CA3164562A1 - Electric motor control unit having redundant control and assembly method therefor - Google Patents

Abstract

Disclosed are an electric motor control unit having redundant control and an assembly method therefor, comprising: a power supply module, connected to mains electricity and outputting a corresponding VDC direct-current power supply to power other modules; an electric motor control module, one electric motor control module controlling one electric motor body; an I/O module, used for signal transmission between a client mainboard or a peripheral device and the electric motor control module; a redundant control module, the function thereof being to activate one standby functional module when any of the functional modules described above fails, thus ensuring that a client system can still work smoothly; and the standby functional module, a module having same functions as a first functional module or a second functional module or a third functional module. The functional modules are assembled and mounted together to form the electric motor control unit, the production thereof is flexible and convenient, has strong adaptability, and reduces research and development cycles; the production is quick and convenient, operational reliability is increased, aftersales maintenance is facilitated, and maintenance costs are reduced.

Description

ELECTRIC MOTOR CONTROL UNIT HAVING REDUNDANT CONTROL AND
ASSEMBLY METHOD THEREFOR
TECHNICAL FIELD
[0001] The disclosure relates to a motor control unit having redundancy control and a combination method thereof.
BACKGROUND

[0002] An air-conditioner outdoor or indoor unit typically includes a centrifugal blower, a furnace blower motor, a compressor motor, or an axial-flow fan motor. The parameters of these motors, such as voltage, power, signal communication, or torque, vary with manufacturers. As shown in FIGS. 2-4, a brushless AC motor or an electronically commutated motor (ECM) typically includes a main body la and a motor controller 2a;
the main body la comprises a stator assembly 12a, a rotor assembly 13a, a housing assembly 11a, and a bearing; the motor controller 2a typically comprises a control box 21a and a control board 22a; and the control board 22a is the integration of function circuits. When an important part breaks down, many technicians choose to replace the whole motor controller or the whole motor instead of repairing the damaged part. This often translates to high replacement costs.

[0003] Electronic components are typically integrated onto one or two circuit boards in the conventional motor controller, which increases hard to meet the needs of different customers. For examples, a customer may need a 5-speed PWM motor controller, a 10VDC motor controller, a 10-speed motor controller matching 0-10VDC, a single motor controller in an outdoor unit, a plurality of motor controllers in an outdoor unit, or a 3 HP
motor controller; the circuit board or the control box typically has a fixed size; and the circuit board only offers limited functions.

[0004] Thus, it is necessary to consider a motor controller with convenient production and assembly, short design and production cycle, and easy maintenance and replacement, and the maintenance cost of the motor controller in the after-sales market is very low.

[0005] When damage occurs to a motor control unit, the broken part should be replaced with a new one that can immediately respond to a control system, thus increasing the operational reliability of the motor control unit.
SUMMARY

[0006] The disclosure provides a motor control unit having redundancy control and a combination method thereof, so as to solve the problems of inflexible and inconvenient production of the motor controller in the after-sales market, long research and development time and production time, inconvenient after-sales maintenance and high maintenance cost.

[0007] The disclosure adopts the following technical solutions.

[0008] The motor control unit having redundancy control comprises:

[0009] a first function module, referring to a power supply module that is connected to an electric supply and converts alternating current to direct current to supply for other function modules;

[0010] a second function module, referring to a motor control module that controls the operation of a motor; the motor control module comprises a motor control microprocessor, an IGBT inverter, and a heat sink; the motor control module receives DC
power and control signals and supplies power to the main body of the motor so as to control the rotational speed, torque, or air volume of the motor;

[0011] a third function module, referring to an I/0 module that allows signal transmission between a main control board or a peripheral device and the motor control module; wherein the motor controller comprises at least one third function module, and a plurality of third function modules is optionally disposed between a main control board or a peripheral device and the motor control module for signal transmission;

[0012] a fourth function module, referring to a redundancy control module that starts a spare function module when the first, second or third function module has an emergency;
and

[0013] a fifth function module, referring to at least one spare function module that performs the same function as the first function module, the second function module, or the third function module.

[0014] The above function modules are combined into a single motor control unit.

[0015] The redundancy control module comprises a redundancy control microprocessor, a plurality of relays, a screen circuit, and a bus access circuit; the bus access circuit allows signal communication between the redundancy control microprocessor and other function modules; the redundancy control microprocessor starts the spare function module via the plurality of relays; and the screen circuit is configured to display the working status of other function modules.

[0016] Optionally, the first function module, the third function module, and the spare function module further independently comprise a network communication unit;
the network communication unit comprises a bus microprocessor, a bus communication access circuit, and a function detection circuit; the function detection circuit performs a function inspection to its function module and transmits the signal to the bus communication access circuit; and data is transmitted between the bus microprocessor and the redundancy control microprocessor via the bus communication access circuit and a data bus.

[0017] Each function module comprises an independent shell, a first circuit board, an interface connector, and a heat sink; the shell comprises metal or plastic;
the first circuit board is disposed in the shell; the interface connector is partially disposed on the first circuit board to allow the transmission of power and control signals; and the heat sink is disposed outside or inside the shell.

[0018] The 1/0 module comprises at least one module selected from the group comprising:

[0019] a multi-speed 24VAC input module that receives a 24VAC signal from the main control board and sends the signal to the motor control module;

[0020] a PWM input module that receives a PWM signal from the main control board and sends the signal to the motor control module;

[0021] a 0-10VDC input module that receives a 0-10VDC signal and sends the signal to the motor control module;

[0022] a RS485 serial communication module that implements a communication protocol supported by a driver for the motor control module;

[0023] a Bluetooth module that allows the motor control module to communicate with an app or a computer for motor configuration;

[0024] a pulse output module that outputs a pulse for representing a motor parameter;
and

[0025] an Ethernet local area network module that supports a TCP/TP protocol for allowing the motor control module to connect into a building control network or to monitor and control the motor parameters over network;

[0026] a human-machine interface (HMI) function module that comprises a color and monochrome screen for offering a high resolution display; the HMI function module is used to display information about the rotational speed, torque or air volume of the motor, making it convenient for the user to perform a configuration setting or experimental test;
and

[0027] a DIP switch module that is connected to motor control module by the interface connector; and the DIP switch module comprises a set of switches for changing the motor parameters.

[0028] The motor control unit further comprises a mechanical mounting base and a second circuit board disposed in the mechanical mounting base; the above function modules are connected to each other via the second circuit board or a plurality of flexible cables so as to allow the transmission of power and control signals.

[0029] The motor control unit comprises two second function modules for controlling the operation of two motors, respectively.

[0030] The at least one spare function module is optionally used as a backup of the power supply module, the motor control module, and the 1/0 module.

[0031] A combination method of the motor control unit comprises dividing the motor control unit into a plurality of function modules according to functions of the motor control unit; and the plurality of function modules comprises:

[0032] a first function module, referring to a power supply module that is connected to an electric supply and converts alternating current to direct current to supply for other function modules; optionally, different power supply modules are formed to match the input voltage and power;

[0033] a second function module, referring to a motor control module that controls the operation of the motor; the motor control module comprises a microprocessor, an IGBT
inverter, and a heat sink; when receiving VDC power and control signals, the motor control module supplies electricity to the motor so as to control the rotational speed, torque, or air volume of the motor; optionally, different motor control modules are formed to match the input power;

[0034] a third function module, referring to at least one I/0 module that allows signal transmission between the motor control module and a main control board or a peripheral device;

[0035] a fourth function module, referring to a redundancy control module that starts a spare function module when the first, second or third function module has an emergency;
and

[0036] a fifth function module, referring to at least one spare function module that performs the same function as the first function module, the second function module, or the third function module.

[0037] The power supply module, the motor control module, the at least one I/0 module, the redundancy control module, and the spare function module are combined into a motor control unit that matches the parameters of the motor.

[0038] The I/0 module comprises at least one module selected from the group comprising: a multi-speed 24VAC input module for receiving a 24VAC signal from the main control board and sending the signal to the motor control module; a PWM
input module for receiving a PWM signal from the main control board and sending the signal to the motor control module; a 0-10VDC input module for receiving a 0-10VDC
signal and sending the signal to the motor control module; a RS485 serial communication module for implementing a communication protocol that is supported by a driver for the motor control module; a Bluetooth module for allowing the motor control module to communicate with an app or a computer for motor configuration; a pulse output module for outputting a pulse that represents a parameter of the motor; an Ethernet local area network module for supporting a TCP/TP protocol that allows the motor control module to connect into a building control network or monitors and controls the motor parameters over network; a human-machine interface (HMI) function module that comprises a color and monochrome screen for offering a high resolution display to show the rotational speed, torque or air volume of the motor, making it convenient for the user to perform a configuration setting or experimental test; and a DIP switch module connected to the motor control module via the interface connector, and the DIP switch module comprises a set of switches for changing the motor parameters.

[0039] Each function module comprises an independent shell, a first circuit board, and other electronic components; the shell comprises metal or plastic; the first circuit board and other electronic components are disposed in the shell; the motor control unit further comprises a mechanical mounting base and a second circuit board disposed in the mechanical mounting base; the above function modules are fixedly disposed on the mechanical mounting base, and connected to each other via the second circuit board to allow the transmission of power and control signals.

[0040] The second circuit board comprises a DC power supply interface and a bus interface, both of which are used to connect the function modules to the second circuit board.

[0041] The following advantages are associated with the motor control unit of the disclosure:

[0042] 1. The motor control unit is divided into a plurality of function modules based on function, comprising: a first function module referring to a power supply module that is connected to an electric supply and converts alternating current to direct current to supply for other modules, and different power supply modules may be formed to match the input voltage and power; a second function module referring to a motor control module that controls the speed, torque or air flow of a motor by receiving VDC power and a control signal, and by supplying a UVW three-phase electric current to the main body of motor;
the motor control module comprises a microprocessor, an IGBT inverter component, and a heat sink; different motor control modules are formed to match the input power; a third function module referring to an I/0 module that allows signal transmission between a main control board or a peripheral device and the motor control module; a fourth function module, referring to a redundancy control module that starts a spare function module when the first function module, the second function module, or the third function module has an emergency; and a fifth function module, referring to at least one spare function module that performs the same function as the first function module, the second function module, or the third function module.

[0043] 2. Other advantages associated with the motor control unit are described with reference to the following embodiments.
DETAILED DESCRIPTION OF THE DRAWINGS

[0044] FIG. 1 is a block diagram of a conventional HVAC system;

[0045] FIG. 2 is a perspective view of a conventional BLDC motor;

[0046] FIG. 3 is a perspective view of a conventional BLDC motor controller;

[0047] FIG. 4 is a cross-sectional view of a conventional BLDC motor;

[0048] FIG. 5 is a block diagram of a motor controller according to Example 1 of the disclosure;

[0049] FIG. 6 is a block diagram for function modules according to Example 1 of the disclosure;

[0050] FIG. 7 is a block diagram of a redundancy control module according to Example 1 of the disclosure;

[0051] FIG. 8 is a perspective view of a function module according to Example 1 of the disclosure;

[0052] FIG. 9 is an exploded view of a redundancy control module according to Example 1 of the disclosure;

[0053] FIG. 10 is a perspective view of a mechanical mounting base according to Example 1 of the disclosure;

[0054] FIG. 11 is an exploded view of a mechanical mounting base according to Example 1 of the disclosure;

[0055] FIG. 12 is an exploded view of a combined motor control unit according to Example 1 of the disclosure;

[0056] FIG. 13 is a perspective view of a combined motor control unit according to Example 1 of the disclosure;

[0057] FIG. 14 is a perspective view of a motor control unit comprising a redundancy control module according to Example of the disclosure;

[0058] FIG. 15 is a block diagram of a network communication unit according to Example 1 of the disclosure;

[0059] FIG. 16 is a block diagram of a power supply module according to Example 1 of the disclosure;

[0060] FIG. 17 is a block diagram of a RS485 serial communication module according to Example 1 of the disclosure;

[0061] FIG. 18 is a block diagram of a PWM input module according to Example 1 of the disclosure; and

[0062] FIG. 19 is a block diagram of a 5-speed 24VAC input module according to Example 1 of the disclosure.
DETAILED DESCRIPTION

[0063] To further illustrate the disclosure, embodiments detailing the motor control unit and the combination method thereof are described below. It should be noted that the following embodiments are intended to describe and not to limit the disclosure.

Example 1

[0064] Referring to FIGS. 5 and 6, a motor control unit comprises:

[0065] a first function module, referring to a power supply module that is connected to an electric supply and converts alternating current to direct current to supply for other function modules;

[0066] a second function module, referring to a motor control module that controls the operation of a motor; the motor control module comprises a motor control microprocessor, an IGBT inverter, and a heat sink; the motor control module receives VDC power and control signals and supplies power to the motor so as to control the rotational speed, torque, or air volume of the motor;

[0067] a third function module, referring to at least one 1/0 module that allows signal transmission between the motor control module and a main control board or a peripheral device;

[0068] a fourth function module, referring to a redundancy control module that starts a spare function module when the first function module, the second function module, or the third function module has an emergency; and

[0069] a fifth function module, referring to at least one spare function module that performs the same function as the first function module, the second function module, or the third function module.

[0070] The above function modules are combined into a single motor control unit.

[0071] Referring to FIG. 7, the redundancy control module comprises a redundancy control microprocessor, a plurality of relays, a screen circuit, and a bus access circuit; the bus-communication access circuit allows signal communication between the redundancy control microprocessor and other function modules; when a function module is broken, the redundancy control microprocessor starts the spare function module via the plurality of relays; and the screen circuit comprises a plurality of LED lights, such as an 8-segment LED screen or a color screen, used to display the running status of each function module (that is, to indicate which function module is broken or running). The redundancy control module further comprises a signal input interface circuit for receiving an external signal.

The signal input interface circuit further comprises at least one 5-speed 24VAC signal input interface. Optionally, the redundancy control module further comprises a PWM
signal input interface circuit, a 0-10VDC signal input interface circuit, a serial communication interface circuit, or a combination thereof. As shown in FIGS. 6 and 7, the redundancy control module comprises N relays numbered JK1, JK2õ JKN; and the N relays are used to start the power supply module, the motor control module, the I/0 module, and the spare function module.

[0072] The function modules are packaged together to form a motor control unit that offers advantages such as high levels of flexibility and adaptability, easy replacement of a single function module, low maintenance cost, and short product development cycle.

[0073] Each function module comprises an independent shell, a first circuit board, an interface connector, and a heat sink; the shell comprises metal or plastic;
the interface connector is partially disposed on the first circuit board to allow the transmission of power and control signals; the heat sink is disposed outside or inside the shell.

[0074] The I/0 module comprises at least one module selected from the group comprising:

[0075] a multi-speed 24VAC input module that receives a 24VAC signal from the main control board and sends the signal to the motor control module;

[0076] a PWM input module that receives a PWM signal from the main control board and sends the signal to the motor control module;

[0077] a 0-10VDC input module that receives a 0-10VDC signal and sends the signal to the motor control module;

[0078] a R5485 serial communication module that implements a communication protocol supported by a driver for the motor control module;

[0079] a Bluetooth module that allows the motor control module to communicate with an app or a computer for motor configuration;

[0080] a pulse output module that outputs a pulse for representing a parameter of the motor; and

[0081] an Ethernet local area network module that supports a TCP/TP protocol for allowing the motor control module to connect into a building control network or monitor and regulate the motor parameters over network;

[0082] a human-machine interface (HMI) function module that comprises a color and monochrome screen for offering a high resolution display; the HMI function module is used to display information about the rotational speed, torque or air volume of the motor, making it convenient for the user to perform a configuration setting or experimental test;
and

[0083] a DIP switch module that is connected to the motor control module through the interface connector; the DIP switch module comprises a set of switches for changing the motor parameters.

[0084] The motor control unit further comprises a mechanical mounting base and a second circuit board disposed in the mechanical mounting base. The above function modules are fixedly disposed on the mechanical mounting base, and connected to each other via the second circuit board or a plurality of flexible cables to allow the transmission of power and control signals.

[0085] The motor control unit comprises two second function modules for controlling the operation of two motor controllers in an indoor or outdoor unit, respectively.

[0086] The at least one spare function module refers to a spare power supply module, a spare motor control module, a spare I/0 module, or a combination thereof.

[0087] As shown in FIGS. 8-14, the first function module, the second function module, the third function module, the fourth function module, and the fifth function module are fixedly disposed on the mechanical mounting base 100; the mechanical mounting base comprises a plurality of power supply bus interfaces 103a and a plurality of data bus interfaces 103b, both of which allow the transmission of power and control signals between the function modules.

[0088] As shown in FIGS. 8-14, each function module comprises an independent shell lb, a first circuit board 2b, a power supply interface 3a, and a bus interface 3b, and a plurality of signal interfaces 3c; the shell comprises metal or plastic; the first circuit board is fixedly disposed in the shell; the number of the signal interfaces is determined according to that of the I/0 modules connected to the motor control module 3c;
the motor control module further comprises a power interface and an output terminal, and the output terminal is connected to the main body of the motor.

[0089] Each of the power supply interface 3a and the bus interface 3b are partially disposed on the first circuit board and exposed on the face of a panel on the shell so as to be electrically connected to one of the plurality of power supply bus interface 103a or the data bus interface 103b.

[0090] The mechanical mounting base 100 comprises a first shell 101, a second shell 102, and a second circuit board 104; the first shell 101 is integrated with the second shell 102 to form a chamber; the second circuit board 104 is disposed in the chamber, and comprises a plurality of power supply bus interfaces 103a and a plurality of data bus interface 103b, both of which are partially inserted through the second circuit board 104 and disposed in multiple rows on the mechanical mounting base 100, each row with one power supply bus interface 103a and one data bus interface 103b.

[0091] When the power supply interface 3a is connected to the power supply bus interface 103a, the electricity is released to the input terminal of the power supply module, and the output terminal of the power supply module outputs the DC
power to a plurality of power supply buses. Vcc 1 represents the high DC bus voltage (e.g., 325VDC) supplied to the IGBT inverter component; Vcc2 represents the low DC bus voltage (e.g., +5VDC) supplied to the motor control microprocessor; and GND represents the ground.
As shown in FIG. 6, the plurality of data buses and the plurality of power supply buses are mounted on the second circuit board inside the mechanical mounting base 100; and the second circuit board further comprises a function circuit for bus communication.

[0092] As shown in FIG. 15, each of the first function modules, the third function module, and the spare function module further comprises a network communication unit;
the network communication unit comprises a bus microprocessor, a bus communication access circuit, and a function detection circuit; the function detection circuit performs a function inspection to the function module in which it is disposed, and transmits the signal to the bus microprocessor; and data is transmitted between the bus microprocessor and the redundancy control microprocessor via the bus communication access circuit and the data bus. Optionally, the motor control module further comprises the bus communication access circuit which enables the motor control microprocessor to access the data bus for data transfer between the motor control microprocessor and other function modules.

[0093] As shown in FIGS. 12 and 13, the power supply module 7, the motor control module 8, the Bluetooth module 9 (i.e., one I/0 module), and the PWM input module (i.e., another I/0 module) are disposed sequentially to form a motor control unit.
Optionally, the motor control unit further comprises an Ethernet local area network module, a DIP switch module, or other function modules.

[0094] As shown in FIG. 14, the motor control unit further comprises a redundancy control module and a plurality of spare function modules so as to keep the motor (or an air conditioning system) running smoothly. The power supply module 7, the motor control module 8, the Bluetooth module 9 (i.e., one I/0 module), the PWM input module (i.e., another I/0 module), the redundancy control module 11, a first spare function module 12 (i.e., a spare power supply module), and a second spare function module 13 (i.e., a spare motor control module), and a third spare function module (i.e., a spare Bluetooth module) are disposed sequentially to form a motor control unit. For example, when the Bluetooth module 9 is broken, the redundancy control module 11 starts the third spare function module 14 to ensure the motor runs smoothly; when the motor control module 8 is broken, the second spare function module 13 starts running under control of the redundancy control module. The screen circuit is used to display the status of the function modules (that is, to indicate which function module is broken or running).

[0095] When the network communication unit is unnecessary, the redundancy control module continuously sends a query to the motor control module to check if the DC bus voltage, rotational speed, torque, air volume and other parameters of the motor are in the present ranges.

[0096] FIG. 16 is a block diagram of a power supply module of the disclosure.
The power supply module comprises a surge protection circuit, a filter circuit, a DC/DC
converter circuit, and a network communication unit; the network communication unit comprises a bus microprocessor, a bus communication access circuit, and a function detection circuit; the function detection circuit performs a function inspection to the function module in which it is disposed, and transmits the signal to the bus microprocessor; and data is transmitted between the bus microprocessor and the redundancy control microprocessor via the bus communication access circuit and a data bus. The power supply module supplies direct current Vccl (e.g., 325VDC), Vcc2 (e.g., 15VDC), Vcc3 (e.g., 5 VDC), and the ground GND; Vcc 1 represents the DC bus voltage supplied to the motor. Vcc2 supplies 15VDC to the IGBT inverter component; and Vcc3 supplies 5VDC to the motor control microprocessor. The function detection circuit is a universal voltage detection circuit that can check if the voltage is in a specific range.

[0097] FIG. 17 is a block diagram of a RS485 serial communication module of the disclosure. The RS485 serial communication module comprises a network communication unit through which the RS485 serial communication module can be inspected for function and allowed to access the data bus. And the signal communication is achieved between the RS485 serial communication module and the redundancy control microprocessor or the motor control module.

[0098] FIG. 18 is a block diagram of a PWM input module of the disclosure. The PWM
input module comprises a network communication unit through which the PWM
input module can be inspected for function and allowed to access the data bus. And the signal communication is achieved between the RS485 serial communication module and the redundancy control microprocessor or the motor control module.

[0099] FIG. 19 is a block diagram of a 5-speed 24VAC input module of the disclosure.
The 5-speed 24VAC input module comprises a network communication unit through which the 5-speed 24VAC input module can be inspected for function and allowed to access the data bus. And the signal communication is achieved between the RS485 serial communication module and the redundancy control microprocessor or the motor control module.

[0100] A spare function module and its redundancy control module are necessary for redundancy control of a function module. In certain examples, a motor control unit comprises a redundancy control module, a motor control module, and a spare motor control module. The motor control module and the spare motor control module are connected to a DC bus of a power supply and a three-phase line of a motor.
Under normal conditions, as the motor control module runs, the spare motor control module is disconnected from the three-phase line by the relay of the spare motor control module and the three-phase line of the motor.

[0101] The redundancy control module continuously communicates with the motor control module via a communication bus so as to check if the motor control module is operated normally. When the redundancy control module does not receive a status code N
consecutive times that is sent by the motor control module based on a communication protocol, the motor control module is considered broken. Then the redundancy control module disconnects the relay of the motor control module, and connects to the relay of the spare motor control module to keep the motor running. To display the status of each function module, an 8-segment LED screen is used to display different numbers or a color LED screen is used to display a prompt or a pattern.

[0102] In certain examples, a motor control unit comprises a motor control module, a redundancy control module, a power supply module, and a spare power supply module.
The power supply module and the spare power supply module are connected to an external power supply (e.g., 460V three-phase AC) and the motor control module. Under normal conditions, the relay of the redundancy control module switches on the power supply module while switching off the spare power supply module.

[0103] The redundancy control module continuously communicates with the power supply module via a communication bus so as to check if the power supply module is operated normally. Understandably, the power supply module comprises a network communication unit. When detecting that the DC bus voltage exceeds a preset threshold N consecutive times, the redundancy control module disconnects the relay of the power supply module and connects to the relay of the spare power supply module. To display the status of different function modules, an LED screen is used to display a prompt or a pattern.

[0104] Other function modules adopt the same redundancy control scheme as the 5-speed function modules of the disclosure, and accordingly not described herein. The motor control unit further comprises a 5-speed 24VAC thermometer that transfers a signal to a 5-speed input module, a 5-speed spare input module, and the redundancy control module.
When a 24VAC signal does not cause the motor to run, the redundancy control module checks N consecutive times the rotational speed, torque, or air volume of the motor so as to confirm the disabled status of the motor. Then the 5-speed input module is switched off and the 5-speed spare input module is switched on.

[0105] The number of the spare power supply module, the spare motor control module, and the 1/0 module is determined by demand and even not required.

[0106] The motor control unit in an indoor unit may be the same part number for used in an outdoor unit so as to match the input voltage and power. The following function module may be taken into account for OEM mass production and aftermarket.

[0107] The first function module, referring to the power supply module, comprises a surge protection circuit, a filter circuit, and a DC/DC converter circuit; and the power supply module converts alternating current to direct current. The following power supply modules with different part numbers are described:

[0108] Part number A101: 120/230/277VAC/60Hz/1Ph, used in a motor of equal to or less than 1/4 HP;

[0109] Part number A102: 120/230/277VAC/60Hz/1Ph, used in 1/3 and 1/2 HP
motor;

[0110] Part number A103: 120/230/277VAC/60Hz/1Ph, used in 3/4 and 1 HP motor;

[0111] Part number A104: 460VAC/60Hz/3Ph, used in 1.2 - 2 HP motor;

[0112] Part number A105: 460VAC/60Hz/3Ph, used in 2.3 - 3.5 HP motor;

[0113] Part number A106: 460VAC/60Hz/3Ph, used in 5 HP motor;

[0114] .............

[0115] Part number Al ON: 575VAC/60Hz/3Ph, in 5 HP motor;

[0116] A power supply module is selected from different part numbers so as to match the input voltage and power; for example, a 1 HP power supply module supplies enough power for two 1/2 HP motors.

[0117] The second function module, referring to a motor control module, that controls the speed, torque or air flow of a motor by receiving DC power and a control signal, and by supplying a UVW three-phase (or multiple-phase) electric current to the main body of the motor; the motor control module comprises a microprocessor, an IGBT
inverter component, and a heat sink. The motor control module further comprises a Hall element and a Hall signal interface; and the Hall element is configured to detect the rotor position based on a Hall signal.

[0118] The motor control module further comprises a first port through which a driver is updated and compatible with an output or input module, thus allowing the user to correct defects or add new functions to the motor control unit. The motor control module further comprises a second port used to connect a computer that allows the user to adjust the motor parameters through programming. The following motor control modules with different part numbers are described:

[0119] Part number B101: used in a DM2 motor of equal to or less than 1/4 HP;

[0120] Part number B102: used in a DM3 motor of equal to or less than 1/4 HP;

[0121] Part number B103: used in a DM2 motor of 1/3 and 1/2 HP;

[0122] Part number B104: used in a DM3 motor of 1/3 and 1/2 HP;

[0123]

[0124] Part number B120: used in a DM2 motor of 5 HP;

[0125] Part number B131: used in a DM3 motor of 5 HP;

[0126] The multiple-speed 24VAV input module comprises a plurality of module components that matches a speed grade and a voltage grade. A corresponding driver is essential for the motor control module to work.

[0127] The RS-485 serial communication module implements a communication protocol, such as Modbus and ClimateTalk, supported by a driver for the motor control module.

[0128] The I/0 module further comprises a specified communication module for date transmission with a client communication module.

[0129] The I/0 module comprises at least one module selected from the group comprising:

[0130] a multi-speed 24VAC input module that receives a 24VAC signal from the main control board and sends the signal to the motor control module; and the part number may be C101;

[0131] a PWM input module that receives a PWM signal from the main control board and sends the signal to the motor control module; and the part number may be C102;

[0132] a 0-10VDC input module that receives a 0-10VDC signal and sends the signal to the motor control module; and the part number may be C103;

[0133] a RS485 serial communication module that implements a communication protocol supported by a driver for the motor control module; and the part number may be C104;

[0134] a Bluetooth module that allows the motor control module to communicate with an app or a computer for motor configuration; and the part number may be C105;

[0135] a pulse output module that outputs a pulse for representing a parameter of the motor; the part number may be C106;

[0136] an Ethernet local area network module that supports a TCP/TP protocol for allowing the motor control module to connect into a building control network or to monitor and control the motor parameters over network; and the part number may be C107;

[0137] a human-machine interface (HMI) function module that comprises a color and monochrome screen for offering a high resolution display; the HMI function module is used to display information about the rotational speed, torque or air volume of the motor, making it convenient for the user to perform a configuration setting or experimental test;
the part number may be C107; and

[0138] a DIP switch module that is connected to motor control module by the interface connector; the DIP switch module comprises a set of switches for changing the motor parameters; and the part number may be C108.

[0139] The examples detailing the above function modules are described as follows:

[0140] Test 1: a commercial air conditioner comprises a 3 HP indoor motor and two 1/3 HP outdoor motors; and each motor operates at five speed levels. A motor control unit for controlling the commercial air conditioner comprises:

[0141] a power supply module (or two or three smaller power supply modules) with a part number for supplying enough power for the three motors;

[0142] a 3HP motor control module with a part number;

[0143] two 1/3 HP motor control modules with part numbers; and

[0144] three 5-speed input modules with part numbers.

[0145] The function modules are integrated to form a motor control unit that shortens the development circle, saves cost, and allows easy maintenance of the motor control unit.

[0146] Test 2: a residential air conditioner comprises a 1/2 HP indoor motor and a 1/4 HP
outdoor motor; the indoor motor operates at 0-10VAC and ten speed levels; and the outdoor motor operates at three speed levels. The indoor motor outputs a pulse signal to a main control board for adjusting the motor speed. A motor control unit for controlling the residential air conditioner comprises:

[0147] a power supply module for supplying enough power for the two motors;

[0148] a 1/2 HP motor control module;

[0149] a 1/4 HP motor control module;

[0150] two 5-speed input modules;

[0151] a 0-10VDC input module; and

[0152] a pulse output module.

[0153] Test 3: a commercial air conditioner comprises a 5 HP indoor motor and two 1/3 HP outdoor motors; and each motor operates at five speed levels. The air conditioner is operated under poor working conditions such as thunderstorms and poor power grid quality, and even its power supply or IGBT inverter component has burned out in the past. A motor control unit for controlling the residential air conditioner comprises:

[0154] a power supply module for supplying enough power for the three motors;

[0155] a spare power supply module;

[0156] a 5 HP motor control module;

[0157] a 5 HP spare motor control module;

[0158] two 1/3 HP motor control modules;

[0159] two 1/3 HP spare motor control modules;

[0160] three 5-speed input module; and

[0161] a redundancy control module.

[0162] The function modules are disposed on a mechanical mounting base 100 and connected to the data bus and the power supply bus on the second circuit board to allow the transmission of power and data, thus forming a motor control unit.

[0163] Compared to a conventional motor control unit, the motor control unit of the disclosure comprises a plurality of independent function modules that allow for easy replacement of a damaged function module, thus reducing the maintenance cost.
Optionally, the function modules are disposed in different positions to satisfy user requirements.
Example 2

[0164] As shown in FIGS. 5 and 16, a combination method of the motor control unit comprises dividing the motor control unit into a plurality of function modules; and the plurality of function modules comprises:

[0165] a first function module, referring to a power supply module that is connected to an electric supply and converts alternating current to direct current to supply for other function modules; optionally, different power supply modules are formed to match the input voltage and power;

[0166] a second function module, referring to a motor control module that controls the operation of the motor; the motor control module comprises a microprocessor, an IGBT
inverter, and a heat sink; when receiving VDC power and control signals, the motor control module supplies electricity to the motor so as to control the rotational speed, torque, or air volume of the motor; optionally, different motor control modules are formed to match the input power;

[0167] a third function module, referring to at least one 1/0 module that allows signal transmission between the motor control module and a main control board or a peripheral device;

[0168] a fourth function module, referring to a redundancy control module that starts a spare function module when the first, second or third function module has an emergency;
and

[0169] a fifth function module, referring to at least one spare function module that performs the same function as the first function module, the second function module, or the third function module.

[0170] The power supply module, the motor control module, the at least one 1/0 module, the redundancy control module, and the spare function module are combined into a motor control unit that matches the parameters of the motor.

[0171] The 1/0 module comprises at least one module selected from the group comprising:

[0172] a multi-speed 24VAC input module that receives a 24VAC signal from the main control board and sends the signal to the motor control module;

[0173] a PWM input module that receives a PWM signal from the main control board and sends the signal to the motor control module;

[0174] a 0-10VDC input module that receives a 0-10VDC signal and sends the signal to the motor control module;

[0175] a RS485 serial communication module that implements a communication protocol supported by a driver for the motor control module;

[0176] a Bluetooth module that allows the motor control module to communicate with an app or a computer for motor configuration;

[0177] a pulse output module that outputs a pulse for representing a parameter of the motor; and

[0178] an Ethernet local area network module that supports a TCP/TP protocol for allowing the motor control module to connect into a building control network or to monitor and control the motor parameters over network;

[0179] a human-machine interface (HMI) function module that comprises a color and monochrome screen for offering a high resolution display; the HMI function module is used to display information about the rotational speed, torque or air volume of the motor, making it convenient for the user to perform a configuration setting or experimental test;
and

[0180] a DIP switch module that is connected to motor control module by the interface connector; the DIP switch module comprises a set of switches for changing the motor parameters.

[0181] Each function module comprises an independent shell, a first circuit board, and other electronic components; the first circuit board and other electronic components are disposed in the shell; the shell comprises metal or plastic; the motor control unit further comprises a mechanical mounting base 100 and a second circuit board disposed in the mechanical mounting base; the above function modules are fixedly disposed on the mechanical mounting base, and connected to each other via second circuit board 104 to allow the transmission of power and control signals.

[0182] The second circuit board 104 comprises a plurality of power supply bus interfaces 103a and a plurality of data bus interface 103b so as to be electrically connected to the mechanical mounting base.

[0183] It will be obvious to those skilled in the art that changes and modifications may be made, and therefore, the aim in the appended claims is to cover all such changes and modifications.

Claims (12)

1. A motor control unit having redundancy control, comprising:
a first function module, referring to a power supply module that is connected to an electric supply and converts alternating current to direct current to supply for other function modules;
a second function module, referring to a motor control module that controls the operation of a motor; the motor control module comprises a motor control microprocessor, an IGBT inverter, and a heat sink; the motor control module receives DC power and control signals and supplies power to the main body of the motor so as to control the rotational speed, torque, or air volume of the motor;
a third function module, referring to an I/0 module that allows signal transmission between a main control board or a peripheral device and the motor control module; wherein the motor controller comprises at least one third function module, and a plurality of third function modules is optionally disposed between a main control board or a peripheral device and the motor control module for signal transmission;
a fourth function module, referring to a redundancy control module that starts a spare function module when the first, second or third function module has an emergency; and a fifth function module, referring to at least one spare function module that performs the same function as the first function module, the second function module, or the third function module.

2. The motor control unit of claim 1, wherein the redundancy control module comprises a redundancy control microprocessor, a plurality of relays, a screen circuit, and a bus access circuit; the bus access circuit allows signal communication between the redundancy control microprocessor and other function modules; the redundancy control microprocessor starts the spare function module via the plurality of relays; and the screen circuit is configured to display a working status of other function modules.

3. The motor control unit of claim 2, wherein the first function module, the third function module, and the spare function module further independently comprise a network communication unit; the network communication unit comprises a bus microprocessor, a bus communication access circuit, and a function detection circuit; the function detection circuit performs a function inspection to its function module and transmits the signal to the bus communication access circuit; and data is transmitted between the bus microprocessor and the redundancy control microprocessor via the bus communication access circuit and a data bus.

4. The motor control unit of claim 1, 2 or 3, wherein each function module comprises an independent shell, a first circuit board, an interface connector, and a heat sink; the shell comprises metal or plastic; the first circuit board is disposed in the shell; the interface connector is partially disposed on the first circuit board to allow the transmission of power and control signals; and the heat sink is disposed outside or inside the shell.

5. The motor control unit of claim 4, wherein the 1/0 module comprises at least one module selected from the group comprising:
a multi-speed 24VAC input module that receives a 24VAC signal from the main control board and sends the signal to the motor control module;
a PWM input module that receives a PWM signal from the main control board and sends the signal to the motor control module;

a 0-10VDC input module that receives a 0-10VDC signal and sends the signal to the motor control module;
a RS485 serial communication module that implements a communication protocol supported by a driver for the motor control module;
a Bluetooth module that allows the motor control module to communicate with an app or a computer for motor configuration;
a pulse output module that outputs a pulse for representing a motor parameter; and an Ethernet local area network module that supports a TCP/TP protocol for allowing the motor control module to connect into a building control network or to monitor and control the motor parameters over network;
a human-machine interface (HMI) function module that comprises a color and monochrome screen for offering a high resolution display; the HMI function module is used to display information about the rotational speed, torque or air volume of the motor, making it convenient for the user to perform a configuration setting or experimental test; and a DIP switch module that is connected to motor control module by the interface connector; and the DIP switch module comprises a set of switches for changing the motor parameters.

6. The motor control unit of claim 4, wherein the motor control unit further comprises a mechanical mounting base and a second circuit board disposed in the mechanical mounting base; the above function modules are connected to each other via the second circuit board or a plurality of flexible cables so as to allow the transmission of power and control signals.

7. The motor control unit of claim 1, 2 or 3, wherein the motor control unit comprises two second function modules for controlling the operation of two motors, respectively.

8. The motor control unit of claim 1, 2 or 3, wherein the at least one spare function module is optionally used as a backup of the power supply module, the motor control module, and the I/0 module.

9. A combination method of a motor control unit having redundancy control, the method comprising dividing a motor control unit into a plurality of function modules according to functions of the motor control unit; and the plurality of function modules comprising:
a first function module, referring to a power supply module that is connected to an electric supply and converts alternating current to direct current to supply for other function modules; optionally, different power supply modules are formed to match the input voltage and power;
a second function module, referring to a motor control module that controls the operation of the motor; the motor control module comprises a microprocessor, an IGBT inverter, and a heat sink; when receiving VDC power and control signals, the motor control module supplies electricity to the motor so as to control the rotational speed, torque, or air volume of the motor;
optionally, different motor control modules are formed to match the input power;
a third function module, referring to at least one I/0 module that allows signal transmission between the motor control module and a main control board or a peripheral device;
a fourth function module, referring to a redundancy control module that starts a spare function module when the first, second or third function module has an emergency; and a fifth function module, referring to at least one spare function module that performs the same function as the first function module, the second function module, or the third function module;

, wherein, the power supply module, the motor control module, the at least one I/0 module, the redundancy control module, and the spare function module are combined into a motor control unit that matches the parameters of the motor.

10. The method of claim 9, wherein the I/0 module comprises at least one module selected from the group comprising: a multi-speed 24VAC input module for receiving a 24VAC signal from the main control board and sending the signal to the motor control module; a PWM input module for receiving a PWM signal from the main control board and sending the signal to the motor control module; a 0-10VDC input module for receiving a 0-10VDC signal and sending the signal to the motor control module; a RS485 serial communication module for implementing a communication protocol that is supported by a driver for the motor control module; a Bluetooth module for allowing the motor control module to communicate with an app or a computer for motor configuration; a pulse output module for outputting a pulse that represents a parameter of the motor; an Ethernet local area network module for supporting a TCP/TP protocol that allows the motor control module to connect into a building control network or monitors and controls the motor parameters over network; a human-machine interface (HMI) function module that comprises a color and monochrome screen for offering a high resolution display to show the rotational speed, torque or air volume of the motor, making it convenient for the user to perform a configuration setting or experimental test; and a DIP switch module connected to the motor control module via the interface connector, and the DIP switch module comprises a set of switches for changing the motor parameters.

11. The method of claim 9 or 10, wherein each function module comprises an independent shell, a first circuit board, and other electronic components; the shell comprises metal or plastic; the first circuit board and other electronic components are disposed in the shell; the motor control unit further comprises a mechanical mounting base and a second circuit board disposed in the mechanical mounting base; the above function modules are fixedly disposed on the mechanical mounting base, and connected to each other via the second circuit board to allow the transmission of power and control signals.

12.
The method of claim 11, wherein the second circuit board comprises a DC
power supply interface and a bus interface, both of which are used to connect the function modules to the second circuit board.

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