USRE50770E1 - Packet-based networking of variable frequency drives - Google Patents

Packet-based networking of variable frequency drives

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Publication number
USRE50770E1
USRE50770E1 US17/876,416 US201717876416A USRE50770E US RE50770 E1 USRE50770 E1 US RE50770E1 US 201717876416 A US201717876416 A US 201717876416A US RE50770 E USRE50770 E US RE50770E
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United States
Prior art keywords
vfd
frame
drive signals
controller
time interval
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US17/876,416
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English (en)
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Michael Reda Samuel
Sami Boutros
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Kimidrive LLC
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Kimidrive LLC
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P7/00—Arrangements for regulating or controlling the speed or torque of electric DC motors
    • H02P7/06—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual DC dynamo-electric motor by varying field or armature current
    • H02P7/18—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual DC dynamo-electric motor by varying field or armature current by master control with auxiliary power
    • H02P7/24—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual DC dynamo-electric motor by varying field or armature current by master control with auxiliary power using discharge tubes or semiconductor devices
    • H02P7/28—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual DC dynamo-electric motor by varying field or armature current by master control with auxiliary power using discharge tubes or semiconductor devices using semiconductor devices
    • H02P7/285—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual DC dynamo-electric motor by varying field or armature current by master control with auxiliary power using discharge tubes or semiconductor devices using semiconductor devices controlling armature supply only
    • H02P7/29—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual DC dynamo-electric motor by varying field or armature current by master control with auxiliary power using discharge tubes or semiconductor devices using semiconductor devices controlling armature supply only using pulse modulation
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Program-control systems
    • G05B19/02—Program-control systems electric
    • G05B19/04—Program control other than numerical control, i.e. in sequence controllers or logic controllers
    • G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
    • G05B19/056—Programming the PLC
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P29/00—Arrangements for regulating or controlling electric motors, appropriate for both AC and DC motors
    • H02P29/02—Providing protection against overload without automatic interruption of supply
    • H02P29/024—Detecting a fault condition, e.g. short circuit, locked rotor, open circuit or loss of load
    • H02P29/0241—Detecting a fault condition, e.g. short circuit, locked rotor, open circuit or loss of load the fault being an overvoltage
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P29/00—Arrangements for regulating or controlling electric motors, appropriate for both AC and DC motors
    • H02P29/02—Providing protection against overload without automatic interruption of supply
    • H02P29/024—Detecting a fault condition, e.g. short circuit, locked rotor, open circuit or loss of load
    • H02P29/027—Detecting a fault condition, e.g. short circuit, locked rotor, open circuit or loss of load the fault being an over-current
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P29/00—Arrangements for regulating or controlling electric motors, appropriate for both AC and DC motors
    • H02P29/60—Controlling or determining the temperature of the motor or of the drive
    • H02P29/66—Controlling or determining the temperature of the rotor
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P29/00—Arrangements for regulating or controlling electric motors, appropriate for both AC and DC motors
    • H02P29/60—Controlling or determining the temperature of the motor or of the drive
    • H02P29/68—Controlling or determining the temperature of the motor or of the drive based on the temperature of a drive component or a semiconductor component
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/12—Monitoring commutation; Providing indication of commutation failure
    • H—ELECTRICITY
    • H03—ELECTRONIC CIRCUITRY
    • H03K—PULSE TECHNIQUE
    • H03K17/00—Electronic switching or gating, i.e. not by contact-making and –breaking
    • H03K17/51—Electronic switching or gating, i.e. not by contact-making and –breaking characterised by the components used
    • H03K17/56—Electronic switching or gating, i.e. not by contact-making and –breaking characterised by the components used by the use, as active elements, of semiconductor devices
    • H03K17/687—Electronic switching or gating, i.e. not by contact-making and –breaking characterised by the components used by the use, as active elements, of semiconductor devices the devices being field-effect transistors
    • H03K17/689—Electronic switching or gating, i.e. not by contact-making and –breaking characterised by the components used by the use, as active elements, of semiconductor devices the devices being field-effect transistors with galvanic isolation between the control circuit and the output circuit
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
    • H04L25/00—Baseband systems
    • H04L25/38—Synchronous or start-stop systems, e.g. for Baudot code
    • H04L25/40—Transmitting circuits; Receiving circuits
    • H04L25/49—Transmitting circuits; Receiving circuits using code conversion at the transmitter; using predistortion; using insertion of idle bits for obtaining a desired frequency spectrum; using three or more amplitude levels ; Baseband coding techniques specific to data transmission systems
    • H04L25/4902—Pulse width modulation; Pulse position modulation
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
    • H04L67/00—Network arrangements or protocols for supporting network services or applications
    • H04L67/01—Protocols
    • H04L67/12—Protocols specially adapted for proprietary or special-purpose networking environments, e.g. medical networks, sensor networks, networks in vehicles or remote metering networks
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/10—Plc systems
    • G05B2219/13—Plc programming
    • G05B2219/13004—Programming the plc
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/10—Plc systems
    • G05B2219/15—Plc structure of the system
    • G05B2219/15117—Radio link, wireless

Definitions

  • VFD variable frequency drives
  • PWM Pulse Width Modulation
  • VFD Variable Frequency Drive
  • FIG. 1 presents a block diagram of a representative VFD 10 providing a drive signal for a motor 16 .
  • VFD 10 comprises a power section 12 , which generates the output current, and a controller 14 , which controls the power section 12 according to programmed and/or user-input parameters.
  • VFD 10 is conventionally connected in a circuit and controlled via a potentiometer, a local Programmable Logic Controller (PLC), or another VFD 10 , depending on the complexity of the required motor control and the application.
  • PLC local Programmable Logic Controller
  • a simple way to explain the functionality of a VFD 10 is to liken the controller 14 , the power section 12 and the motor it drives to the brain, the muscles and the rest of the human body, respectively.
  • the brain sends to the muscles the necessary electric signals to move a body part in precisely the desired way.
  • Feedback signals sent to the brain via the nervous system impart to the brain the location of the body part, its speed, and the resistance it experiences, if any.
  • the sensors that measure these quantities in a human body are the eyes and the muscles themselves. If the weight of the body or external loads is hindering the desired motion profile, the eyes communicate to the brain, in a sense, the actual speed which the brain may find to be below the desired one.
  • the muscles inform the brain about their need for more contraction to generate enough force to overcome resisting loads.
  • the eye is an incremental speed encoder or resolver mounted on the motor shaft, and the muscle contraction is the VFD's output current delivered to the motor. Muscles contain a mechanism that measures such contractions.
  • the power section 12 contains current sensors to measure the current it delivers to the motor 16 and feed it back to the controller (brain).
  • the power section 12 includes six power transistors such as insulated-gate bipolar transistors (IGBTs) or MOSFETs, each with an antiparallel free-wheeling diode.
  • IGBTs or MOSFETs are arranged in three half-bridges with each half-bridge consisting of two transistors: an upper one and a lower one connected to the positive and negative rails of a DC link respectively.
  • the motor current is output from the midpoint between the upper and lower transistors of each half-bridge.
  • This additional transistor turns on and off in such a manner to keep the DC link voltage within a certain admissible range in order to avoid excessive voltage increase during electric braking.
  • the six (or seven) transistors exist in one enclosure called an IGBT module, a transistor module, or a power module, possibly also with a voltage rectifier and possibly transistor gate driver circuitry is also incorporated.
  • the power section 12 also sends various feedback signals to the controller 14 , indicating output current, the DC link voltage, the transistor module's temperature, the actual motor shaft speed and/or position, various fault signals indicating overvoltage or overcurrent in the power section 12 , and the like.
  • the controller 14 produces the six (or seven) ‘gate’ signals that operate to switch the power transistors on and off. These gate signals cause the transistors to generate a PWM voltage, the fundamental frequency of which closely tracks the required instantaneous speed of the driven motor.
  • the decision to perform a certain motion profile can originate locally in the brain, or be transmitted to it from another external master or peer.
  • the first case corresponds to a VFD controller 14 sophisticated enough to be programmed to produce complex motion profiles depending on external observations.
  • the second case corresponds to a VFD 10 taking its commands from a master controller 18 , also depicted in FIG. 1 .
  • the master controller 18 may be a programmable logic controller (PLC) driving a group of VFDs 10 in one location, a master VFD 10 in a master/slave connection scenario, or a peer VFD 10 in a decentralized installation scenario.
  • PLC programmable logic controller
  • VFD 10 one example of the later control arrangement is in partitioned conveyor applications, where each partition of the conveyor is run by a separate drive (combination of VFD 10 and motor 16 ).
  • proximity sensors or neighboring VFDs 10 communicate to a VFD 10 when to take over and when to stop.
  • the master controller 18 may provide high-level commands to the VFD 10 , such as speed, position, or torque setpoints, and various parameter settings; the VFD 10 may additionally provide feedback signals to the master controller 18 .
  • VFD 10 may contain additional circuits not depicted in the block diagram of FIG. 1 .
  • a VFD 10 may contain a DC power supply providing operating power to various electronic boards, a heat sink to dissipate excessive heat generated by power transistors, a gate driver circuit that acts as a current amplifier to strengthen the “weak” gate signals issued by the controller and make them capable of driving the power transistors, a means of input/output such as a keypad or a screen for the operator to inspect and give control commands and other accessories, and the like.
  • one or more VFDs are connected to a packet network and some of the control functions normally performed by the VFD controller(s) are performed by a software controller located in the packet network.
  • the packet network could be a wired or wireless network.
  • the control of the VFDs can be (1) centralized using some centralized software controller communicating to the VFDs over the packet network, and/or (2) distributed, in which case VFDs can peer with each other over the packet network, to communicate control state—such as for example a VFD asking the next VFD on a conveyor belt to take over.
  • Control can be geographically separated from the VFD, so a larger, more powerful computer or a handheld device can be used to monitor or remotely control the VFD.
  • Controller issues not only higher level commands but rather the low-level gate signals themselves to turn power transistors on and off to realize its desired motion profile.
  • Those gate signals are computed at the remote computer and sent to the VFD over the packet network in the downlink direction.
  • Controller receives detailed feedback on instantaneous motor speed, motor temperature, transistor temperature, motor torque, motor current, DC bus voltage, etc., to aid in generating the gate signal computations. These feedback signals are transmitted over the packet network in the uplink direction.
  • a L2/L3 network address is assigned to each of a plurality of VFDs, and any VFD may be monitored and controlled remotely like any enterprise IT application.
  • Data between the VFD and the external controller is transmitted in blocks (packets) in both directions.
  • packet format encodings are proposed, to carry the necessary bits to encode what's needed to control/monitor a given VFD.
  • a simple transport protocol such as IP or UDP may be used to carry the packet frames between the VFD(s).
  • TTIs transmission time intervals
  • Typical PWM frequency is 4, 8, 12 or 16 kHz which can be easily supported by a packet network.
  • SW PLC controllers
  • the federation of controllers can additionally provide active/active and active/standby redundancy.
  • Converging to the packet network for the control/monitor of a network of VFD(s) will benefit from the resiliency and redundancy available in the packet network.
  • Software controllers can run on premise or remotely from a public cloud. Control can also be provided via mobility application. This control could be from a centralized controller or could be from one (super) VFD to another VFD.
  • One embodiment relates to a method of controlling one or more VFDs, each VFD configured to generate a PWM signal to drive a motor. For each controlled VFD, a plurality of drive signals are calculated; the drive signals configured to switch a plurality of power transistors in the VFD for a time interval, to generate a desired PWM signal. The plurality of drive signals is wirelessly transmitted to each controlled VFD, in advance of the time interval in which they are to be applied, in at least a main downlink (DL) frame of a transmission packet.
  • DL main downlink
  • Another embodiment relates to a controller configured to control one or more VFDs, each VFD configured to generate a PWM signal to drive a motor.
  • the controller includes a wireless transceiver and a processor operatively connected to the wireless transceiver.
  • the processor is configured to, for each controlled VFD, calculate a plurality of drive signals to switch a plurality of power transistors in the VFD for a time interval, to generate a desired PWM signal.
  • the processor is further configured to wirelessly transmit the plurality of drive signals, to each controlled VFD, in advance of the time interval in which they are to be applied, in at least a main downlink (DL) frame of a transmission packet.
  • DL main downlink
  • Yet another embodiment relates to a method of generating a PWM signal to drive a motor, by a VFD controlled by a remote controller.
  • a plurality of drive signals for a time interval is wirelessly received from the controller, in a main downlink (DL) frame of a received packet.
  • DL main downlink
  • a plurality of power transistors is switched, according to the received drive signals, to generate the PWM signal.
  • Still another embodiment relates to a VFD configured to generate a PWM signal to drive a motor.
  • the VFD is controlled by a remote controller and includes a wireless transceiver and a processor operatively connected to the wireless transceiver.
  • the processor is configured to wirelessly receive from the controller, in a main downlink (DL) frame of a received packet, a plurality of drive signals for a time interval; and in a subsequent time interval, switch a plurality of power transistors, according to the received drive signals, to generate the PWM signal.
  • DL main downlink
  • FIG. 1 is a block diagram of a conventional VFD.
  • FIG. 2 illustrates a network of VFDs according to an embodiment of the disclosure
  • FIG. 3 illustrates a structure for uplink (UL) frames sent from a VFD to a master controller.
  • FIG. 4 illustrates a structure for downlink (DL) frames sent from a controller to a VFD.
  • FIG. 5 illustrates an exemplary header for the UL frames.
  • FIG. 6 illustrates an exemplary header for the DL frames.
  • FIG. 7 illustrates an exemplary method 100 implemented by a remote controller of controlling one or more VFDs.
  • FIG. 8 illustrates an exemplary method 200 implemented by a VFD of generating a PWM signal to drive a motor.
  • FIG. 9 is a schematic diagram of an exemplary VFD without an on-board controller.
  • FIG. 10 is a schematic diagram of an exemplary VFD with an on-board controller.
  • FIG. 11 is a schematic diagram of an exemplary controller.
  • FIG. 12 is a detailed block diagram of an exemplary VFD without an on-board controller.
  • FIG. 13 is a detailed block diagram of an exemplary VFD with an onboard controller.
  • FIG. 14 is another detailed block diagram of an exemplary VFD without an on-board controller.
  • FIG. 2 illustrates a new connection scheme between VFDs 20 on a certain site. This connection scheme allows the VFDs 20 to communicate with each other as well as with the outside world.
  • Each VFD 20 can be viewed as a node in an Internet-of-Things (IoT) network and the backbone is a packet-based network.
  • IoT Internet-of-Things
  • the connection scheme enables the generation of the low level gate signals that operate to switch the power transistors in the power section 22 ( FIG. 10 ) of the VFD 20 to be moved to the master controller 30 .
  • the AP 40 acting as a mediator between the VFD 10 and the controller 20 can be eliminated altogether or integrated in the controller 20 itself.
  • FIG. 2 depicts a packet-based VFD network according to one or more embodiments including a plurality of VFD 20 in two groups, labeled BSS 1 and BSS 2 .
  • FIG. 2 also shows the possibilities for locating a master controller 30 . It can be co-located in the same BSS, in a different BSS, or geographically separated from the industrial site. This is why a packet gateway 50 is needed to connect the DS to the wired Internet to carry over the data to and from the controller's distant location. If a master controller 30 is co-located in the same BSS, it can even be incorporated with one of the VFDs 20 , which can be thought of as a ‘super VFD’.
  • a super VFD 20 has the capabilities of driving its own load in addition to communicating with and giving drive instructions to other VFDs 20 over the packet network as explained herein.
  • uplink and downlink information are transmitted in packets between the VFD 20 and the controller 30 /super VFD 20 .
  • motion control is realized by pulse width modulation (PWM), where the time dimension is divided into small intervals (PWM periods).
  • PWM pulse width modulation
  • the controller 30 makes decisions on which power transistors (IGBTs or MOSFETs) to turn on or off in order to realize a certain average voltage and hence current within this interval.
  • The, PHY, MAC and Network layer protocols of a packet network such as narrowband IoT, 802.xxx or Bluetooth, or modified versions of them, may be utilized in this scenario.
  • Each VFD 20 will have a universal L2 or L3 address in order to destine a certain data packet to it, unlike the circuit-switched case where no address is needed.
  • This addressing can be absolute or relative to the BSS, i.e., its address is a concatenation of an absolute group address assigned to the BSS and a relative address. If it is an L2 address, then it becomes a part of the MAC header.
  • the time domain is divided into short intervals equal to the PWM period (inverse of PWM frequency) or its half. Each one of these intervals is called a transmission time interval (TTI).
  • TTI transmission time interval
  • the VFD 20 may send an uplink (UL) packet to the controller 30 reporting values of certain physical quantities and parameters.
  • UL uplink
  • the controller 30 sends a downlink (DL) packet instructing the VFD 20 as to which power transistors are switched on and off in the next TTI, as well as sending to it the values of some parameters.
  • DL downlink
  • the VFD 20 is also be given the capability to run ‘headless’ where it regains authority over its own power transistors and issues the gate signals that turn them on and off.
  • UL and DL packets must carry certain information to enable the proper operation of the VFDs.
  • the VFD 20 constructs a main MAC frame, referred to herein as the main uplink (UL) frame, that contains fields for, e.g., instantaneous motor speed (either estimated by the inverter or measured if an encoder is mounted on the motor shaft), instantaneous motor current, IGBT module temperature, rotor temperature and DC bus voltage.
  • UL uplink
  • the processing power of the VFD 20 is not high enough to estimate the motor speed locally and report it, it can send a certain bit pattern (for example all-ones) in the speed field or in a separate field to instruct the controller 30 to do the speed estimation given reported current and voltage values. It can also indicate to the controller in a separate field whether the reported speed is measured or estimated.
  • the VFD 20 does not have to transmit the main UL frame every TTI. It may be instructed by the controller 30 to transmit every NT TTIs if the UL traffic becomes too high or if the operation of the VFD 20 does not require that frequent reporting.
  • the VFD 20 may construct a second MAC frame called an ‘auxiliary UL frame’ on which it reports periodically the type, length and value (TLV) or simply the type and value (TV) of its various parameters. In case it reports parameters in TV format, then the length of the value field must be known to both the VFD 20 and the controller 30 .
  • An auxiliary UL frame may be transmitted every TTI, every NT or whenever the controller 30 requests it. If the auxiliary frame is not mandated every TTI, then a field indicating its existence in the current transmission must be included in the MAC header after the address field.
  • the new controller 30 may request the transmission of certain parameters for example in case of controller handover (one controller 30 hands over the provisioning of one VFD 20 to a new controller 30 ) in order for the new serving controller 30 to know the operating parameter values of the VFD 20 .
  • parameters defining VFD's ramp up or ramp down times do not change unless the controller 30 updates them.
  • parameters can be divided into NP groups each assigned a group ID and only one group is transmitted every time an auxiliary frame is transmitted in a round robin fashion, ii) they may be transmitted only when the controller 30 requests the transmission of a certain group or iii) in controller handover scenarios, the controller 30 may request the transmission of all groups one after the other.
  • a field in the MAC header of the main UL frame must indicate which parameter group is being transmitted.
  • a group may contain only one parameter
  • Downlink (DL) MAC frames from the master controller 30 to the VFD 20 comprise a main and auxiliary frames, referred to as the main DL frame and auxiliary DL frame respectively.
  • the main DL frame contains six fields (two for each output phase) to indicate the switch on and off time offsets, relative to the beginning of the TTI, of each power transistor.
  • a seventh field for the brake chopper (BRC) transistor may also be included. Since the switching pattern of lower transistors is the complement of the upper ones, the number of fields is reduced from six to three in one embodiment. If multilevel switching is used, the number of fields may be increased. Again, those of skill in the art may define specific fields in the main DL frame, so long as their order is known to the VFD 20 and the controller 30 . An example is shown in FIG. 4 .
  • an auxiliary DL frame may be included after the main DL frame and its inclusion must be indicated by a certain field in the MAC header of the main DL frame. It may include a field requesting the VFD 20 to transmit the values of a certain parameter group or it may set parameter values in a TLV or TV format.
  • controller 30 Whenever the controller 30 again asserts control, it sends the VFD 20 a request to give up its own controller 28 and follow low-level gate signals transmitted by the controller 30 in the main DL frame. Requests from the controller 30 to the VFD 20 to run headless or to claim back leadership can be done via a certain DL header field.
  • the controller 30 may instruct the VFD 20 to run a training session to collect the motor parameters.
  • This session can be run by a local on-board controller 28 or by sending the low-level gate signals from the controller 30 to the VFD 20 as described above.
  • the VFD 20 sends back the motor model parameters to the controller in the auxiliary frame. There must be a field in the header of the UL frame indicating if the auxiliary frame carries motor parameters or VFD parameters in TV format.
  • the UL header should contain the fields shown in FIG. 5 , but not necessarily in the shown order.
  • the second field carries the ID of the parameter group being reported in the auxiliary field. A certain value of this field can be reserved to identify motor model parameters in the motor training process.
  • the third and fourth fields are to acknowledge the controller request that VFD 20 run headless based on parameter values in auxiliary field or return control respectively. The last field is reserved for future use.
  • the DL header should contain the fields shown in FIG. 6 , but not necessarily in the shown order.
  • the STA address field can be a single VFD address, a multicast address or a broadcast address.
  • the controller requests for the VFD 20 to transmit a certain parameter group.
  • it instructs the VFD 20 to run headless or to return control to the controller 30 .
  • the last field is reserved for future use.
  • communications between a controller 30 and VFD 20 , or between VFDs 20 are made over a secure packet tunnel; this tunnel can be, e.g., an SSL VPN or an IPSec tunnel to prevent Denial of Service attacks to VFD 20 .
  • an authentication mechanism is used to authenticate the secure communication between the controller and a given VFD 20 .
  • FIG. 7 illustrates an exemplary method 100 implemented by a remote controller 30 , i.e. geographically separate, of controlling one or more VFDs 20 .
  • Each VFD 20 is configured to generate a PWM signal to drive a motor.
  • the controller 30 calculates a plurality of drive signals to switch a plurality of power transistors in the VFD 20 for a first time interval to generate a desired PWM signal (block 110 ).
  • the controller 30 wirelessly transmits, in advance of the first time interval, the plurality of drive signals to respective VFDs 20 (block 120 ).
  • the drive signals for each VFD 20 are transmitted in downlink (DL) frames of a transmission packet.
  • DL downlink
  • wirelessly transmitting a plurality of drive signals comprises transmitting a plurality of drive signals in a plurality of successive time intervals including the first time interval, wherein the drive signals transmitted in one of the successive time intervals is effective for the next time interval.
  • the drive signals comprise separate indications to switch each power transistor on or off, and also indicate the timing of the switching.
  • One embodiment of method 100 further comprises an indication to switch a braking transistor on or off, and also indicate the timing of the switching.
  • the timing of each transistor switching signal is an offset from the beginning of the next time interval.
  • One embodiment of method 100 further comprises, in one or more of the time intervals, additionally transmitting commands or parameter values to one or more VFDs in an auxiliary DL frame of the transmission packet.
  • the same drive signals, commands, or parameter values are broadcast to two or more controlled VFDs.
  • the drive signals, commands, or parameter values are transmitted individually to each controlled VFD.
  • One embodiment of method 100 further comprises transmitting a command in an auxiliary DL frame for the VFD to run autonomously, and ceasing the transmission of drive signals in a main DL frame to the autonomous VFD.
  • One embodiment of method 100 further comprises transmitting a command in an auxiliary DL frame for the VFD to be controlled, and resuming the transmission of drive signals in a main DL frame to the autonomous VFD.
  • One embodiment of method 100 further comprises, in one or more of the time intervals, receiving from one or more VFDs feedback about the VFD or motor state in a main uplink (UL) frame of a received packet.
  • the controller 30 is contained within a first VFD and wirelessly transmits the drive signals to a second VFD 20 .
  • FIG. 8 illustrates an exemplary method 200 implemented by a VFD 20 of generating a PWM signal to drive a motor where the VFD 20 is controlled by a remote, i.e. geographically separate, controller 30 .
  • the VFD 20 wirelessly receives from the controller 30 , in a main downlink (DL) frame of a received packet, a plurality of drive signals for a time interval (block 210 ).
  • the VFD 20 in a subsequent time interval, switching a plurality of power transistors, according to the received drive signals, to generate the PWM signal.
  • wirelessly receiving a plurality of drive signals comprises receiving the plurality of drive signals in each successive time interval, and wherein a subsequent time interval comprises the next time interval.
  • the drive signals comprise separate indications to switch each power transistor on or off, and also indicate the timing of the switching.
  • the drive signals further comprise an indication to switch a braking transistor on or off, and also indicate the timing of the switching.
  • the timing of each transistor switching signal is an offset from the beginning of the next time interval.
  • Some embodiments of the method 200 further comprise, in one or more of the time intervals, additionally receiving commands or parameter values in an auxiliary DL frame of the received packet.
  • Some embodiments of the method 200 further comprise receiving a command in an auxiliary DL frame to run autonomously, and generating drive signals to switch the transistors.
  • Some embodiments of the method 200 further comprise receiving a command in an auxiliary DL frame to again be controlled, and resuming switching the transistors according to drive signals received in each time interval from the controller.
  • Some embodiments of the method 200 further comprise, in one or more of the time intervals, wirelessly transmitting to the controller feedback about the VFD or motor state in a main uplink (UL) frame of a transmitted packet.
  • UL main uplink
  • the feedback includes one or more of instantaneous motor speed, instantaneous motor current, power transistor temperature, motor rotor temperature, DC bus voltage, and an indication for the controller to calculate motor speed from current and voltage.
  • Some embodiments of the method 200 further comprise, in one or more of the time intervals, wirelessly transmitting to the controller the value of one or more parameters in an auxiliary uplink (UL) frame of a transmitted packet.
  • UL auxiliary uplink
  • the controller 30 is contained within a first VFD and wirelessly transits the drive signals to a second VFD 20 .
  • FIG. 9 illustrates an exemplary VFD 20 according to one embodiment without an on-board controller 28 .
  • the VFD 20 comprises a power section 22 and a wireless transceiver/signal adapter 24 .
  • the wireless transceiver/signal adapter 24 combines a wireless transceiver (e.g., Bluetooth, Narrowband IoT, Profibus, etc.) with a signal adapter for processing the signals transmitted and received by the VFD 20 .
  • the signal processing includes, for example, coding and decoding of signals filtering, signal conversion and formatting.
  • the wireless transceiver/signal adapter comprises a microprocessor, hardware circuit, or other processing circuit.
  • the wireless transceiver/signal adapter 24 also contains a sense ADC that converts temperatures and currents to a digital form for transmission.
  • the wireless transceiver/signal adapter 24 receives gate signals from the master controller 30 and outputs the gate signals to the power section 22 and outputs the gate signals to the power section 22 .
  • the power section 22 generates the motor drive signals for driving the motor 16 .
  • FIG. 10 illustrates an exemplary VFD 20 according to one embodiment with an on-board controller 28 .
  • the VFD 20 comprises a power section 22 and a wireless transceiver/signal adapter 24 .
  • the wireless transceiver/signal adapter 24 combines a wireless transceiver (e.g., Bluetooth, Narrowband IoT, Profibus, etc.) with a signal adapter for processing the signals transmitted and received by the VFD 20 .
  • the signal processing includes, for example, coding and decoding of signals filtering, signal conversion and formatting.
  • the signal adapter comprises a microprocessor, hardware circuit, or other processing circuit.
  • the wireless transceiver/signal adapter 24 also contains a sense ADC that converts temperatures and currents to a digital form for transmission.
  • the wireless transceiver/signal adapter 24 receives gate signals and/or control signals from the master controller 30 and passes them to the local controller 28 .
  • the local controller 28 outputs the gate signals to the power section 22 received from the master controller 30 to the power section 22 .
  • the local controller 28 may generated the gate signal locally and output the gate signals to the power section 22 .
  • the local controller 28 can exchange control signals with the master controller 30 via the wireless transceiver/signal adapter 24 .
  • FIG. 11 illustrates an exemplary controller 30 according to one embodiment without an on-board controller 28 .
  • the controller 30 comprises a processing 32 , memory 34 , and a wireless transceiver 36 (e.g., Bluetooth, Narrowband IoT, Profibus, etc.).
  • the processing circuit 32 comprises one or more microprocessors, hardware circuits, firmware, or a combination thereof for generating the gate signals as herein described and for controlling the operation of the VFDs 20 .
  • Processing circuit 32 executes computer program instructions which are stored in memory 34 .
  • Memory 34 stores the computer programs and data needed by the processing circuit 32 to perform its functions.
  • Memory 34 may comprise both non-volatile memory (e.g.
  • FIG. 12 is a detailed block diagram of an exemplary VFD 20 without an on-board controller.
  • the embodiment in FIG. 12 corresponds generally to the schematic drawing in FIG. 9 .
  • the power section 22 is represented by the components of the VFD 20 shown in blue.
  • FIG. 13 illustrates an exemplary controller 30 according to one embodiment without an on-board controller 28 .
  • the embodiment in FIG. 12 corresponds generally to the schematic drawing in FIG. 10 .
  • the power section 22 is represented by the components of the VFD 20 shown in blue.
  • Embodiments of the present invention present numerous advantages over VFDs 20 according to the prior art.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Signal Processing (AREA)
  • Physics & Mathematics (AREA)
  • Computer Networks & Wireless Communication (AREA)
  • General Physics & Mathematics (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Automation & Control Theory (AREA)
  • Health & Medical Sciences (AREA)
  • Computing Systems (AREA)
  • General Health & Medical Sciences (AREA)
  • Medical Informatics (AREA)
  • Inverter Devices (AREA)
  • Control Of Ac Motors In General (AREA)
  • Selective Calling Equipment (AREA)
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US11022959B2 (en) * 2018-10-10 2021-06-01 Infineon Technologies Austria Ag Wireless communication integrated with a motor control integrated circuit within a same chip package
JP7337731B2 (ja) 2020-02-28 2023-09-04 株式会社東芝 無線制御システム及び無線制御方法
JP7387546B2 (ja) 2020-07-02 2023-11-28 株式会社東芝 無線装置およびインバータシステム
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US20190312537A1 (en) 2019-10-10
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