• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
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    • 专利摘要:
    method for the automatic implementation of diagnostics and prognostics for drives. an electric motor drive system includes a fan configured to cool the power electronics of the electric motor drive system. the electric motor drive system also includes a temperature sensor arranged near a fan air inlet and configured to detect an ambient temperature of the air entering the air inlet. in addition, the electric motor drive system includes a processor coupled to communicate with the temperature sensor and configured to determine at least one of the two: a prognosis for the drive or a power reduction requirement based on the detected ambient temperature.
    公开号:BR102014006156B1
    申请号:R102014006156-8
    申请日:2014-03-14
    公开日:2021-04-27
    发明作者:Bruce William Weiss；Robert Michael Michalski；Lixiang Wei；Garron Koch Morris；Brian Patrick Brown
    申请人:Rockwell Automation Technologies, Inc；
    IPC主号:
    专利说明:

    BACKGROUND
    [001] The present invention relates in general lines to the field of electronic power devices, and especially to the implementation of diagnostics and prognosis for electric motor drives based on a measured drive input temperature.
    [002] There are a multitude of applications in the drive industry for motors of various types. In many applications, a motor drive includes a circuit for driving an electromagnetic machine such as a brushed or brushless motor, stepper motor or other electromechanical actuator. Such motors and actuators can be arranged internally or externally in their respective motor drives. A multiplicity of motor drives can be positioned in all different parts of a factory or manufacturing site. In the case of higher power applications, multiphase motors are usually used with separate motor drives that can be positioned in cabinets in the general vicinity of the driven motor.
    [003] The motor drives in general are designed for an efficiency of only a certain percentage of the maximum rated power for the device. When machines are new and for most of their service life, the rated power may remain as originally assigned, although a small reduction in power is acceptable due to environmental conditions, age of the machine and other factors. That is, the motor drive has the reduced power of a maximum current output to meet a specific power reduction requirement for the motor drive, effectively reducing the drive and motor performance. This demand for power reduction may be different when the motor drive is operated at different ambient temperatures, which can have an adverse impact both on the performance of the machines and can also reduce their useful life. In addition, a series of predictions can be determined for a motor drive based on the ambient temperature at which the motor drive operates.
    [004] To perform the calculations of the various diagnoses, prognoses and so on, motor drives often include temperature sensors located on a motor drive circuit board. Such temperature sensors are usually found right inside the motor drive itself, confined by a protective housing and surrounded by elements that can affect the temperature measurement. In some motor drives, a processor estimates the ambient temperature measurement from the internal operating temperature of the motor drive by applying an energy balance equation. This estimate can be very accurate when the motor drive is initially operated. Unfortunately, over time, this estimate may become less accurate due to operational inefficiencies and the degradation of the internal cooling mechanisms of the motor drive. Consequently, it has now been recognized that it is desirable to have a motor drive with an improved detection of the ambient temperature, in order to be able to provide a user with more accurate information on the diagnosis and prognosis for the motor drive. SHORT DESCRIPTION
    [005] In a first modality, an electric motor drive system includes a fan configured to cool electronic power components of the electric motor drive system. The electric motor drive system also includes a temperature sensor arranged in the vicinity of an air inlet of the fan and configured to detect an ambient temperature of air entering the air inlet. In addition, the electric motor drive system includes a processor coupled to communicate with the temperature sensor and configured to determine at least one of the two: a prognosis for the drive or a diagnosis for the drive, based on the detected ambient temperature.
    [006] In another embodiment, an electric motor drive system includes a first fan configured to cool the electronic power components of a first motor drive and a second fan configured to cool the electronic power components of a second drive. motor. The electric motor drive system also includes a first temperature sensor arranged in the vicinity of a first air inlet of the first fan and configured to detect a first ambient temperature of air entering the first air inlet. In addition, the electric motor drive system includes a second temperature sensor arranged in the vicinity of a second air inlet of the second fan and configured to detect a second ambient temperature of air entering the second air inlet. In addition, the electric motor drive system includes a processor that is coupled to communicate with the first and second temperature sensors and configured to determine at least one of the two: a prediction for the drive or a diagnosis for the drive for each one of the two: the first and the second detected ambient temperature.
    [007] In another modality, a method includes the detection of an ambient air temperature by means of a temperature sensor arranged in the vicinity of an air inlet of a fan of an electric motor drive. The fan is configured to cool the electronic power components of the electric motor drive by means of air sucked through the air inlet. The method also includes the determination by means of a coupled processor for communication with the temperature sensor, at least one of the two: a prognosis for the drive or a diagnosis for the drive, based on the detected ambient temperature. DRAWINGS
    [008] These and other characteristics, aspects and advantages of the modalities being described will become better understood when the detailed description that follows is read with reference to the attached drawings in which the same characters represent equal parts in all drawings, in which:
    [009] Figure 1 is a schematic diagram of a motor drive with an inlet temperature sensor according to an embodiment of the present invention;
    [010] Figure 2 is a schematic diagram of a motor drive system having a multiplicity of motor drive power modules to drive a single motor according to a modality of the present invention;
    [011] Figure 3 is a schematic diagram of the electronic power switching circuit of the motor drive of Figure 1 according to an embodiment of the present invention;
    [012] Figure 4 is a block diagram illustrating the various functions performed by the control circuit of a motor drive equipped with an inlet temperature sensor in accordance with an embodiment of the present invention;
    [013] Figure 5 is a process flow chart illustrating a method for determining thermal system defects in accordance with an embodiment of the present invention;
    [014] Figure 6 is a process flow chart illustrating a method for determining the life span of the power module according to an embodiment of the present invention;
    [015] Figure 7 is a flow chart illustrating a method for determining the life of the ventilator according to one embodiment of the present invention;
    [016] Figure 8 is a perspective view of a fan assembly of the motor drive of Figure 1 according to an embodiment of the present invention;
    [017] Figure 9 is an exploded perspective view of the fan assembly of Figure 8 according to an embodiment of the present invention;
    [018] Figure 10 is a perspective view of certain components of a motor drive within the fan assembly of Figures 8 and 9 according to an embodiment of the present invention; and
    [019] Figure 11 is a perspective view of the motor drive having the fan assembly of Figures 8 and 9 according to an embodiment of the present invention. DETAILED DESCRIPTION
    [020] The modalities that are being described are focused on systems and methods for determining prognosis and diagnostics for electric motor drive systems. More specifically, the systems and methods described in this document use a measurement of the ambient air temperature to determine the prognosis and diagnostics for the drive. The ambient air temperature can be measured directly using a temperature sensor located in the vicinity of an air inlet of the motor drive. The temperature measurement at the air inlet may be more accurate than an estimate of the ambient temperature which is calculated from an internal temperature of the power module of the motor drive. Thus, the systems and methods described in this document can provide more accurate prognoses and diagnoses for starting the engine while operating the engine. By implementing certain actions based on the predictions and diagnoses determined, the motor drive systems can receive better control of preventive maintenance and drive, which can ultimately lead to a more efficient operation of the drive and an extended service life. motor start. The techniques discussed below can be applied to any desirable electric motor drive system, to a system with a multiplicity of motor drives operating in parallel to drive a single process.
    [021] Referring now to the drawings, Figure 1 is a block diagram of a motor drive system 10 illustrating various components of a motor drive 12. Motor drive 12 can include control circuit 14, for example , conductor circuit 16, and power circuit 18. Power circuit 18 can receive three-phase power 20 and feed a motor 24 with three-phase power 22. Power circuit 18 can include, for example, electronic power switching circuit. Control circuit 14 and conductor circuit 16 can include a control circuit board and several optional function circuits. Conductor circuit 16 can send switching signals from power circuit 18 to quickly close and open, resulting in a three-phase waveform supply to all output terminals 26, 28 and 30. Conductor circuit 16 is controlled by the control circuit control 14 that can operate autonomously, or that can respond to commands launched from a remote control monitor over a network. Similarly, the operation of the conductive circuit 16 can be coordinated by means of the control circuit 14 with that of other drives. Many different control schemes and functions can be implemented by a control circuit processor 14, and programs for this operation can be stored on the control panel, such as for closed circuit speed control, closed circuit torque control , control of the power reduction of the drive, among many others.
    [022] The drive of the motor 12 can include a fan 32 to provide the cooling of the circuit (of the power circuit 18, for example) that is inside the drive of the motor 12. The fan 32 can be configured to suck in air relatively cold environment into the motor 12 drive, as shown by arrows 34, and direct the air through a duct or a wind tunnel that stores the various circuits. As will be discussed in more detail below, the embodiments of the present invention can include a temperature sensor 36 disposed in the vicinity of an air inlet of the fan 32 and used to detect the temperature of the ambient air entering the air inlet. The temperature sensor 36 can provide feedback signals of the ambient temperature to the control circuit 14, by means of a power / fan control cable 38 of the motor drive 12, for example, or wirelessly. The control circuit 14 can conduct various calculations in substantially real time to determine prognoses and diagnostics (such as the requirements for power reduction of the drive, for example) of the motor drive 12 based on the detected inlet temperature. Such calculations can provide more accurate predictive predictions for a user than would be available without the input temperature sensor 36. In addition, control circuit 14 can provide greater control of motor drive 12 based on these calculations to increase expectation of service life and operational efficiency of the motor drive 12.
    [023] Temperature sensor 36 can be located in close proximity to a fan inlet in several other arrangements of the motor drive system 10. The detection of the inlet temperature, for example, can be applied to a motor drive system 10 which uses a multiplicity of separate motor drives 12 to drive a single process. Figure 2 is such a modality, having two or more motor drives or drive modules 12 operationally coupled in parallel to drive motor 24. In the illustrated mode, each of the motor drives 12 is equipped with conductor circuit 16 and with the power circuit 18. However, the control circuit 14 used to control the conductive circuit 16 for each of the motor drives 12 can be located remote from the motor drives 12. Any number of motor drives 12 can be added or removed from the motor drive system 10 to condition a desired amount of the power with which the motor 24 is fed.
    [024] In such modalities, each of the motor drives 12 can be equipped with the temperature sensor 36 disposed in the vicinity of an air inlet of the fan 32. In the illustrated embodiment a first motor drive 50 includes a first fan 52 with a first temperature sensor 54. Similarly, a second motor drive 56 includes a second fan 58 with a second temperature sensor 60. Each of the temperature sensors 54 and 60 can be coupled for communication to the control circuit 14 by means of the respective cables 62 and 64. In such modalities, the control circuit 14 can be configured to determine prognoses for each of the motor drives 50 and 56 based on the respective inlet air temperature measurements.
    [025] Calculations conducted using control circuit 14 can be used to identify one or more of the motor drives 12 that are experiencing operational difficulties. If internal defects or contaminants are reducing the amount of cooling that occurs on motor drive 12, for example, the change in temperature between the ambient temperature and the internal temperature of a drive can be significantly less than the change in temperature of another drive connected in parallel. In response, the control circuit 14 can emit signals to warn a user that a specific motor 12 drive is not operating effectively. In other embodiments, two or more motor drives 12 can be coupled in parallel, as shown, each having its own control circuit 14 with a processor for determining and / or implementing diagnostics and prognoses for the drives. In such cases, the control circuit 14 of each of the motor drives 12 can be connected to one another via the control structure to control the operation of the motor 24.
    [026] Figure 3 is a schematic diagram showing components of power circuit 18 in detail. In the illustrated embodiment, power circuit 18 includes electronic power switching circuit. The power circuit 18 can be located inside a power conversion module of the motor drive 12. As mentioned above, the power circuit 18 typically receives three-phase power 20 as an input, such as from the power network. The three-phase power source is electrically coupled to a set of input terminals 70, 72, and 74 that provide three-phase AC power at a constant frequency to rectifier circuit 76. Rectifier circuit 76 includes components, such as diodes 78, that perform a complete rectification of the waveform of the three-phase voltage waveform. After rectification all phases of the incoming energy are combined by providing DC power to a low side 80 and a high side 82 of a DC bar. The inductors 84 can be coupled to both the high side and the low side of the DC bus and act as chokes to uniform the rectified DC voltage waveform. One or more filter capacitors 86 can connect the high side 82 and the low side 80 of the DC bus and are also configured to uniform the rectified DC voltage waveform. Together, inductors 84 and capacitors 86 serve to remove most of the ripples from the waveform, so that the DC bus carries a waveform that closely approximates that of a true DC voltage. It should be noted that the three-phase implementation described in this document is not intended to be limiting, and the invention can be used in a single-phase circuit, as well as a circuit designed for applications other than motor drives.
    [027] An inverter 88 is coupled to the DC bus and generates a three-phase output waveform to the one desired to drive the motor 24 connected to the output terminals, 26, 28 and 30. Within the illustrated inverter 88, two bipolar transistors of insulated port (IGBTs) 90 are coupled in series for each phase. The pair of transistors 90 can be coupled to the emitter collector between the high side 82 and the low side 80 of the DC bus. Three of these pairs of transistors are then coupled in parallel to the DC bus up to a total of six transistors 90. Each of the output terminals 26, 28 and 30 is coupled to one of the outputs between one of the pairs of transistors 90. The conductor circuit 16 sends a signal to transistors 90 to close and open quickly, resulting in a three-phase waveform output through output terminals 26, 28 and 30. Conductor circuit 16 is controlled by control circuit 14, based on the various inputs. Such entries may include, for example, operator entries received from an operator interface. In addition, the control circuit 14 can receive feedback 91 which represents a current operational state of the motor drive 12. Such feedback 91 can include sensor feedback from one or more sensors (from temperature sensor 36, for example) arranged in the entire engine drive system 10.
    [028] In some embodiments, the motor 122 drive can be a regenerative motor drive configured to operate in a regenerative phase of operation sometimes and in the drive operation described above at other times. In the regenerative phase of the operation, the rectifier circuit 76 can allow the inertial energy or braking energy of the three-phase motor 24 to be redirected back to the main network (power network, for example) of the three-phase power 20. As will be noted by those versed in technique, during regenerative operation, motor 24 behaves like a three-phase generator. Consequently, switches in the rectifier circuit 76 can be switched by the conductive circuit 16 in such a way as to allow the alternating current passing through the DC bus to return to the supply network, thus recapturing the inertial energy of the motor 24.
    [029] As noted above, motor drive 12 can be equipped with fan 32 to cool power circuit 18 during the entire drive operation. As shown, the fan 32 can be positioned on the motor drive 12 in such a way that the air drawn in through the air inlet of the fan 32 (arrows 34, for example) is directed through the power circuit 18 of the motor drive 12. The air can provide cooling for the electronic power switching components, which otherwise could overheat due to the rapid opening and closing movements of the transistors 90. The arrows 92 represent the air flowing through each rectifier circuit 76, on the side high 82, and low side 80 of the DC bus, and inverter 88. Power circuit 18 can reside entirely on a single circuit board that is arranged in a motor drive housing 12, and the fan can direct air of cooling through the circuit board. In some embodiments, air can flow through the conductive circuit 16 and / or the control circuit 14 as well, depending on whether these components are located in the motor drive 12 or not and depending on the spatial arrangement of the components in relation to the fan 32.
    [030] As noted above, temperature sensor 36 located near the air inlet of fan 32 can provide input temperature feedback for controlling motor drive 12 and for determining relatively accurate prognosis and diagnostics of the motor drive 12. Figures 1-3 represent modalities of motor drive systems 10 that can use inlet temperature measurement to determine reliability calculations, remaining life estimate, drive health assessment, health assessment component (fan 32, for example), power reduction requirements and other information to promote the efficient operation of one or more motor drives 12. These modalities are intended to be illustrative and not limiting, so that the temperature sensor 36 can also be arranged in close proximity to fan 32 of any other type of motor drive system or 10.
    [031] Having now described several types of motor drive systems 10 that can use the described inlet temperature sensor, a more detailed description of the uses of the detected temperature will be given. For this purpose, Figure 4 is a block diagram showing several functions that can be conducted by a motor drive processor 12, the processor being coupled for communication to the temperature sensor 36 according to the techniques described. The processor can include any desired processing system used to conduct the calculations described in this document. The processor may include, for example, a microprocessor located in the control circuit 14 of the motor drive system 10. The control circuit 14 can send control signals to the conductive circuit 16 for the execution of several actions determined based on the calculations of the processor.
    [032] Inputs 100 on the processor may include, but are not limited to, an air temperature measurement 112 and any number of several trigger counters 114. Air temperature measurement 112 may include a signal indicating the air temperature sent from the sensor temperature 36 to the processor at different times during operation of the motor 122. In some embodiments, the temperature sensor 36 can send such signals to the processor at a predetermined interval, especially when temperature measurement 112 is used as feedback 91 for control the functions of the control circuit 14. In other embodiments, the temperature sensor 36 can provide the measurement of air temperature 112 to the processor at desired times based on the receipt of a signal from the processor. This may be the case when temperature measurement 112 is used to determine predictions and to provide predictions to an operator on demand.
    [033] In addition to temperature measurement 112, the processor can receive signal inputs that correspond to the drive 114 counters present in the motor 12 drive. These drive counters 114 can include any additional parameters that are determined or counted at regular intervals for provide feedback 91 to control motor drive 12. Drive 114 counters may include, for example, a fan run time, a fan speed and a thermal module. The fan run time represents the time during which the fan 32 operated, and the fan speed represents the substantially instantaneous speed of the fan 32. The temperature of the module can represent a temperature of one or more internal components of the motor drive 12 , as determined by means of embedded temperature sensors. One or more temperature sensors can continuously monitor, for example, the temperatures of transistors 90 in power circuit 18. This can allow the processor to determine a change in temperature between ambient air (detected by means of temperature sensor 36, for example). example) and the power circuit 18 (detected by means of the embedded temperature sensors, for example). Other drive counters 114 can also be provided as inputs 110 to the processor.
    [034] The processor can use inputs 110 to conduct any number of desired calculations 118. Such calculations 118 can be conducted at any point in time during the operation of motor drive 12, so that they are calculations substantially close to real time. Based on calculations 118, the processor can determine at least one of the two: the prognosis for the drive or a diagnosis for the drive during the operation of the motor drive 12. The 118 calculations can be conducted as a code executed through the processor , the code being stored in a memory or other medium readable by a non-transitory computer coupled to the processor. The processor can calculate several different parameters or diagnostics related to the operation of the drive, and some non-limiting examples are given in the illustrated mode. These calculated parameters may include, for example, a fan life 120, a power reduction requirement of drive 122, a reliability of drive 124, a life of power module 126, and an operating time 128.
    [035] The life of the fan 120 can be an expected life or the remaining life of the fan 32, as determined based on the fan speed, fan operating time, and air temperature measurement 112. A the power reduction requirement of the drive 122 can be calculated based on the measurement of air temperature 112, since the power reduction requirement for a specific motor 12 drive is generally related to the ambient temperature at which the drive is operated of motor 12. More specifically, when motor drive 12 operates at a higher ambient temperature, the maximum permissible power output of motor drive 12 must be lower, so that the internal components of the drive (power circuit 18, for example) are not overheated. Similarly, motor drive 12 can operate at higher amperages when operating in an environment with a relatively lower ambient temperature. By adjusting (increasing or decreasing, for example) the amperage of the motor drive 12 according to the ambient temperature, it may be possible to extend the life of the motor drive 12.
    [036] The reliability of the drive 124 can be a measure of the capacity that the drive of the motor 122 has to perform its designated function (output power at a desired reduction, for example) over a certain period of time. This reliability of drive 124 can be expressed in terms of a probability that motor drive 12 will fail, and can be determined based at least partially on the measurement of air temperature 112. The service life of power module 126 may consist of an expectation lifetime, or the remaining life of the power conversion module (power circuit 18, for example) of motor drive 12, as determined based on a change in temperature in all components of the power module. Run time 128 can be an amount of time for which motor drive 12 has been operated, determined by a drive counter 114 in control circuit 14, conductor circuit 16, or power circuit 18. The time of operation 128 can be useful for determining prognoses related to efficiency or the remaining service life of the motor drive 12.
    [037] Some of the computations 118 performed by the processor can be used to provide relatively accurate predictions 130 for the motor drive 12, while others can be used to generate control signals for the execution of various actions 132 through the circuit of control 14. Predictions 130 may include any information that serves as a prediction related to the performance of the drive, including the life of the fan 120, the reliability of the drive 124, the life of the power module 126, the life of a capacitor 134, and thermal system defects 136. The life of capacitor 134 can be an expected total life or the remaining life of one or more capacitors 86 in power circuit 18, and can be determined based on temperature measurement 112. The processor can signal to an operator interface indicating to the user the life of capacitor 134 or to provide a warning when capacitor 86 is almost needing replacement. Defects in thermal system 136 can be determined based on the efficiency of a cooling system of the motor drive 12, or the amount of heat that the cooling system removes from the internal components of the motor drive 12 at a given inlet temperature. donate. Based partially on the measurement of air temperature 112, the processor can determine whether defects or degradation are present in the cooling system. Such defects may include, for example, the accumulation of dust on a heat collector of the power circuit 18, the non-passage of air through the motor drive 12 at a sufficiently high flow rate, the improper installation of thermal system components , a clogged filter, and so on. An operator can conduct maintenance services on the motor drive 12, when such thermal defects are identified by the motor drive system 10 to increase the operational efficiency of the motor drive 12.
    [038] The processor can be configured to determine any number of the predictions 130 listed above, among others, related to the operation of the motor drive 12. Again, the predictions 130 may depend on the temperature of the environment in which the motor drive 12 is operated . Thus, an accurate measurement of the ambient temperature may be desirable to accurately determine the predictions 130. A relatively more accurate measurement of the ambient temperature can be obtained by means of the temperature sensor 36 arranged at the fan inlet, as opposed to the embedded sensors. inside the motor drive circuits.
    [039] In addition to providing predictions 130 during the entire operation of the motor drive 12, the processor can provide outputs to the components (control circuit 14, for example) of the motor drive 12 to perform various actions 132. These actions 132 can include control of engine drive operations 12 or providing information (forecasts 130 or warnings, for example) to an operator.
    [040] In the illustrated modality, actions 132 include the setting (block 138) of a nominal drive ampere, so that motor drive 12 operates within the calculated drive ampere reduction requirement 122. This setting may involve reducing the amperage output of the motor drive 12 when the air temperature measurement 112 is relatively high. Similarly, when the air temperature measurement 112 is relatively low, the nominal amperage adjustment may involve increasing the amperage output of the motor drive 12. This can ensure that the power circuit 18 operates with a relative efficiency (service life of the highest estimated power module 126, for example) although it continues to operate within the power reduction requirement 122. That is, a control circuit processor 14 adjusts the performance of motor drive 12 based on drive power reduction requirement determined 122.
    [041] Setting (block 140) a fan speed of fan 32 is another action 132 that can be performed based on calculations 118 and / or forecasts 130 determined by the processor. In some embodiments, the fan speed may be reduced when the air temperature measurement 122 is lower, to extend the life of the fan 120 and / or the life of the power module. In other embodiments, the fan speed can be reduced to maintain a desired overall efficiency of the motor drive 12. As noted, the processor can send commands to an operator interface to warn a user of potential inefficiencies or a maintenance request. . As an example, the actions 132 requested by the processor may include a warning that the thermal system is obstructed 142 based on the identified thermal system defects 136 inside the motor drive 12.
    [042] Figures 5-7 show in detail some examples of calculations 118 d, predictions 130 determined, and actions 132 performed by control circuit 14 as outlined in Figure 4. More specifically, Figure 5 is a process flow chart of a method 150 to determine thermal system defects 136 and perform certain actions 132 based on the determination. Method 140 includes measuring (block 152) the air temperature at the Tin inlet. This is the measurement of the air temperature 112 determined by the temperature sensor 36 in the vicinity of the air inlet. In addition, method 150 includes measuring (block 154) a TNTC temperature of the negative temperature coefficient of IGBT (NTC). This is a temperature of one or more of the transistors 90 in the power circuit 18 of the motor drive 12 and can be measured using a temperature sensor embedded in the power circuit 18. The temperature sensor can be an NTC sensor or any another desirable sensor. Using these monitored temperatures as inputs, control circuit 14 can calculate (block 156) an increase in Trise temperature. This value can represent a change in air temperature between the inlet of the fan 32 and the power circuit 18, calculated according to the following expression: Trise - TNTC - Tin (1)
    [043] In addition to determining Trise, method 150 may include the calculation of IGBT PIGBT losses (block 158). These calculated losses represent power lost in the entire power circuit 18 by heat generated by the fast switching transistors 90. The calculation for determining the losses can be based on the controlled operation (switching the speed, for example) of the power circuit 18. The control circuit 14 can determine this operation, and the expected losses associated with it. In addition, control circuit 14 can determine whether there are defects in thermal system 136 based on a relationship 160 between calculated Trise 162 and calculated PIGBT 164. The relationship 160 between Trise 162 and PIGBT may indicate that motor drive 12 is defective of specific thermal system 136 (obstruction or lack, for example) or that the motor drive 12 is operating as desired (normally, for example).
    [044] Control circuit 14 can perform an evaluation 166 based on ratio 160 to determine a current operational state of the thermal system of the motor drive 12. Control circuit 14 can determine, for example, that a component of the thermal system motor 12 is blocked. The “clogged” determination can be made when Trise is higher than expected for the PIGBT of the power circuit 18. This may indicate that the cooling and / or heat collector of the motor drive 12 is not providing the expected cooling to the internal components of the motor drive 12 and thus may be clogged. In response to this determination, the control circuit 14 can generate (block 168) an obstructed airflow warning. This warning may correspond to the obstructed thermal system warning 142 in Figure 4. This warning may indicate to an operator that an air filter or heat collector from the motor drive 12 is obstructed, that the fan 32 is degraded, or that the flow of air through the motor drive 12 is otherwise obstructed.
    [045] The control circuit 14 can determine by means of evaluation 166 that a component of the thermal system of the motor drive 12 is absent. The “absent” determination can be made when the Trise is lower than expected for the PIGBT of the power circuit 18. This may indicate that the cooling air is passing through the motor drive 12 at a flow rate above that required to cool power circuit 18. In response to this determination, control circuit 14 may generate (block 170) a missing filter warning to indicate to an operator that an air filter is missing from motor drive 12 or that it is in use a wrong type of fan 32.
    [046] Figure 6 is a process flow chart of a method 176 for determining the service life of the power module 126 of the motor drive 12 based in part on the measurement of the air temperature 112. As in method 150 of the Figure 5, this method 176 can compare the calculated Trise and the calculated PIGBT. In method 1276, a different relationship 178 between Trise and PIGBT can be used to determine whether transistors 90 are operating normally, are close to the point of needing a replacement or are already in need of a replacement. This relationship 178 can be related to the service life of the power module 126 discussed with reference to Figure 4.
    [047] Control circuit 14 can perform an 180 evaluation based on relationship 178 to determine a current operational state of power circuit 18. Control circuit 14, for example, can determine that one or more of transistors 90 need to be replaced, when, according to relation 178, the PIGBT is lower than expected for the heat output by the power circuit 18 (based on Trise, for example). In response to this determination, the control circuit 14 can provide signals to generate (block 182) an IGBT replacement warning. This warning can include, for example, a visualization or sequence of texts on a display or a warning, from an operator interface in communication with the control circuit 14. The text can be read like this, for example: “IGBT are close to the end of its useful life. Replace soon ”. Based on the signals received from the control circuit 14, the operator interface can indicate to an operator that the power module (circuit board, for example) that contains the IGBTs must be replaced. If the 180 evaluation indicates that one or more of the IGBTs are nearing the end of their useful life (“warning”), the warning can be posted (block 184) in a register that is an integral part of the control circuit 14 or is separate from it . The control circuit 14 can access the record, using this information and other information stored in the record to improve the predictions 130 determined.
    [048] Figure 7 is a process flow chart of a method 190 for determining fan life 120 of fan 32 based in part on measuring air temperature 112, and for implementing various actions in response to fan life 120 determined. As in the case of methods 150 and 176, previously described, method 190 includes the measurement (block 152) of Tin. In addition, method 190 includes the determination (block 192) of an operating time t of the motor drive 12, using, for example, a drive counter 114 specific to the motor drive 12. Method 190 also includes the determination ( block 194) of a fan speed (in RPMs, for example) of fan 32 using another of the drive counters 114 on the motor drive 12. Measurement of air temperature 112, run time, and fan speed they can all be provided as inputs 196 to determine the remaining life of the fan 198 based on a specific ratio 200 of the inputs 196. That is, the remaining life of the fan 198 is a function of each of the inputs 196.
    [049] Control circuit 14 can conduct an assessment 202 of the remaining life of fan 198 at regular intervals and implement certain actions in response to assessment 202. Control circuit 14, for example, can determine that fan 32 should be substituted. This may be the case where the speed of the fan is significantly reduced, compared to the speed of the fan it should have when the motor drive 12 was operating at a given ambient temperature, and the operating time of the motor 12 continued to increase over time. as the electronic power components operate. When this determination is made, the control circuit 14 can generate (block 204) a fan replacement warning, which can consist of a visualization or through a visible or audible message to an operator. The warning message may include, for example: “Fan near the end of its service life. Replace soon ”. In response to the evaluation 202 which gives a relatively low remaining life of the fan 198, the control circuit 14 may issue (block 206) a warning in a register. As noted above, the control circuit 14 can control the operation of a plurality of motor drives 12 operating in parallel. The warning for replacing the fan can be specific to fan 32 of a specific motor drive 12, so that the operator knows which motor drive 12 has a fan 32 that needs replacement. Similarly, the control circuit 14 can carry out warnings or actions in response to the other evaluations 166 and 180 for a specific motor drive 12 of a multiplicity of connected motor drives 12.
    [050] Having now described several examples of calculations, prognosis and actions that can be performed based on an ambient air temperature, Figures 8-11 give a more detailed description of the physical layout of the temperature sensor 36 that detects this temperature. More specifically, Figure 8 is a perspective view of a fan assembly 230 that has the fan 32 of the motor drive 12. The fan assembly 230 can be separated from the other internal components of the motor drive 12, as shown, or then the fan 32 can be incorporated directly into a wall of a housing that surrounds the motor drive circuits. In the illustrated embodiment, the fan assembly 230 includes a fan housing 232 that confines the fan 32, a fan impeller 234 of the fan 332 disposed in the fan housing 232, a fan motor (not shown), an air inlet 236, and a set of cables 238. The fan motor rotates impeller 234 at a desired fan speed based on signals from control circuit 14. Fan 32 draws in air through air inlet 236, as shown by arrows 240 In the illustrated embodiment, the impeller 234 is designed in such a way that the fan 32 pushes the air upwards through the motor drive 12, as shown by the arrows 242. Other arrangements of the fan assembly 230 may also be possible.
    [051] Figure 9 is an exploded perspective view of the fan assembly 230, showing the temperature sensor 36 disposed in the vicinity of the air inlet 236. In the illustrated arrangement, the temperature sensor 36 is located adjacent to a rear side of the fan housing 232, so that it is not in a direct path of the air flow through the motor drive 12. It may be desirable to position the temperature sensor 36 away from the direct air flow, so that the measurement of the temperature is not affected by changes in fan speed.
    [052] In the illustrated embodiment, temperature sensor 36 is located inside cable assembly 238, and temperature sensor 36 can use a cable connector 250 from cable assembly 238. Cable connector 250 directs wires 252 between fan motor 254 of fan assembly 230 and motor drive circuits 12. Control and feedback signals (indicative of fan speed, for example) can run between control circuit 14 and fan motor 254 by means of wires 252. In addition, one of the wires 252 can forward the energy (240V, for example) to the fan motor 254 of the power conversion circuit of the motor drive 12. Together with the communication and the power sent to the fan motor 254, one of the wires 252 can carry a signal indicating the ambient temperature from the temperature sensor 36 to the control circuit 14. Each of the wires 252 can be routed via the power / communication cable 38 from the fan assembly 230 to the control circuit 14, as described above with reference to Figures 1 and 2. In this way, the temperature sensor 36 can be incorporated into existing structures of the fan assembly 230 of the motor drive 12.
    [053] Temperature sensor 36, together with wires 252, can be confined by a cover box 256, which protects temperature sensor 36 from contamination by dirt and other foreign objects. In one embodiment, the temperature sensor 36 may be a negative temperature coefficient (NTC) sensor, although other types of temperature sensors may be used in other modalities. As illustrated, temperature sensor 36 can be mounted or attached to fan housing 232. Fan housing 232 can be sheet metal or some other good thermally conductive material, so that the temperature of fan housing 232 is approximately consistent with the ambient temperature of the air. The mass of the fan housing 232 can act as a temperature attenuation filter, so that the temperature sensor 36 provides a stable signal to the control circuit 14. In other embodiments, however, the temperature sensor 36 can be positioned outdoors to detect the ambient temperature of the air.
    [054] The illustrated location of the temperature sensor 36 can provide a relatively solid and reliable reading of the air temperature. In other embodiments, the temperature sensor 36 can be incorporated in the fan assembly 230 in different ways. The temperature sensor 36 can be mounted, for example, inside the fan housing 232. This can be especially useful if the motor of the fan 254 and wires 252 are located inside the fan housing 232. In addition, the temperature sensor 36 can be mounted along an inlet air duct of the motor drive 12, so that the duct is located immediately downstream (in the direction of the arrows 242 in Figure 8, for example) of the fan 32. Again, other provisions of the temperature sensor 36 located in the vicinity of an air inlet of the fan 32 can be used to directly detect an ambient temperature of the motor drive 12.
    [055] Figure 10 is a perspective view of motor drive components 12 having a fan assembly 230 of Figures 8 and 9. As noted, fan motor 254 can receive control and power from the motor drive circuit. 12 via power / control cable 38, and the same power / control cable 38 can provide temperature feedback signals from temperature sensor 36 to control circuit 14. In other embodiments, temperature sensor 36 can be configured to provide the temperature feedback signals to the wireless control circuit 14. That is, the temperature sensor 36 can be coupled for communication to a processor of the control circuit via a wireless connection. In the illustrated embodiment, a power interface circuit board 272 is coupled to the power / control cable 38 (via a wire connection 274). The power interface circuit board 272 can supply the necessary power to operate the fan 32 and to communicate with the fan motor 254 in response to the control signals received from the control circuit 14. The control circuit 14 in turn instead it can be located inside the motor drive 12 or outside the motor drive 12. In some embodiments, the power interface circuit board 272 can be part of a control circuit 14.
    [056] As shown in Figure 11, all (or practically all) components of motor drive 12 can be confined in a drive housing 276. Fan assembly 230 can be located at the bottom of motor drive 12, drawing in air into the motor drive 12 and up through it to cool the internal components (power circuit 18, for example). By detecting the temperature near the air inlet of the fan 32, it may be possible to determine a more accurate ambient temperature of the motor drive 12 than would be possible by estimating the ambient temperature from the feedback of the sensors embedded in the drive circuits of motor 12. The relatively low cost temperature sensor 36 can leverage the hardware architecture already present in motor drive 12 to allow relatively accurate predictions and advanced drive control. This advanced control can allow the motor drive 12 to inform the customer about the reliability of the drive and its service life during the operation of the motor drive 12, increase the amount of production activity, and ultimately extend the life of the motor drive. 12.
    [057] Although only certain features of the invention have been illustrated and described in the present invention, many modifications and changes will occur to those skilled in the art. It should, therefore, be understood that the appended claims are intended to cover all such modifications and alterations that fall within the true spirit of the present invention.
    权利要求:
    Claims (20)
    [0001]
    1. Electric motor drive system (10) comprising a fan (32) configured to cool the electronic power components (18) of the electric motor drive system (10), a processor (14), coupled for communication to the sensor temperature (36) and configured to determine at least one prognosis for the drive or a diagnosis for the drive, based on the detected ambient temperature characterized by a temperature sensor (36) being arranged in the vicinity of an air inlet of the fan ( 32) and configured to detect an ambient temperature of the air entering the air inlet.
    [0002]
    2. Electric motor drive system (10), according to claim 1, characterized in that the processor (14) is configured to determine at least one prognosis for the drive or the diagnosis of the drive during the operation of the drive system electric motor (10).
    [0003]
    3. Electric motor drive system (10), according to claim 1, characterized by at least the prognosis for the drive or the diagnosis for the drive comprises an expected life of the fan (120).
    [0004]
    4. Electric motor drive system (10), according to claim 1, characterized by at least one prognosis for the drive or the diagnosis for the drive comprises a reliability of the electric motor drive system (12).
    [0005]
    5. Electric motor drive system (10), according to claim 1, characterized by at least one prognosis for the drive or the diagnosis for the drive comprises a life expectancy of a power conversion module (126) .
    [0006]
    6. Electric motor drive system (10), according to claim 1, characterized by at least one prognosis for the drive or the diagnosis for the drive comprises a life expectancy of a capacitor of the electric motor drive system (134).
    [0007]
    7. Electric motor drive system (10), according to claim 1, characterized by at least one prognosis for the drive or the diagnosis for the drive comprises a defect in the thermal system of the electric motor drive system (136) .
    [0008]
    8. Electric motor drive system (10), according to claim 1, characterized in that the diagnosis for the drive comprises a power reduction requirement (122) of the electric motor drive system (10).
    [0009]
    9. Electric motor drive system (10) according to claim 8, characterized in that the processor (14) is configured to emit a control signal to adjust the performance of the electric motor drive system (10) based on in the determined power reduction requirement (122).
    [0010]
    10. Electric motor drive system (10), according to claim 1, characterized in that the processor (14) is configured to emit a control signal to adjust a fan speed based on the determined prognosis (140).
    [0011]
    11. Electric motor drive system (10), according to claim 1, characterized in that the processor (14) is configured to emit a control signal to provide an alert indication to an operator based on the determined prognosis.
    [0012]
    12. Electric motor drive system (10), according to claim 1, characterized in that the temperature sensor is arranged in the inlet air duct of the electric motor drive system.
    [0013]
    13. Electric motor drive system (10), according to claim 1, characterized in that the temperature sensor is disposed adjacent to a fan housing (232) of the electric motor drive system.
    [0014]
    14. Electric motor drive system (10), according to claim 1, characterized by comprising a control circuit communicatively coupled to the temperature sensor by means of a cable configured to direct power and / or control signals between the control circuit and the fan.
    [0015]
    15. Electric motor drive system (10), according to claim 1, characterized by comprising control circuits coupled for communication to the temperature sensor by means of a wireless connection.
    [0016]
    16. Electric motor drive system (10), according to claim 1, characterized in that the processor (14) is coupled to communicate with two or more temperature sensors (36) arranged in the vicinity of the air inlets of two or more more respective motor drives (12) and, where the processor (14) is configured to determine at least one prognosis for the drive or a diagnosis for the drive for each of the motor drives (12).
    [0017]
    17. Method characterized by comprising: - detecting an ambient temperature of the air by means of a temperature sensor (36) arranged in the vicinity of an air inlet of a fan (32) of an electric motor drive (12), in which the fan (32) is configured to cool electronic power components (18) of the electric motor drive (12) by means of air sucked through the air inlet; e- determine, by means of a processor (14) coupled for communication to the temperature sensor (36), at least one prognosis for the drive and a diagnosis for the drive, based on the detected ambient temperature.
    [0018]
    18. Method according to claim 17, characterized in that it comprises the adjustment of a performance of the drive device based on the diagnosis for the determined drive.
    [0019]
    19. Method, according to claim 17, characterized in that it comprises the generation of a warning based on the prediction of the determined drive.
    [0020]
    20. Method, according to claim 17, characterized in that it comprises detecting a power module temperature by means of a temperature sensor (36) arranged in the vicinity of the power electronic components (18), calculating a temperature difference between the ambient air temperature detected and the temperature of the detected power module, and determine the prognosis for the drive based on the calculated temperature difference.
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    同族专利:
    公开号 | 公开日
    EP2778822A2|2014-09-17|
    US9092030B2|2015-07-28|
    BR102014006156A2|2016-02-10|
    CN104047880B|2017-06-16|
    EP2778822B1|2021-12-08|
    CN104047880A|2014-09-17|
    US20140265976A1|2014-09-18|
    EP2778822A3|2015-03-25|
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    法律状态:
    2016-02-10| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|
    2018-11-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2020-01-14| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-07-28| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
    2021-04-06| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-04-27| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 14/03/2014, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US13/803,472|2013-03-14|
    US13/803,472|US9092030B2|2013-03-14|2013-03-14|Method to implement drive diagnostics and prognostics automatically|
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