Packet-Networked VFD Control for Remote PWM Coordination

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current VFD control systems are limited by the need for a co-located master controller, which complicates programming, maintenance, and requires cumbersome cable connections, and lacks flexibility in real-time adjustments.

Innovation Solution

Implementing a packet-switched network to remotely control VFDs, allowing geographically separated controllers to send low-level gate signals and receive feedback, enabling decentralized and scalable control through a packet network.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a co-located master controller is used to control VFDs, then real-time control and coordination are achieved, but programming complexity and maintenance difficulty increase

Engineering Contradiction:

Improvereal-time controlVSAvoidprogramming complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides the control system into modular VFD units, each with integrated control capabilities. Instead of one complex master controller, multiple independent VFDs can operate autonomously or coordinate through simple peer-to-peer communication, reducing programming complexity while maintaining real-time control

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each VFD unit is equipped with its own controller that can independently generate PWM signals and control power transistors. The VFDs perform self-control and can autonomously coordinate with neighboring units, eliminating the need for complex external master controller programming

Inventive Principle:

Principle #25Self-service

2Reliability

If a co-located master controller is used to control VFDs, then centralized control is achieved, but physical connections and maintenance requirements increase

Engineering Contradiction:

Improvecontrol coordinationVSAvoidmaintenance difficulty

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The control function is segmented and distributed to each VFD unit rather than centralized in one master controller. This modular approach allows individual VFDs to be maintained or replaced independently without affecting the entire system, significantly easing repair and maintenance operations

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each VFD contains its own controller and can operate independently, providing built-in redundancy and fault tolerance. If one VFD fails, others continue operating, and maintenance can be performed on individual units without system shutdown

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If traditional VFD control systems are used, then simple setups are achieved, but flexibility for real-time adjustments and advanced algorithms is limited

Engineering Contradiction:

Improvesetup simplicityVSAvoidreal-time adjustment flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The VFD controllers are designed to be dynamic and reconfigurable, allowing real-time adjustment of control parameters and algorithms. The system can adapt to different operating conditions and implement advanced control strategies without requiring complex reconfiguration or additional hardware

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUSRE50770E1Packet-based networking of variable frequency drives

Publication Date: 2026.01.27 KIMIDRIVE LLC

AI summary

One or more Variable Frequency Drives (VFD) are connected to a packet network and the power transistor drive signals normally generated by the VFD to produce a desired Pulse Width Modulated (PWM) motor drive signal are generated by a software controller located in the packet network and transmitted to the VFD. The control of the VFDs can be (1) centralized using some centralized software controller communicating to the VFDs over the packet network, and/or (2) distributed, in which case VFDs can peer with each other over the packet network, to communicate control state.