Motor interface controller having an integrated power supply

Patent metadata

Field	Value
Publication number	US-9419552-B2
Application number	US-201414302064-A
Country	US
Kind code	B2
Filing date	Jun 11, 2014
Priority date	Jun 11, 2014
Publication date	Aug 16, 2016
Grant date	Aug 16, 2016

Abstract

A motor assembly broadly includes a motor, a motor controller, and an interface controller having an integrated power supply. The integrated power supply includes an AC to DC power conversion and voltage reduction component. The motor controller and the interface controller receive line voltage electrical power without the need for an external transformer.

First claim

The invention claimed is:

1. A motor assembly comprising:
a motor comprising:
a stator;
a rotor;
a motor case enclosing the stator and the rotor; and
an output shaft connected to the rotor and extending from an opening in the motor case;

a motor controller connected to the motor for controlling operation of the motor, the motor controller comprising:
a digital signal processor; and
an isolated interface circuit connected to the digital signal processor for providing fault protection to the digital signal processor; and

an interface controller for communicating with the motor controller, the interface controller comprising:
a housing;
a user interface for receiving user input commands;
a micro-controller positioned within the housing, the micro-controller being connected to the user interface for receiving the user input commands therefrom and being connected to the motor controller for instructing the motor controller how to control operation of the motor; and
an integrated AC to DC power conversion and power voltage reduction component positioned within the housing and connected to the micro-controller for converting AC power received from an external power source to DC power and for reducing the power voltage received by the micro-controller,
the digital signal processor being configured to convert commands from the interface controller into motor controlling signals for controlling operation of the motor.

2. The motor assembly of claim 1 , wherein the power conversion and power voltage reduction component comprises a power switching component.

3. The motor assembly of claim 1 , wherein the motor controller further comprises:
an AC to DC power conversion component for converting AC power received from an external power source to DC power;
a DC power reduction component for reducing the voltage of the DC power received from the AC to DC power conversion component; and
a DC to AC power inverter for converting the DC power to AC power.

4. The motor assembly of claim 3 , wherein the DC to AC power inverter converts the DC power to three phase AC power.

5. The motor assembly of claim 1 , wherein the interface controller further comprises a power input terminal configured to be wired to the motor controller for receiving high voltage power from the external power source via the motor controller.

6. The motor assembly of claim 1 , wherein the interface controller and the motor controller are each configured to separately receive high voltage power from the external power source.

7. The motor assembly of claim 1 , wherein the power voltage reduction component of the interface controller electrically isolates the micro-controller of the interface controller from high voltage power.

8. The motor assembly of claim 1 , wherein the housing of the interface controller is removably attachable to an outer surface of a case of the motor controller.

9. The motor assembly of claim 1 , wherein the interface controller is compatible with a number of different motor models.

10. The motor assembly of claim 1 , wherein the interface controller is housed substantially within a case of the motor controller.

11. The motor assembly of claim 1 , wherein the motor is a variable speed AC induction or permanent magnet motor and the interface controller is configured to allow a user to select a motor speed, motor torque, or other motor operating command via the user interface of the interface controller.

12. A motor assembly comprising:
a motor comprising:
a stator;
a rotor;
a motor case enclosing the stator and the rotor; and
an output shaft extending from an opening in the motor case;

a motor controller connected to the motor for controlling operation of the motor, the motor controller comprising:
a digital signal processor including a CPU and a memory;
an isolated interface circuit connected to the digital signal processor for providing fault protection to the digital signal processor;
a motor controller power input terminal for receiving high voltage AC electrical power from an external power source;
an AC to DC power conversion component for converting the AC power to DC power for powering the digital signal processor and for powering the motor;
a DC power switching component for reducing the voltage of a portion of the DC power for providing reduced voltage DC power to the digital signal processor;
a DC to AC power inverter for converting the DC power to three phase AC power; and
a motor controller power output terminal connectable to the motor for providing electrical power to the motor; and

an interface controller for communicating with the motor controller, the interface controller comprising:
a housing;
a user interface for receiving user input commands;
a micro-controller positioned within the housing, the micro-controller being connected to the user interface for receiving the user input commands therefrom and being connected to the motor controller for instructing the motor controller how to control operation of the motor; and
an integrated AC to DC power conversion and power switching component positioned within the housing and connected to the micro-controller for converting AC power received from an external power source to DC power and for reducing the power voltage received by the micro-controller,
the interface controller being compatible with a number of motor models.

13. The motor assembly of claim 1 , wherein the motor controller further comprises a plurality of electrical connection points for connecting to external devices.

14. The motor assembly of claim 13 , wherein the electrical connection points are 4-wire connection points.

15. The motor assembly of claim 13 , wherein the electrical connection points are 16-pin connection points.

16. The motor assembly of claim 1 , wherein the user interface includes a touchscreen for receiving user input commands.

17. The motor assembly of claim 1 , wherein the motor controller includes a shell configured to enclose the digital signal processor and the isolated interface circuit.

18. The motor assembly of claim 17 , wherein the shell includes a plurality of ventilation openings for allowing cool air to circulate into the shell.

19. The motor assembly of claim 1 , wherein the interface controller further comprises an input terminal wired to a terminal of the motor controller for receiving AC power therethrough.

Assignees

• Nidec Motor Corp

Inventors

• Schock Christopher D
• Bomkamp Randy L

Classifications

• H02K11/05

  Rectifiers associated with casings, enclosures or brackets · CPC title

• H02P6/085 Primary

  in a bridge configuration · CPC title

• H02M5/42 Primary

  by static converters · CPC title

• H02P6/14

  Electronic commutators · CPC title

• H02K11/33 Primary

  Drive circuits, e.g. power electronics (H02K11/38 takes precedence) · CPC title