Abstract: A circuit for driving a motor of a compressor includes a microcontroller, which includes an op-amp, a comparator, a first serial interface, and a first dedicated pin. The op-amp amplifies a value indicating current in a power factor correction converter, which includes a power switch. The comparator asserts a comparison signal in response to the amplified value exceeding a reference value. The comparison signal is output on the first dedicated pin. A programmable logic device (PLD) includes a second serial interface in communication with the first serial interface and a second dedicated pin. The comparison signal is received on the second dedicated pin and the PLD receives control messages from the microcontroller via the second serial interface. The PLD sets a value in an off-time register based on a control message from the microcontroller. The PLD controls the power switch according to the comparison signal and the off-time register.

Abstract: A control system for a refrigeration system motor includes an angle determination module that generates an output rotor angle indicating a desired angle of a rotor of the motor. A control module controls the motor based on the output rotor angle. An estimator module determines an estimated rotor angle. A transition module generates a transition signal in response to convergence of the estimator module. Upon startup, the angle determination module generates the output rotor angle based on a first rotor angle. Upon generation of the transition signal, the angle determination module generates the output rotor angle based on the first rotor angle and the estimated rotor angle. After generation of the transition signal, the angle determination module reduces a contribution of the first rotor angle to the output rotor angle over time until the output rotor angle is based on the estimated rotor angle independent of the first rotor angle.

Abstract: A refrigeration system for a vehicle includes a compressor in fluid communication with a condenser and an evaporator. The compressor includes a variable speed motor and employs capacity modulation using refrigerant injection. The condenser and the evaporator include variable speed fans. The refrigeration system includes a battery to supply power to the refrigeration system. The battery is charged by one or more sources of power including the vehicle. The refrigeration system includes a control module configured to monitor one or more characteristics of the battery and to control one or more operating parameters of one or more of the compressor, the condenser, and the evaporator based on the one or more characteristics of the battery.

Abstract: A refrigeration system includes a startup mode control module that receives at least one parameter associated with operation of a compressor of the refrigeration system, determines whether the at least one parameter indicates that the compressor is in a high ambient temperature startup condition, and selects, based on the determination, between a normal startup mode and a high ambient temperature startup mode. A compressor control module operates the compressor in the normal startup mode in response to the startup mode control module selecting the normal startup mode, operates the compressor in the high ambient temperature startup mode in response to the startup mode control module selecting the high ambient temperature startup mode, and transitions from the high ambient temperature startup mode to the normal startup mode after a predetermined period associated with operating in the high ambient temperature startup mode.

Abstract: A control circuit for a motor of a compressor includes an inverter control module configured to control power switching devices of an inverter to generate output voltages from a DC power supply. The output voltages are applied to windings of the motor. A current control module is configured to generate voltage signals based on a torque demand. The inverter control module controls the power switching devices according to the voltage signals. A selector is configured to output one of an open loop torque value and a closed loop torque value as the torque demand. An open loop torque module is configured to generate the open loop torque value. The open loop torque module is configured to apply an upper limit to the open loop torque value. The upper limit is based on a voltage of the DC power supply.

Abstract: A control system for a refrigeration system motor includes an angle determination module that generates an output rotor angle indicating a desired angle of a rotor of the motor. A control module controls the motor based on the output rotor angle. An estimator module determines an estimated rotor angle. A transition module generates a transition signal in response to convergence of the estimator module. Upon startup, the angle determination module generates the output rotor angle based on a first rotor angle. Upon generation of the transition signal, the angle determination module generates the output rotor angle based on the first rotor angle and the estimated rotor angle. After generation of the transition signal, the angle determination module reduces a contribution of the first rotor angle to the output rotor angle over time until the output rotor angle is based on the estimated rotor angle independent of the first rotor angle.

Abstract: A PFC circuit is provided. A first bridge rectifier receives an AC voltage. A power converter includes a switch and receives an output of the first bridge rectifier, converts the output to a first DC voltage, and supplies the first DC voltage to a DC bus to power a compressor. A second bridge rectifier receives the AC voltage and bypasses at least one of the first bridge rectifier, a choke and a diode of the PFC circuit to provide a rectified AC voltage out of the second bridge rectifier to the DC bus to power the compressor. A control module controls operation of a driver to transition the switch between open and closed states to adjust a second DC voltage on the DC bus, where the second DC voltage, depending on the AC and second DC voltages, is based on the first DC voltage or the rectified AC voltage.

Abstract: A PFC circuit is provided. A bridge rectification circuit receives an AC voltage and generates a rectified AC voltage. A power converter converts the rectified AC voltage to a first DC voltage, where the power converter includes a switch and supplies the first DC voltage to a DC bus to power a compressor. A current sensor detects an amount of current. A control module, while operating in a correction mode: based on the rectified AC voltage, a phase angle of the rectified AC voltage, a second DC voltage of the DC bus, or the detected amount of current, control operation of the switch to transition between operating in a high activity mode and an inactive or low activity mode; transition the switch between open and closed states while in the high and low activity modes; and maintain the power converter in an OFF state while in the inactive mode.

Abstract: A drive includes: an inverter power circuit that applies power to an electric motor of a compressor from a direct current (DC) voltage bus; and a power factor correction (PFC) circuit that outputs power to the DC voltage bus based on input alternating current (AC) power. The PFC circuit includes: (i) a switch; (ii) a driver that connects a control terminal of the switch to a first reference potential when a control signal is in a first state and that connects the control terminal of the switch to a second reference potential when the control signal is in a second state; and (iii) an inductor that charges and discharges based on switching of the switch. The drive also includes a control module that generates the control signal based on a measured current through the inductor and a predetermined current through the inductor.

Abstract: A drive circuit is provided and includes a rectification circuit, a buck converter, a first inverter, and a second inverter. The rectification circuit is configured to rectify a first AC voltage signal to generate a rectified voltage signal. The buck converter is configured to downconvert the rectified voltage signal to a DC voltage signal, wherein the DC voltage signal is supplied to a DC bus. The first inverter is configured to convert the DC voltage signal to a second AC voltage signal and supply the second AC voltage signal to a compressor motor. The second inverter is configured to convert the DC voltage signal to a third AC voltage signal and supply the third AC voltage signal to a condenser fan motor. Peak voltages of the second AC voltage signal and the third AC voltage signal are less than peak voltages of the first AC voltage signal.

Abstract: A converter circuit is provided and includes: a first EMI filter connected to AC lines and includes one or more across-the-line capacitors; a charging circuit that receives power from the first EMI filter and limits an amount of current passing from the first EMI filter to a DC bus; and a PFC circuit of a compressor drive that provides PFC between an output of the charging circuit and a generated first DC voltage. The PFC circuit includes: a rectification circuit that rectifies the power from the AC lines or a charging circuit output; and a second EMI filter connected downstream from the rectification circuit and including a DC bus rated capacitor. The second EMI filter outputs a filtered DC signal based on a rectification circuit output. The PFC circuit, based on the second EMI filter output, outputs the first DC voltage to the DC bus to power the compressor drive.

Abstract: A drive includes an inverter power circuit that applies power to an electric motor of a compressor from a direct current (DC) voltage bus. A power factor correction (PFC) circuit outputs power to the DC voltage bus based on input alternating current (AC) power. The PFC circuit includes: (i) a switch having a first terminal, a second terminal, and a control terminal; (ii) a driver that switches the switch between open and closed states based on a control signal; (iii) an inductor that charges and discharges based on switching of the switch; and (iv) a circuit that outputs a signal indicating whether the switch is in the open state or the closed state based on a voltage across the first and second terminals of the switch.

Abstract: A circuit for driving a motor of a compressor includes a microcontroller, which includes an op-amp, a comparator, a first serial interface, and a first dedicated pin. The op-amp amplifies a value indicating current in a power factor correction converter, which includes a power switch. The comparator asserts a comparison signal in response to the amplified value exceeding a reference value. The comparison signal is output on the first dedicated pin. A programmable logic device (PLD) includes a second serial interface in communication with the first serial interface and a second dedicated pin. The comparison signal is received on the second dedicated pin and the PLD receives control messages from the microcontroller via the second serial interface. The PLD sets a value in an off-time register based on a control message from the microcontroller. The PLD controls the power switch according to the comparison signal and the off-time register.

Abstract: A method of operating an electric motor is disclosed. The method includes: determining a d-axis resistance of an electric motor and a Q-axis resistance of the electric motor as a function of a bulk current; determining a d-axis inductance of the electric motor and a Q-axis inductance of the electric motor as a function of the bulk current; generating an estimated flux of the electric motor based on the d-axis resistance of the electric motor, the Q-axis resistance of the electric motor, the d-axis inductance of the electric motor, and the Q-axis inductance of the electric motor; generating an estimated angle of the electric motor based on the estimated flux of the electric motor; and, based on the estimated angle of the electric motor, controlling switching of an inverter that powers the electric motor.

Abstract: A method of operating an electric motor is disclosed. The method includes: starting the electric motor in an open loop control mode; operating an estimator that estimates operating conditions of the electric motor; and, while the electric motor is in the open loop control mode, evaluating a first parameter of the estimator. The method further includes: in response to the evaluation of the first parameter, determining whether the estimator has converged; and in response to a determination that the estimator has not converged within a predetermined period of time after starting the electric motor, signaling a first fault condition.

Abstract: A control system for a motor in a refrigeration system includes an angle determination module configured to generate an output rotor angle indicative of a desired angle of a rotor of the motor. The control system controls current supplied to the motor based on the output rotor angle. The control system determines an estimated rotor angle of the motor. The angle determination module, upon startup of the motor, generates the output rotor angle based on a first rotor angle. Upon generation of a transition signal, the angle determination module generates the output rotor angle based on both the first rotor angle and the estimated rotor angle. Subsequent to generation of the transition signal, the angle determination module reduces a contribution of the first rotor angle to the output rotor angle over time until the output rotor angle is based on the estimated rotor angle independent of the first rotor angle.

Abstract: A method of operating an electric motor is disclosed. The method includes: starting the electric motor in an open loop control mode; operating an estimator that estimates operating conditions of the electric motor; and, while the electric motor is in the open loop control mode, evaluating a first parameter of the estimator. The method further includes: in response to the evaluation of the first parameter, determining whether the estimator has converged; and in response to a determination that the estimator has not converged within a predetermined period of time after starting the electric motor, signaling a first fault condition.

Abstract: A controller includes a voltage determination module, a bus voltage command module, and a power factor correction (PFC) control module. The voltage determination module determines a desired direct current (DC) bus voltage for a DC bus electrically connected between a PFC module and an inverter power module that drives a motor. The voltage determination module determines the desired DC bus voltage based on at least one of torque of the motor and speed of the motor. The bus voltage command module determines a commanded bus voltage based on the desired DC bus voltage. The PFC control module controls the PFC module to create a voltage on the DC bus that is based on the commanded bus voltage.

Abstract: A control circuit for a motor of a compressor includes an inverter control module configured to control power switching devices of an inverter to generate output voltages from a DC power supply. The output voltages are applied to windings of the motor. A current control module is configured to generate voltage signals based on a torque demand. The inverter control module controls the power switching devices according to the voltage signals. A selector is configured to output one of an open loop torque value and a closed loop torque value as the torque demand. An open loop torque module is configured to generate the open loop torque value. The open loop torque module is configured to apply an upper limit to the open loop torque value. The upper limit is based on a voltage of the DC power supply.

Abstract: A system includes a pulse-width modulation (PWM) module, a subtraction module, an error reducing module, and a summing module. The PWM module controls switching of an inverter that powers a motor. The PWM module controls the switching based on a first angle in a first mode and a second angle in a second mode. The subtraction module determines a difference between the first and second angles. The error reducing module (i) stores the difference when a transition from the first mode to the second mode is commanded and (ii) decreases a magnitude of the stored difference to zero. The summing module calculates a sum of the stored difference and the second angle. The PWM module controls the switching based on the sum in the second mode.