Abstract: A circuit board with integrated fusing includes an insulating substrate having a circuit trace formed on a surface thereof, the circuit trace including a first circuit trace portion and a second circuit trace portion. A fusible link electrically connects the first circuit trace portion to the second circuit trace portion, the fusible link including a planar surface extending from the first circuit trace portion to the second circuit trace portion. A dielectric reflow encapsulates the fusible link on the planar surface from the first circuit trace portion to the second circuit trace portion.

Abstract: A circuit board with integrated fusing includes an insulating substrate having a circuit trace formed on a surface thereof, the circuit trace including a first circuit trace portion and a second circuit trace portion. A fusible link electrically connects the first circuit trace portion to the second circuit trace portion, the fusible link including a planar surface extending from the first circuit trace portion to the second circuit trace portion. A dielectric reflow encapsulates the fusible link on the planar surface from the first circuit trace portion to the second circuit trace portion.

Abstract: A motor control system for selectively controlling power from a power source to a load includes a PCB structure and a power converter affixed to the PCB structure that is operable to provide a controlled output power to the load. The motor control system also includes a standalone protection and control module mounted onto the at least one PCB structure so as to be electrically coupled therewith, the standalone protection and control module further including a front-end switching unit comprising a plurality of switching devices operable to selectively interrupt and control power flow from the power source to the power converter and to a bypass path that bypasses the power converter and a back-end switching unit positioned downstream from the front-end switching unit and comprising a plurality of switching devices operable to selectively interrupt power flow from the power converter and the bypass path to the load.

Abstract: A motor control system includes a VFD unit comprising a rectifier circuit having a plurality of phase legs each including thereon an upper switching unit and a lower switching unit, an inverter connected to the rectifier circuit by way of a DC link and having a plurality of switches therein controllable to provide a three-phase AC output power to a load, and a bypass relay unit comprising a bypass relay coupled to each of the phase legs of the rectifier circuit downstream from the lower switching unit. An isolation contactor unit is positioned between the inverter and the load and operable to selectively connect/disconnect the inverter to/from the load. The bypass relay unit is operable in a first and second positions to couple the rectifier circuit to the inverter and to couple the rectifier circuit to a bypass path that bypasses the inverter.

Abstract: A motor control system for selectively controlling power from a power source to a load includes a PCB structure and a power converter affixed to the PCB structure that is operable to provide a controlled output power to the load. The motor control system also includes a standalone protection and control module mounted onto the at least one PCB structure so as to be electrically coupled therewith, the standalone protection and control module further including a front-end switching unit comprising a plurality of switching devices operable to selectively interrupt and control power flow from the power source to the power converter and to a bypass path that bypasses the power converter and a back-end switching unit positioned downstream from the front-end switching unit and comprising a plurality of switching devices operable to selectively interrupt power flow from the power converter and the bypass path to the load.

Abstract: A motor control system for selectively controlling power from a power source to a load includes a PCB structure and a power converter affixed to the PCB structure that is operable to provide a controlled output power to the load. The motor control system also includes a standalone protection and control module mounted onto the at least one PCB structure so as to be electrically coupled therewith, the standalone protection and control module further including a front-end switching unit comprising a plurality of switching devices operable to selectively interrupt and control power flow from the power source to the power converter and to a bypass path that bypasses the power converter and a back-end switching unit positioned downstream from the front-end switching unit and comprising a plurality of switching devices operable to selectively interrupt power flow from the power converter and the bypass path to the load.

Abstract: An AC-AC power converter, such as a motor soft starter, includes an input connectable to an AC source with a disconnect switch, an output connectable to an AC load, and phase lines connecting the input and output to transmit power. In-line solid-state switching blocks are connected between line terminals and load terminals of the AC source and AC load, respectively, such that each phase line includes a solid-state switching block connected thereto. Free-wheeling solid-state switching blocks are connected to the load terminals at one end and together at a common connection at another end, such that each phase line includes a free-wheeling solid-state switching block connected thereto. Each of the in-line and free-wheeling solid-state switching blocks comprises a bi-directional switching block that selectively controls current and withstands voltage in both directions. The switching blocks also provide soft-starter functions, variable speed control, and integrated circuit breaker protection capability.

Abstract: A circuit board with integrated fusing includes an insulating substrate having a circuit trace formed on a surface thereof, the circuit trace including a first circuit trace portion and a second circuit trace portion. A fusible link electrically connects the first circuit trace portion to the second circuit trace portion, the fusible link including a planar surface extending from the first circuit trace portion to the second circuit trace portion. A dielectric reflow encapsulates the fusible link on the planar surface from the first circuit trace portion to the second circuit trace portion.

Abstract: A motor control system for selectively controlling power from a power source to a load includes a PCB structure and a power converter affixed to the PCB structure that is operable to provide a controlled output power to the load. The motor control system also includes a standalone protection and control module mounted onto the at least one PCB structure so as to be electrically coupled therewith, the standalone protection and control module further including a front-end switching unit comprising a plurality of switching devices operable to selectively interrupt and control power flow from the power source to the power converter and to a bypass path that bypasses the power converter and a back-end switching unit positioned downstream from the front-end switching unit and comprising a plurality of switching devices operable to selectively interrupt power flow from the power converter and the bypass path to the load.

Abstract: A motor control system includes a VFD unit comprising a rectifier circuit having a plurality of phase legs each including thereon an upper switching unit and a lower switching unit, an inverter connected to the rectifier circuit by way of a DC link and having a plurality of switches therein controllable to provide a three-phase AC output power to a load, and a bypass relay unit comprising a bypass relay coupled to each of the phase legs of the rectifier circuit downstream from the lower switching unit. An isolation contactor unit is positioned between the inverter and the load and operable to selectively connect/disconnect the inverter to/from the load. The bypass relay unit is operable in a first and second positions to couple the rectifier circuit to the inverter and to couple the rectifier circuit to a bypass path that bypasses the inverter.

Abstract: A motor control system for selectively controlling power from a power source to a load is provided. The motor control system includes at least one PCB structure and a plurality of protection and control components mounted onto the at least one PCB structure so as to be electrically coupled therewith. The plurality of protection and control components includes a power converter operable to provide a controlled output power to the load, a plurality of switching devices operable to selectively control power flow from the power source into the power converter and to bypass the power converter, and one or more protection devices configured to selectively interrupt current flow from the power source to the power converter during a fault condition. The motor control system also includes a housing enclosing the at least one PCB structure and the plurality of protection and control components.

Abstract: A motor control system for selectively controlling power from a power source to a load is provided. The motor control system includes at least one PCB structure and a plurality of protection and control components mounted onto the at least one PCB structure so as to be electrically coupled therewith. The plurality of protection and control components includes a power converter operable to provide a controlled output power to the load, a plurality of switching devices operable to selectively control power flow from the power source into the power converter and to bypass the power converter, and one or more protection devices configured to selectively interrupt current flow from the power source to the power converter during a fault condition. The motor control system also includes a housing enclosing the at least one PCB structure and the plurality of protection and control components.

Abstract: An AC-AC power converter, such as a motor soft starter, includes an input connectable to an AC source with a disconnect switch, an output connectable to an AC load, and phase lines connecting the input and output to transmit power. In-line solid-state switching blocks are connected between line terminals and load terminals of the AC source and AC load, respectively, such that each phase line includes a solid-state switching block connected thereto. Free-wheeling solid-state switching blocks are connected to the load terminals at one end and together at a common connection at another end, such that each phase line includes a free-wheeling solid-state switching block connected thereto. Each of the in-line and free-wheeling solid-state switching blocks comprises a bi-directional switching block that selectively controls current and withstands voltage in both directions. The switching blocks also provide soft-starter functions, variable speed control, and integrated circuit breaker protection capability.

Abstract: A system and method for estimating operating characteristics of an induction motor is disclosed. The system includes a motor control device that is electrically connectable between a motor and a power source. The motor control device includes a plurality of switching devices comprising at least one thyristor corresponding to a respective phase of the motor. The motor control device also includes a controller programmed to disconnect the power source from the motor for a predetermined time period following a first plurality of cycles of a mains phase voltage of the power source. The controller is further programmed to measure a back-emf voltage during the predetermined time period, estimate an operating characteristic of the motor from the measured back-emf voltage, and trigger the plurality of switching devices to reconnect the power source to the motor following estimation of the operating characteristic.

Abstract: A system for measuring soft starter current includes a current monitoring system having a controller and a current transfer device that includes a first solid state switching device. A first current sensor is coupled to the first solid state switching device and the controller to sense off-state current of the first solid state switching device. The controller is configured to determine an operational status of the first solid state switching device.

Abstract: A system and method for estimating operating characteristics of an induction motor is disclosed. The system includes a motor control device that is electrically connectable between a motor and a power source. The motor control device includes a plurality of switching devices comprising at least one thyristor corresponding to a respective phase of the motor. The motor control device also includes a controller programmed to disconnect the power source from the motor for a predetermined time period following a first plurality of cycles of a mains phase voltage of the power source. The controller is further programmed to measure a back-emf voltage during the predetermined time period, estimate an operating characteristic of the motor from the measured back-emf voltage, and trigger the plurality of switching devices to reconnect the power source to the motor following estimation of the operating characteristic.

Abstract: A system and method for automatically defining and tuning operating parameters for a motor control device with minimal or no operator input is disclosed. The system includes a motor control device electrically connectable to an AC motor and a controller that is programmed to define a motor start-up function based on a rated current of the motor, the motor start-up function comprising an initial torque factor and an initial ramp time. The controller also triggers switching devices of the motor according to the motor start-up function to inject current into the motor during a first trial run, monitors operating conditions of the motor and motor control device during the first trial run, modifies the motor start-up function based on the monitored operating conditions, and triggers the plurality of switching devices according to the modified motor start-up function to inject current into the motor during a subsequent trial run.

Abstract: A system and method for automatically defining and tuning operating parameters for a motor control device with minimal or no operator input is disclosed. The system includes a motor control device electrically connectable to an AC motor and a controller that is programmed to define a motor start-up function based on a rated current of the motor, the motor start-up function comprising an initial torque factor and an initial ramp time. The controller also triggers switching devices of the motor according to the motor start-up function to inject current into the motor during a first trial run, monitors operating conditions of the motor and motor control device during the first trial run, modifies the motor start-up function based on the monitored operating conditions, and triggers the plurality of switching devices according to the modified motor start-up function to inject current into the motor during a subsequent trial run.

Abstract: A system for measuring current includes a current monitoring system comprises a current sensor configured to sense a first current passing through a conductor and a voltage conversion device coupled to the current sensor and configured to receive a second current from the current sensor and convert the second current into a first voltage. A first scaling circuit is coupled to the voltage conversion device and configured to convert the first voltage to a second voltage proportional to the first current based on a first scaling factor, and a second scaling is circuit coupled to the voltage conversion device and configured to convert the first voltage to a third voltage proportional to the first current based on a second scaling factor, wherein the second scaling factor is different from the first scaling factor.

Abstract: A system for measuring soft starter current includes a current monitoring system having a controller and a current transfer device that includes a first sold state switching device. A first current sensor is coupled to the first solid state switching device and the controller to sense off-state current of the first solid state switching device. The controller is configured to determine an operational status of the first solid state switching device.