Rockwell Automation Technologies Incorporated

Reliance Electric Technologies, LLC

Baldor Electric Company

Reliance Electric Industrial Company

Michael J Melfi

Zhenhuan Yuan

Semyon Royak

Robert H Schmidt

Donald L Nisley

Xikai Sun

Brian Fast

Arun K Guru

Robert J Breitzmann

Mark Melvin Harbaugh

John M Kasunich

John Balcerak

Gennadi Sizov

Linglai Li

Robert F McElveen, Jr

Kun Wei

Sidney Bell

Galen E Burdeshaw

Stephen Umans

Richard J Budzynski

Kristin N Yee

Daniel Pixler

Barron D Grant

Thomas S Evon

Stanley E Wallace

Jerry J Pollack

Brian T Concannon

Chris E Gottlieb

Sunil R Gaddam

Daniel J Stelzner

Patricia L Smith

John Early

Wesley L Haynes

John R Early

John A Balcerak

A system to reduce eddy currents and the resulting losses in a synchronous motor includes at least one pick-up coil mounted to the rotor. Each pick-up coil may be located proximate a pole on the rotor. A voltage applied to the stator to control the synchronous motor includes both a fundamental component and harmonic components. The fundamental component interacts with a magnetically salient structure in each pole on the rotor to cause rotation of the rotor. The harmonic components induce a voltage in the pick-up coil. The portion of the harmonic components that induce a voltage in the pick-up coil no longer generate eddy currents within the motor. The energy harvested by the pick-up coil may also be utilized in a function other than driving the motor, such as powering a sensor mounted on the rotor.

System and method for wireless power transfer to a rotating member in a motor

The subject matter disclosed herein describes a method and system to monitor and identify vibrations in a rotational mechanical system. Various fault conditions in a rotating machine operating at variable speeds may be identified, at least in part, by identifying the multiple of the fundamental frequency, or order, at which the vibration occurs. The orders of vibration present in a measured vibration signal may be determined by finding an order spectrum of a measured vibration signal in the position domain. A fault vector is generated from the order spectrum that identifies the magnitude of each order of vibration present in the measured vibration signal. The fault vector may be plotted on a radar chart to provide a visual indication of the type of fault present in the mechanical system. Evaluation models for each fault determines a probability and magnitude for each fault condition being present in the sampled vibration signal.

Method and apparatus for online condition monitoring of variable speed motor applications

A motor having a circuit board including at least two MEMS sensors. The circuit board is mounted within a housing of the motor using the same fasteners as an encoder of the motor. Mounting the MEMS sensors to the circuit board simplifies assembly of the motor and standardizes the positioning of the MEMS sensors within the housing, while the overall motor footprint is unaffected.

Board mounted microelectromechanic system (MEMS) sensors for motor diagnostics and analytics

A method comprises providing a line-start synchronous motor. The motor has a stator, a rotor core disposed within the stator, and a motor shaft. In accordance with a step of the method, a coupling for coupling a load to the motor is provided. The coupling has a motor shaft attachment portion configured to provide substantially concentric contact around the shaft at the end of the motor shaft. The coupling has a load attachment portion configured to operatively connect to a load. In accordance with a step of the method, a load is coupled to the motor with the coupling, and driven from start to at least near synchronous speed during steady state operation of the motor with a load coupled thereto. The motor shaft attachment portion may comprise a bushing assembly with matching and opposed tapered surfaces that cooperate to secure the motor shaft attachment portion around the motor shaft.

Coupling with concentric contact around motor shaft for line start synchronous motor

A method for synchronizing a high inertial load with a line-start synchronous motor involves providing a rotor core with rotor bars being formed of a highly conductive material. In accordance with one aspect of the method, a user is directed to operatively couple a load to the motor and drive the load from start to at least near synchronous speed during steady state operation of the motor with the load coupled thereto. The load has an inertia that is greater than an inertia associated with a load driven by a like motor subjected to an equivalent range of starting current but having rotor bars formed from a conductive material having a conductivity lower than that the highly conductive material.

High conductivity rotor cage for line start permanent magnet motor

A mechanical soft-start type coupling is used as an interface between a line start, synchronous motor and a heavy load to enable the synchronous motor to bring the heavy load up to or near synchronous speed. The soft-start coupling effectively isolates the synchronous motor from the load for enough time to enable the synchronous motor to come up to full speed. The soft-start coupling then brings the load up to or near synchronous speed.

System and method to allow a synchronous motor to successfully synchronize with loads that have high inertia and/or high torque

A line-start synchronous motor has a housing, a rotor shaft, and an output shaft. A soft-start coupling portion is operatively coupled to the output shaft and the rotor shaft. The soft-start coupling portion is configurable to enable the synchronous motor to obtain synchronous operation and to drive, at least near synchronous speed during normal steady state operation of the motor, a load having characteristics sufficient to prevent obtaining normal synchronous operation of the motor when the motor is operatively connected to the load in the absence of the soft-start coupling. The synchronous motor is sufficiently rated to obtain synchronous operation and to drive, at least near synchronous speed during normal steady state operation of the motor, a load having characteristics sufficient to prevent obtaining normal synchronous operation of the motor when the motor is operatively connected to the load in the absence of the soft-start coupling.

Synchronous motor with soft start element formed between the motor rotor and motor output shaft to successfully synchronize loads that have high inertia and/or high torque

A system and method are provided whereby at least two motors driven by an inverter coupled to a DC bus are configured to alternate between regenerative and injection braking such that at least one motor is placed in regenerative braking mode and at least one motor is placed in motoring mode. Energy is simultaneously placed on and removed from the DC bus in a manner allowing a large current to flow in as many motors as possible, for fast stoppage of load inertia. At least one motor may be placed in regenerative braking mode and at least one motor in DC injection mode, such that energy is simultaneously placed onto and removed from the DC bus, respectively. Further, a single motor may be is alternated between regenerative braking and DC injection braking, such that energy is alternately placed onto and removed from the DC bus, respectively.

Electric braking of machinery with a plurality of inverter-fed motors

A system and method for protecting a motor drive unit from an associated motor includes a motor drive unit protection system. The motor drive unit protection system includes at least one switch configured to be connected between a motor drive unit and a plurality of motor leads of the motor driven by the motor drive unit. The motor drive unit protection system also includes a controller configured to monitor the motor drive unit or the motor to determine a fault condition indicative of the motor potentially operating as a generator. Upon determining the fault condition, the controller is configured to cause the at least one switch to connect the plurality of motor leads together to protect the motor drive unit from the motor when the motor is operating as a generator.

System and method for protecting a motor drive unit from motor back EMF under fault conditions

A permanent magnet motor having a rotor and a stator and configured such that when the leading edge of each pole of the rotor aligns with a stator tooth the trailing edge of that pole is generally not aligned with a stator tooth.

Cogging reduction in permanent magnet machines

In accordance with certain exemplary embodiments, the present technique provides methods and apparatus for providing operating power to a complementary device to an induction device based uninterruptible power source (UPS) via a direct current (dc) bus. In one embodiment, the UPS includes a flywheel that stores kinetic energy during conventional operating conditions, e.g., external power is available. During such operating condition, the external power operates the induction device as an induction motor. However, when external power is lost, i.e., a transient operating condition, power conversion circuitry of the UPS provides ac power to the induction device such that the induction device operates above its synchronous speed and, as such, acts as an induction generator. However to improve the operating of the exemplary UPS, it includes second power conversion circuitry that converts both generated and received power to a power level that is desirable to complementary device cooperating with the induction device.

Methods and apparatus for ride-through operation of a complementary device to a transient power source

In accordance with exemplary embodiments, the present invention provides a transient power source that includes a flywheel that stores kinetic energy. In the event of a loss of main or operating power, the kinetic energy stored in the flywheel is converted into electrical energy. As one example, the rotation of the flywheel drives a generator that converts this mechanical (i.e., kinetic energy) into electrical energy. Additionally, the exemplary flywheel, as one embodiment, generates a cooling airflow for various components of the electrical machine. Thus, the rotation of the flywheel not only generates power, but also cools the various components of the transient power source as well.

Apparatus and method for flywheel based cooling

In accordance with certain exemplary embodiments, the present technique provides methods and apparatus for providing transient and uninterrupted power to protected loads. As one example, the present invention provides an induction device that operates as an induction motor to energize a kinetic energy storage device, such as a flywheel, during conventional operating conditions. However, in the event of a loss of primary power, the induction device, which is fed ac power at variable frequencies, begins to operate as an induction generator. For example, by varying the frequency of the input ac power such that the synchronous speed of the motor is exceeded by the rotating flywheel, the induction device acts as an induction generator and provides a transient operating power to the downstream loads until an auxiliary power source, such as a diesel generator, is brought on line.

Apparatus and method for transient and uninterruptible power

In accordance with certain embodiments, the present technique provides a reduced current field-oriented-control scheme. For example, the present technique provides a method of controlling an induction device in which a predetermined reduction factor is employed to reduce the flux-current vector of a field-oriented-control scheme. By reducing this vector, less current and less power are drawn by the induction device, in turn reducing resistive heating and stator core losses, for instance.

Modified field oriented control

Technique for reducing bearing current discharges in a system by increasing the surface area between the shaft and the frame of the system and thereby increasing the rotor to frame capacitance.

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Euclid, OH, United States of America

Michael J Melfi