Solid State Motor Control Circuit for HVAC ECMs

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Solution Overview

Problem

HVAC systems with electronically commutated motors (ECMs) face inefficiencies and cost issues due to the need for multiple taps and bulky mechanical relays or switches to manage different operating parameters, which complicates control and requires redesign or replacement of existing motor designs.

Innovation Solution

A control circuit using solid state switching devices and DC control signals to manage motor taps, allowing the motor to operate at different parameters without applying AC signals to multiple taps, thereby eliminating the need for mechanical relays and providing cost and space savings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple taps are used on the motor to enable different operating parameters, then the motor's adaptability is improved, but the device complexity increases due to the need for multiple switches or relays

Engineering Contradiction:

Improvemotor operating parametersVSAvoidcontrol circuit complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies universality by enabling a single tap to perform multiple functions through the use of solid state switching devices that can generate different signal patterns (AC-like and DC-like) from one tap, eliminating the need for multiple taps and associated mechanical switches or relays

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If mechanical relays or switches are used to control motor taps, then the motor control functionality is achieved, but the device complexity and space requirements increase

Engineering Contradiction:

Improvemotor control functionalityVSAvoidswitching device complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces mechanical relays or switches with solid state switching devices that use electronic signal processing to control motor taps, eliminating moving parts and reducing device complexity while maintaining full motor control functionality

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If AC signals are applied to multiple taps to control motor operation, then the motor can operate at different parameters, but the loss of energy increases due to multiple active circuits

Engineering Contradiction:

Improvemotor operating parametersVSAvoidenergy consumption

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent uses periodic AC-like signal patterns applied to a single tap to emulate traditional multi-tap AC control, allowing the motor to operate at different parameters while energizing only one tap at a time, thereby reducing energy loss compared to having multiple AC circuits active simultaneously

Inventive Principle:

Principle #19Periodic action

Data Source

PatentUS9178447B2Control circuits for motors and related methods

Publication Date: 2015.11.03 COPELAND COMFORT CONTROL LP

AI summary

Control circuits and related methods are provided. One exemplary control circuit includes a solid state switching device for coupling to a first tap of a motor and a control device coupled to the solid state switching device. The control device is configured to switch the solid state switching device to apply a signal to the first tap in response to a demand for operation of the motor at a second parameter to operate the motor at the second parameter. The control device is also configured to switch the solid state switching device to apply a signal to the first tap in response to a demand for operation of the motor at a first parameter to operate the motor at the first parameter.