Claims:
1. A controller for an induction motor coupled to a power source, said controller comprising:
a circuit for providing a voltage signal in phase with voltage applied to the motor from the power source;
a circuit for coupling a power load to an output of the motor controller, the motor controller adapted to operate in one or more modes of application, where each mode contains a number of parameters for configuring the motor controller, these modes of application indicating basic control principles to be chosen; and
wherein the controller is characterized in that comprising a plurality of communication interfaces adapted to select and/or monitor at least one mode of application from the modes of application utilizing at least a communication interface selected from the plurality of communication interfaces.

2. The controller as claimed in claim 1, wherein the plurality of communication interfaces comprise of a Human Machine Interface (HMI) of a personal computer (PC), an user interface or a display of the motor controller, a Global System for Mobile communication (GSM), a digital input, an analog input and a Global Positioning System (GPS).

3. The controller as claimed in claim 2, wherein the user interface or the display adapted to give command for selection and/or monitor utilizing at least a serial communication protocol, preferably a Modbus protocol, provided for communication.

4. The controller as claimed in claim 2, wherein the GSM is adapted to give command for selection and/or monitor from a remote location.

5. The controller as claimed in claim 2, wherein the digital inputs and analog inputs are adapted to give command for selection and/or monitor from a remote location.

6. The controller as claimed in claim 2, wherein the GPS is adapted to provide a position of the motor controller.

7. The controller as claimed in claim 2, wherein the plurality of communication interfaces can further comprise of an interface connector adapted to couple with any or combination of one or more portable memory devices, Ethernet, Profibus, ether-cat, a plug and play device or a computer bus.

8. A method for operating a motor controller, wherein the motor controller is configured by way of parameters, the method comprising the steps of:
Connecting an input of the motor controller to a power source;
connecting a power load to an output of the motor controller, the motor controller adapted to operate in one or more modes of application, where each mode contains a number of parameters for configuring the motor controller, these modes of application indicating basic control principles to be chosen; and
wherein the method for operating is characterized in that comprising the steps of:
providing a plurality of communication interfaces allocated for the motor controller;
selecting and/or monitoring at least one mode of application from the modes of application utilizing at least a communication interface selected from the plurality of communication interfaces.

9. The method as claimed in claim 8, wherein the plurality of communication interfaces comprise of a Human Machine Interface (HMI) of a personal computer (PC), an user interface or a display of the motor controller, a Global System for Mobile communication (GSM), a digital input, an analog input, a RS485 communication port and a Global Positioning System (GPS).

10. The method as claimed in claim 9, wherein the plurality of communication interfaces can further comprise of an interface connector adapted to couple with any or combination of one or more portable memory devices, Ethernet, Profibus, ether-cat, a plug and play device or a computer bus, and wherein:
the user interface or the display adapted to give command for selection and/or monitor utilizing at least a serial communication protocol, preferably a Modbus protocol, provided for communication; and/or
the GSM is adapted to give command for selection and/or monitor from a remote location; and/or
the digital inputs and analog inputs are adapted to give command for selection and/or monitor from a remote location; and/or
the GPS is adapted to provide a position of the motor controller.
, Description:TECHNICAL FIELD

[0001] The present disclosure generally relates to the field of power control systems. In particular, it pertains to, but not by way of limitation, an improved controller for induction motors having a plurality of interfaces.

BACKGROUND

[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Three Phase Low Voltage (LV) drives are used for industrial applications such as driving induction motors coupled with pumps, fans, elevators etc. There are various means of controlling motors through commands given to drive/ motor controller for driving motor e.g. Keypad, digital input/output, PLCs, other external signals.
[0004] A motor controller is a device or group of devices that serves to govern in some predetermined manner the performance of an electric motor. A motor controller might include a manual or automatic means for starting and stopping the motor, selecting forward or reverse rotation, selecting and regulating the speed, regulating or limiting the torque, and protecting against overloads and faults. Motor controllers can be manually, remotely or automatically operated. They may include only the means for starting and stopping the motor or they may include other functions. An electric motor controller can be classified by the type of motor it is to drive such as permanent magnet, servo, series, separately excited, and alternating current. A motor controller is connected to a power source such as a battery pack or power supply, and control circuitry in the form of analog or digital input signals.
[0005] With the advancement of the technology in the field of controllers, there are various ways for communicating or commanding with the controllers and thereby with the motors or loads connected to the same. On such ways is provided in the United States Patent 5909372 A which discloses a method and system for improving the user interface between operator and motor controller in particular in frequency meter. According to the invention, instead of presenting all information on a display at one time, a method of programming the motor controller is suggested, in which the operator is guided through the Set up procedure, so that only relevant parameters are displayed on the different views. Another aspect of the invention is a method of programming a motor controller not in terms of parameter and parameter numbers, but in physical, technical and process terms. In this Way, a high level mode of programming a motor controller is achieved, because the user interface does not deal with the less interesting motor controller specific parameter, but instead allow the operator to program the unit in terms he use.
[0006] There are many such prior-art documents which clearly provide various means/mechanism for communicating with the motor controllers and also there are various such prior-art documents that improve the existing means/mechanism for communicating with the motor controllers. However, the inventors recognized that existing motor controllers have limitations of using a limited communication means in a single motor controller which somehow restricts the applicability and usability of the motor controller and also creates inconvenience for the operators by restricting the controlling mechanisms for the motor controller. What prior-art is lacking is that a possibility of a motor controller having all the possible or a plurality of communication means which enables the operators to communicate with the motor controller by any of the plurality of communication means according the operators convenience.
[0007] The aforementioned limitations of the existing motor controllers are recognized by the inventors hereof and some or all of these limitations have been addressed by various embodiments of the current invention.
[0008] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0009] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0010] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0011] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0012] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

SUMMARY

[0013] The aforementioned limitations of the existing motor controllers are recognized by the inventors hereof and some or all of these limitations have been addressed by the current invention by providing a motor controller having multiple communication means within the same hardware i.e. within the same drive module.
[0014] An object of the present disclosure is to provide multi/various communication system for controlling induction motor within the same hardware or same controller i.e. various modules are able to communicate to central controller for motor control application wherein user can choose the mode of communication for motor control as per his requirement and availability.
[0015] Aspects of the present disclosure relate, but not by way of limitation, to a low voltage (LV) drives for motor control with various applications such as textiles, agriculture, elevator etc. In an embodiment, an improved controller for induction motors having a plurality of interfaces is disclosed. Such improved controller can be used for industrial applications such as driving induction motors couples with pumps, fans, elevators etc.
[0016] An aspect of the present disclosure provides a controller for an induction motor coupled to a power source. The controller includes a circuit for providing a voltage signal in phase with voltage applied to the motor from the power source, and a circuit for coupling a power load to an output of the motor controller. The motor controller is adapted to operate in one or more modes of application, where each mode contains a number of parameters for configuring the motor controller, these modes of application indicating basic control principles to be chosen.
[0017] In an aspect, the controller is characterized in that having a plurality of communication interfaces adapted to select and/or monitor at least one mode of application from the modes of application utilizing at least a communication interface selected from the plurality of communication interfaces.
[0018] In an aspect, such plurality of communication interfaces are used to program, re-program, configure, and/or reconfigure the firmware or software associated with the motor controller and/or a motor connected to the same.
[0019] In an aspect, the plurality of communication interfaces comprise of a Human Machine Interface (HMI) of a personal computer (PC), an user interface or a display of the motor controller, a Global System for Mobile communication (GSM), a digital input, an analog input and a Global Positioning System (GPS).
[0020] In an aspect, the user interface or the display adapted to give command for selection and/or monitor utilizing at least a serial communication protocol, preferably a Modbus protocol, provided for communication. The GSM is adapted to give command for selection and/or monitor from a remote location. The digital inputs and analog inputs are adapted to give command for selection and/or monitor from a remote location. The GPS is adapted to provide a position of the motor controller.
[0021] In an aspect, the plurality of communication interfaces can further comprise of an interface connector adapted to couple with any or combination of one or more portable memory devices, Ethernet, Profibus, ether-cat, a plug and play device or a computer bus.
[0022] An aspect of the present disclosure relates to a method for operating a motor controller, wherein the motor controller is configured by way of parameters. The method includes the steps of connecting an input of the motor controller to a power source; and connecting a power load to an output of the motor controller, the motor controller adapted to operate in one or more modes of application, where each mode contains a number of parameters for configuring the motor controller, these modes of application indicating basic control principles to be chosen.
[0023] In an aspect, the method for operating is characterized in that comprising the steps of providing a plurality of communication interfaces allocated for the motor controller; and selecting and/or monitoring at least one mode of application from the modes of application utilizing at least a communication interface selected from the plurality of communication interfaces.
[0024] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0026] FIG. 1 illustrates an exemplary communication interfaces for controlling of a motor and parameter monitoring, in accordance with an embodiment of the present disclosure.
[0027] FIG. 2 illustrates an exemplary block diagram illustrating a communication layout for LV drive, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0028] The following is a detailed description of embodiments of the disclosure illustrated in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0029] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0030] A motor controller is a device or group of devices that serves to govern in some predetermined manner the performance of an electric motor. A motor controller might include a manual or automatic means for starting and stopping the motor, selecting forward or reverse rotation, selecting and regulating the speed, regulating or limiting the torque, and protecting against overloads and faults. Motor controllers can be manually, remotely or automatically operated. They may include only the means for starting and stopping the motor or they may include other functions. An electric motor controller can be classified by the type of motor it is to drive such as permanent magnet, servo, series, separately excited, and alternating current. A motor controller is connected to a power source such as a battery pack or power supply, and control circuitry in the form of analog or digital input signals.
[0031] Prior-art shows various means/mechanism for communicating with the motor controllers and also there are various such prior-art documents that improve the existing means/mechanism for communicating with the motor controllers. However, the inventors recognized that existing motor controllers have limitations of using a limited communication means in a single motor controller which somehow restricts the applicability and usability of the motor controller and also creates inconvenience for the operators by restricting the controlling mechanisms for the motor controller. What prior-art is lacking is that a possibility of a motor controller having all the possible or a plurality of communication means which enables the operators to communicate with the motor controller by any of the plurality of communication means according the operators convenience.
[0032] The aforementioned limitations of the existing motor controllers are recognized by the inventors hereof and some or all of these limitations have been addressed by various embodiments of the current invention.
[0033] Accordingly, embodiments of the present disclosure provide multi/various communication system for controlling induction motor within the same hardware or same controller i.e. various modules are able to communicate to central controller for motor control application wherein user can choose the mode of communication for motor control as per his requirement and availability.
[0034] Aspects of the present disclosure relate, but not by way of limitation, to a low voltage (LV) drives for motor control with various applications such as textiles, agriculture, elevator etc. In an embodiment, an improved controller for induction motors having a plurality of interfaces is disclosed. Such improved controller can be used for industrial applications such as driving induction motors couples with pumps, fans, elevators etc.
[0035] An aspect of the present disclosure provides a controller for an induction motor coupled to a power source. The controller includes a circuit for providing a voltage signal in phase with voltage applied to the motor from the power source, and a circuit for coupling a power load to an output of the motor controller. The motor controller is adapted to operate in one or more modes of application, where each mode contains a number of parameters for configuring the motor controller, these modes of application indicating basic control principles to be chosen.
[0036] In an aspect, the controller is characterized in that having a plurality of communication interfaces adapted to select and/or monitor at least one mode of application from the modes of application utilizing at least a communication interface selected from the plurality of communication interfaces.
[0037] In an aspect, such plurality of communication interfaces are used to program, re-program, configure, and/or reconfigure the firmware or software associated with the motor controller and/or a motor connected to the same.
[0038] In an aspect, the plurality of communication interfaces comprise of a Human Machine Interface (HMI) of a personal computer (PC), an user interface or a display of the motor controller, a Global System for Mobile communication (GSM), a digital input, an analog input and a Global Positioning System (GPS).
[0039] In an aspect, the user interface or the display adapted to give command for selection and/or monitor utilizing at least a serial communication protocol, preferably a Modbus protocol, provided for communication. The GSM is adapted to give command for selection and/or monitor from a remote location. The digital inputs and analog inputs are adapted to give command for selection and/or monitor from a remote location. The GPS is adapted to provide a position of the motor controller.
[0040] In an aspect, the plurality of communication interfaces can further comprise of an interface connector adapted to couple with any or combination of one or more portable memory devices, Ethernet, Profibus, ether-cat, a plug and play device or a computer bus.
[0041] An aspect of the present disclosure relates to a method for operating a motor controller, wherein the motor controller is configured by way of parameters. The method includes the steps of connecting an input of the motor controller to a power source; and connecting a power load to an output of the motor controller, the motor controller adapted to operate in one or more modes of application, where each mode contains a number of parameters for configuring the motor controller, these modes of application indicating basic control principles to be chosen.
[0042] In an aspect, the method for operating is characterized in that comprising the steps of providing a plurality of communication interfaces allocated for the motor controller; and selecting and/or monitoring at least one mode of application from the modes of application utilizing at least a communication interface selected from the plurality of communication interfaces
[0043] In an embodiment, the present invention relates to multi/various communication systems for controlling induction motor within the same hardware or same controller i.e. various modules are able to communicate to central controller for motor control application wherein user can choose the mode of communication for motor control as per his requirement and availability.
[0044] In an embodiment, the present invention relates the control of the drive/controller for motor control through various communication modules accessible to the user within a single controller. In an exemplary implementation, the controller is characterized by control of the motor through human machine interface (HMI) with keypad, another control is through remotely control of motor through digital input/output connected to the controller, another control of motor is through a serial communication interface provided on main controller, another control of motor can be provided through GSM module interface provided on the main controller.
[0045] In an implementation, the basic module of the motor controller arrangement consists of various communication modes through which user can control the motor as per availability of any of the communication modules and as per need at the site. The communication modules can be isolated from the external world to the controller electrically which provides safety concern for communication modules and damage in case where isolation is not provided.
[0046] FIG. 1 illustrates an exemplary communication interfaces for controlling of a motor and parameter monitoring, in accordance with an embodiment of the present disclosure. In an embodiment, FIG. 1 shows a main controller 101 card wherein the communication interfaces are made, main power card 100 wherein the AC power is provided wherein the inverter modules powers the motor based on the switching command from the controller card / main controller 101.
[0047] The plurality of communication interfaces, such as but not limited to, a Human Machine Interface (HMI) of a personal computer (PC), an user interface or a display of the motor controller, a Global System for Mobile communication (GSM), a digital input, an analog input and a Global Positioning System (GPS) are shown in FIG. 1.
[0048] In an example, the display/HMI card 103 which includes a keypad for motor control and data monitoring on LCD display, the digital input 104 for providing commands from external PLC (programmable logic controller) or switches, the analog input 108 for providing commands from external PLC (programmable logic controller) or switches, an RS485 communication port 105 wherein PC interface/ or external communication modules can be used for motor control, are shown.
[0049] In an example, the digital output module 106 and analog output module 107 for parameter/data monitoring are shown in FIG. 1 wherein the analog parameters such as motor frequency, voltage and current can be observed and through the digital output 107 such as relays or transistors can be driven for alarms or indication or to control other external circuit can be used.
[0050] In an embodiment, the main controller card 101 can be interfaces to GSM/GPS card for controlling the motor through mobile networks. Thus, the entire communication interfaces are provided within the same architecture providing facility for user to controller the motor and observe the parameters with the communication modules available at ones end.
[0051] In an embodiment, apart from controlling the motor and parameter observations through the above said communication modules, the digital input 104 and the analog input 108 can be used for programming of controller for powering motor i.e. sequential event trigger or using the multiple digital inputs for start/stop/reset or even speed control of motor driving load.
[0052] FIG. 2 illustrates an exemplary block diagram illustrating a communication layout for LV drive, in accordance with an embodiment of the present disclosure. In an embodiment, as discussed in FIG. 1 above, the main controller 101 is communicated to various interfaces and this arrangement has been provided within the same hardware, thus multiple communication arrangement with PC/external interface 103 for database and controller information to PC, GSM interface or other external interface 202, Input/output modules such as digital input 104/ digital output 106, analog input 108/ analog output 107 and also the display module interface 204 has been provided. All this interface modules can be used to control and monitor the motor parameters by communicating with controller and asking controller to behave the motor as per the communication command from modules to controller.
[0053] To summarize the invention, the present disclosure provides a controller having multiple communications, HMI PC, display and GSM and GPS module within the same hardware i.e. within the same drive module. In an embodiment, display can have a Modbus protocol having good range up to 700 meters, GSM module can give command to system or log the data from system (having coverage area equal to range of cell phone) GPS can give position of the system. Digital inputs and Analog inputs can give command remotely. Digital outputs and analog outputs can show the parameters. In an implementation, the controller also has a provision for future add on modules like Ethernet, Profibus, ether-cat etc, is provided and hence such modules can be plugged into the present system without making any changes.
[0054] Although the preferred embodiments have been described, it should be pointed out that changes are possible and attainable without departing from the scope of the present invention.
[0055] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0056] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION

[0057] The present disclosure provides a controller having multiple communications, HMI PC, Display and GSM and GPS module within the same hardware i.e. within the same drive module.