WikiPatents - Community Patent Review
Create Free Account  |  License or Sell Your Patent  |  WikiPatents Marketplace  |  WikiPatents Blog
Username:  Password:  
    
Advanced Search
A.C. induction motor energy conserving power control method and apparatus    
United States Patent4806838   
Link to this pagehttp://www.wikipatents.com/4806838.html
Inventor(s)Weber; Harold J. (313 Washington St., P.O. Box 6161, Holliston, MA 01746)
AbstractElectric power consumed by an a.c. induction motor is measured and sensed changes in power factor are used to modulate the combined magnetic flux produced in the motor field by two sets of RUN windings. A main RUN winding set, which normally couples fully with the a.c. power, is engineered to have sufficient ampere-turns to produce just enough magnetic flux to operate the motor with a light load and maintain a moderately high power factor. Motor driven load increases are determined by sensing a corresponding increase in the power factor of the main RUN winding set, whereupon power flow to a secondary RUN winding is proportionately increased. Considerable energy savings occurs when the motor drives a fluctuating load due to reduced magnetic field excitation under all but full load conditions, with the result that energy ordinarily wasted by eddy currents, copper losses, and poor power factor operation is considerably lessened. Other possible losses due to harmonic distortion of the a.c. power waveform brought about by the phase-delayed thyristor control of the second run winding power are mostly swamped out and masked by the parallel, always-on major power draw by the main run winding. A motor speed-sensitive switch or relay may divert current around the thyristor and fully excite the second run winding during motor start-up, thereby producing full available motor torque during start-up while negating any electrical stress on the control thyristor.
   














 Title Information Submit all comments and votes
 
Patent Text Patent PDF Print Page Summary File History
Plain text PDF images Print Summary File History
Drawing from US Patent 4806838
A.C. induction motor energy conserving power control method and apparatus - US Patent 4806838 Drawing
A.C. induction motor energy conserving power control method and apparatus
Inventor     Weber; Harold J. (313 Washington St., P.O. Box 6161, Holliston, MA 01746)
Owner/Assignee    
Patent assignment
All assignments
Publication Date     February 21, 1989
Application Number     07/197,566
PAIR File History     Application Data   Transaction History
Image File Wrapper   Patent Term   Fees
Litigation
Filing Date     May 23, 1988
US Classification     318/729 318/775
Int'l Classification     H02P 005/40
Examiner     Smith Jr.; David
Assistant Examiner    
Attorney/Law Firm    
Address
Parent Case    
Priority Data    
USPTO Field of Search     318/775 318/776 318/777 318/729 318/809 318/340 318/331 318/438
Patent Tags     a.c. induction motor energy conserving power control
   
Enter a comma (,) or semicolon (;) between multiple tag words/phrases.
Describe this patent:
 Amusing   
 Clever   
 Complex   
 Efficient   
 Historic   
 Important   
 Innovative   
 Interesting   
 Practical   
 Simple   
[no votes]
Patent WIKI

Share information and news about this patent, including information and news about the technology, inventors, company, ligation and licensing.

 References Submit all comments and votes
 
*references marked with an asterisk below are user-added references
 U.S. References
 
Add a new US reference:  
ReferenceRelevancyCommentsReferenceRelevancyComments
4533857
Chang
318/729
Aug,1985

[0 after 0 votes]
4453118
Phillips
318/779
Jun,1984

[0 after 0 votes]
4266177
Nola
318/810
May,1981

[0 after 0 votes]
4263540
Brandt
318/775
Apr,1981

[0 after 0 votes]
4052648
Nola
318/810
Oct,1977

[0 after 0 votes]
3819996
Habisohn
318/777
Jun,1974

[0 after 0 votes]
 Foreign References
 Other References
 Market Review Submit all comments and votes
   
Market Size
Estimate the gross annual revenues of the relevant market sector:
> $10B
$5B - $10B
$2B - $5B
$500M - $2B
$100M - $500M
$10M - $100M
$1M - $10M
$500K - $1M
$100K - $500K
< $100K
[No votes]
$0
 
$0   $2.5B   $5B   $7.5B   $10B
Market Share
Estimate the percentage of the relevant market sector this invention will capture:
75% - 100%
50% - 74.99%
25% - 49.99%
10 - 24.99%
5 - 9.99%
2 - 4.99%
1 - 1.99%
< 1%
[No votes]
0.0%
 
0%   25%   50%   75%   100%
Reasonable Royalty
What percentage of gross sales should the inventor or assignee be paid?
75% - 100%
50% - 74.99%
25% - 49.99%
10 - 24.99%
5 - 9.99%
2 - 4.99%
1 - 1.99%
< 1%
[No votes]
0.0%
 
0%   25%   50%   75%   100%
Public's "Guesstimation" of Royalty Value
Market SizeN/A[No votes]
xMarket ShareN/A[No votes]
xReasonable RoyaltyN/A[No votes]

N/A

License Availablity
If you are NOT the owner or assignee, answer here:
Yes, license is available for purchase

No, license is not currently available



[No votes]
License Availablity
If you ARE the owner or assignee, answer here:
Yes, license is available for purchase

No, license is not currently available



[No votes]
Competitive Advantage
Does this invention have a significant competitive advantage over similar technologies?
Yes

No



[No votes]
Most helpful competitive advantage comment
[No comments]

Commercial Alternatives
Are there viable commercial alternatives for this invention?
Yes

No



[No votes]
Most helpful commercial alternative comment
[No comments]

 Technical Review Submit all comments and votes
 Claims Submit all comments and votes
 


What I claim as the essence of my instant invention is:

1. Power control method for use with an electric induction motor,

comprising the steps of:

providing a source of alternating current electric power;

providing the motor with plural RUN winding means;

coupling a first RUN winding means with the source;

variably coupling a second RUN winding means with the source;

sensing reactive power factor of the electric power drawn from the source by the RUN winding means;

increasing the variable coupling when an increase in the power factor is sensed; and,

decreasing the variable coupling when a decrease in the power factor is sensed.

2. Power control method of claim 1 comprising the further steps of:

sensing instant voltage phase of the a.c. power coupled with the RUN winding means;

sensing instant reactive current phase of the a.c. power current flow coupled with the RUN winding means; and,

determining the reactive power factor by measuring the instant difference between the sensed voltage phase and the sensed current phase.

3. Power control method of claim 1 comprising the further steps of:

predetermining a minimum value of FULL LOAD motor power factor;

coupling substantially full a.c. power between the source and the second RUN winding means whenever the sensed power factor is higher than the predetermined minimum value power factor.

4. Power control method of claim 1 comprising the further steps of:

predetermining a minimum value of FULL LOAD motor power factor;

coupling substantially full a.c. power between the source and the second RUN winding means whenever the sensed power factor is higher than the predetermined minimum value power factor;

predeterming a maximum value of MINIMUM LOAD motor power factor;

coupling substantially no a.c. power between the source and the second RUN winding means whenever the sensed power factor is lower than the predetermined maximum value power factor; and,

proportionally coupling a.c. power between the source and the second RUN winding means for power factor values between the maximum value of MINIMUM LOAD motor power factor (minimum coupling) and the minimum value of MAXIMUM LOAD motor power factor (maximum coupling).

5. Power control method of claim 4 comprising the further steps of:

selecting an ampere/turns factor for the first RUN winding means suitable to produce sufficient motor field flux density to sustain operation with a minimum load coupled with the motor; and,

selecting an ampere/turns factor for the second RUN winding means suitable to produce sufficient motor field flux density such that when coupled fully with the source of a.c. power and combined with the flux density produced by the first RUN winding means, the combined flux density is sufficient to sustain operation of the motor when fully loaded.

6. Power control method of claim 1 comprising the further step of:

producing integral cycle control of any increase or decrease in variable coupling between the source and the second RUN winding means in which both half-cycles of any acted-upon full power cycle have about the same portion of ON time.

7. Power control method of claim 1 comprising the further steps of:

inductively coupling an ancillary pickup winding means with the first RUN winding means;

sensing the phase angle difference between the lagging voltage phase induced in the pickup winding means relative with the instant a.c. voltage phase coupled effectively across the first RUN winding means; and,

determining at least a relative value of reactive power factor thereform for producing control of the variable coupling between the source and the second RUN winding means.

8. Power control apparatus for use with an electric induction motor, comprising:

source of alternating current electric power;

induction motor means including at least a first RUN winding means and a second RUN winding means effective for producing motor field excitation;

means for coupling an inconstant load means with said motor means;

means for coupling the first RUN winding means with the electric power source;

means for producing variable a.c. electric power coupling between the source and the second RUN winding means;

means for sensing power factor; and,

means coupled with said power factor sensing means and said variable a.c. electric power coupling means, effective to produce a controlled increase in the coupling of a.c. power between the source and the second RUN winding means whenever an increase in power factor is sensed; and to produce a controlled decrease in the coupling of a.c. power between the source and the second RUN winding means whenever a decrease in power factor is sensed.

9. Power control apparatus of claim 8 further including means for starting the motor comprising:

START winding means;

means for initially coupling the START winding means with the a.c. power source;

means for decoupling the START winding means for the a.c. power source whenever the motor has attained substantial running speed; and,

means for coupling essentially full a.c. electric power between the source and the second RUN winding means whenever the START winding means is coupled with the a.c. power source.

10. Power control apparatus of claim 8 further comprising:

means for predetermining a non-linear relationship between the controlled increase and controlled decrease in the coupling of a.c. power with the second RUN winding relative with sensed changes in power factor; and,

means for coupling said predetermining means operatively with said means which produces said controlled increase and decrease.

11. Power control apparatus of claim 8 wherein said variable power coupling means comprises a.c. power phase control thyristor means coupled effectively between the a.c. power source and the second RUN winding means.

12. Power control apparatus of claim 11 wherein said variable power coupling means comprises means for producing integral power cycle symmetry of phase controlled a.c. power flow therethrough in which both half-cycles of any acted-upon full power cycle have about the same portion of ON time.

13. Power control apparatus of claim 8 wherein said power factor sensing means comprises:

means for sensing voltage zero-crossover of the a.c. power VOLTAGE PHASE cycle which essentially appears across the motor RUN winding means;

means for sensing current zero-crossover of the a.c. power CURRENT PHASE cycle which essentially appears flowing through the RUN winding means;

means coupled with said sensing means for determining an effective cycle-by-cycle phase delay signal indicative of the instant time difference between the sensed VOLTAGE PHASE cycle and the sensed lagging CURRENT PHASE cycle zero-crossover values; and,

means for adapting the determined phase delay signal coupled therewith into a control signal coupblable with the variable a.c. power coupling means and effective to produce an increase of a.c. power coupling therethrough whenever the determined time difference decreases, whilst a.c. power coupling therethrough decreases whenever the determined time difference increases.

14. Power control apparatus of claim 13 further comprising:

means for predetermining a minimum phase difference signal; and,

means for coupling the minimum phase difference signal with the measured phase delay signal adapting means, whereby essentially full a.c. power is coupled through the variable a.c. power coupling means whenever the measured phase difference is of a duration effectively less than the value of the minimum phase difference signal.

15. Power control apparatus of claim 8 further comprising:

means for combining the electromagnetic fields produced by the first RUN winding means and the second RUN winding means to provide motor field excitation.

16. Power control apparatus of claim 13 further comprising:

means for sensing CURRENT flow through the motor RUN winding means that includes providing a secondary pickup winding means tightly coupled magnetically with the RUN winding means resulting in an induced a.c. potential across the pickup coil means having a lagging phase relative with the voltage phase coupled across the RUN winding means; and,

means coupled with the pickup winding means effective for sensing zero-crossover of the induced a.c. potential.

17. Induction motor power control means comprising:

alternating current power source;

induction motor means including:

means for producing a first electromagnetic field;

means for producing a second electromagnetic field;

means for combining said electromagnetic fields;

means providing a rotatable output member;

means coupling said combined fields with said member and effective to produce rotation of said member;

means for coupling an inconstant load means with the output member;

means for coupling said first electromagnetic field producing means with said power source;

means for variably coupling said second electromagnetic field producing means with said power source;

means for sensing phase lag of the a.c. power flow between the electromagnetic field producing means and the power source relative with instant voltage phase of the power source; and,

means for determining a controlled increase in the efficacy of the variable coupling when the sensed phase lag decreases, and for determining a controlled decrease in the efficacy of the variable coupling when the sensed phase lag increases.

18. Power control means of claim 17 further comprising:

means for coupling substantially full a.c. power between said source and said second electromagnetic field producing means preferably as electrical contact set means coupled in shunt with said variable coupling means whenever said rotating member is running at less than a predetermined speed; and,

means for interrupting said full power coupling means whenever said rotating member is running higher than said predetermined speed.

19. Power control means of claim 17 wherein:

said means for sensing phase lag of the a.c. power which flows substantially through the electromagnetic field producing means further comprises induction pickup means inductively coupled with said field producing means resulting in an induced a.c. potential across the pickup coil means having a lagging phase relative with the a.c. voltage coupled across the field producing means.

20. Power control means of claim 17 further comprising:

said first electromagnetic field producing means comprising winding means predetermined to produce sufficient magnetic flux density to operate the motor means under minimum load; and,

said second electromagnetic field producing means comprising winding means predetermined to produce sufficient magnetic flux density which, when combined with the magntic flux density produced by said first field producing means, is sufficient to operate the motor means under full load.
 Description Submit all comments and votes
 


FIELD OF INVENTION

My invention relates to fractional and integral horsepower electric induction motors particularly of the kind manufactured in large volume for use on major appliances, refrigerators, and air conditioners which drive a load that routinely varies over a range between full load and less than full load. The principal object for my invention is to teach a controller which serves to produce considerable ENERGY SAVINGS through load-related reduction of power flow to the motor under all but the full load conditions.

BACKGROUND OF INVENTION

A.c. induction motors find ubiquitous application in major appliances, refrigerators, air-conditioners, and other machines of all sorts. Induction motors are cheap and simple to manufacture, and have an enviable record for long-term reliability without attention. Induction motors are relatively efficient electrically, when fully loaded. When lightly loaded, they also are notorious for wasting considerable amounts of electricity by consuming far more electrical power than what they are called upon to deliver as operating torque from their output shaft. It is this later rather troublesome shortcoming of common induction motors which needs improvement, and it is believed that this invention now can offer considerable relief.

To give some scope to the impact which induction motors have on society, one may consider that "125 million household refrigerators and freezers in operation today require the electricity from 30 standard (large sized) 1,000-megawatt power plants." ("Scientific American", Vol. 258, No. 4, April 1988, Page 56, in an article `Energy-efficient Buildings` by Arthur Rosenfeld and David Hafemeister.) Virtually all such refrigerators use induction motors. Considerable waste occurs because refrigerators do operate with varying mechanical load demands, while the typical hermetically sealed compressor assembly contains an induction motor which is sized to handle the worst case, ableit `normal`, compression load demand imposed upon it without frequent stalling. The result is simple: much of the time the motor is operating at less than full load and wasting a considerable amount of energy. Merely improving the dynamic operating efficiency of such a motor a mere ten-percent or so may result in the power saving equivalent to that afforded by 3 of the large 1,000 megawatt power plants, which are said to cost several billion dollars to construct. Some perspective of what this means can be obtained by considering an article which appeared in "New England Business" magazine, May 2, 1988, on pages 39-40 wherein the New England Power Pool (an organization which represents the region's utilities) estimates that by 1995 about 4,000-megawatts of additional generating capacity (on top of the present 23,000-megawatts of current capacity) would be needed just to keep up with demand growth. You also need to keep in mind that the highly controversial New Hampshire `Seabrook Unit I` and Plymouth, Mass. `Pilgram` nuclear power generating facitlities produce a combined power of only 1,820-megawatts: far less than what might be conserved through better induction motor operating efficiencies!Hence, improved efficiency in motor operation for refrigerators, air-conditioners, and other machines could down-scale the demand growth and alleviate some of the pressures which now exist in getting additional capacity on-line. Needless to say, greater improvements in motor efficiency can afford even more spectacular economic savings in power plant needs and reductions in attendant `wasteful` consumption of non-renewable fuel resources. Such further improvement in induction motor operating efficiency is precisely what is brought about by my instant invention.

Modern induction motors are often designed to operate with very high magnetic field flux densities in the stator structure. The result is near-saturation of the core material, with high eddy current losses. In addition, the windings may be designed to operate with high current densities that results in considerable heating due to winding resistance losses. Such winding losses are further aggravated in many cheaply designed appliance motors through the use of aluminum wire in lieu of the better and generally more efficient copper wire windings. Motor design my be dictated by competitive market conditions, resulting in agressive cost cutting. Cheap designs commonly translate into producing motors having high operating levels and the result may be a motor which operates with reasonable efficiency under full load, while under light load it is a wasteful of considerable energy. High temperature rise in a lightly loaded (or unloaded) motor is a sure sign indicating poor electrical operating efficiency. Modern motors operate very hot under all conditions of loading, which translates into poor overall performance efficiency when a widely varying load is being driven by the motor.

In earlier U.S. Pat. Nos. 4,052,648 and 4,266,177 Frank Nola describes how the a.c. pwoer fed to an induction motor might be controlled and therefore bring about some improvement in electrical efficiency. While he does measure the power factor of the operating motor and therefrom determines various control values for regulating the total power input of the motor run winding set by conventional phase-angle controlled firing of a triac, he greatly reduces and in some cases may negate any purported improvement by virtue of the severe a.c. power waveform harmonic distortion which his system reflects into the electric utility system. Nola also describes apparatus which is fraught with possibilities for maladjustment and drift, and wherein the correct operating points are not pre-established by design but rather they must be somewhat tailored to each unit which might be manufactured, resulting in a relatively labor-intensive and costly product. Column 3, lines 40-47 and column 6, lines 50-66 of U.S. Pat. No. 4,266,177 particularly describes the kind of twiddling that is needed to set the device's operating points relative with any particular motor's observed performance.

In yet another U.S. Pat. No. 4,533,857, Ten-Ho Chang et al show a motor controller which in effect measures the apparent current drawn by an induction motor and therefrom develops a variously retarded phase-angle control signal which fires a triac and thus modulates the total power flow to the motor. Like Nola, Chang et al shows the turn-ON of the full motor running current at some delayed point during each a.c. half-cycle and of course such an approach is fraught with severe harmonic distortion of the a.c. power flow (as reflected into the a.c. power lines), accompanied by resulting inefficiencies that may exceed any gain which could otherwise be obtained from use of the controller. Chang also does not recognize nor allow for the common characteristic of cheap induction motors wherein the lightly loaded (or even unloaded) apparent motor current may be only a little less than what full load motor current is. Although the motor current is lagging by perhaps 60 degrees or more, the actual measurable current which develops across the current transformer (Tr-2 in Chang's teaching) will be quite nearly the same as what develops under full motor load, when the motor current might lag by 30-degrees or less. A typical appliance motor, such as the General Electric type 5KH46JR15S has been found to draw about 7.9 amperes under full load, and yet continue to draw nearly 7 amperes of apparent current under NO-LOAD. Power factor also varied from about 80-85% under FULL-LOAD, to about 20-30% under NO-LOAD. This of course means that little change in current occurs and the circuit of Chang would operate ineffectively because slight changes in a.c. line voltage bring about more substantial changes in motor current than what changes in motor load produce. Chang is silent regarding compensation of apparent motor current changes which merely relate to commonplace a.c. line voltage fluctuations.

Noise, in the form of hum and buzz, are byproducts of stressful motor operating conditions. Magnetostrictive effects tend to produce substantial noise in the motor's structure, paticularly when stressed with the strong and abrupt changes in flux brought about by phase-delayed thyristor power control. These abrupt changes in induction fields can also set up other parasitic vibrations which, aside from being audibly annoying, can lead to premature structural fatigue of the motor's components (such as a vibrating loop of wire which eventually breaks off). Refrigerators and, to a lesser extent, air conditioners are frequently annoying sources of audible noise, albeit not particularly high in the sense of loudness on the commonly cited decibel scale for noise sources. Load related modulation of power flow to such motors may therefore serve to substantially abate such undesirable noise and result in a more acceptable product.

SUMMARY

A.c. induction motors provide a very economical and time proven source of mechanical power for driving major appliances, air conditioners, and other kinds of domestic and commercial machines. The time-proven dependability of induction motors is exceptional, and years of product engineering have, in most cases, resulted in a simple and cost effective configuration using few parts. It is thus desirable to retain all these advantages of the induction motor, while coming forth with a meaningful reduction in energy waste which occurs when the motor is less than fully loaded.

Production of electric power in America is reaching a point where the utility companies in many parts of the nation will soon be nearing 100% capacity. Unless more generating capacity is soon built, brown-outs, power grid failures, and other cataclysmic power distribution events are likely to occur with increasing frequency because no reserve power capacity is available or being readied. In view of the many years it takes to get even a single new nuclear or conventional electric power generating facility on-line means that there is no quick and simple solution to this looming energy-crunch dilemma. The building of additional power plants is also a fundamentally costly proposition. Such cost can be illustrated by a 500-megawatt gas-fired power plant located in Burrillville, R.I. which cost about $320-million dollars and by a $300-million dollar plant planned for Woonsocket, R.I. which is oil-fired and produces a mere 180-megawatts. It therefore behooves manufacturers of any kind of apparatus that tends to waste a lot of electricity, relative to what it really "uses" to drive a load, to develop more ENERGY EFFICIENT schemes. Paramount in this arena of everyday power wasters are the ubiquitous induction motors, such as found on most major appliances and in air conditioners. Induction motors are subject for being `singled out` as power wasters due to the hunge number of such motors which find extended operation every day in out modern society. They often power machines and appliances which regularly operate daily for substantial periods of time. It is common that induction motors are desired by appliance and machine designers for any application where the motor will see a lot of use, due to their time-proven reliability and nearly zero-maintenance requirements. They also lend themselves to hermetic refrigeration compressor assemblies because there are no brushes to wear out or cause contamination of the refrigerant (and oil).

Ordinary engineering practice produces induction motor designs which operate with high magnetic field flux densities, high current density through the windings, and with a minimum of structure. The General Electric `Form V` industry standard no. 4096 motor, typically used with Whirlpool and Kenmore brand electric clothes dryers is representative of such minimal modern design practice. Producing about 1/3 horsepower, this motor draws about 5.6 amperes (full load), while under reduced load the apparent motor current remains about 5 amperes, albeit the power factor decreases substantially. Clearly it would be advantageous if the apparent motor current were to reduce in approximate relation with load decrease, while at the same time the power factor remains about constant. Without dynamic control of the motor operating conditions, such relatively constant power factor operation is unattainable in induction motors of ordinary (and economimcally cheap) design. My instant invention now teaches a controller which can expedite such a desirable characteristic from virtually any cheap motor design through the mere inclusion of two sets of RUN windings, one of which is constantly excited to provide sufficient magnetic field flux to drive the motor's rotor under reduced load conditions, while the other RUN winding is increasingly excited as the load increases. The combining of the separate magnetic fields produced by the two RUN winding sets serves to provide a variable operating flux density in the motor which is just sufficient to keep the motor running without stalling under any load condition between that of reducd load and full load, while at the same time economizing on the use of electrical energy. The inclusion of the second set of RUN windings in even cheap motors such as the aforementioned General Electric `Form V` or a `Form J` style imposes no significant manufacturing difficulty because the meter inclusion of a second set of RUN windings is little different from the manufacturing practice involved in winding separate START and RUN windings in the first place: e.g., the maker merely winds three sets of windings (with the two RUN windings being wound with somewhat lighter gauge wire) instead of the usual two winding sets.

DESCRIPTION OF DRAWINGS

My invention is illustrated with nine sheets of drawings showing twelve figures.

FIG. 1 - Functional diagram showing principal elements which comprise my invention.

FIG. 2 - Waveforms depicting signals which are essential for understanding the advantageous performance of my invention.

FIG. 3 - Operational diagram showing general circuitry configuration which enables practice of my invention.

FIG. 4 - Waveforms depicting signals which are found in the circuitry configuration shown in FIG. 3.

FIG. 5 - Modification of general circuit configuration of FIG. 3 to include a memory device which modifies the controller's dynamic characteristics.

FIG. 6 - Graphical plot of change in thyristor gate control signal delay relative with motor current phase lag.

FIG. 7 - Hookup of electrical elements of a typical refrigerator with my invention's control circuits.

FIG. 8 - Circuit for providing limited thyristor control range for the secondary RUN winding.

FIG. 9 - Circuit which adapts the circuit of FIG. 8 to give a different thyristor phase delay control range.

FIG. 10 - Waveforms depicting signals which are found in the circuitry configurations of FIG. 8 and FIG. 9.

FIG. 11 - Circuit which adapts the circuit of FIG. 8 to skew the thyristor phase delay control range even into the next half cycle.

FIG. 12 - Inductive pickup produces a sample of the RUN windinging lagging current phase.

DESCRIPTION OF MY INVENTION

My invention involves the use of an induction motor of ordinary commercial design which has been engineered to include two (or more) RUN winding sets. Ordinarily, a main RUN winding set is coupled directly with the a.c. power source, while a secondary RUN winding set is variably coupled through a thyristor with the a.c. power source. The main RUN winding set is predetermined to have sufficient ampere/turn capacity to produce the flux density to excite the motor field and achieve normal operation for light motor loads. The secondary RUN winding set is further predetermined to have sufficient additional ampere/turn capacity to produce additional magnetic field flux density which adds with the main RUN winding set flux density so as to obtain reliable operation of the motor in the range between that of a light load, which is excited by the main RUN winding set alone, up to a condition of full motor load. The main RUN winding set ordinarily is of more substantial construction, thereby providing a greater portion of the motor's total magnetic field excitation. A.c. phase control, or variable-phase power control as referred to in my invention is used in the general context which is more particularly explained in technical literature, such as in the General Electric Co. (Syracuse, N.Y.) "SCR Manual", 4-th Edition, Edited by F.W. Gutzwiller (especially sections 9 and 10).

In FIG. 1 the a.c. induction motor 10 is provided with a rotor 10-1 (that functionally drives a mechanical load which is not shown), a START winding 10-2, a main RUN winding 10-3, and a secondary RUN winding 10-4. In addition, the motor may include a `start` capacitor 10-21 and a centrifugal `start` switch 10-22. The main RUN winding couples directly with the a.c. power line L1, and through the current phase sensor 40 with power line L2. Thus, the main RUN winding is fully excited by the a.c. line power.

A voltage phase sensor 30 couples via lines 32-1, 32-2 with the a.c. power lines L1, L2 and produces a `voltage phase` signal on line 34 that couples with the input PE of the phase detector 50. Current flowing through the main RUN winding 10-3 also couples through the current phase sensor 40 (via lines 42-1, 42-2) which produces a lagging `current phase` signal on line 44 that couples with the input PI of the phase detector 50.

The phase detector 50 determines the phase difference between the `voltage phase` (reference) signal and the lagging `current phase` (error) signal, producing a phase difference signal on line 52 that couples with a proportional controller 60. The proportional controller functions to determine a range of proportional power control signals on line 62 in response to changes in the phase difference signal provided on line 52. The proportional controller usually determines the outputted signal on line 62 to have a larger dynamic range of electrical degrees of change than what is presented on the input signal line 52. It is common that an induction motor may have a range of lagging current which extends between about -20 degrees and -60 degrees (for example). Meanwhile, it is usually desirable that the thyristor 20 be enabled to phase control the power coupled with the secondary RUN winding 10-4 over a much wider range: say from about -0 to -180 degrees. In fact, in may practical motor applications it may be desirable to obtain the full 180 degree control of the thyristor gate delay with a mere 10 to 20 degree variation in motor current phase leg. How this expanded phase control variation is produced is one of the important aspects of my invention which shall be further explained.

A d.c. power supply 70 provides a source of low d.c. voltage 72-1, 72-2 for operation of the attendant electronic circuits which comprise the operational circuits that make up my invention.

In FIG. 2 I depict some waveforms which may give better understanding of my invention's central improvement. The waveform AE is typical of the kind of a.c. power control afforded by the earlier teachings of the mentioned Nola and Chang et al patents. You will see that the abrupt phase controlled turn-ON portion AEAA of the waveform AEBA gives rise to sudden changes in a.c. line conditions, and that these changes occur for every power half-cycle such as shown AEAB for the other half-cycle AEBB. When the phase-delay is even greater (in excess of -90 degrees), the half-cycle waveforms AEDA, AEDB are shown to have even shorter and more severe turn-ON AECA, AECB pulse transistions which cause the sudden power changes reflected into the a.c. power line to look almost like `spikes`. The result of such operation is power loss caused by the severe harmonic distortion of the power line waveforms, resistance losses due to the high current surge once turn-ON occurs, electrical noise, `flickering` of lights connected with the same power line, and other undesirable effects.

With my invention, the main RUN winding (such as winding 10-3 of FIG. 1) is fully excited by the a.c. waveform RWA of FIG. 2. This results in a symmetrical power flow RWAA, RWAB having negligible distortion. The controlled secondary RUN winding (such as winding 10-4 of FIG. 1) is partially excited by a thyristor controlled power flow represented by waveform RWB. In this case, the half-cycle waves are abruptly turned-ON RWBA, RWBB by the thyristor, and when sufficiently delayed may even appear like short `spikes` RWBC, RWBD. When combined with the steady, full-cycle power draw RWA of the main winding, the controlled power flow RWB is merely a portion of the total power flow, as shown by waveform RWC. The composite waveform RWCA, RWCB represents that of the steady power draw RWA combined with the controlled power draw RWB. In a like way, the waveform portion RWCC, RWCD shows the combination of the steady power draw RWA with the abrupt spikes RWBC, RWBD of waveform RWB. You should take particular note of the minimal effect the phase controlled secondary RUN winding power draw has on the overall waveform character, as shown by the composite waveform RWC. The improvement is surprising and leads to a remarkable increase in operating efficiency of my invention over that of the prior art.

A circuit overview for my invention appears in FIG. 3 and includes an induction motor 10 and the attendant RUN windings 10-3, 10-4. The main RUN winding 10-3 couples through a resistor 10-31 to the a.c. power line: the result is a voltage drop across the resistor having a phase relationship which mirrors the lagging current flow through the main RUN winding. The secondary RUN winding 10-4 couples with a triac 120, which includes a gate 122 that may turn the triac ON to obtain power flow from the a.c. power lines L1, L2. The capacitor 126-1 and resistor 126-2 operate as a snubber network to protect the triac against problems which may arise due to fast-rising voltage changes which may occur when the driven load appears inductive (e.g., fast dv/dt changes which can produce erratic commutation). The additional set of switch contacts 10-41 operate in concert with the `start` switch contacts 10-22 and therefore are closed during motor starting. The contacts serve to bypass the heavy start-up current rush around the triac 120. This novel arrangement protects the triac from unecessary abuse and enables the use of a motor economical, smaller rated triac because it has to merely handle the secondary RUN winding current when the motor is properly running, and not the excess current drawn during motor starting.

Inputs `A` and `B` of a voltage zero-cross detector 130 couple essentially with the a.c. line voltage (waveform E of FIG. 4) which appears across the line terminals L1, L2. A brief pulse signal (waveform XE of FIG. 4) is produced on line 134 each time the voltage waveform EA, EB goes through zero EXA, EXB (e.g., two pulses per cycle). The voltage pulse on line 134 couples with the SET input of a flip-flop latch 150, which when `set` produces a HIGH logic level on the Q output

Inputs `A` and `B` of a current zero-cross detector 140 couple with the a.c. voltage signal (waveform I of FIG. 4) which develops as a voltage drop across resistor 10-31 due to (lagging) current flow in the run winding 10-3. As a result, two pulses (waveform XI of FIG. 4) are produced on line 144 for each a.c. current cycle. As depicted in the waveform XI, the pulses XIAA, XIAB coincide in time with the less-lagging current waveform IAA, IAB zero-cross coincidence IAXA, IAXB. When the current lags more (as brought on by reduced power factor, or lighter motor loading) as shown by waveform IBA, IBB the zero cross pulses XIBA, XIBB shift in relative time to coincide with the zero-crossover coincidence IBAX, IBXB of the current waveform. In practice of my invention, the timing of the current zero-cross pulses XIBA, XIBB constantly shift about in time relative with the voltage zero-cross pulses XEA, XEB. The pulses produced on lien 144 then couple with the RESET input of the flip-flop 150, and when reset has ocurred a LOW logic level appears on the Q output. As shown by waveform LQ of FIG. 4, the latch 150 /Q output 152 signal (waveform LAA of FIG. 4) is set LOW by the voltage zero-cross, is held low for a period of time, and then returns HIGH (depicted by waveform LBA1, LBB1 or LBA2, LBB2 of FIG. 4) when the current zero-cross pulse XIAA, XIAB (or XIBA, XIBB) occurs.

The /Q output 152 from latch 150 couples with the RESET input of a delay counter 160. The delay counter is clocked from pulses on line 182-1 and is predetermined to count-up to a preestablished value on bus 160-1 which produces a LOW output from the decoder 162 on line 164 that couples with the RESET input of counter 166. It is my intent that counter 160 `delays` the onset of counter 166 operation for a brief period of time which coincides with the least value of lag delay (e.g., highest power factor) which may be reasonably expected from the induction motor load. When RESET of counter 166 goes `low` the counter will be clocked and advance by 0 to 15 counts (for example) depending upon the time which lapses between the decoder producing a LOW signal on line 164, and the occurrance of the next zero-cross current pulse. If current lag is relatively large (as with a light motor load) counter 166 advances further than what has time to do if the motor is more heavily loaded and the current lag is less. Waveform CP of FIG. 4 shows the relationship between the clock pulses CPN and the variations in timing of the current signal produced reset of latch 150 as depicted by waveforms LBA1 and LBA2.

The advanced states on the counter 166 output bus 166-1 couple with the DATA input of an edge triggered latch 170. The input data is thus transferred to the output bus 170-1 the instant the /Q output of latch 150 goes HIGH. Latch 170 thusly serves to store the most recent count value while the counter 166 is recounting during the next time period. In order to produce symmetrical a.c. power control (which acts to reduce harmonic distortion and line imbalance losses) I provide that each controlled a.c. power cycle is self-completing: i.e., the first and second half-cycles are of about the same duration. A divide-by-two flip-flop 158 is clocked from the latch 150 Q output LOW-to-HIGH transistions, producing a pulse on line 158-1 the transistion of which is in-phase with the a.c. power voltage phase. The resulting pulse serves the CLOCK the edge-triggered data latch 172 that effectively transfers the byte signal on bus 170-1 to bus 172-1 once during every a.c. power voltage phase cycle.

A clock 180 produces a relatively high-frequency signal which is divided-down by the counter 182, producing a signal of necessary frequency to clock counters 160 and 166. In addition, a lower-frequency signal (say 1,920 hertz for 60 hertz a.c. power) couples with the CLOCK input of a 4-bit counter 184. The RESET input of the counter couples with the voltage zero-cross pulse signal on line 134, and is therefore reset at the onset of each a.c. power half-cycle. After reset, the counter quickly advances from count `0` to count `15` (binary 0000 to binary 1111) on bus 186. A comparator 174 receives an A-IN signal from the latch 172 output data bus 172-1 and a B-IN signal from the counter 184 output bus 186. When the counter 184 `counts-UP` to a binary weight signal that equates to the stored binary signal appearing on bus 172-1, coincidence of A=B in the comparator produces a HIGH pulse signal on output 174-1 that couples through the triac driver 124 to produce a signal on line 122 that operates the gate of the thyristor 120 to effectively turn the thyristor ON during the rest of the instant a.c. power half-cycle. Waveform TG in FIG. 4 depicts the thyristor gate turn-ON signal pulse timing relative with the plural clock pulses CPN. To interpret this waveform, it shall be seen that the pulse TGPA occurs at the onset of the a.c. power 180-degree half-cycle when the signal on bus 172-1 is binary 0000 because coincidence occurs in the comparator immediately at the start of the half-cycle. Conversely, if the signal on bus 172-1 has a binary weight of 1111 then counter 184 must count-UP 16 steps and thus coincidence in the comparator is delayed in time until near the end of the half-cycle, as depicted by pulse TGPB. Of course different byte signal weights on data bus 172-1 will produce pulses having timing intermediate of TGPA and TGPD (i.e., laying between about 0- and 180-degrees of electrical phase delay prior to thyristor 120 turn-ON.

A computer program can serve to develop the best clock frequency choices, as determined by specifying a range of minimum and maximum current phase delay (e.g., power factor range). Furthermore, the values can be optimized to restrict the dynamic range of thyristor control. For example, the values can be determined such that the thyristor always operates over a range of phase delays considerably less than the full 0- to 180-degree maximum capability. The following program may be utilized for such operative selections:

__________________________________________________________________________ 10 'DETERMINATION FOR CLOCK FREQUENCY OF PHASE-LAG COUNTER @:CFPLC.BAS V1.0 20 '(c) H. Weber -=- K1VTW -=- 4/11/88 -=- CP/M-80 -=- MBASIC-80 -=- DEC VT-180 30 GOSUB 650:GOSUB 660 35 PRINT:GOSUB 645 40 PRINT "THIS PROGRAM WILL QUICKLY DETERMINE THE CLOCK FREQUENCY FOR THE" 50 PRINT "PHASE-LAG ACCUMULATOR COUNTERS RELATIVE WITH DIFFERENT POWER FACTORS." 55 GOSUB 645 60 GOSUB 670 70 INPUT "LOAD Motor Model No. or Description: ",MN$ 80 IF LEN(MN$)>30 THEN 30 90 PRINT:INPUT "Enter MAXIMUM LOAD Current Lag in Degrees ",PFA 100 IF PFA>90 OR PFA<0 THEN 90 110 PRINT:INPUT "Enter MINIMUM LOAD Current Lag in Degrees ",PFB 120 IF PFB>90 OR PFB<0 THEN 110 130 IF PFA>PFB THEN 90 140 PRINT:INPUT "Accumulator Counter Division Factor `n` ",NF 150 IF NF<2 OR NF>256 OR NF>INT(NF) THEN 140 160 PRINT:INPUT "Enter Power Line Frequency (Hertz) ",LF 170 IF LF<25 OR LF>400 THEN 160 180 PRINT:INPUT "Enter MINIMUM Thyristor