Electronically commutated motor zero-watt standby power consumption

Patent metadata

Field	Value
Publication number	US-12334780-B2
Application number	US-202217864604-A
Country	US
Kind code	B2
Filing date	Jul 14, 2022
Priority date	Jul 18, 2021
Publication date	Jun 17, 2025
Grant date	Jun 17, 2025

Abstract

A heating, ventilation, and air conditioning (HVAC) system includes a blower assembly including a blower motor; and an electronically commutated motor (ECM) controller in electrical communication with the blower motor, the ECM controller including: a rectifier electrically connected to an alternating current (AC) input source, the rectifier being configured to receive AC electricity from the AC input source and convert the AC electricity to direct current (DC) electricity; a DC electrical circuit including a first DC electrical circuit loop and a second DC electrical circuit loop, the rectifier being configured to circulate the DC electricity through the DC electrical circuit; and a relay located within the first DC electrical circuit loop, the relay being configured to open to break the first DC electrical circuit loop and close to complete the first DC electrical circuit loop in order to reduce standby power consumption of the ECM controller.

First claim

What is claimed is:

1. A heating, ventilation, and air conditioning (HVAC) system comprising:
a blower assembly comprising a blower motor; and
an electronically commutated motor (ECM) controller in electrical communication with the blower motor, the ECM controller comprising:
a rectifier electrically connected to an alternating current (AC) input source, the rectifier being configured to receive AC electricity from the AC input source and convert the AC electricity from the AC input source to direct current (DC) electricity;
a DC electrical circuit comprising a first DC electrical circuit loop and a second DC electrical circuit loop, the rectifier being configured to circulate the DC electricity through the DC electrical circuit;
a relay located within the first DC electrical circuit loop, the relay being configured to open to break the first DC electrical circuit loop and close to complete the first DC electrical circuit loop in order to reduce standby power consumption of the ECM controller;
a DC-to-DC converter electrically connected to the rectifier, the DC-to-DC converter being configured to receive the DC electricity at a first voltage from the rectifier and convert the DC electricity from the first voltage to at least one of a second voltage or a third voltage, the second voltage and the third voltage being less than the first voltage;
a rectifier-to-converter line electrically connecting the rectifier to the DC-to-DC converter, wherein DC electricity is configured to flow from the rectifier to the DC-to-DC converter through the rectifier-to-converter line; and
a converter-to-rectifier line electrically connecting the DC-to-DC converter to the rectifier, wherein the DC electricity is configured to flow from the DC-to-DC converter to the rectifier through the converter-to-rectifier line,
wherein the relay is located within the converter-to-rectifier line, the relay being configured to open the first DC electrical circuit loop within the converter-to-rectifier line and close the first DC electrical circuit loop within the converter-to-rectifier line.

2. The HVAC system of claim 1 , further comprising:
an equipment control board configured to transmit an activation signal to the relay and close the relay to complete the first DC electrical circuit loop.

3. The HVAC system of claim 2 , wherein the equipment control board is configured to transmit the activation signal to the relay to close the relay and complete the first DC electrical circuit loop when activation of the blower motor is desired.

4. The HVAC system of claim 1 , further comprising:
an equipment control board or a system control unit configured to transmit an activation signal to the relay to close the relay and complete the first DC electrical circuit loop.

5. The HVAC system of claim 4 , wherein the equipment control board is configured to transmit the activation signal to the relay to close the relay and complete the first DC electrical circuit loop when activation of the blower motor is desired.

6. The HVAC system of claim 1 , further comprising:
an inverter electrically connected to the rectifier and the DC-to-DC converter, the inverter configured to change the DC electricity received from the rectifier and the DC-to-DC converter to AC converted electricity and provide said AC converted electricity to the blower motor.

7. The HVAC system of claim 6 , further comprising:
a converter-to-processor line;
a processor-to-inverter line; and
a processor electrically connected to the DC-to-DC converter through the converter-to-processor line, the processor being configured to receive DC electricity at the third voltage from the DC-to-DC converter, wherein the processor is electrically connected to the inverter through the processor-to-inverter line and is configured to transmit a blower activation signal to the blower motor through the processor-to-inverter line and the inverter.

8. The HVAC system of claim 7 , further comprising:
an equipment control board configured to transmit an activation signal to the relay to close the relay and complete the first DC electrical circuit loop, wherein the equipment control board is configured to transmit a blower activation signal to the processor.

9. The HVAC system of claim 8 , wherein the equipment control board is configured to transmit the activation signal to the relay to close the relay and complete the first DC electrical circuit loop when activation of the blower motor is desired.

10. A method of operating a heating, ventilation, and air conditioning (HVAC) system, comprising:
transmitting an activation signal to a relay located within a first DC electrical circuit loop in a DC electrical circuit of an electronically commutated motor (ECM) controller, the relay being configured to close and complete the first DC electrical circuit loop in response to the activation signal;
operating a blower motor using electricity from the DC electrical circuit;
receiving, using a rectifier, AC electricity from an AC input source;
converting, using the rectifier, the AC electricity from the AC input source to DC electricity;
providing, using the rectifier, the DC electricity to the DC electrical circuit;
receiving, using a DC-to-DC converter, the DC electricity from the rectifier at a first voltage;
converting, using the DC-to-DC converter, the DC electricity from the first voltage to at least one of a second voltage and a third voltage, the second voltage and the third voltage being less than the first voltage; and
providing, using the DC-to-DC converter, the DC electricity at the second voltage to the rectifier via a converter-to-rectifier line, wherein the relay is located within the converter-to-rectifier line, the relay being configured to open the first DC electrical circuit loop within the converter-to-rectifier line and close the first DC electrical circuit loop within the converter-to-rectifier line.

11. The method of claim 10 , further comprising:
converting, using an inverter, DC electricity from the DC electrical circuit to AC converted electricity; and
providing, using the inverter, the AC converted electricity to the blower motor.

12. The method of claim 10 , further comprising:
transmitting a blower activation signal to a processor within the DC electrical circuit, the processor being configured to receive the DC electricity at the third voltage from the DC-to-DC converter, wherein the processor is electrically connected to an inverter through the processor-to-inverter line; and
transmitting, using the processor, the blower activation signal to the blower motor through the processor-to-inverter line and the inverter.

13. The method of claim 12 , wherein the activation signal is configured to be transmitted when the blower activation signal is transmitted.

14. A computer program product embodied on a non-transitory computer readable medium, the computer program product including instructions that, when executed by a processor, cause the processor to perform operations comprising:
transmitting an activation signal to a relay located within a first DC electrical circuit loop in a DC electrical circuit of an electronically commutated motor (ECM) controller, the relay being configured to close and complete the first DC electrical circuit loop in response to the activation signal;
operating a blower motor using electricity from the DC electrical circuit;
wherein the relay is located in converter-to-rectifier line electrically connecting a DC-to-DC converter and a rectifier within the first DC electrical circuit loop, and wherein the relay is configured to open the first DC electrical circuit loop

Assignees

• Carrier Corp

Inventors

• Blake Jonathan
• Arnedo Luis
• Smyth Michael S

Classifications

• Y02B30/70

  Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating · CPC title

• H02K11/30

  Structural association with control circuits or drive circuits · CPC title

• H02K11/20

  for measuring, monitoring, testing, protecting or switching (rectifiers H02K11/04; power electronics H02K11/33) · CPC title

• H02P27/047

  V/F converter, wherein the voltage is controlled proportionally with the frequency · CPC title

• F24F1/00

  Room units for air-conditioning, e.g. separate or self-contained units or units receiving primary air from a central station · CPC title