator and the rotor comprises permanents magnets and ferromagnetic core, or including where the stator is a wound stator, or where the motor is an AC or DC motor;

determining with the signal processor, microcontroller or signal processing module e corresponding signaling containing information about the speed of rotation of the motor, based upon the signaling received;

configuring or forming the motor housing with a hole therein; and

mounting internally a Hall Effect sensor inside the motor, including through the hole.

22. A method according to claim 21, wherein the method comprises providing with the signal processor, microcontroller or signal processing module the corresponding signaling as control signaling containing information to control the operation of the motor, including where the motor control is used to control the flow of fluids from a pump.