KR20240165952A - Active vibration control system - Google Patents

Abstract

The present disclosure provides a circulatory power generator system (100) incorporating a safety device component. The safety device component provides a braking system to the circulatory power generator, whereby the rotor of the circulatory power generator is brought to a rapid stop in response to a predetermined sensor output or a manual override of the circulatory power generator system.

Description

Active vibration control system

Cross-reference to related applications

This application claims priority to U.S. Provisional Application No. 63/322,858, filed March 23, 2022, which is incorporated herein by reference.

Fixed wing and rotary wing aircraft frequently experience unwanted vibrations within the aircraft fuselage. Circular force generators (CFGs) have been used to dampen or at least reduce these unwanted vibrations. However, the systems that control the CFGs can fail or operate in a way that also creates dangerous vibrations. These failures can take the following forms:

·Unsafe airframe resonance due to low or high rotor speed;

·Damage to the aircraft or CFG due to CFG force magnitudes greater than desired;

·Increased aircraft vibration caused by inaccurate CFG force phasing.

Additionally, current CFG systems do not provide for controlled stopping of the CFG rotor. In current CFG systems, the CFG rotor is allowed to spin freely until friction brings it to a stop. During this time, aircraft vibrations can cause the rotor to "re-energize", creating a "hula-hoop" effect and increasing airframe vibrations. The following disclosure provides improvements in the design and operation of a CFG system that overcomes the identified shortcomings and also rapidly brakes the CFG rotor to a safe speed or even a complete stop.

FIG. 1 illustrates a typical prior art CFG system (01). The CFG system (01) has three main components: a cyclic force generator (CFG) (5); a command circuit (30); and a monitoring system (50). The CFG (5) can have a plurality of rotors, each supporting a mass. The command circuit (30) provides primary control for the CFG (5), while the monitoring system (50) provides safety control for the CFG (5). The CFG (5) includes at least one electric motor (10). The command circuit (30) includes a force command digital bus (41), a command processor (32), a speed and/or position sensor (36a), a control power supply (38), an electrical circuit (39), an electromagnetic interference (EMI) filter with lightning protection (43), a low voltage control power supply (37), and a motor drive (34). The monitoring system (50) includes a second power source identified as a motor power source (52), an electrical circuit (53), a monitor processor (54), a vibration sensor (57), and a speed and/or position sensor (36b). Current from the motor power source (52) is transmitted to the motor drive (34) through a second EMI filter (63) with lightning protection. The monitoring system (50) provides safety control of 5 by interrupting the flow of current to the motor drive (34) by opening a relay (56) when an unsafe condition occurs (an incorrect force, vibration, or speed as determined by the monitor processor and the vibration, speed, and/or position sensors).

In one aspect, the present disclosure describes a cyclic force generator system (CFG system) including an electric motor, the electric motor having a rotor, a stator core, a primary winding, and a braking coil. The rotor supports a mass that rotates in accordance with the rotation of the rotor. The CFG system includes a command circuit and a monitoring system. The command circuit includes a command processor and a sensor that monitors the rotational speed and/or radial position of the mass or the rotor, the sensor being in electronic communication with the command processor. The command circuit also includes a first power source that provides current to the electric motor via a first electrical circuit. The monitoring system includes a monitor processor that controls a first relay. While the CFG system is operating, the first relay is closed and positioned within the first electrical circuit. The monitor processor provides control to the first relay such that opening of the first relay by the monitor processor removes current from the electric motor. While the CFG system is operating, a second relay is opened within a second electrical circuit (159). The monitor processor provides control to a second relay, the closure of which activates the braking coil. The monitoring system may also include a vibration sensor that provides data to the monitor processor.

In one aspect, the present disclosure describes a cyclic force generator system (CFG system) including an electric motor, the electric motor having a rotor, a stator core, a primary winding, and a braking coil. The rotor supports a mass that rotates in response to the rotation of the rotor. The CFG system includes a command circuit and a monitoring system. The command circuit includes a command processor and a sensor that monitors the rotational speed and/or radial position of the mass or the rotor, the sensor being in electronic communication with the command processor. The command circuit also includes a first power source that provides current to the electric motor via a first electrical circuit. The monitoring system includes a monitor processor that controls a first relay and a second relay. While the CFG system is operating, the first relay is closed and positioned within the first electrical circuit. While the CFG system is operating, the second relay is opened within the second circuit. The monitoring system also includes a second sensor that monitors the rotational speed and/or radial position of the mass or the rotor, the second sensor being in electronic communication with the monitor processor. The monitor processor provides control to the first relay, such that opening of the first relay by the monitor processor removes current from the electric motor. The monitor processor also provides control to the second relay, the closing of which activates the braking coil. The monitoring system may also include a vibration sensor that provides data to the monitor processor.

In one aspect, the present disclosure describes a cyclic force generator system (CFG system) including an electric motor, the electric motor having a rotor, a stator core, a primary winding, and a braking coil. The rotor supports a mass that rotates in accordance with the rotation of the rotor. The CFG system includes a command circuit and a monitoring system. The command circuit includes a command processor and a motor drive device in electronic communication with the command processor. The command circuit also includes a sensor that monitors a rotational speed and/or a radial position of the mass or the rotor, the sensor being in electronic communication with the command processor. The command circuit also includes a first power source that provides current to the electric motor via a first electrical circuit. The monitoring system includes a second power source that provides current to the motor drive device via a second electrical circuit. The monitoring system also includes a monitor processor that controls the first relay and the second relay. While the CFG system is operating, the first relay is closed and positioned within the first electrical circuit. While the CFG system is operating, the second relay is closed and positioned within the second circuit. The monitoring system also includes a second sensor that monitors the rotational speed and/or radial position of the mass or rotor, the second sensor being in electronic communication with the monitor processor. The monitoring system also includes a third opening relay positioned within the third electrical circuit. The monitor processor provides control for the first and second relays such that opening of the first and second relays by the monitor processor removes current from the electric motor. The monitor processor also provides control for the third relay, wherein closing of the third relay activates the braking coil. The monitoring system may also include a vibration sensor that provides data to the monitor processor.

In another aspect, the present disclosure provides a method of controlling a force generator system (CFG system). The CFG system includes an electric motor, the electric motor having a rotor, a stator core, a primary winding, and a brake coil. The rotor supports a mass that rotates in response to rotation of the rotor. The CFG system includes a command circuit and a monitoring system. The command circuit includes a command processor and a sensor that monitors a rotational speed and/or radial position of the mass or rotor, the sensor being in electronic communication with the command processor. The command circuit also includes a first power source that provides current to the electric motor via a first electrical circuit. The monitoring system includes a monitor processor that controls a first relay. During operation of the CFG system, the first relay is closed and positioned within the first electrical circuit. The monitor processor provides control to the first relay such that opening of the first relay by the monitor processor removes current from the electric motor. A second opening relay is positioned within the second electrical circuit (159). The monitor processor provides control of the second relay, closure of which activates the braking coil. The method operates the CFG system by rotating the rotor and mass while monitoring the rotational speed and/or radial position of the mass and/or rotor using the sensor. The monitoring system may also include a vibration sensor that provides data to the monitor processor. The command processor calculates the force generated by the mass and rotor as they rotate, and the command processor manages current to the electric motor. The monitor processor interprets the data received from the sensor, and energizes the braking coil by closing the second relay when the data from the sensor indicates an out-of-range condition for the rotational speed or position of the mass or the rotor position. The monitor processor may also interpret the data from the vibration sensor, and energize the braking coil in response to the interpreted data.

In another aspect, the present disclosure provides a method of controlling a force generator system (CFG system). The CFG system includes an electric motor, the electric motor having a rotor, a stator core, a primary winding, and a brake coil. The rotor supports a mass that rotates in response to rotation of the rotor. The CFG system includes a command circuit and a monitoring system. The command circuit includes a command processor and a sensor that monitors a rotational speed and/or a radial position of the mass or the rotor, the sensor being in electronic communication with the command processor. The command circuit also includes a first power source that provides current to the electric motor via a first electrical circuit. The monitoring system includes a monitor processor that controls a first relay and a second relay. The first relay is closed and positioned within the first electrical circuit. The second relay is open and positioned within the second circuit. The monitoring system also includes a second sensor that monitors the rotational speed and/or the radial position of the mass or the rotor, the second sensor being in electronic communication with the monitor processor. The monitor processor provides control for the first relay such that opening of the first relay by the monitor processor removes current from the electric motor. The monitor processor provides control for the second relay, wherein closing of the second relay activates the brake coil. The monitoring system may also include a vibration sensor that provides data to the monitor processor. The method operates the CFG system by rotating the rotor and the mass while monitoring the rotational speed and/or radial position of the mass and/or the rotor using the first and second sensors. The command processor calculates the force generated by the mass and the rotor as they rotate, and the command processor manages current to the electric motor. The monitor processor interprets data received from the second sensor and energizes the brake coil when data from the second sensor indicates an out-of-range condition for the rotational speed or position of the mass or the rotor position. The monitor processor may also interpret data from the vibration sensor and energize the brake coil in response to the interpreted data.

In another aspect, the present disclosure provides a method of controlling a force generator system (CFG system). The CFG system includes an electric motor, the electric motor having a rotor, a stator core, a primary winding, and a brake coil. The rotor supports a mass that rotates in response to rotation of the rotor. The CFG system includes a command circuit and a monitoring system. The command circuit includes a command processor and a motor drive device in electronic communication with the command processor. The command circuit also includes a sensor that monitors a rotational speed and/or a radial position of the mass or the rotor, the sensor being in electronic communication with the command processor. The command circuit also includes a first power source that provides current to the electric motor via a first electrical circuit. The monitoring system includes a second power source that provides current to the motor drive device via a second electrical circuit. The monitoring system also includes a monitor processor that controls the first relay and the second relay. The first relay is closed and positioned within the first electrical circuit. The second relay is closed and positioned within the second circuit. The monitoring system also includes a second sensor monitoring the rotational speed and/or radial position of the mass or rotor, the second sensor being in electronic communication with the monitor processor. The monitoring system also includes a third opening relay positioned within the third electrical circuit. The monitor processor provides control of the first and second relays such that opening of the first and second relays by the monitor processor removes current from the electric motor. The monitor processor provides control of the third relay, wherein closing of the third relay activates the braking coil. The monitoring system may also include a vibration sensor providing data to the monitor processor. The method operates the CFG system by rotating the rotor and the mass while monitoring the rotational speed and/or radial position of the mass and/or rotor using the first and second sensors. The command processor calculates a force generated by the mass and rotor as they rotate, and the command processor manages current to the electric motor. The monitor processor interprets data received from the second sensor and energizes the brake coil by closing the third relay when data from the second sensor indicates an out-of-range condition for the rotational speed or position of the mass or the rotor position. The monitor processor may also interpret data from the vibration sensor and energize the brake coil in response to the interpreted data.

Figure 1 provides a block diagram of a prior art CFG system.
FIG. 2 provides a block diagram of one embodiment of an improved CFG system with the brake coil circuit in an inactive state and the CFG system in a normal operating mode.
FIG. 3 provides a perspective view of the main internal components of an improved electric motor for use in the disclosed CFG system.
FIG. 4 provides a front view of the main internal components of an improved electric motor for use in the disclosed CFG system.
Figure 5 provides a cut-away view of an electric motor component taken along line 5 of Figure 4.
Figure 6 provides a cut view taken along line 6-6 of Figure 5.
Figure 7 is a cross-sectional side view illustrating an exemplary mechanical assembly of a circulating power generator. The embodiment of Figure 7 does not include a braking coil.
Figure 8 is an exploded perspective view illustrating an exemplary mechanical assembly of a circulating power generator.
Figure 9 is a partially exploded perspective view illustrating some of the motor components of the circulatory power generator.
Figure 10 provides a perspective view of the mass of the CFG installed on the rotor.
Figure 11 generally illustrates the unbalanced rotor of a circulating power generator and the vector force resulting from the rotation of the unbalanced rotor.
Figure 12 illustrates force generation using a cyclic force generator having two co-rotating unbalanced rotors to provide a CFG by generating a cyclic force with controllable magnitude and phase.
FIG. 13 provides a block diagram of one embodiment of an improved CFG system in which the brake coil circuit is active (i.e., energized) and the CFG system is in an inactive mode.

The drawings included in this application illustrate certain aspects of the embodiments described herein. However, the drawings should not be considered as exclusive embodiments. The disclosed subject matter is capable of considerable modification, alteration, combination, and equivalents in form and function, as will occur to those skilled in the art having the benefit of this disclosure.

The present disclosure may be more readily understood by reference to this detailed description. For simplicity and clarity of illustration, reference numerals may be repeated, where appropriate, among different drawings to indicate corresponding or similar elements. The following description should not be considered to limit the scope of the embodiments described herein. The drawings are not necessarily to scale, and certain parts may be exaggerated in proportion to better illustrate details and features of the present disclosure. Furthermore, the phraseology and terminology employed herein are for the purpose of description and should not be considered limiting, except as specifically stated.

Throughout this disclosure, the terms “about,” “approximately,” and variations thereof are used to indicate that the values include inherent variations or errors of the devices, systems, or measurement methods employed, as will be appreciated by those skilled in the art.

An improved CFG system (100) will now be described with reference to FIGS. 2 to 12. The CFG system (100) is suitable for use in connection with any structure or vehicle that benefits from a reduction in structural vibration.

Referring to FIG. 2, the CFG system (100) has three main components: a cyclic force generator (CFG) machine assembly (105); a command circuit (130); and a monitoring system (150). The CFG machine assembly (105) may have a plurality of rotors (112), each of which directly or indirectly supports a mass (113). See FIGS. 7-9. The command circuit (130) provides primary control for the CFG machine assembly (105), while the monitoring system (150) provides safety control for the CFG machine assembly (105), including the ability to override the command circuit (130). Thus, the monitoring system (150) provides safety during operation of the CFG system (100). The CFG machine assembly (105) includes at least one electric motor (110). In some embodiments, each electric motor (110) includes an integral braking coil (118), as described in more detail with reference to FIGS. 3 through 6 below. In other embodiments having multiple motors (110), a single braking coil (118) is sufficient.

Figures 7-9 illustrate an exemplary CFG machine assembly (105) without an integrated braking coil (118). Figures 3-6 illustrate an improvement to the electric motor (110) of the CFG machine assembly (105), wherein at least one stator core (114) of the electric motor (110) is modified to incorporate a braking coil (118).

As illustrated in FIGS. 7-10, a typical CFG machine assembly (105) includes one or more motors (110). Each motor (110) includes a stator core (114) and a rotor (112). In the illustrated embodiment, the stator core (114) is mounted to an end plate (115). The rotor (112) of each electric motor (110) is coupled to rotate about a stationary central shaft (119) by bearings (122) mounted within the motor (110). A rotating mass (113) is eccentrically connected to each rotor (112) such that rotation of the rotor (112) about the shaft (119) generates a "circular" force. The CFG machine assembly (105) also includes a command processor (132) that monitors the rotational position of the rotating mass (113). In the embodiments illustrated in FIGS. 7-10, the speed/position sensors (136a, 136b) take the form of Hall sensors (160b) that monitor the position of the target magnet (160a). FIG. 9 illustrates only the motor portion of the rotor (112) when the mass (113) is omitted. FIG. 10 illustrates the mass (113) supported by the rotor (112). The configurations illustrated in FIGS. 7-10 are merely one exemplary arrangement, and the specific number and positioning of the rotors and sensors used in the CFG machine assembly (105) may be modified based on various design considerations for the application environment. For example, the rotor (112) may directly or indirectly support the mass (113), or the rotor (112) may drive a separate rotor that directly or indirectly supports the mass (113).

The command circuit (130) provides primary operational control for the electric motor (110), thereby controlling the magnitude, phase and frequency of the force generated by the CFG machine assembly (105). The command circuit (130) includes a force command digital bus (141), a command processor (132), a speed and/or position sensor (136a), a control power supply (138), an electromagnetic interference (EMI) filter with lightning protection (143), a low voltage control power supply (137), a primary winding (116), and a motor drive (134).

As illustrated in FIG. 2, a speed and/or position sensor (136a) monitors the operation of the CFG machine assembly (105) and provides data to the command processor (132). The command processor (132) also receives radial speed, force command, force magnitude and phase data of the reference rotor (112) via the force command digital bus (141). Typically, the force magnitude and phase are calculated using the radial position of the rotor (112) as described below. The command processor (132) determines the desired position of each rotor (112) from the force commands and then compares this to the actual speed and rotor position measurements provided by 136a within a control loop to ensure that the actual rotor position and speed approximate the commanded position and speed so that the actual generated forces approximate the commanded forces with little error. The command processor (132) is preprogrammed to interpret the received data and then provide motor commands to the motor drive unit (134). The motor drive unit (134) changes the rotational speed and position of the rotor (112) within the CFG machine assembly (105) in response to the received commands by controlling the voltage and current supplied to the electric motor (110), thereby managing the phase and force magnitude generated by the CFG machine assembly (105).

As illustrated in FIG. 2, during normal operation of the CFG system (100), current is passed from the control power supply (138) to the EMI filter (143) and then to the low voltage control power supply (137). The current from the low voltage control power supply (137) passes through a closing relay (155) located in the circuit (139) before reaching the motor drive (134). Thus, opening the relay (155) provides the ability to remove low voltage power from the motor drive (134). Similarly, opening the relay (156) provides the ability to remove high voltage power supplied to the motor drive (134). As illustrated in FIG. 2, the monitor processor (154) controls the first and second relays (155, 156). Thus, two different means of removing power to the motor drive (134) (and the motor (110)) are provided for redundancy and safety. As used herein, the term "relay" includes solid state relays and other electronic switching devices, including but not limited to, devices for interrupting or completing an electrical circuit. For consistency, this disclosure generally refers to "relay" throughout. Typical operation of a CFG system (100) refers to applying an input voltage from a motor power source (152) to a motor drive device (134) within a predetermined range, depending on the type of CFG system (100). Most CFG systems utilize a 28 volt nominal or 270 volt nominal supply to the motor drive device (134).

With continued reference to FIG. 2, the CFG system (100) also includes a monitoring system (150) that provides safety control of the electric motor (110) and the CFG machine assembly (105) by interrupting the flow of electrical supply voltage to the motor drive device (134) and the electric motor (110) and providing electronic braking to the motor (110) via the braking coil (118) and circuit (159). The monitoring system (150) includes a second power source identified as a motor power source (152), a monitor processor (154), a vibration sensor (157), a speed and/or position sensor (136b), a braking coil (118) integrated into the electric motor (110), and a third relay (158) located within the circuit (159). As illustrated in FIG. 2, while the CFG system (100) is operating, the third relay (158) is kept open by the monitor processor (154) as long as the voltage supplied to the monitoring system (150) is greater than a predetermined level. Similarly, while the CFG system (100) is operating, the relays (155, 156) are kept closed by the monitor processor (154). In most cases, this voltage level will be determined by the operating conditions of the CFG system (100), i.e., the application. Since the third relay (158) is kept open during normal operation of the CFG system (100), a voltage loss will cause the closing of the relay (158) and the energization of the circuit (159), and the same voltage loss will cause the opening of the relays (155, 156).

As illustrated, the relay (158) comprises a two-pole switch that is actuated by the relay (158). However, the relay (158) may take the form of a solid-state switching electronic device or an electromechanical relay capable of energizing, i.e., completing, the circuit (159). The type of relay selected for the relay (158) will depend on the environment of the CFG system (100). Safety critical operations, such as an aircraft environment, may require a two-pole configuration. As described above, during normal operation of the CFG system (100), the monitor processor (154) interrupts current in the circuit (159) by holding the relay (158) in the open position. Thus, the relay (158) does not provide current flow unless actuated, i.e., closed, in response to the monitor processor (154). As illustrated in FIG. 13, operation of the relay (158) completes the circuit (159), which causes the rotor (112) to rotate within the braking coil (118) to effect braking action. Additional circuitry may be included as part of the unit self-test to verify continuity or other characteristics of the braking coil (118) and proper functioning of the brake control circuit. The configuration of the braking coil (118) is illustrated in detail in FIGS. 3, 4, and 6.

As illustrated in FIG. 2, the motor power supply (152) also provides current to the motor drive (134) through the circuit (153). Current from the motor power supply (152) passes through a second EMI filter (163) having lightning protection. Positioned within the circuit (153) between the EMI filter (163) and the motor drive (134) is a second relay (156). During normal operation of the CFG system (100), the monitor processor (154) maintains the relay (156) in a closed position. As with the relay (155), opening the relay (156) provides the ability to remove power from the motor drive (134). Again, the number and type of relays used to interrupt current to the motor drive (134) will vary depending on the application. FIG. 2 provides an exemplary embodiment of a circuit used to control and manage the operation of the CFG (100) including a braking coil (118) with relays (155, 156, and 158) in position for normal operation of the CFG system (100). Other circuit embodiments are possible. For example, the embodiment illustrated in FIG. 2 is particularly useful in aircraft. As such, this embodiment utilizes two relays (155, 156) to provide redundant safety during aircraft operation. However, the present invention will find applicability in any architecture where vibration cancellation is desired. In environments where redundancy is not required, the monitoring system (150) will perform satisfactorily with a single relay positioned to remove power from the motor drive unit (134). Where redundancy is not a requirement, a single speed and/or position sensor (136a) may replace a pair of speed and/or position sensors (136a, 136b). When a single sensor (136a) is used, appropriate electrical communication is provided to both the command processor (132) and the monitor processor (154). Likewise, FIG. 2 illustrates separate power supplies (138, 152) providing current to the motor drive (134) via separate relays (155, 156). However, the CFG (100) may be configured to use a single power supply with internal partitioning of the electrical circuitry to achieve the same operation. As a further option, the relays (155, 156) may be replaced by a single double pole relay or switch similar to relay (158).

In the embodiment of FIG. 2, the monitor processor (154) receives data from the speed and/or position sensor (136b) and from the vibration sensor (157). The monitor processor (154) is preprogrammed to interpret the received data and subsequently provide operational control to the relays (155, 156) and the relay (158). When the CFG machine assembly (105) experiences a fault or out-of-range condition as determined by the data provided by the vibration sensor (157) or sensor(s) (136b) (vibration, speed, rotor position, CFG forces which can be estimated from the speeds of all rotors and rotor positions), the monitor processor (154) interprets the received data and uses its internal programming to generate commands that direct the opening of the relays (155, 156) and the closing of the relay (158). See FIG. 13. Accordingly, the monitor processor (154) removes power from the motor drive device (134) to override the command circuit (130).

Upon closing of the relay (158), the rotation of the rotor (112) within the braking coil (118) generates a torque opposing the rotation of the rotor (112) due to the eddy current induced within the braking coil (118). Therefore, the rotation of the rotor (112) within the braking coil (118) generates a current which is subject to the electrical resistance of the circuit (159) and the optional resistor (165). Consequently, upon completion of the circuit (159) by closing of the relay (158), the braking coil (118) can generate a braking action on the rotor (112). The resulting braking action causes the rotor (112) of the CFG machine assembly (105) to quickly reach a safe speed or optionally come to a complete stop. In most embodiments, a complete stop of the rotor (112) is not necessary since reducing the angular speed to a safe speed will generally alleviate the unsafe condition that would trigger the closing of the relay (158) and the opening of the relays (155, 156). Additionally, as the rotor (112) decelerates to a safe speed, friction within the machine components will cause the rotor(s) (112) to come to a complete stop.

In the embodiment of FIG. 2, the monitor processor (154) also communicates with an external controller (not shown) via a bidirectional bus (151). The data exchanged via the bidirectional bus (151) causes the external controller(s) to interpret the data from the monitor processor (154) and instruct the monitor processor (154) to close relay (158) by corresponding opening of relays (155, 156) to activate the braking coil (118). Thus, the activation of the braking coil (118) and the deactivation of the electric motor (110) may occur in response to the data received from the external controller(s). For example, when installed on an aircraft, the external controller may take the form of an override switch suitable for operation by a flight crew member. Thus, the monitor processor causes the flight crew to temporarily deactivate the CFG system (100).

FIGS. 3 through 6 illustrate an electric motor (110) incorporating a braking coil (118). The electric motor (110) includes a rotor (112), a stator core (114), and a primary winding (116). As previously noted, the rotor (112) supports a rotating mass (113) (shown only in FIGS. 7 through 9). The primary winding (116) has a traditional three-phase configuration. Additionally, the electric motor (110) has been modified to incorporate a braking coil (118). The windings of the braking coil (118) are positioned on the same stator core (114) as the primary winding (116). As illustrated in FIG. 3, the braking coil (118) is positioned on the inner diameter of the stator core (114), and the primary winding (116) is positioned on the outer diameter of the stator core (114). An electrical insulating material (120) physically separates the braking coil (118) from the primary winding (116) in each slot of the stator core (114) to provide protection against short circuits between the braking coil (118) and the primary winding (116). The insulating layer (120) may be any suitable insulating material commonly used in electric motors. One example of an insulating material suitable for use as the insulating layer (120) is Nomex® 410, sold by Dupont. Nomex® 410 is a family of insulating papers that provide high specific dielectric strength, mechanical toughness, flexibility and resilience. However, any insulator commonly used in electric motors will suffice to provide the required dielectric protection.

The braking coil (118) is a single winding that occupies about 10% to about 50% of all slots of the stator. As a result, incorporating the braking coil (118) into the electric motor (110) does not significantly increase the overall size of the electric motor (110). Additionally, the braking coil (118) uses a wire gauge and conductor length sufficient to provide braking action to the rotor (112) after the relay (158) is closed and the circuit (159) is completed. The wire gauge and length combined with the rotation of the rotor(s) (112) generates a current in the circuit (159). The resistance to current flow within the circuit (159) and the braking coil (118) is sufficient to overcome the inertial energy of the rotating rotor(s) (112), so that the rotor(s) (112) reach a safe speed or come to a complete stop within a predetermined time upon closing the relay (158) and opening the relays (155, 156). In order to limit the size of the electric motor (110), the wire gauge and length are not sized to overcome the torque generated by the primary winding (116) when the relays (155, 156) are closed, i.e., when the primary winding (116) is energized.

The actual size of the electric motor (110), including the braking coil (118), including the wire gauge and length, will be determined by the size and mass of the rotor(s) (112) and the operating environment of the CFG system (100). In particular, the braking coil (118) should be designed to use a wire gauge and length that provides the necessary electrical resistance such that the resulting current generated by the braking coil (118) after the relay (158) closes is less than a value that dissipates the energy generated during the braking event to an acceptable level of heat. Optional additional resistors (165) may be incorporated into the braking coil circuit (159), if desired, to ensure adequate resistance, heat dissipation, and operating limits of the components within the circuit (159). In some embodiments, incorporating additional resistors (165) or other electrical components within the circuit (159) limits the current within the circuit (159) to a range of about 8 to 15 amperes. In most embodiments, about 10 amperes is sufficient. The resistor (165) is applied in series with the braking coil (118) when in use. However, in some embodiments, a single winding of wire of the braking coil (118) will provide the required braking torque and the ability to dissipate the heat generated during a short duration, high energy stopping event. The selection of the gauge, wire length, and overall size of the braking coil (118) can be determined using knowledge of the inertial energy generated by the rotor (112) during electric motor operation.

Therefore, to provide the desired safe operation of the CFG machine assembly (105) after a detected fault or out-of-range condition, the braking coil (118) must overcome the inertial torque generated by the rotor(s) (112) and cause the rotor(s) (112)(s) to reach a safe speed or come to a complete stop within a period of time that does not cause damage to the CFG machine assembly (105) or the supporting structure. As mentioned above, the braking coil (118) can be designed to brake the rotor (112) rotating at 30 Hz and reduce its speed to less than 5 Hz within 0.5 seconds. Braking torque, are as follows:

Here, k _t is the torque constant of the brake coil (118), i is the current in the brake coil (118), ε is the back electromotive force (emf), and R is the total resistance of the brake circuit (relay (158), circuit (159), and brake coil (118)). As the rotor (112) rotates, a back electromotive force (or “counter” emf) is generated in the brake coil (118). The closing relay (158) essentially converts the rotor (112) and brake coil (118) into a generator, causing current to flow through the resistive elements of the circuit (159). As with any generator, the rotating rotor (112) must overcome the resistance generated by the eddy currents in the brake coil (118) and the electrical resistance in the circuit (159) in order to continue to rotate. In this case, the resulting resistance dissipates the inertial torque of the rotor(s) (112), resulting in a deceleration of the rotor(s) (112). Note that the inductance of the braking circuit is not included in the calculations, as it is usually a minor factor. The torque can also be expressed as a function of the back-EMF constant k _b and the rotor speed ω:

As the speed decreases, the back EMF decreases, so the braking torque decreases as the rotor slows down, i.e., the current generated by the braking coil (118) decreases. Bearing friction causes the rotor (112) to stop at the reduced speed. The motor constants (k _t , k _b ) are characteristics of the braking coil design that depend on the wire gauge, number of turns, magnet strength, air gap relative to the rotor, and the length and diameter of the motor (110). Therefore, the braking torque for a given motor is proportional to the rotor speed and the resistance of the braking circuit. Increasing the number of coil turns and wire length or increasing the strength of the motor magnets will result in a higher braking torque, which will cause the rotor to decelerate more quickly. A lower resistance (R) will result in more current flowing in the circuit, but will decrease the duration of the braking event. Note that the inductance has been omitted again for the reasons stated earlier. Finally, selective selection of the wire gauge of the braking coil (118) can affect R, k _t and k _b to control the resulting current in the braking coil (118) and circuit (159).

As illustrated in FIG. 2 and described above, during normal operation of the CFG (100), the relays (155, 156) remain closed, thereby energizing the motor drive device (134) and the electric motor (110) to drive the CFG mechanical assembly (105). Since the relay (158) remains open during normal operation of the CFG (100), the braking coil (118) remains inactive. Thus, during normal operation of the CFG (100), the braking coil (118) and the rotor (112) function as an electric generator with no electrical load. The braking coil (118) generates an open-circuit voltage having an amplitude and frequency proportional to the speed. However, since there is no electrical load, no current is generated in the braking coil (118) or the circuit (159). As a result, the braking coil (118) does not apply electromagnetic braking torque to the rotor (112) during normal operation of the CFG machine assembly (105).

In most embodiments, a voltage sensor (167) provides an additional safeguard to the operation of the CFG system. The voltage sensor (167) monitors the voltage of the current flowing from the EMI filter (163) to the monitor processor (154) and reports data regarding the voltage of the current to the monitor processor (154). In the event that the voltage sensor (167) reports a voltage drop below a predetermined value to the monitor processor (154), the monitor processor (154) is programmed to automatically initiate an abort routine that includes closing the relay (158) to energize the circuit (159) and also opening the relays (155, 156) to override the command circuit (130). Typically, the voltage to the monitor processor (154) is in the range of about 1.1 volts to about 3.6 volts, depending on the processor input voltage requirements. If the voltage drops to within 5% of the desired lower limit, an automatic abort routine of the monitor processor (154) is triggered. If the voltage exceeds the desired upper limit for a period of approximately 0.05 seconds, an automatic shutdown routine of the monitor processor (154) is triggered. Thus, in the event that there is a possibility of loss of the monitoring system (150) due to improper voltage at the monitor processor (154), the programming of the monitor processor (154) provides for a safe shutdown of the CFG system (100).

Likewise, optional integration of a temperature sensor (169) improves the safe operation of the CFG system (100). Both the command circuit (130) and the monitoring system (150) may include temperature sensors as key components. For example, in the command circuit (130), the temperature sensor (169) is associated with the command processor (132) and the motor drive (134). In the monitoring system (150), the temperature sensor (169) is associated with the monitor processor (154). Additional temperature sensors may be associated with the stator core (114) or the electric motor (110). Each temperature sensor (169) communicates data directly or indirectly with the monitor processor (154). The monitor processor (154) is preprogrammed with the temperature range of each temperature sensor appropriate to the associated components and the operating conditions of the CFG system (100). If the monitor processor (154) determines that the sensed temperature of the relevant component is outside a predetermined range, the monitor processor (154) energizes the circuit (159) by closing the relay (158) and also overrides the command circuit (130) by opening the relays (155, 156). Additional temperature sensors (169) having the same capabilities may be incorporated into the CFG system (100) as needed to provide for safe shutdown of the CFG system (100).

Referring to FIG. 2, the ability of the CFG system (100) to ensure safe operation of the CFG machine assembly (105) is described. As reflected in FIG. 2, the ability of the monitoring system (150) to override the command circuit (130) provides the desired safe control for the CFG machine assembly (105). During operation of the CFG system (100), the monitor processor (154) continuously receives data from the vibration sensor (157) or the speed/position sensor (136b) and uses preprogrammed software to interpret this data to determine if a fault condition exists. (As previously noted, in situations where redundancy is not required, the sensor (136a) may be configured for use in the monitoring system (150). Upon detecting a fault condition that requires the CFG machine assembly (105) to be disabled, or upon receiving an override command from an external source, the monitor processor (154) directs the opening of relays (155, 156) and the closing of relay (158). See FIG. 13. The opening of relays (155, 156) prevents the motor drive (134) from controlling the motor (110) by removing current from both the motor drive (134) and the motor (110). Thus, upon removing power from the motor drive (134), the motor (110) begins to free rotate. The closing of relay (158) completes the circuit (159) and allows interaction of the rotor (112) and the braking coil (118) to generate current within the circuit (159). As previously described, the generation of current (159) creates a resistance to rotation of the rotor (112) associated with the braking coil (118). Optionally, the monitor processor (154) may be programmed to provide a time delay between the determination of a fault requiring the interruption of the CFG (100) and the actual implementation of the interruption process. This programmed delay allows the monitor processor (154) the option to determine if the detected fault is transient in nature.

As previously mentioned, closing the relay (158) energizes the circuit (159) and applies an electrical load to the brake coil (118). During this time, the brake coil (118) and the rotor (112) continue to function as an electrical generator. However, when an electrical load is present, the brake coil (118) and the rotor (112) convert kinetic energy into electrical power to power the circuit (159), which power is dissipated as heat energy generated when the current flows through the electrical resistance. In the example provided by FIG. 2, the current flowing in the brake coil (118) is a function of the rotor speed, the brake coil motor constant, the brake coil winding resistance, and any additional resistance present in the brake control circuit of the monitoring system (150), i.e., elements within the circuit (159) such as the relay (158), the optional resistor (165), and the brake coil (118). The electromagnetic braking torque applied to the rotor (112) is proportional to the current flowing in the braking coil (118), as determined by the above formula. Higher current results in greater torque and faster deceleration, but increased electrical and thermal stresses on the relay (158), circuit (159), and braking coil (118) must be considered as limiting factors. As previously mentioned, the winding resistance of the braking coil (118) may be sufficient to limit the current; however, it may be desirable to add an optional resistor (165) to the circuit (159) in series with the braking coil (118) to further limit the current.

As previously described, the default state of the relays (155, 156) is the open position. Similarly, the default state of the relay (158) is the closed position, as illustrated in FIG. 13. Therefore, during normal operation, the voltage supplied to the command circuit (130) and the monitor system (150) ensures that the relays (155, 156) are maintained in the closed position and the relay (158) is maintained in the open position, as illustrated in FIG. 2. Therefore, a loss of power from the motor power supply (152) to the monitoring system results in the CFG system (100) reverting to a safe mode, as illustrated in FIG. 13.

Accordingly, the CFG system (100) and the method of operating the CFG system (100) provide the ability to reduce the rotational speed of the rotor (112) to a safe range in response to a sensed or calculated unsafe condition. The sensed unsafe condition may be determined by the monitor processor (154) when interpreting data received from the sensors (136b) and the vibration sensors (157). Such conditions may include one or more of overspeed or underspeed of the rotor(s) (112), incorrect rotor (112) position, excessive vibration, or a phase of the generated CFG force or forces that are determined to be out of range or calculated. An out of range condition for any of these factors may be identified by the monitor processor (154) as a criterion for overriding the command system (130) and energizing the circuit (159).

As is known to those skilled in the art, CFG forces and phases can be calculated using rotor speed and position. For example, the index pulses generated by sensors (136a or 136b) can be used to provide estimates of the speed and phase position of each rotor, which can then be used to estimate forces. Equation (1) below illustrates a method for calculating the force of one rotor.

F=mrω ² cos(ωt+φ) Mathematical formula (1)

In equation (1), m is the mass of the mass (113), r is the radius of rotation of the mass (113), ω is the rotational velocity, t is time, and φ is the rotational phase position of the mass (113). FIG. 11 provides a visual representation of the force generated by the CFG. The determination that the CFG force and phase are out of range may occur within the pre-programmed monitor processor (154) or by another pre-programmed controller located external to the monitoring system (150) but communicating with the monitor processor via the bidirectional command bus (151). FIG. 12 illustrates a method for calculating the force output of two rotors (CFGs). In FIG. 11, the phase (φ) of the first unbalanced mass within the CFG with respect to the second unbalanced mass within the CFG (i.e., the relative phase) determines the magnitude of the resulting torque vector. The resulting forces for the zero and maximum force cases on the unbalanced masses of the CFG are illustrated in Fig. 12. When the force is zero, the relative phase (φ ₂ -φ ₁ ) is 180 degrees, and the resulting force torque vector has a magnitude of zero. When the force is maximum, the relative phase (φ ₂ -φ ₁ ) is 0 degrees, and the resulting torque vector has a maximum magnitude of 2|F|. For relative phases (φ ₂ -φ ₁ ) between 0 and 180 degrees, the magnitude of the resulting torque vector is between 0 and the maximum value. The collective phase (γ) of the torque vectors can be varied to provide a phase among the CFGs. By controlling the phase (φ) of each unbalanced mass in the CFG, the magnitude and absolute phase of the torque vectors generated by the CFG can be controlled.

Accordingly, the present invention comprises a method of safely shutting down a CFG system (100). The method utilizes a monitoring system (150) to identify an out-of-range criterion as described above, which requires overriding the command circuit (130) and causing the rotor (112) to return to a safe speed. In the method, data from at least one speed and/or position sensor (136a or 136b) provides data to a monitor processor (154). Additionally, a vibration sensor (157) provides data regarding vibration within a structure supporting the CFG system (100). If the monitor processor (154) determines that an out-of-range condition exists for any of the monitored conditions, the monitor processor closes a relay (158) to energize the circuit (159) and opens the relays (155, 156) to override the command circuit. As described above, the resulting current within the circuit (159) generates a torque opposing the rotation of the rotor (112), slowing the rotor (112) to a safe speed. Below a certain speed, friction within the CFG machine assembly (105) causes the rotor (112) to stall. Optionally, a manual override may be provided to the operator of the structure supporting the CFG system (100), so that a manual stop may be performed without waiting for the monitor processor (154) to override the command circuit (130). The manual stop may be performed by the operator of the structure supporting the CFG system (100) directly sending a command to the monitor processor (154) via the circuit (151), or by removing power provided by the motor power supply (152) from the monitoring system (150).

Other embodiments of the present invention will be apparent to those skilled in the art. Accordingly, the foregoing description is intended only to enable and illustrate the general use and method of the present invention. Accordingly, it is intended that the following claims define the true scope of the invention.

Claims (59)

It is a circulation power generator system,
An electric motor (110), the electric motor having a rotor (112), a stator core (114), a primary winding (116), and a braking coil (118);
A mass (113) supported by the rotor;
As a command circuit (130), the command circuit:
Command processor (132);
A sensor (136a or 136b) for monitoring the rotational speed and/or radial position of a mass or rotor, the sensor being in electronic communication with a command processor;
A command circuit comprising a first power supply source (138), the first power supply source providing current to an electric motor through a first electric circuit (139);
A monitoring system (150) is included, wherein the monitoring system:
As a monitor processor (154), the monitor processor controls a first relay (155), the first relay is positioned within the first electrical circuit, and the monitor processor provides control to the first relay such that opening of the first relay by the monitor processor removes current from the electric motor;
A circulating power generator system comprising a second relay (158), the second relay being positioned within a second electrical circuit (159), the monitor processor providing control over the second relay, wherein closure of the second relay activates a braking coil. In the first paragraph, the braking coil:
A braking coil winding supported by a stator core, the braking coil winding forming a secondary winding separate from the primary winding on the stator core;
A circulating power generator system comprising an insulator separating the windings of the braking coil from the primary winding. A circulating power generator system, wherein in the second paragraph, the braking coil winding has a length and gauge sufficient to induce current in the second electrical circuit when the second relay is closed. A circulating power generator system, wherein, in the first aspect, when the second relay is closed, the second electric circuit has an electrical resistance, and when the second relay is closed, the resistance provided by the braking coil winding, when combined with the resistance of the second electric circuit, produces a braking action on the rotor of the electric motor. In the first paragraph,
When the second relay is closed, the second electrical circuit has electrical resistance,
When the second relay is closed, the braking coil winding has electrical resistance;
A circulating force generator system in which the resistance of the second electric circuit in combination with the resistance of the braking coil produces a braking action on the rotor of the electric motor sufficient to overcome the inertial energy generated by the rotation of the rotor, and which braking action is sufficient to bring the rotor to a safe rotation speed upon detection of an error by the monitor processor. A circulating power generator system, wherein in the first aspect, the stator core has a series of slots for supporting the windings, and the braking coil windings occupy about 10% to about 50% of all the slots of the stator core. A circulating power generator system, further comprising an insulator positioned between the primary winding and the braking coil, in the first aspect. A circulating force generator system, further comprising a vibration sensor (157) in the first aspect, wherein the vibration sensor is in electronic communication with the monitor processor. In the first paragraph, the monitoring system:
A second power supply source (152) that provides current to a motor driving device through a third electric circuit (153);
A circulating power generator system further comprising a third relay positioned within the third electrical circuit, wherein opening of the third relay is controlled by the monitor processor to remove current from the motor drive device. A circulatory power generator system, wherein the command processor is programmed to control the motor drive device in response to the sensor. A circulating power generator system, wherein the monitor processor is programmed to control the first and second relays in response to data received from the sensor. A circulating power generator system, wherein the monitor processor is programmed to control the first and second relays in response to data received from an external source. A circulating force generator system, wherein the monitor processor is programmed to control the first and second relays in response to data received from the vibration sensor. In the first aspect, the monitor processor is programmed to interpret data received from the sensor, external source or vibration sensor and to override operation of the command circuit when any of the following error conditions is determined: overspeed of the rotor, underspeed of the rotor, rotor position outside a predetermined range, magnitude outside a predetermined range, or vibration exceeding a predetermined value. A cyclic force generator system. It is a circulation power generator system,
An electric motor (110), the electric motor having a rotor (112), a stator core (114), a primary winding (116), and a braking coil (118);
A mass (113) supported by the rotor;
As a command circuit (130), the command circuit:
A first sensor (136a) for monitoring the rotational speed and/or radial position of the mass or rotor, the first sensor being in electronic communication with the command processor;
A command circuit comprising a first power supply source (138), the first power supply source providing current to an electric motor through a first electric circuit (139);
A monitoring system (150) is included, wherein the monitoring system:
As a monitor processor (154), the monitor processor controls a first relay (155), the first relay is positioned within the first electrical circuit, and the monitor processor provides control to the first relay such that opening of the first relay by the monitor processor removes current from the electric motor;
A second sensor (136b) for monitoring the rotational speed and/or radial position of the mass or rotor, the second sensor being in electronic communication with the monitor processor;
A circulating power generator system comprising a second relay (158), the second relay being positioned within a second electrical circuit (159), the monitor processor providing control over the second relay, wherein closure of the second relay activates a braking coil. In paragraph 15, the braking coil:
A braking coil winding supported by a stator core, the braking coil winding forming a secondary winding separate from the primary winding on the stator core;
A circulating power generator system comprising an insulator separating the windings of the braking coil from the primary winding. A circulating power generator system in claim 16, wherein the braking coil winding has a length and gauge sufficient to induce current in the second electrical circuit when the second relay is closed. A circulating power generator system in accordance with claim 15, wherein when the second relay is closed, the second electric circuit has an electrical resistance, and when the second relay is closed, the resistance provided by the braking coil winding, when combined with the resistance of the second electric circuit, produces a braking action on the rotor of the electric motor. In Article 15,
When the second relay is closed, the second electrical circuit has electrical resistance,
When the second relay is closed, the braking coil has electrical resistance;
A circulating force generator system in which the resistance of the second electric circuit in combination with the resistance of the braking coil produces a braking action on the rotor of the electric motor sufficient to overcome the inertial energy generated by the rotation of the rotor, and which braking action is sufficient to bring the rotor to a safe rotation speed upon detection of an error by the monitor processor. A circulating power generator system, wherein in claim 15, the stator core has a series of slots for supporting the windings, and the braking coil windings occupy about 10% to about 50% of all the slots of the stator core. A circulating power generator system, further comprising an insulator positioned between the primary winding and the braking coil, in claim 15. A circulating force generator system, further comprising a vibration sensor (157) in accordance with claim 15, wherein the vibration sensor is in electronic communication with the monitor processor. In paragraph 15, the monitoring system:
A second power supply source (152) that provides current to a motor driving device through a third electric circuit (153);
A circulating power generator system further comprising a third relay positioned within the third electrical circuit, wherein opening of the third relay is controlled by the monitor processor to remove current from the motor drive device. A circulatory power generator system, wherein the command processor is programmed to control the motor drive device in response to the first sensor. A circulating power generator system, wherein the monitor processor is programmed to control the first and second relays in response to data received from the second sensor. A circulating power generator system, wherein the monitor processor is programmed to control the first and second relays in response to data received from an external source. A circulating force generator system, wherein the monitor processor is programmed to control the first and second relays in response to data received from the vibration sensor. In claim 15, the monitor processor is programmed to interpret data received from the second sensor, the external source, or the vibration sensor and to override operation of the command circuit when any of the following error conditions is determined: overspeed of the rotor, underspeed of the rotor, rotor position outside a predetermined range, magnitude outside a predetermined range, or vibration exceeding a predetermined value. A cyclic force generator system. It is a circulating power generator system,
An electric motor (110), the electric motor having a rotor (112), a stator core (114), a primary winding (116), and a braking coil (118);
A mass (113) supported by the rotor;
As a command circuit (130), the command circuit:
Command processor (132);
A motor driving device (134) in electronic communication with a command processor, which provides current to a primary winding;
A first sensor (136a) for monitoring the rotational speed and/or radial position of the mass or rotor, the first sensor being in electronic communication with the command processor;
A command circuit comprising a first power supply source (138), the first power supply source providing current to the motor drive device through a first electric circuit (139);
A monitoring system (150) is included, wherein the monitoring system:
A second power supply source (152) that provides current to a motor driving device through a second electric circuit (153);
A monitor processor (154), wherein the monitor processor controls a first relay (155), the first relay is positioned within a first electrical circuit, the monitor processor controls a second relay (156), the second relay is positioned within a second electrical circuit, and the monitor processor provides control for the first and second relays such that opening of the first and second relays by the monitor processor removes current from the motor drive device;
A second sensor (136b) for monitoring the rotational speed and/or radial position of the mass or rotor, the second sensor being in electronic communication with the monitor processor;
A circulating power generator system comprising a third relay (158), the third relay being positioned within a third electrical circuit (159), the monitor processor providing control over the third relay, the closure of the third relay activating the braking coil. In paragraph 29, the braking coil:
A braking coil winding supported by a stator core, the braking coil winding forming a secondary winding separate from the primary winding on the stator core; and,
A circulating power generator system comprising an insulator separating the windings of the braking coil from the primary winding. A circulating power generator system in claim 30, wherein the braking coil winding has a length and gauge sufficient to induce current in the third electrical circuit when the third relay is closed. In Article 29,
When the third relay is closed, the third electrical circuit has electrical resistance;
When the third relay is closed, the braking coil has electrical resistance;
A circulating force generator system in which the resistance of the third electric circuit in combination with the resistance of the braking coil produces a braking action on the rotor of the electric motor sufficient to overcome the inertial energy generated by the rotation of the rotor, and which braking action is sufficient to bring the rotor to a safe rotation speed upon detection of an error by the monitor processor. A circulating power generator system, wherein in claim 29, the stator core has a series of slots for supporting the windings, and the braking coil windings occupy about 10% to about 50% of all the slots of the stator core. A circulating power generator system, further comprising an insulator positioned between the primary winding and the braking coil, in claim 29. A circulatory power generator system, further comprising a vibration sensor (157) in electronic communication with the monitor processor in claim 29. A circulatory power generator system, wherein the command processor is programmed to control the motor drive device in response to the first sensor. A circulating power generator system, wherein the monitor processor is programmed to control the first, second and third relays in response to data received from the second sensor. A circulating power generator system, wherein in claim 29, the monitor processor is programmed to control the first, second, and third relays in response to data received from an external source. A circulating force generator system, wherein the monitor processor is programmed to control the first, second and third relays in response to data received from the vibration sensor. In claim 29, the monitor processor is programmed to interpret data received from the second sensor, the external source, or the vibration sensor and to override operation of the command circuit when any of the following error conditions is determined: overspeed of the rotor, underspeed of the rotor, rotor position outside a predetermined range, magnitude outside a predetermined range, or vibration exceeding a predetermined value. A cyclic force generator system. A method for controlling a power generator system,
As a step of providing a power generator system, the power generator system:
An electric motor (110), the electric motor having a rotor (112), a stator core (114), a primary winding (116), and a braking coil (118);
A mass (113) supported by the rotor;
As a command circuit (130), the command circuit:
Command processor (132);
A sensor (136a or 136b) for monitoring the rotational speed and/or radial position of a mass or rotor, the sensor being in electronic communication with a command processor;
A command circuit comprising a first power supply source (138), the first power supply source providing current to an electric motor through a first electric circuit (139);
A monitoring system (150) is included, wherein the monitoring system:
As a monitor processor (154), the monitor processor controls a first relay (155), the first relay is positioned within the first electrical circuit, and the monitor processor provides control to the first relay such that opening of the first relay by the monitor processor removes current from the electric motor;
A step of including a second relay (158), the second relay being positioned within a second electrical circuit (159), the monitor processor providing control for the second relay, wherein closure of the second relay activates a braking coil;
A step of operating a force generating system by rotating the rotor and the mass while monitoring the rotational speed and/or radial position of the mass and/or the rotor using a sensor, wherein the command processor calculates the force generated by the mass and the rotor when the mass and the rotor rotate, and the command processor manages current to the electric motor;
A step of interpreting data received from a sensor using a monitor processor;
A method for controlling a force generator system, comprising the step of energizing a braking coil when data from a sensor indicates an out-of-range condition for the rotational speed or position of the mass or the rotor position. A method for controlling a force generator system, wherein the step of energizing the braking coil in claim 41 further comprises the step of opening a first relay and closing a second relay. A method for controlling a force generator system in claim 41, wherein the step of energizing the brake coil induces a current in the second electrical circuit, the induced current generating a torque opposing the rotation of the rotor to slow the rotation of the rotor. In claim 41, the monitoring system comprises a vibration sensor (157), the vibration sensor is in electronic communication with the monitor processor, and the method comprises:
A step for monitoring a vehicle supporting a circulating force generator system for vibration by a vibration sensor;
A step in which a vibration sensor provides vibration data to a monitor processor, wherein the monitor processor has an upper limit for vibration programmed; and,
A method for controlling a force generator system, further comprising the step of energizing a braking coil when the monitor processor determines that the vibration has exceeded an upper limit. A method for controlling a force generator system in accordance with claim 41, wherein the monitor processor interprets data received from the sensor and determines whether a force generated by the rotation of the mass is within a predetermined range of velocity, phase and magnitude, and wherein the monitor processor energizes the braking coil when it determines that any one of the velocity, phase or magnitude is outside the predetermined range. A method for controlling a power generator system,
As a step of providing a power generator system, the power generator system:
An electric motor (110), the electric motor having a rotor (112), a stator core (114), a primary winding (116), and a braking coil (118);
A mass (113) supported by the rotor;
As a command circuit (130), the command circuit:
Command processor (132);
A first sensor (136a) for monitoring the rotational speed and/or radial position of the mass or rotor, the first sensor being in electronic communication with the command processor;
A command circuit comprising a first power supply source (138), the first power supply source providing current to an electric motor through a first electric circuit (139);
A monitoring system (150) is included, wherein the monitoring system:
As a monitor processor (154), the monitor processor controls a first relay (155), the first relay is positioned within the first electrical circuit, and the monitor processor provides control to the first relay such that opening of the first relay by the monitor processor removes current from the electric motor;
A second sensor (136b) for monitoring the rotational speed and/or radial position of the mass or rotor, the second sensor being in electronic communication with the monitor processor;
A step of including a second relay (158), the second relay being positioned within a second electrical circuit (159), the monitor processor providing control for the second relay, wherein closure of the second relay activates a braking coil;
A step of operating a force generator system by rotating the rotor and the mass while monitoring the rotational speed and/or radial position of the mass and/or the rotor using the first and second sensors, wherein the command processor calculates the force generated by the mass and the rotor when they rotate, and the command processor manages current to the electric motor;
A step of interpreting data received from a second sensor using a monitor processor;
A method for controlling a force generator system, comprising the step of energizing a braking coil when data from a second sensor indicates an out-of-range condition for the rotational speed or position of the mass or the rotor position. A method for controlling a force generator system, wherein the step of energizing the braking coil in claim 46 further comprises the step of opening a first relay and closing a second relay. A method for controlling a force generator system in accordance with claim 46, wherein the step of energizing the brake coil induces a current in the second electrical circuit, the induced current generating a torque opposing the rotation of the rotor to slow the rotation of the rotor. In claim 46, the monitoring system comprises a vibration sensor (157), the vibration sensor is in electronic communication with the monitor processor, and the method comprises:
A step for monitoring a vehicle supporting a circulating force generator system for vibration by a vibration sensor;
A step in which a vibration sensor provides vibration data to a monitor processor, wherein the monitor processor has an upper limit for vibration programmed; and,
A method for controlling a force generator system, further comprising the step of energizing a braking coil when the monitor processor determines that the vibration has exceeded an upper limit. In claim 46, a method for controlling a force generator system, wherein the monitor processor interprets data received from the second sensor and determines whether a force generated by the rotation of the mass is within a predetermined range of speed, phase and magnitude, and the monitor processor energizes the braking coil when it determines that any one of the speed, phase or magnitude is outside the predetermined range. A method for controlling a power generator system,
As a step of providing a power generator system, the power generator system:
An electric motor (110), the electric motor having a rotor (112), a stator core (114), a primary winding (116), and a braking coil (118);
A mass (113) supported by the rotor;
As a command circuit (130), the command circuit:
Command processor (132);
A motor driving device (134) in electronic communication with a command processor, which provides current to a primary winding;
A first sensor (136a) for monitoring the rotational speed and/or radial position of the mass or rotor, the first sensor being in electronic communication with the command processor;
A command circuit comprising a first power supply source (138), the first power supply source providing current to the motor drive device through a first electric circuit (139);
A monitoring system (150) is included, wherein the monitoring system:
A second power supply source (152) that provides current to a motor driving device through a second electric circuit (153);
A monitor processor (154), wherein the monitor processor controls a first relay (155), the first relay is positioned within a first electrical circuit, the monitor processor controls a second relay (156), the second relay is positioned within a second electrical circuit, and the monitor processor provides control for the first and second relays such that opening of the first and second relays by the monitor processor removes current from the motor drive device;
A second sensor (136b) for monitoring the rotational speed and/or radial position of the mass or rotor, the second sensor being in electronic communication with the monitor processor;
A step of including a third relay (158), the third relay being positioned within a third electrical circuit (159), the monitor processor providing control over the third relay, the closure of the third relay activating the braking coil;
A step of operating a force generator system by rotating the rotor and the mass while monitoring the rotational speed and/or radial position of the mass and/or the rotor using the first and second sensors, wherein the command processor calculates the force generated by the mass and the rotor when they rotate, and the command processor manages current to the electric motor;
A step of interpreting data received from a second sensor using a monitor processor;
A method for controlling a force generator system, comprising the step of energizing a braking coil by closing a third relay when data from a second sensor indicates an out-of-range condition for the rotational speed or position of the mass or for the rotor position. A method for controlling a force generator system in claim 51, wherein the step of energizing the braking coil further comprises the step of opening the first and second relays and closing the third relay. A method for controlling a force generator system in claim 51, wherein the step of energizing the brake coil induces a current in the second electrical circuit, the induced current generating a torque opposing the rotation of the rotor to slow the rotation of the rotor. In claim 51, the monitoring system comprises a vibration sensor (157), the vibration sensor is in electronic communication with the monitor processor, and the method comprises:
A step for monitoring a vehicle supporting a circulating force generator system for vibration by a vibration sensor;
A step in which a vibration sensor provides vibration data to a monitor processor, wherein the monitor processor has an upper limit for vibration programmed; and,
A method for controlling a force generator system, further comprising the step of energizing a braking coil when the monitor processor determines that the vibration has exceeded an upper limit. In claim 51, a method for controlling a force generator system, wherein the monitor processor interprets data received from the second sensor and determines whether a force generated by the rotation of the mass is within a predetermined range of speed, phase and magnitude, and wherein the monitor processor energizes the braking coil when it determines that any one of the speed, phase or magnitude is outside the predetermined range. In Article 9, Article 23 or Article 29,
Further comprising at least one temperature sensor, wherein the temperature sensor is associated with a component selected from the group consisting of a command processor, a motor drive device, a monitor processor, a stator core or an electric motor;
A temperature sensor is a circulating power generator system that communicates data with the monitor processor. In clause 51, the power generator system:
Further comprising at least one temperature sensor in data communication with the monitor processor, wherein the temperature sensor is associated with a component selected from the group consisting of a command processor, a motor drive device, a monitor processor, a stator core or an electric motor;
A method for controlling a force generator system further comprising the step of energizing a braking coil when the monitor processor determines that data provided by the temperature sensor indicates that the sensed temperature is outside a predetermined range. In claim 1, claim 15 or claim 29,
Further comprising a voltage sensor, the voltage sensor being positioned to monitor the voltage of the current to the monitor process and to provide voltage data to the monitor processor;
A circulating power generator system, wherein the monitor processor is programmed to initiate an abort routine, which includes energizing the braking coil when the voltage to the monitor processor, as determined by the voltage sensor, drops to within 5% of a predetermined lower limit or exceeds a predetermined upper limit for at least 0.05 seconds. In Article 41, Article 46 or Article 51,
A step of providing a voltage sensor for monitoring the voltage of the current provided to the monitor processor, wherein the voltage sensor communicates data with the monitor processor; and,
Further comprising the step of reporting voltage data to the monitor processor using the voltage sensor,
A method for controlling a force generator system, wherein when the voltage sensor reports a voltage drop within 5% of a predetermined lower limit or a voltage exceeding a predetermined upper limit for at least 0.05 seconds, the monitor processor initiates an interrupt routine to override the command circuit and energize the brake coil.