Abstract: Controllers for controlling hybrid motor drive circuits configured to drive a motor are provided herein. A controller is configured to drive the motor using an inverter when a motor commanded frequency is not within a predetermined range of line input power frequencies, and couple line input power to an output of the inverter using a first switch device when the motor commanded frequency is within the predetermined range of line input power frequencies.

Abstract: A drive circuit for a permanent split capacitor (PSC) motor includes an inverter, a solid state switch, and a contactor coupled in parallel with the solid state switch. The inverter is configured to supply variable frequency current to the PSC motor over a first duration. The solid state switch is configured to supply line frequency current to the PSC motor at the expiration of the first duration. The contactor is configured to supply the line frequency current to the PSC motor over a second duration beginning when the contactor closes after expiration of the first duration.

Abstract: An alternating current (AC) motor system and control methods are provided herein. The AC motor system includes a motor having a first rated horsepower and configured to be coupled to a power source, and a drive circuit configured to be electrically coupled between the power source and the motor. The drive circuit has a second rated horsepower that is lower than the first rated horsepower.

Abstract: Controllers for controlling hybrid motor drive circuits configured to drive a motor are provided herein. A controller is configured to drive the motor using an inverter when a motor commanded frequency is not within a predetermined range of line input power frequencies, and couple line input power to an output of the inverter using a first switch device when the motor commanded frequency is within the predetermined range of line input power frequencies.

Abstract: A motor control assembly for an electric motor. The motor control assembly is configured to be coupled to the electric motor, and includes a wireless communication module, an input power connector, and an inverter module. The wireless communication module is configured to receive a wireless signal from a system controller. The input power connector is configured to receive a DC voltage from an external power supply module. The inverter module is coupled to the wireless communication module and the input power connector. The inverter module is configured to convert the DC voltage to an AC voltage to operate the electric motor according to the wireless signal.

Abstract: A centrifugal fan is described. The fan uses a blade that is tapered across the span of the blade. The taper can be larger towards the end opposite of the inlet or larger at the inlet. The blade may be backwardly inclined and/or curved. The fan may also include a turning vane.

Abstract: In one embodiment, a permanent magnet rotor is provided. The permanent magnet rotor includes at least one permanent magnet and a substantially cylindrical rotor core including an outer edge and an inner edge defining a central opening. The rotor core includes a radius R, at least one pole, and at least one radial aperture extending radially though the rotor core from the outer edge to a predetermined depth less than the radius. The at least one radial aperture is configured to receive the at least one permanent magnet. The rotor further includes at least one protrusion extending into the at least one radial aperture, the at least one protrusion positioned substantially along a bottom of the at least one radial aperture and configured to facilitate retention of the at least one permanent magnet within the at least one radial aperture.

Abstract: An electric motor controller for controlling an electric motor and methods of determining a loss of phase condition for at least one phase of three-phase input power provided to an electric motor controller are provided. The controller is configured to obtain phase sample data representing an input power electrical characteristic for at least one phase of three-phase power received by the controller and receive direct current (DC) bus data representing a measured DC bus electrical characteristic. The controller is also configured to calculate a ratio between the phase sample data and the DC bus data, and determine that a loss of phase condition exists for a phase of the three-phase power when the ratio exceeds a predetermined threshold.

Abstract: Methods and systems for programming an electric motor are provided. An electric motor controller configured to be coupled to an electric motor is configured to control the electric motor to produce torque when direct current (DC) link voltage has up to 100% voltage ripple. The controller includes a first power input, a second power input, and a third power input, an energized line detection device, and a microprocessor. Each power input is configured to receive power from an alternating current (AC) power source. The energized line detection device is configured to sense which power input has received power from the AC power source and output an isolated signal. The microprocessor is coupled downstream from the energized line detection device and is configured to determine an operating profile for the electric motor based on the isolated signal.

Abstract: A dual-drive electric motor control system configured to drive a first electric motor and a second electric motor is provided. The system includes a shared front-end motor drive circuit for converting AC input voltage from an AC voltage source to a DC-link voltage. A first control system has a first inverter coupled to the shared front-end motor drive circuit, and a first switch device configured to couple the AC voltage source directly to the first electric motor. The system further includes a second control system having a second inverter coupled to the shared front-end motor drive circuit, and a second switch device configured to couple the AC voltage source directly to the second electric motor.

Abstract: A controller and methods for hybrid operation control of an electric motor in an electric motor system are provided. The controller is configured to receive a speed command for operating the electric motor, measure available voltage on an inverter configured to provide conditioned AC voltage to the electric motor, and determine a winding phase angle difference based on the received speed command and the measured available inverter voltage. The controller is also configured to adjust a phase angle difference between winding voltage commands for the switches of the inverter using the determined winding phase angle difference, and apply the winding voltage commands including the adjusted phase angle difference to the inverter switches to control the electric motor.

Abstract: In one embodiment, a permanent magnet rotor is provided. The permanent magnet rotor includes at least one permanent magnet and a substantially cylindrical rotor core including an outer edge and an inner edge defining a central opening. The rotor core includes a radius R, at least one pole, and at least one radial aperture extending radially though the rotor core from the outer edge to a predetermined depth less than the radius. The at least one radial aperture is configured to receive the at least one permanent magnet. The rotor further includes at least one protrusion extending into the at least one radial aperture, the at least one protrusion positioned substantially along a bottom of the at least one radial aperture and configured to facilitate retention of the at least one permanent magnet within the at least one radial aperture.

Abstract: An interleaved bridgeless power factor correction (PFC) converter-based motor drive system is provided. The system includes a first inductor coupled to a second inductor. The coupled first and second inductors are coupled to a first input configured to be coupled to a first line of an alternating current (AC) power supply. The system also includes a third inductor coupled to a fourth inductor. The coupled third and fourth inductors are coupled to a second input configured to be coupled to a second line of the AC power supply. The system further includes a digital active power factor correction (PFC) controller configured to cause current in at least one of the coupled first and second inductors and the coupled third and fourth inductors to be interleaved.

Abstract: An electric motor controller and methods of determining which input power line of a plurality of input power lines of a motor drive controller has been energized are provided. An electric motor controller configured to be coupled to an electric motor includes a plurality of power input lines configured to receive an alternating current (AC) input voltage from an AC power source, an energized line detection device configured to sense that a power input line has been energized by the AC power source, and configured to output an isolated signal, and a rectifier configured to convert the AC input voltage having a frequency to a direct current (DC) voltage. The controller also includes a computing device coupled downstream from the energized line detection device and configured to determine which input power line has been energized.

Abstract: A control system for a permanent split capacitor (PSC) motor is provided herein. The control system includes a motor drive circuit configured to condition AC input voltage from an AC voltage source to an output voltage for operating the PSC motor at a variable speed. The control system also includes a switch device configured to couple the AC input voltage from the AC voltage source directly to the PSC motor for operating the PSC motor at a fixed speed.

Abstract: Hybrid motor drive circuits configured to drive a motor are provided herein. A hybrid motor drive circuit includes an inverter coupled to the motor and configured to drive the motor when a motor commanded frequency is not within a predetermined range of line input power frequencies. The hybrid motor drive circuit also includes a first switch device configured to couple line input power to an output of the inverter when the motor commanded frequency is within the predetermined range of line input power frequencies.

Abstract: Protection of an electric motor drive controller from a transient voltage is described herein. The transient voltage is provided by an alternating current (AC) power line that includes a line conductor, a neutral conductor, and a ground conductor. The transient voltage protection system includes a first stage protection device coupled to an input of a rectifier of the motor drive controller. The first stage protection device is configured to suppress the transient voltage to prevent damage to the motor drive controller. The transient voltage protection system also includes a second stage protection device coupled between the rectifier and an inverter of the motor drive controller. The second stage protection device is configured to further suppress the transient voltage to prevent damage to the inverter.

Abstract: A controller configured to be coupled to an electric motor. The controller including a processor programmed to receive a signal indicating a stopping command of the electric motor, and control a current such that a capacitor coupled to the electric motor is not overcharged by regenerative energy when a stopping of the electric motor has commenced, wherein controlling the current includes one of the following: upon receiving the signal indicating the stopping command of the electric motor, ramping the current down below a threshold level, or upon receiving the signal indicating the stopping command of the electric motor, forcing the current to circulate in motor windings to prevent regeneration of energy in the capacitor.

Abstract: An electric motor controller for controlling an electric motor and methods of determining a loss of phase condition for at least one phase of three-phase input power provided to an electric motor controller are provided. The controller is configured to obtain phase sample data representing an input power electrical characteristic for at least one phase of three-phase power received by the controller and receive direct current (DC) bus data representing a measured DC bus electrical characteristic. The controller is also configured to calculate a ratio between the phase sample data and the DC bus data, and determine that a loss of phase condition exists for a phase of the three-phase power when the ratio exceeds a predetermined threshold.

Abstract: An air moving system including an electric motor, a load coupled to the electric motor, and a motor drive controller coupled to the electric motor is provided. A DC voltage generated from an AC input voltage provided to the electric motor tends towards zero at about twice a frequency of the AC input voltage. The motor drive controller includes an adjustment control module configured to receive a measurement of an instantaneous motor current value for the electric motor, determine a flux component value based on the instantaneous motor current value, and determine, based at least in part on the flux component value and a flux component demand value, an adjusted flux component demand value that causes the motor drive controller to adjust an operation such that an average flux component value based on the flux component value is substantially similar to the flux component demand value.