Motor Programming Tool With Isolation Transformer
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Solution Overview
Problem
Existing motor programming tools are inadequate for high voltage applications, as they pose risks of electrical shock and arc flash damage, and often require high insertion forces that can damage terminals, with directional indicators that may not be visible at all times.
Innovation Solution
A motor programming tool with a tool body, wiring, and an energy-limited transformer that provides high voltage power and communicates programming signals to a programmable controller, featuring an interface to selectively engage the motor connection block, mechanical connections for secure engagement, and a visual indicator for power presence, along with an interlock to ensure safe high voltage provision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior art programming tools use gendered terminals for frictional engagement, then the tools can be securely connected to the connection block, but high insertion or engagement forces are required that can damage the terminals
Solution Approach 1:
The patent inverts the traditional gendered terminal engagement approach by using a receptacle-type interface on the programming tool that receives a plug-type connector from the connection block. This reversal eliminates the need for high frictional engagement forces while maintaining secure electrical connection, as the plug receptacle mechanism provides natural mechanical guidance and connection without requiring excessive insertion force.
2Adaptability or versatility
If prior art programming tools provide high voltage power, then they can program high voltage motors, but users are at risk of electrical shock and arc flash damage
Solution Approach 1:
The patent introduces an isolation transformer as an intermediary device between the high voltage power source and the programming tool interface. This transformer provides galvanic isolation, blocking direct electrical shock paths to the user while still allowing high voltage power to be delivered to the motor for programming operations. The transformer acts as a safety mediator that enables high voltage functionality without exposing the user to direct shock hazards.
3Loss of information
If prior art programming tools use directional lights to indicate power presence, then power status can be indicated, but the lights may not be visible to users at all times
Solution Approach 1:
The patent employs multi-color LED indicators that change color or illuminate in different patterns to indicate various power and operational states. These LEDs are positioned to be visible from multiple angles and are supplemented with reflective surfaces or housing features that enhance visibility. The use of distinct colors (e.g., green for safe, red for dangerous voltage) provides intuitive visual feedback that remains visible throughout the programming operation.
4Power
If prior art programming tools lack electrical isolation, then they can provide full power, but users are protected against electrical shock
Solution Approach 1:
The isolation transformer serves as an intermediary that enables full power delivery to the motor while simultaneously providing galvanic isolation to protect against arc flash damage. The transformer's magnetic coupling allows power transfer without direct electrical connection, preventing arc flash hazards from reaching the user or damaging sensitive programming electronics while maintaining full voltage and current capability for motor programming.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The tool ensures safe and effective programming of high voltage motors by providing electrical isolation and protecting against arc flash, while minimizing terminal damage and ensuring visible indication of high voltage presence, thus addressing the limitations of prior tools.
Implementation Method 1
The energy-limited transformer may have an electrically isolated high impedance secondary winding and may be otherwise configured both to provide an electrical isolation to protect against an electrical shock to a user of the tool
Implementation Method 2
The energy-limited transformer may have an electrically isolated high impedance secondary winding and may be otherwise configured both to provide an electrical isolation to protect against an electrical shock to a user of the tool and to provide a low energy output to protect against an arc flash damage to the electric motor
Data Source
AI summary
A tool for programming a controller of an electric motor by engaging a connection block of the motor and providing high voltage power and communicating programming signals to the controller. The tool includes a body having an interface for engaging the connection block, and internal wiring presenting tool terminals at the interface for making contact with corresponding motor terminals to allow for providing power and communicating signals between the tool and the controller. An energy-limited transformer having an isolated high impedance secondary winding provides both electrical isolation to protect against shock and low energy output to protect against arc flash. Redundant interlocks include a software interlock which allows the power to be present at the interface only during actual programming of the controller. A light ring encircling the body indicates the presence of high voltage and is visible from multiple directions.