HVAC actuator and ASIC for an HVAC actuator

Abstract

A heating, ventilation, and air conditioning (HVAC) actuator (1) for actuating an actuated part (2) in an HVAC system, wherein the HVAC actuator (1) comprises an electric motor (10) and a controller (11) configured to control the electric motor (10), the controller (11) comprising an application-specific integrated circuit (ASIC) (12), the ASIC (12) comprising an analog circuit (14) and a digital circuit (13), the analog circuit (14) of the ASIC (12) being configured to generate a motor current (14) for the electric motor (10), the digital circuit (13) of the ASIC (12) being configured to generate control signals for controlling the analog circuit (14), and the digital circuit (13) of the ASIC (12) comprising a motor control circuit (17), a microprocessor (15), which controls the motor control circuit (17), and a storage unit (16) in which a program code is stored,which is set up to control the microprocessor (15).

Description

AREA OF REVELATION

[0001] The present disclosure relates to an HVAC (heating, ventilation and air conditioning) actuator and an ASIC (application-specific integrated circuit) for an HVAC actuator. In particular, the present disclosure relates to an HVAC actuator comprising an electric motor and a controller configured to control the electric motor to actuate an actuated part in an HVAC system, as well as an ASIC for the HVAC actuator. BACKGROUND OF THE REVELATION

[0002] Actuators with a controller and an electric motor are widely known and used to actuate a variety of components in numerous applications, such as controlling dampers or valves in HVAC systems. These HVAC actuators are typically equipped with a reduction gear to actuate a variety of loads with the required precision and accuracy. A typical HVAC system usually contains several HVAC actuators requiring different operating parameters, such as range of motion, torque, speed, and control mode. Specifically, operation in position control, speed control, or torque control mode may be required. For cost-effectiveness in both installation and maintenance, it is desirable to use standardized HVAC actuators.To use multi-purpose HVAC actuators that can be used in a variety of applications.

[0003] Furthermore, in the interest of cost efficiency in manufacturing, maintenance and upgrades, it is desirable to provide a uniform control system for different sizes of HVAC actuators, which include electric motors of varying sizes and drive power for a wide variety of loads and applications. GENERAL DESCRIPTION OF THE REVELATION

[0004] The objective of this disclosure is to provide an HVAC actuator and an ASIC for an HVAC actuator. In particular, the subject of this disclosure is to provide an HVAC actuator and an ASIC for an HVAC actuator, wherein the HVAC actuator and the ASIC do not exhibit at least some of the disadvantages of the prior art.

[0005] According to the present disclosure, these objectives are addressed by the features of the independent claims. Furthermore, additional advantageous embodiments are described in the dependent claims and the description.

[0006] According to the present disclosure, the aforementioned objectives are achieved in particular by comprising an HVAC actuator for actuating an actuated part in an HVAC system, an electric motor, and a controller configured to control the electric motor. The controller includes an ASIC comprising an analog circuit and a digital circuit. The analog circuit of the ASIC is configured to generate a motor current for the electric motor. The digital circuit of the ASIC is configured to generate control signals for controlling the analog circuit. The digital circuit of the ASIC includes a motor control circuit, a microprocessor that controls the motor control circuit, and a memory unit in which program code is stored that is configured to control the microprocessor. For example, the program code is implemented as firmware that is configured to control the microprocessor.

[0007] In one embodiment, the program code is configured to control the microprocessor to operate selectively in either an autonomous mode or an externally controlled mode. In autonomous mode, the microprocessor periodically repeats a sequence of steps programmed in the program code to operate the HVAC actuator. In externally controlled mode, the microprocessor executes a subset of the steps programmed in the program code in response to an external microcontroller that defines this subset of steps.

[0008] In one embodiment, the analog circuit includes output terminals and is configured to provide drive signals for an external analog power stage circuit located outside the ASIC and connected to the output terminals.

[0009] In one embodiment, the ASIC's motor control circuitry is configured to execute various selectable types of motor control. These motor control types include more than one of the following: sensorless position sensing, Hall-effect sensors for position sensing, and / or potentiometer-based position sensing. Sensorless position sensing includes, for example, back EMF (back electromotive force) and rotor induction-based position sensing.

[0010] In one embodiment, the ASIC's motor control circuitry is configured to execute various selectable motor control modes. These modes include more than one of the following: torque control, speed control, and / or position control. The motor control mode is selected, for example, by a motor control mode selector stored in a non-volatile memory unit of the controller or ASIC, which can be read by the microprocessor.

[0011] In one embodiment, the program code is configured to control the ASIC's microprocessor to execute various selectable types of control circuits. These control circuit types include more than one of the following: air volume control, differential pressure control, and / or flow control. The selection of the control circuit type is achieved, for example, by a control circuit type selector stored in a non-volatile memory unit of the controller or ASIC, which can be read by the microprocessor.

[0012] In one embodiment, the digital circuitry of the ASIC is configured to execute various selectable types of actuators. The actuator types include more than one of the following: a modulating actuator, an open / close actuator, or a three-point actuator. The actuator type is selected, for example, by an actuator type selector stored in a non-volatile memory unit of the controller or ASIC, which can be read by the microprocessor.

[0013] In one embodiment, the digital circuitry of the ASIC is configured to process various selectable end-stop types. These end-stop types include more than one of the following: a mechanical end stop, an end stop with a limit switch, a freewheel end stop, a sensor end stop, or a position counter end stop. The end-stop type is selected, for example, by an end-stop type selector stored in a non-volatile memory unit of the controller or ASIC, which can be read by the microprocessor.

[0014] In one embodiment, the HVAC actuator comprises a non-volatile memory unit and a near-field communication (NFC) circuit connected to and configured with the non-volatile memory unit to store configuration parameters received from an external communication device located outside the HVAC actuator. The ASIC's digital circuitry is configured to generate control signals using the configuration parameters stored in the non-volatile memory unit. In alternative or additional embodiments, the configuration parameters stored in the non-volatile memory unit are received via a communication interface other than NFC, such as another wireless or wired communication interface.In another alternative embodiment, the configuration parameters are changed by replacing the non-volatile memory unit in which the first configuration parameters are stored with another non-volatile memory unit in which the second configuration parameters are stored.

[0015] The configuration parameters stored in the non-volatile memory unit include, for example, at least one of the following elements: operating speed, direction of rotation, communication interface address, input mode, type of analog input, configuration of analog inputs and outputs for sensors and feedback, torque or force limit, end stop positions, position control range, enabling or disabling auxiliary switches, switching positions of auxiliary switches, position setpoints, fail-safe positions, control mode, type of motor control, linear or rotary actuator, position adjustment range, motor configuration parameters, including torque limit, motor constant, number of pole pairs or inductance, control parameters, including control gains for position, speed, current control or monitoring, allowing the user to set the input mode, allowing storage of performance indicators, and end stop type.Disable NFC communication, control mode of the microprocessor (15) to display autonomous mode or externally controlled mode, operating parameters for certain functions, including narrow switching limit, number of engine revolutions for the transmission disengagement function, hand crank speed, spring return, speed ramp or reduced speed near the end stops, or configuration parameters for the spring return actuator.

[0016] In one embodiment, the HVAC actuator comprises a non-volatile memory unit and an NFC circuit connected to the non-volatile memory unit. The ASIC's digital circuitry is configured to generate operating performance indicators associated with the electric motor's power output and store them in the non-volatile memory unit. The NFC circuitry is configured to read the operating performance indicators from the non-volatile memory and transmit them to the external communication device.

[0017] The operational performance indicators include, for example, at least one of the following elements: total operating time, operating time in different temperature ranges, minimum operating temperature, maximum operating temperature, maximum motor temperature, minimum operating voltage, maximum operating voltage, number of power failures, number of watchdog resets, number of motor starts / stops, number of motor direction changes, number of movements to mechanical end stops, histogram of travel time in relation to torque, histogram of maximum torque for different position ranges, number of overload events, minimum and maximum end position displacements, supercapacitor status, indicator of successful commissioning, indicator of power supply to the actuator in the field, or indicator of actuator reconfiguration in the field.

[0018] In one embodiment, at least one of the non-volatile memory units or the NFC circuit is integrated into the ASIC.

[0019] In one embodiment, the program code is configured to control the microprocessor to reject a write request received from the external communication device if the write request aims to write a data value to the non-volatile memory unit that is no different from the data value currently stored in the non-volatile memory unit, or if the write request exceeds a number of allowed write operations, for example, within a specific time period. The number of allowed write operations is increased over time up to a maximum number of write operations. For example, the number of allowed write operations is increased by the microprocessor, e.g., at regular intervals.

[0020] In one embodiment, the ASIC comprises an interface configured to connect to the digital circuitry of the ASIC at least one of the following elements: a temperature sensor, a flow sensor, a pressure sensor, a Hall sensor, an external ASIC located outside the ASIC, an external microcontroller located outside the ASIC, or a supercapacitor module located outside the ASIC.

[0021] In one embodiment, the digital circuit includes a read / write memory unit that the microprocessor can access, and the program code is configured to control the microprocessor to exchange data between the read / write memory unit and the external microcontroller via the interface.

[0022] In one embodiment, the interface comprises at least one of the following elements: a serial communication line interface and / or a parallel communication bus interface.

[0023] In one embodiment, the HVAC actuator comprises a printed circuit board, and the electric motor and the control system are arranged on the printed circuit board.

[0024] In one embodiment, the ASIC includes a charge pump controller configured to provide power to the HVAC actuator.

[0025] In addition to the HVAC actuator, this disclosure also relates to an application-specific integrated circuit (ASIC) for an HVAC actuator. The ASIC comprises an analog circuit and a digital circuit. The analog circuit of the ASIC is configured to generate a motor current for the electric motor of the HVAC actuator. The digital circuit of the ASIC is configured to generate control signals for controlling the analog circuit. The digital circuit of the ASIC comprises a motor control circuit, a microprocessor that controls the motor control circuit, and a memory unit in which program code is stored that is configured to control the microprocessor.

[0026] Further embodiments and features of the ASIC are described above in connection with the ASIC of the actuator for HVAC systems. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The present revelation is further explained by way of example with reference to the drawings in which: Fig. Figure 1 shows a block diagram schematically illustrating an HVAC actuator with a controller comprising an ASIC with an analog circuit and a microprocessor to control the electric motor of the HVAC actuator to actuate an actuated part in an HVAC system; Fig. 2 a block diagram showing schematically illustrating an HVAC actuator with a controller comprising an ASIC with an analog circuit and a microprocessor, wherein the analog circuit includes output terminals to provide drive signals for an external analog power stage that drives the electric motor of the HVAC actuator; Fig. Figure 3 shows a block diagram schematically illustrating an HVAC actuator with a controller comprising an ASIC with an analog circuit, a microprocessor, a non-volatile memory unit for storing configuration parameters for the ASIC, and an optional communication interface for receiving the configuration parameters from an external device; Fig. Figure 4 shows a block diagram schematically illustrating an HVAC actuator with a controller that includes an ASIC with an interface for connecting external devices such as temperature sensors, flow sensors, pressure sensors, Hall sensors, an external ASIC, an external microcontroller and / or a supercap module; Fig. Figure 5 shows a block diagram schematically illustrating the data and signal flow associated with an ASIC of an HVAC actuator, the ASIC comprising an analog circuit and a digital circuit with a microprocessor; Fig. Figure 6 shows a block diagram schematically representing an HVAC actuator with a printed circuit board on which the electric motor of the HVAC actuator and a controller with ASIC for controlling the electric motor are arranged; Fig. Figure 7 shows a block diagram schematically illustrating an ASIC for controlling an HVAC actuator, wherein the ASIC comprises an analog circuit and a microprocessor for controlling the electric motor of the HVAC actuator; Fig. Figure 8 shows a block diagram schematically illustrating an ASIC for controlling an HVAC actuator, wherein the ASIC comprises an analog circuit and a microprocessor, the analog circuit comprising output terminals to provide drive signals for an external analog power stage that drives the electric motor of the HVAC actuator; Fig. Figure 9 shows a block diagram schematically illustrating an ASIC for controlling an HVAC actuator, wherein the ASIC comprises an analog circuit, a microprocessor, a non-volatile memory unit for storing configuration parameters for the ASIC, and an optional communication interface for receiving the configuration parameters from an external device; Fig. Figure 10 shows a block diagram schematically illustrating an ASIC for controlling an HVAC actuator, wherein the ASIC includes an interface for connecting external devices such as temperature sensors, flow sensors, pressure sensors, Hall sensors, an external ASIC, an external microcontroller or a supercap module; Fig. Figure 11 shows a flowchart illustrating a sequence of steps for operating the ASIC microprocessor optionally in an autonomous mode or in an externally controlled mode; Fig. 12 shows a flowchart illustrating a sequence of steps performed by the ASIC's microprocessor in autonomous mode or in an externally controlled mode; Fig. 13 shows a flowchart illustrating a sequence of steps for operating the ASIC microprocessor in an operating mode based on stored configuration parameters; Fig. Figure 14 shows a flowchart to illustrate a sequence of steps for controlling write requests directed to non-volatile memory by the ASIC's microprocessor. DETAILED DESCRIPTION OF THE EXECUTION FORMS

[0028] In the Fig. 1-6, reference number 1 refers to an actuator for HVAC. As in the Fig. As shown in Figures 1-6, the HVAC actuator 1 comprises an electric motor 10 and a controller 11. In a preferred embodiment, the electric motor 10 is a brushless direct current (BLDC) motor, i.e., a brushless permanent magnet motor. As shown in the Fig. As shown schematically in Figures 1-5, the HVAC actuator 1 is configured to actuate an actuated part 2 in an HVAC system. The actuated part 2 is, for example, a valve or a damper for regulating the flow of a fluid in a pipe or duct of the HVAC system. As shown in the Fig. As further shown in 1-6, the controller 11 comprises an ASIC 12, which is also used in the Fig. 7-10 is shown as a separate component.

[0029] As in the Fig. As shown in Figures 1-10, the ASIC 12 comprises a digital circuit 13 and an analog circuit 14.

[0030] The analog circuit 14 comprises a power stage circuit configured to generate the motor current 141 for the electric motor 10. The power stage circuit includes three half-bridges for supplying the three phases of the electric motor 10. The power stage generates the phase currents for supplying the three phases of the electric motor 10. The power stage circuit is configured, for example, to drive the phases sinusoidally using pulse-width modulation (PWM). In one embodiment, the analog circuit 14 generates an identification signal that assigns the version or power level of the analog circuit 14 to the digital circuit 13, e.g., a 200W power stage or a 600W power stage. The same digital circuit 13 can be used for different versions of the analog circuit 14.

[0031] The digital circuit 13 is configured to generate control signals for controlling the analog circuit 14. As shown in the Fig. As shown in Figures 1-10, the digital circuit 13 comprises a microprocessor 15, a memory unit 16, and a motor control circuit 17. The memory unit 16 stores program code configured to control the microprocessor 15. This program code represents the firmware for the ASIC 12, or controller 11. The microprocessor 15 is configured to control the motor control circuit 17. In other words, the program code stored in the memory unit 16 controls the microprocessor 15 to control the motor control circuit 17. The motor control circuit 17 generates the control signals for the analog circuit 14. The motor control circuit 17 is configured to perform various selectable / configurable types of motor control, such as position control, speed control, and / or torque control. The microprocessor 15 generates the setpoints for the motor control circuit 17.The setpoints depend on the selected / configured type of motor control. More precisely, the microprocessor 15 generates setpoints for position, speed, or torque for the motor control circuit 17, depending on whether position control, speed control, or torque control is selected / configured as the type of motor control. The microprocessor 15 also provides limit values ​​to the motor control circuit 17, which depend on the selected / configured type of motor control, e.g., power, speed, and / or torque limit values ​​for position control, or power and / or speed limit values ​​for torque control.

[0032] Depending on the configured / selected type of motor control, the motor control circuit 17 operates as a position control, speed control, or torque control, using the corresponding setpoints and limit values ​​of the microprocessor 15. The motor control circuit 17 controls the position, speed, or torque by generating the control signals for the analog circuit 14 using three-phase pulse-width modulation (PWM). The motor control circuit 17 also provides feedback to the microprocessor 15 regarding the current position, speed, and / or torque of the electric motor 10. While the microprocessor 15 performs a sequence of monitoring functions or steps, e.g., at a rate of several milliseconds, the motor control circuit 17 performs time-critical real-time functions at a comparatively higher rate, e.g., at a rate of several microseconds.The motor control circuit 17 is further configured to execute various selectable / configurable types of motor control, e.g. a motor control with sensorless position detection, a motor control with Hall sensors for position detection and / or a motor control with a potentiometer for position detection.

[0033] As in the Fig. As schematically indicated by dashed lines 2-5 and 8-10, ASIC 12 is configured to be combined with an external analog power stage 3, for example, in cases where the power stage of the built-in analog circuit 14 does not provide sufficient power for the electric motor 10 being used. For these cases, the analog circuit 14 of ASIC 12 includes output terminals 18 and is configured to provide drive signals (control) for an external analog power stage 3, which is connected to the output terminals 18. The external analog power stage 3 is configured to generate the motor current 142 for the electric motor 10. Typically, as described above in connection with the analog circuit 14, the external analog power stage 3 includes three half-bridges for supplying the three phases of the electric motor 10.It should be noted that in cases where the built-in power stage of ASIC 12 is used, the output terminals 18 can be reconfigured and used as digital output terminals to output other values ​​or signals from the digital circuit 13. For example, the output of a charge pump controller (integrated into ASIC 12) can be routed to the output terminals 18.

[0034] In the Fig. In references 3-5 and 9-10, reference digit 4 refers to a non-volatile memory unit, e.g., an electrically erasable, programmable solid-state memory (EEPROM). The non-volatile memory unit 4 is configured to store configuration parameters for the HVAC actuator 1 and its controller 11. As described in the Fig. As shown schematically in Figures 3-5 and 9-10, the controller 11 in some embodiments further comprises a communication interface 5 connected to the non-volatile memory unit 4, e.g., a near-field communication (NFC) circuit. In these embodiments, an external mobile communication device 6, such as a mobile phone, smartwatch, tablet, or laptop, can access the non-volatile memory unit 4 via the communication interface 5. In particular, the external communication device 6 can read configuration parameters from the non-volatile memory unit 4 and write them to it. Those skilled in the art will understand that other communication interfaces, in particular wired communication interfaces and / or communication buses, can also be provided and used to access the non-volatile memory unit 4.

[0035] As in the Fig. 9 and Fig. As shown schematically in Figure 10, in some embodiments the non-volatile memory unit 4 and / or the communication interface 5, in particular the NFC circuit, is / are integrated into the ASIC 12. Alternatively, the communication interface 5, in particular the NFC circuit, is connected to the ASIC 12 via a (serial) I2C interface.

[0036] Fig. Figure 13 shows an exemplary sequence of steps for writing and storing configuration parameters in the non-volatile memory unit 4 and for the controller 11 to use the stored configuration parameters.

[0037] In step S10, the communication device 6 generates and transmits a write request for a control parameter to the controller 11 via the communication interface 5. Depending on the embodiment, the write request is processed directly by the communication interface 5, which stores the received configuration parameter in the non-volatile memory unit 4, or the write request is processed by the microprocessor 15, as described below with reference to Fig. 14 is described in more detail. Alternatively, configuration parameters are written to the non-volatile memory unit 4 in a writing device separate from the HVAC actuator 1, and the non-volatile memory unit 4 is then inserted into and connected to the HVAC actuator 1 and its controller 11.

[0038] In step S11, the microprocessor 15 reads configuration parameters from the non-volatile memory unit 4. The microprocessor 15 reads most of the configuration parameters during startup ("booting"). Depending on the design and / or configuration, the restart or "reboot" is triggered by resetting the power supply or in response to the writing of the configuration parameters. The configuration parameters can be written to the non-volatile memory unit 4 via NFC communication using the NFC circuit, both when the actuator 1 is powered on and when it is not. In step S12, the microprocessor 15 sets up various operating modes, which depend on and utilize the configuration parameters read from the non-volatile memory unit 4, as mentioned above and explained in more detail below.

[0039] It is noted here that writing configuration parameters via the NFC circuit to the non-volatile memory unit 4 (e.g., an EEPROM) in power-off mode has the advantage that the HVAC actuator 1 can be configured before its installation, e.g., with locally configurable parameters, before it is mounted and connected to the power supply, thus enabling faster and more flexible configuration of the HVAC actuator 1. In steps S4 / S9, the microprocessor 15 controls the HVAC actuator 1 according to the operating modes set in step S12, as mentioned above and explained in more detail below.

[0040] Fig. Figure 14 shows an exemplary sequence of steps that the microprocessor 15 performs to process a write request received via the communication interface 5 from an external device 6.

[0041] In step S100, a permissible number of write operations is set as a "credit". The initial value for the permissible number of write operations is read, for example, by microprocessor 15 as a configuration parameter from non-volatile memory 4.

[0042] In the optional step S108, the microprocessor 15 adjusts the allowed number of write operations, i.e., the "credit," to increase the number of permissible write operations, for example, up to a set maximum number of write operations, thus renewing or refreshing the "credit" over time. For instance, the microprocessor 15 executes step S108 periodically or at fixed time intervals, the duration of which can vary over time.

[0043] In step S101, the device 6 generates the write request for a configuration parameter and transmits it via the communication interface 5 to the controller 11, where it is received and processed by the microprocessor 15.

[0044] In step S102, the microprocessor 15 checks whether the received write request is to write a data value to non-volatile memory unit 4 that does not differ from the data value currently stored in non-volatile memory unit 4. If the received write requests would not change the data value already stored in non-volatile memory unit 4, processing continues in step S106, where the write request is acknowledged; otherwise, processing continues in step S103.

[0045] In step S103, microprocessor 15 checks whether there is still "credit," i.e., whether the allowed number of write operations is still positive and therefore the received write request would not exceed the allowed number of write operations. If the received write requests would not exceed the allowed number of write operations, processing continues in step S104; otherwise, processing continues in step S107, where the write request is rejected.

[0046] In step S104, microprocessor 15 stores the received data value in non-volatile memory unit 4. In step S105, microprocessor 15 reduces the allowed number of write operations, i.e., the "credit" is reduced. Subsequently, in step S106, microprocessor 15 acknowledges the write request.

[0047] In the Fig. In references 4-5 and 10, reference numeral 19 refers to an interface for connecting external devices to the digital circuitry of ASIC 12. Interface 19 comprises a serial communication line interface and / or a parallel communication bus interface. Interface 19 also includes analog interfaces, including analog input terminals for receiving analog setpoint signals, potentiometer signals for control, analog sensor signals (e.g., temperature sensor signals), and analog output terminals (e.g., for providing analog feedback signals, e.g., to a higher-level control system). Interface 19 is configured to connect external devices located outside the ASIC 12 of the HVAC actuator 1, such as temperature sensors, flow sensors, pressure sensors, Hall sensors, other external ASICs, an external microcontroller 7, and / or a supercapacitor module, to ASIC 12.Interface 19 is further configured to receive external setpoints for the HVAC actuator 1, e.g., from a user terminal or a building control or management system. In one embodiment, interface 19 comprises a serial MP bus slave interface configured to receive MP commands and transmit MP responses and to enable / disable the MP bus watchdog. In another embodiment, interface 19 is configured to function as an MP master gateway and to receive and forward master signals from an MP bus. For example, interface 19 is configured to function as an MP bus relay that receives and forwards incoming MP packets to and from an external microcontroller 7 via the wired actuator interface.This allows the external microcontroller 7 to receive, filter, and transmit MP packets without having to implement its own driver and analog circuitry for MP bus communication. The functions of receiving, interpreting, and executing MP commands addressed to the HVAC actuator 1, as well as sending back responses, are implemented, for example, in the digital circuitry of the ASIC 12 or its firmware. It should be noted that the digital circuitry of the ASIC 12 or its firmware is configured to operate as an MP bus master or MP bus slave; accordingly, the external microcontroller 7 will operate as an MP bus slave or MP bus master. In one embodiment, communication via NFC occurs when the device is powered on using the MP protocol, for example, for configuring, commissioning, and monitoring the HVAC actuator 1 and its ASIC.

[0048] In one embodiment, the ASIC 12 further comprises a charge pump controller (not shown) configured to provide power to the HVAC actuator 1.

[0049] The microprocessor 15, or rather its program code, is configured to exchange data between the memory unit 16 and the external microcontroller 7 or other external devices via interface 19. In other words, the microprocessor 15 is configured to exchange data with the external microcontroller 7 or other external devices via the memory unit 16 and interface 19.

[0050] Fig. Figure 5 shows an overview of some data and signal flows that are mapped using ASIC 12. As in Fig. As shown in Figure 5, the microprocessor 15 of the ASIC 12 receives program code stored in the memory unit 16 of the ASIC 12 and is controlled by it. Controlled by the program code, the microprocessor 15 reads configuration parameters from the non-volatile memory unit 4 of the control unit 11, sets an operating mode, and operates according to the configuration parameters. Controlled by the program code, the microprocessor 15 also receives data and signal values ​​from external devices 7 via interface 19, such as temperature values ​​from a temperature sensor, flow values ​​from a flow sensor, pressure values ​​from a pressure sensor, motor position values ​​from a potentiometer or Hall sensor, synchronization data, and / or signals from an external microcontroller, etc. Controlled by the program code, the microprocessor 15 also generates setpoint values ​​for the motor control circuit 17, e.g.,Using some of the data and signal values ​​from external devices 7, the motor control circuit 17 generates control signals for the analog circuit 14 and / or drive signals for an analog power stage 3. Depending on the control or drive signals of the motor control circuit 17, the analog circuit 14 or the analog power stage 3 generates motor currents 141, 142 for the electric motor 10.

[0051] Fig. Figure 6 shows an exemplary configuration in which the controller 11, including the ASIC 12, and the electric motor 10 are arranged on a common circuit board 100.

[0052] The following sections describe various examples of configuration parameters and their use by the controller 11 and the microprocessor 15.

[0053] As mentioned above, the configuration parameter geared towards the type of motor control determines whether the motor control circuit 17 operates as a motor control with sensorless position detection, as a motor control with Hall sensors for position detection, or as a motor control with a potentiometer for position detection.

[0054] Sensorless position sensing includes, for example, position sensing using back electromotive force (BEMF) and position sensing based on rotor induction. The microprocessor 15 operates according to the selected / configured type of motor control.

[0055] The configuration parameter relating to the type of motor control determines whether the motor control circuit 17 operates with position control, speed control, or torque control. The microprocessor 15 operates according to the selected / configured type of motor control.

[0056] Another configuration parameter, relating to the type of control circuit, determines whether the microprocessor 15 performs air volume control, differential pressure control, or flow control. The microprocessor 15 processes received setpoints and data / signal values ​​according to the selected / configured type of control circuit, e.g., as an airflow value, differential pressure value, or flow rate value.

[0057] Another configuration parameter, relating to the type of actuator, determines whether the digital circuit 13, in particular the microprocessor 15, operates the electric motor 10, for example, as a modulating actuator, as an opening / closing actuator, or as a three-point actuator. The microprocessor 15 processes received setpoints and data / signal values ​​according to the selected / configured actuator type.

[0058] Another configuration parameter, relating to the type of end stop, determines whether the digital circuit 13, specifically the microprocessor 15, implements and processes a mechanical end stop, a limit switch end stop, a freewheel end stop, a sensor end stop, or a position counter end stop. Depending on the selected / configured type of end stop, the motor control circuit 17 determines and provides different feedback signals that are processed by the microprocessor 15. For example, with a mechanical end stop, the feedback signals include a rotation indicator and a torque limit indicator; with a freewheel end stop, the feedback signals include a freewheel indicator; with a sensor end stop, the feedback signals include a sensor value; and with a position counter end stop, the feedback signals include a position or counter value.

[0059] Further configuration parameters relate to the operation of the actuator 1 or its electric motor 10 and other components. Configuration parameters for operation include, for example, the running speed, the direction of rotation, the communication interface address, the input mode, the type of analog input, the configuration of analog inputs and outputs for sensors and feedback, the torque or force limit, the end stop positions, the position control range, the activation or deactivation of auxiliary switches, the switching positions of the auxiliary switches, the position setpoints, the fail-safe positions, the control mode, the type of motor control, whether the actuator is linear or rotary, the position adjustment range, the motor configuration parameters including torque limit, motor constant, number of pole pairs, or inductance, and control parameters including control gains for position, speed, current control, or monitoring.which allow the user to set the input mode, enable the storage of performance indicators, activate the type of end stop, deactivate NFC communication, the microprocessor control mode assigned to autonomous mode or externally controlled mode, operating parameters for specific functions including tight closing of the switching threshold, the number of motor revolutions for the transmission release function, the hand crank speed, spring return, speed ramp or reduced speed near the end stops, or the configuration parameters of the spring return actuator.

[0060] Another configuration parameter, the operating mode configuration parameter, relates to the operating mode of the microprocessor 15 itself. The microprocessor 15, or rather its program code, is configured to operate either in an autonomous mode or in an externally controlled mode.

[0061] As in the upper part of Fig. As shown in Figure 12, the microprocessor 15, in autonomous mode, executes a state machine and repeatedly performs a fixed sequence of steps SEQ [1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16], which are executed in the program code stored in the non-volatile memory unit 4 (as shown in Figure 12). Fig. 11 with reference number S4).

[0062] In the externally controlled mode, which is in Fig. As shown in Figure 12 (lower part), the microprocessor 15 executes one or more subgroups SUB1, SUB2 of these steps / tasks (in the Fig. 11 and Fig. 12 (designated with the reference number S9), which are defined by an external microcontroller. After executing a subset of steps, e.g., SUB1 or SUB2, the microprocessor 15 hands over control to the external microcontroller, which executes its own steps (as in the Fig. 11 and Fig. 12 with reference numeral S6) and can define a further subset of steps to be executed by the microprocessor 15 (as shown in Fig. 11 with the reference number S7 assigned). In the example of the Fig. 12 The external microcontroller specifies that the microprocessor 15 executes the subsets SUB1 and SUB2 with steps [1 3 5] and [11 12 13 14 15 16] of the program code stored in the non-volatile memory unit 4. More precisely, in step S7 ( Fig. 11) The external microcontroller defines a first subset SUB1 with steps [1 3 5] in memory unit 16, and in step S9 the microprocessor 15 executes the first subset SUB1 with steps [1 3 5] defined by the external microcontroller and hands control over to the external microcontroller. Subsequently, in step S6 the external microcontroller executes its own steps and in step S7 sets a second subset SUB2 with steps [11 12 13 14 15 16]. After regaining control, the microprocessor 15 executes the second subset SUB2 with the steps [11 12 13 14 15 16] defined by the external microcontroller and hands control back over to the external microcontroller. In this way, multiple switches of control between the microprocessor 15 and the external microcontroller can occur within a control loop.

[0063] The SEQ sequence of steps executed by the microprocessor 15 includes, for example: reading digital inputs; acquiring current operating values ​​of the electric motor 10, e.g., motor position, torque, actuator position; reading external setpoints for the HVAC actuator 1, e.g., via interface 19; determining whether an exceptional situation exists, such as a power failure, synchronization error, gearbox problem, etc.; processing control input signals, e.g., inverting; processing actuator functions, such as tight closing, anti-sticking function, overload detection, braking function, etc.; generating setpoints for the motor control circuit 17; generating and outputting feedback, e.g., via interface 19, e.g., the current motor position, e.g., for a higher-level control system, such as a building management system; transmitting the setpoints to the motor control circuit 17; and outputting digital values.

[0064] Essentially, in autonomous mode, microprocessor 15 repeatedly executes the defined sequence of steps SEQ to generate the setpoints for motor control circuit 17. In autonomous mode, a scheduler of ASIC 12 is active and manages the execution of the entire SEQ sequence of successive steps in a fixed order, e.g., repeating every 100 ms. In externally controlled mode, however, microprocessor 15 does not execute the complete SEQ sequence of steps to generate the setpoints; instead, the sequence is divided between microprocessor 15 and external microcontroller 7. In other words, some steps, e.g., the subset SUB, are executed by microprocessor 15, while other steps are executed by external microcontroller 7. In externally controlled mode, the scheduler of ASIC 12 is deactivated, and external microcontroller 7 is responsible for scheduling and control.This makes it possible, for example, to execute controls that require more processing power on the external microcontroller 7. The microprocessor 15 and the external microcontroller 7 use a common data pool in the memory unit 16 for data exchange, e.g., the volatile memory of the microprocessor 15. It should be noted that individual steps of the sequence are atomic, i.e., they cannot be executed partially.

[0065] Fig. Figure 11 shows an exemplary sequence of steps for operating the microprocessor 15 in autonomous or externally controlled mode.

[0066] In step S1, the configuration parameter for the operating mode in the non-volatile memory unit 4 is set to autonomous mode, e.g., by the communication unit 6 or another configuration device. For example, the operating mode is set during manufacturing configuration via NFC communication or via wired communication.

[0067] In step S2, the microprocessor 15 reads the operating mode configuration parameter set in the non-volatile memory unit 4. The operating mode is read during the commissioning or restart of the HVAC actuator 1.

[0068] In step S3, the microprocessor 15 checks whether the operating mode (configuration parameter) is set to autonomous mode.

[0069] If the operating mode (configuration parameter) is set to autonomous mode, the microprocessor 15 proceeds in step S4 with the execution of the defined step sequence SEQ [1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16] of the program code stored in the memory unit 16. As in Fig. As schematically shown in Figure 11, the microprocessor 15 reads and writes working data to the memory unit 16 in step(s) S40 during the processing of the fixed sequence of steps SEQ. As schematically shown in loop S4*, the step sequence SEQ is executed repeatedly, e.g., at an assigned interval, e.g., every 100 ms. Otherwise, if the operating mode (control parameter) is set to an externally controlled mode, the microprocessor 15 continues processing in step S8.

[0070] In step S6, the external microcontroller 7 processes its own steps and tasks, and in step S7, it sets the steps to be executed by the microprocessor 15, e.g., by setting these steps in the memory unit 16. As in Fig. As shown schematically in Figure 11, the external microcontroller 7 reads and writes working data to memory unit 16 during step(s) S60 while processing its steps. Specifically, the external microcontroller 7 reads and writes working data to the memory shared with the microprocessor 15 in order to cooperate with the microprocessor 15. Thus, the external microcontroller 7 writes working data to memory unit 16 for use in subsequent steps executed by the external microcontroller 7 and / or the microprocessor 15. The external microcontroller 7 also reads working data from memory unit 16 that was previously stored by the microprocessor 15 (see steps S9 and S90).

[0071] In step S8, the microprocessor 15 reads the subset (e.g. SUB1 or SUB2) of the steps to be processed, as set, for example, by the microcontroller 7 in the memory unit 16.

[0072] In step S9, the microprocessor 15 executes the subset of steps (e.g., SUB1 or SUB2) as configured by the microcontroller 7. As in Fig.As shown schematically in Figure 11, the microprocessor 15 reads and writes working data to the memory unit 16 in step(s) S90 during the processing of the subset of steps, e.g., SUB1 or SUB2. Specifically, the microprocessor 15 reads and writes working data to the memory shared with the external microcontroller 7 in order to cooperate with the external microcontroller 7. Thus, the microprocessor 15 reads working data from the memory unit 16, which was previously stored by the external microcontroller 7, and writes working data to the memory unit 16 for use in subsequent steps executed by the external microcontroller 7 (see steps S6 and S60) and / or the microprocessor 15 (see steps S9 and S90).

[0073] In addition to reading configuration parameters stored in the non-volatile memory unit 4, the microprocessor 15 and / or the program code are further configured to store operating performance indicators in the non-volatile memory unit 4. These operating performance indicators can be read by an external device 6 via the communication interface 5, for example, wirelessly via NFC. The operating indicators are, for example, associated with the power output of the electric motor.The operational performance indicators include, for example, one or more of the following: total operating time, operating time in different temperature ranges, minimum operating temperature, maximum operating temperature, maximum motor temperature, minimum operating voltage, maximum operating voltage, number of power failures, number of watchdog resets, number of motor starts / stops, number of motor direction changes, number of travel movements to mechanical end stops, histogram of travel time versus torque, histogram of maximum torque for different position ranges, number of overload events, minimum and maximum end position displacements, supercapacitor status, indication of successful commissioning, indication that the actuator has been powered on in the field, or indication that the actuator has been reconfigured in the field.

[0074] It should be noted that the description presents the sequence of steps in a specific order, but a person skilled in the art will understand that the order of at least some of the steps could be changed without deviating from the scope of the disclosure.

Claims

[1] A heating, ventilation and air conditioning (HVAC) actuator (1) for actuating an actuated part (2) in an HVAC system, wherein the HVAC actuator (1) comprises an electric motor (10) and a controller (11) configured to control the electric motor (10), the controller (11) comprising an application-specific integrated circuit (ASIC) (12), the ASIC (12) comprising an analog circuit (14) and a digital circuit (13), the analog circuit (14) of the ASIC (12) being configured to generate a motor current (14) for the electric motor (10), the digital circuit (13) of the ASIC (12) being configured to generate control signals for controlling the analog circuit (14), and the digital circuit (13) of the ASIC (12) comprising a motor control circuit (17), a microprocessor (15), which controls the motor control circuit (17), and a storage unit (16) in which a program code is stored,which is set up to control the microprocessor (15). [2] The HVAC actuator (1) according to claim 1, wherein the program code is configured to control the microprocessor (15) to operate either in an autonomous mode or in an externally controlled mode, wherein in autonomous mode the microprocessor (15) periodically repeats a sequence of steps (SEQ) programmed in the program code to operate the HVAC actuator (1), and in externally controlled mode the microprocessor (15) executes a subset (SUB) of the steps programmed in the program code in response to an external microcontroller (7) that defines the subset of steps (SUB). [3] The HVAC actuator (1) according to one of claims 1 or 2, wherein the analog circuit (14) comprises output terminals (18) and is configured to provide drive signals to an external analog power stage circuit (3) located outside the ASIC (12) and connected to the output terminals (18). [4] The HVAC actuator (1) according to any one of claims 1 to 3, wherein the motor control circuit (17) of the ASIC (12) is configured to perform various selectable types of motor control, wherein the types of motor control include more than one of the following types: motor control using sensorless position sensing, motor control using Hall sensors for position sensing, or motor control using a potentiometer for position sensing. [5] The HVAC actuator (1) according to any one of claims 1 to 4, wherein the motor control circuit (17) of the ASIC (12) is configured to perform various selectable types of motor control, wherein the types of motor control include more than one of the following: torque control, speed control or position control. [6] The HVAC actuator (1) according to any one of claims 1 to 5, wherein the program code is configured to control the microprocessor (15) of the ASIC (12) to execute various selectable types of control circuits, the types of control circuits comprising more than one of the following: air volume control, differential pressure control and / or flow control. [7] The HVAC actuator (1) according to any one of claims 1 to 6, wherein the digital circuit of the ASIC (12) is configured to execute various selectable types of actuators, the types of actuators comprising more than one of the following: a modulating actuator, an opening-closing actuator or a three-point actuator. [8] The HVAC actuator (1) according to any one of claims 1 to 7, wherein the digital circuit of the ASIC (12) is configured to process various selectable types of end stops, wherein the types of end stops include more than one of the following: a mechanical end stop, an end stop with limit switch, a freewheel end stop, a sensor end stop or a position counter end stop. [9] The HVAC actuator (1) according to any one of claims 1 to 8, wherein the HVAC actuator (1) comprises a non-volatile memory unit (4) and an NFC circuit (5) connected to the non-volatile memory unit (4) and configured to store configuration parameters received from an external communication device (6) located outside the HVAC actuator (1) in the non-volatile memory unit (4); and the digital circuit (13) of the ASIC (12) is configured to generate the control signals using the configuration parameters stored in the non-volatile memory unit (4). [10] The HVAC actuator (1) according to any one of claims 1 to 9, wherein the HVAC actuator (1) comprises a non-volatile memory unit (4) and an NFC circuit (5) connected to the non-volatile memory unit (4); the digital circuit of the ASIC (12) is configured to generate operating performance indicators associated with the power of the electric motor (10) and to store them in the non-volatile memory unit (4); and the NFC circuit (5) is configured to read the operating performance indicators in the non-volatile memory (4) and to transmit the operating performance indicators to the external communication device (6). [11] An application-specific integrated circuit, ASIC (12), for an HVAC actuator (1) according to any one of claims 1 to 10, wherein the ASIC (12) comprises an analog circuit (14) and a digital circuit (13), wherein the analog circuit (14) of the ASIC (12) is configured to generate a motor current (141) for the electric motor (10) of the HVAC actuator (1), wherein the digital circuit (13) of the ASIC (12) is configured to generate control signals for controlling the analog circuit (14), wherein the digital circuit of the ASIC (12) comprises a motor control circuit (17), a microprocessor (15) that controls the motor control circuit (17), and a memory unit (4) in which a program code is stored that is configured to control the microprocessor (15).

Images