RU2816698C2 - Drive mechanism with built-in battery - Google Patents

Abstract

FIELD: machine building.

SUBSTANCE: invention relates to a motor-driven drive. To this end, disclosed is a drive device comprising a drive motor; control module; an input for receiving an external power supply; and an accumulator battery. Accumulator battery is electrically connected for selective actuation of drive motor and is made with possibility of electric connection to external power supply for charging. Control module is made with the possibility during the accumulator battery charging: receive data characterizing the measured battery charge level; compare the measured charge level with a predetermined charge level required for completion of at least two battery disconnection events when powered by a single battery, wherein the battery disconnection event includes movement of the drive device to the uninterrupted operation position.

EFFECT: reduced downtime of equipment and safe resumption of operation after a disconnection event.

24 cl, 3 dwg

Description

Field of technology

The present invention generally relates to a motor driven drive device, such as a valve drive, including a built-in battery.

State of the art

Power for a motor-driven actuator, such as a valve actuator, typically comes from AC power. However, such actuators are known to be powered by a backup (often external) battery to ensure uninterrupted operation of the valve by utilizing power from the battery source in the event of an AC power failure. Thus, such drives, under normal power conditions, operate from a local AC source. However, if this power source is lost, the actuator automatically switches to battery power, allowing the valve to be moved to a predetermined (often externally) uninterrupted operating position.

However, charging such batteries usually requires some time, such as tens of minutes or hours, and during this time the drive will generally not be able to operate. This downtime often results in significant production and financial losses.

One solution is to provide a means of quickly recharging the battery upon completion of battery operation to minimize downtime. However, this results in shorter battery life. There are also significant limitations on the battery's operating temperature range, which limits the ability of the battery-containing drive to be used in a variety of environments.

It is the object of the present invention, in its embodiments, to solve at least some of these problems.

Disclosure of the invention

According to a first aspect of the present invention, there is provided a motor driven drive device comprising:

- drive motor;

- control module;

- input for receiving external power supply and

- an electrically connected battery for selectively driving the drive motor, configured to be electrically connected to an external power supply for charging;

In this case, the control module while charging the battery is configured to:

- receive data characterizing the measured battery charge level;

- compare the measured charge level with a predetermined charge level required to complete at least two battery shutdown events when powered by the battery alone, wherein the battery shutdown event includes the drive device transitioning to a non-interruptible operating position; And,

- if the measured charge level is equal to or greater than the specified charge level, indicate the battery status to other components associated with the drive device;

wherein the control module, during subsequent operation of the drive device, is configured to:

- detect and determine the validity of the external power supply and, if the external power supply is determined to be invalid, issue an instruction for a battery disconnection event causing the battery to discharge while there will still be enough charge in the battery to complete at least one more battery disconnection event; And

- subsequently detect when the external power supply becomes acceptable and resume operation of the drive device from the external power supply while simultaneously recharging the battery to at least a predetermined charge level.

A valid external power source is one that is present and provides the specified level of power necessary or greater than that required to operate the drive motor, perform any auxiliary functions of the drive unit, and charge the battery (if necessary). An invalid external power supply is one that is missing or does not provide the specified power level.

A battery disconnect event may cause the drive unit to transition to a fail-safe state when powered by battery power alone. The driving device can move to the fail-safe state by driving the drive motor in the direction of the fail-safe position when powered by battery power alone.

The specified charge level may be sufficient to complete three, four, or more battery shutdown events when powered by battery power alone.

One or more of the following: a drive motor, a control module, and a battery may be located in the drive housing. One or more shells may be formed within the drive housing.

The drive device may further comprise a transmission configured to connect the drive motor to an external device to be driven. The transmission may be located in the drive housing. The transmission may include a shaft and may be configured to connect the drive device to an external device via the shaft. The shaft can be driven by a drive motor through a gearbox. The drive motor may be a reversible electric motor. The external device may be a valve. The external device may be a damper.

In embodiments, the control module may be configured to prevent operation of the drive device if the measured charge level is less than a second predetermined charge level required to complete one battery shutdown event.

Data indicative of the measured battery charge level may include voltage and/or electrical charge measurement values.

The control module can be additionally configured to:

- receive data characterizing the state of the external power supply;

- receive data characterizing the level and/or state of charge of the battery; And

- cause the battery to be charged from an external power supply when the external power supply is determined to be valid and present and the battery requires charging.

The drive device may further comprise at least one temperature measuring device coupled to the battery.

During battery charging, the control module can be additionally configured to:

- receive from said at least one temperature measuring device data characterizing the measured temperature associated with the battery;

- compare the measured temperature with the first set limit temperature and,

- if the measured temperature is higher than the first set limit temperature, cause a reduction in the charging current supplied from the external power supply to the battery in order to extend the service life of the battery.

The control module may be configured to cause a decrease in the charging current supplied from the external power supply to the battery until the sensed temperature reaches a first predetermined limit temperature or falls below if the sensed temperature is higher than the first predetermined temperature.

The battery may comprise a plurality of secondary lithium/nickel metal hydride/nickel cadmium cells arranged and configured for use in explosion-proof environments.

The drive device may further include a balanced charging circuit as well as circuitry designed to provide overvoltage, overcurrent, and undervoltage protection to the battery cells relative to normal/target voltage and current levels.

The drive device may further comprise at least one heating device coupled to the battery. During battery charging, the control module can be additionally configured to:

- compare the measured temperature with the second set limit temperature and,

- if the measured temperature is less than the second predetermined limit temperature, cause the at least one heating device to be turned on until the measured temperature reaches the second predetermined limit temperature or rises above.

The control module may be further configured to delay simultaneous recharging of the battery until the temperature of the battery is between the first and second predetermined temperature limits.

The external power supply may be a renewable and/or captured energy source.

The drive device may further comprise auxiliary systems. Ancillary systems may include sensors and/or transducers connected by wired or wireless communication to a remote location to monitor process conditions regarding the drive device and transmit representative data. Communications can only be used when data needs to be transferred to or from a remote location.

The external power supply may be configured to run auxiliary systems of the drive device.

The external power supply may charge the battery, which may be configured to start auxiliary systems and selectively drive the drive motor.

The drive device may further comprise a built-in control module configured to:

- control selective actuation of the drive motor in accordance with a given control process and

- receive data from a remote location, the configuration of which provides the ability to update and/or change the control process.

The control module may be configured to transmit information to the user about the battery charge level, condition and/or malfunctions of the battery. Data regarding battery charge level, battery status and/or fault conditions (collectively referred to herein as “data”) may be presented to the user on a local display, such as a drive display screen. The local display may further provide a visual indication of the data. Alternatively or additionally, the data may be transmitted digitally to a remote location for monitoring, such as by a control system. Digital data can be transmitted remotely via a network (wired and/or wireless). Alternatively or additionally, data may be transmitted remotely using discrete signals, such as using a relay. The data can be presented in the form of a data log.

The control module may be configured to operate in a variety of operating modes, events, and actions in addition to a battery disconnect event. The variety of operating modes, events, and actions may include mains and battery off modes, mains and battery activation modes, and standalone mode; as well as mains and battery disconnect events, mains and battery activation events, and offline events. The control module may be configured to prevent operation of the drive device if the control module determines a fault condition in the battery and/or determines that the battery charge level is below a permissible shutdown level.

The mains activation and deactivation modes are commonly referred to as normal operating modes. Mains activation and shutdown events are commonly referred to as normal operating events.

The control module in shutdown modes may be configured to ensure that the drive device transitions to the uninterrupted operation position, in particular before reaching any other middle position and/or any other transition limit. A battery disconnect event may cause the drive unit to transition to a fail-safe state when powered by battery power alone. A mains failure event may cause the drive unit to transition to a fail-safe state when powered by mains alone.

The control module in activation modes may be configured to cause operation from an external power supply of any auxiliary systems of the drive device, including causing the battery to be charged from an external power supply until a transition command is received. In response to a transition command, the control module may cause the drive unit powered by the battery alone to transition in the form of a battery activation event, resulting in the battery being discharged. Mains activation events can occur when the control module causes a transition of a drive device powered by the external power supply alone.

In off-grid mode, the drive unit can be powered by an intermittent power supply, such as solar panels or wind generators. Electrical power from these sources can be supplied directly to the drive device and can be used in place of mains power in cases where adequate mains power cannot be provided. An offline event can occur when the control module causes a transition of a drive device powered by the offline power supply alone.

In accordance with a second aspect of the present invention, there is provided a battery management system for a motor driven device, comprising:

- battery control module;

- drive motor;

- input for receiving external power supply and

- an electrically connected battery for selectively driving the drive motor and configured to be electrically connected to an external power supply for charging;

wherein the battery control module while charging the battery is configured to:

- receive data characterizing the measured battery charge level;

- compare the measured charge level with a predetermined charge level required to complete at least two battery shutdown events when powered by the battery alone, wherein the battery shutdown event includes the drive device transitioning to a non-interruptible operating position; And,

- when the measured charge level becomes equal to or exceeds the specified charge level, indicate the battery status to other internal components associated with the drive device;

wherein the battery control module during subsequent operation of the drive device is configured to:

- detect and determine the validity of the external power supply and, if the external power supply is determined to be invalid, command a battery disconnect event causing the battery to discharge while there will still be enough charge in the battery to complete at least one more battery disconnect event; And

- subsequently detect when the external power supply becomes acceptable and resume operation of the drive device from the external power supply while simultaneously recharging the battery to at least a predetermined charge level.

A valid external power source is one that is present and provides the specified level of power necessary or greater than that required to operate the drive motor, perform any auxiliary functions of the drive unit, and charge the battery (if necessary). An invalid external power supply is one that is missing or does not provide the specified power level.

A battery disconnect event may cause the drive unit to transition to a fail-safe state when powered by battery power alone. The driving device can move to the fail-safe position by driving the drive motor in the direction of the fail-safe position when powered by the battery alone.

The specified charge level may be sufficient to complete three, four, or more battery shutdown events when powered by battery power alone.

The drive motor and/or battery may be located in the drive housing. One or more shells may be formed within the drive housing.

The drive device may further comprise a transmission configured to connect the drive motor to an external device to be driven. The transmission may be located in the drive housing. The transmission may include a shaft and may be configured to connect the drive device to an external device via the shaft. The shaft can be driven by a drive motor through a gearbox. The drive motor may be a reversible electric motor. The external device may be a valve. The external device may be a damper.

In embodiments, the battery control module may be configured to prevent operation of the drive device if the measured charge level is less than a second predetermined charge level required to complete one battery shutdown event.

Data indicative of the measured battery charge level may include voltage and/or electrical charge measurement values.

The battery management module may be further configured to:

- receive data characterizing the state of the external power supply;

- receive data characterizing the level and/or state of charge of the battery; And

- cause the battery to be charged from an external power supply when the external power supply is determined to be valid and present and the battery requires charging.

The drive device may further comprise at least one temperature measuring device coupled to the battery.

The battery control module during charging of the battery can be further configured to:

- receive from said at least one temperature measuring device data characterizing the measured temperature associated with the battery;

- compare the measured temperature with the first set limit temperature and,

- if the measured temperature is higher than the first set limit temperature, cause a reduction in the charging current supplied from the external power supply to the battery in order to extend the service life of the battery.

The battery management module may be configured to operate in a selected one of a variety of operating modes, events, and actions in addition to a battery disconnect event. The variety of modes, events and actions may include mains and battery off modes, mains and battery activation modes and offline mode; as well as mains and battery disconnect events, mains and battery activation events, and offline events. The battery control module may be configured to prevent operation of the drive device if the control module determines a fault condition in the battery and/or determines that the battery charge level is below a permissible shutdown level.

The mains activation and deactivation modes are commonly referred to as normal operating modes. Mains activation and shutdown events are commonly referred to as normal operating events.

The shutdown modes may optionally be configured to allow the drive device to move to the non-interruptible operating position, in particular before reaching any other middle position and/or any other travel limit. A battery disconnect event may cause the drive unit to transition to a fail-safe state when powered by battery power alone. A mains failure event may cause the drive unit to go into a fail-safe state when powered by mains alone.

The battery control module in activation modes may be configured to cause external power operation of any auxiliary systems of the drive device, including causing the battery to be charged from external power until a transition command is received. In response to a transition command, the control module may cause the battery-powered drive device to transition in the form of a battery activation event, which results in the battery being discharged. Mains activation events can occur when the battery management module causes a transition of a drive device powered by the external power supply alone.

In off-grid mode, the drive unit can be powered by an intermittent power supply such as solar panels or wind generators. Electrical power from these sources can be supplied directly to the drive unit and used in place of mains power in cases where adequate mains power cannot be provided. An off-line event can occur when the battery management module causes a drive device to transition that is powered by the off-line power supply alone.

The battery control module, during battery charging, may be configured to receive data indicative of the measured battery cell life and impedance, compare that data to a predetermined performance profile, and, if the measured cell impedance is greater than the predetermined profile, cause a voltage reduction charge.

The battery control module, during discharging of the battery, may be configured to receive data indicative of a measured temperature associated with the battery, compare the measured temperature to a predetermined limit temperature, and, if the measured temperature is below the predetermined limit temperature, cause the lower limit of the discharge voltage to be reduced.

The battery control module, during discharging of the battery pack, may be configured to receive data indicative of a measured temperature associated with the battery pack, compare the measured temperature with a predetermined second limit temperature, and, if the measured temperature is less than a predetermined temperature, cause the heating device associated with the battery pack to turn on. battery.

The battery control module may be further configured to delay simultaneous recharging of the battery until the temperature of the battery is between the first and second predetermined temperature limits.

The battery management module may be configured to detect and determine the validity of an external power supply and:

(i) if the external power supply is valid and a valid shutdown command has been received, cause a shutdown event powered by the external power supply; A

(ii) if the external power supply is invalid or is determined to be invalid and/or a valid shutdown command is received and/or a mains disconnection event occurs, switch from a shutdown event supplied with energy from the external power supply to a battery disconnection event causing a discharge battery so that there is still enough charge left in the battery to complete at least one more battery shutdown event.

The battery control module may be configured to provide normal operation of the engine-driven drive device while the battery is in either a standby state or a charging state unless the external power supply is determined to be invalid and/or a valid command is received shutdown, so that a shutdown event supplied with energy from the external power supply or a battery shutdown event is respectively executed.

The battery management module may be further configured to:

- check the condition of the battery according to any one or more of the following parameters: cell condition, rate of degradation and/or service/maintenance requirements;

- generate data characterizing one or more parameters; And

- transmit data:

◊ to a local display (for example, the drive display screen), which provides a visual indication of the data if necessary; and/or,

◊ to a remote location for monitoring (eg using a control system) via a network (wired and/or wireless) and/or via discrete signals (eg using a relay).

The data may be in the form of a data log.

Brief description of drawings

Embodiments of the present invention are described below by way of example only and with reference to the accompanying drawings, in which:

Fig. 1 is a diagram illustrating a valve drive;

Fig. 2 is a block diagram illustrating the configuration of an actuator, a battery, and a valve actuator control module; And

Fig. 3 is a block diagram illustrating a battery control method.

Carrying out the invention

Embodiments of the present invention particularly relate to valve and damper actuators, for example, in the electric power industry, oil and gas flow control, shipbuilding, water supply and manufacturing industries. Such valve actuators typically have an output shaft driven by a reversible electric motor through a gearbox, such as a worm gearbox, that can move the output shaft in any direction to open or close a valve coupled through a valve stem to the output shaft.

In fig. 1 shows a valve actuator comprising a main shell 1 and a terminal shell 2. The shells are hermetically sealed to maintain water tightness and protect internal components. The main body houses the control modules 3, such as the position control device and the load cell, as well as the drive gear 4. Inside the cover on the main shell, a display and local controls 5 can be placed.

A battery 6 is installed in the main shell and is electrically connected to the drive. The drive further includes a battery control module 7 for controlling the battery and operation of the drive mechanism.

The battery contains multiple cells, such as secondary lithium cells, which are usually connected in series, with diode protection between the cells.

The exact number of cells and wiring configuration used will depend, at least to some extent, on the capacity and power achieved, as well as how much space is available to accommodate the resulting battery pack. Recycled lithium cells can be used in the type of valve actuator described above as they are suitable for use in explosion-proof applications. However, other suitable types of cells, such as nickel metal hydride or nickel cadmium, can be used instead.

The type of battery described above has an intelligent balancing charging circuit to protect the battery cells from over-charging or over-discharging (also known as over-voltage, over-current and under-voltage protection, respectively). Secondary battery cells have a limited optimal temperature range, and additional circuitry is provided to protect against overheating, as well as heat sink holes in the cell body.

In fig. 2 shows the configuration of the drive 10, the control module 12, and the battery 14. The control module 12 may integrate the above-mentioned functions of balanced charging and overvoltage, overcurrent and undervoltage protection; but this is not necessary and these functions can also be implemented in a separate module/separate PCB. The following describes the main features of the drive control module battery management function. While all of the above major features are described as part of the same control module, the functionality of the drive control module can also be implemented in a modular form, in which one or more functions are implemented in separate devices/PCBs and/or remotely from other functions.

The valve actuator embodiments, and in particular the battery used therein, have three operating modes, referred to herein as shutdown mode, battery activation mode, and offline mode, as well as five operating modes: normal, power off, battery off, battery activation and autonomous; as well as several resulting actions, each of which is based on the fact that a battery of the type described above is built into the valve actuator and communicated with it through battery control functionality implemented as part of the actuator control module. In embodiments of the invention, all of the above modes can be implemented using the same hardware, as well as using different corresponding (switchable) configurations. In off-grid operation, additional equipment can be used to convert (usually) solar energy into electrical energy.

The following is a description of the battery management system in shutdown mode with operating events such as normal operation, network shutdown and battery shutdown, as well as command loss and power loss actions. However, many aspects apply to all operating modes, events and activities.

The control module and associated battery management process provide (for the battery) active voltage and current control, diagnostics (localized within the valve actuator), status feedback, low temperature management (using heaters to improve performance and maintain battery cells within their optimal operating temperature range), as well as high temperature management to extend battery cell life. In this exemplary embodiment, the valve actuator (and associated battery and control module) will be suitable for use in explosion-proof and non-explosion-proof environments in the temperature range of -50° to 70°C.

The battery is polled by the battery management (or drive control) module to determine battery temperature, battery capacity, battery voltage, and the level of charge remaining in the battery or battery cells. The present invention is not limited in terms of the method for determining these parameters. The main utility and advantage of the control module according to this embodiment is that it uses these measured/calculated parameters to control the battery, make decisions and perform what is best for the user and/or the battery based on these parameters. Based on these parameters, it can also report a battery failure, a level of battery management that was previously not possible in this technical field.

One of the main advantages is that it was previously impractical to use a battery in a valve or damper actuator that complies with explosion-proof regulations, except in special cases. While recycled lithium and similar battery cell technologies can be used in explosion-proof and other hazardous environments, their optimal operating temperature range is limited and they require careful management (especially during charging and discharging). Thus, embodiments of the present invention attempt to solve these problems. Overheating protection is provided both by electronic means and by using heat-dissipating holes in the element housing. The battery pack additionally uses heaters when the ambient temperature drops below the setpoint (and adjustable) value set by the drive control module. Thus, these measures can be used to maintain the optimal operating temperature of the battery cells for both charging and discharging, and can be selectively turned on and off by the control module as necessary. At high temperatures, the drive control module can make decisions about when to charge the battery and at what rate to charge it, thereby extending the operating temperature range and extending battery life.

It should be noted that the battery will inevitably degrade over the life of the valve actuator. The available battery capacity is particularly severely degraded at temperatures below 0°C and at the end of the battery life. The drive control module may have a built-in map of such degradation and, in combination with battery capacity measurements, can vary the charge level and voltage to maximize battery life and performance at different stages of its life. Additionally, there may be a built-in battery capacity map with temperature that can be used to allow the control module to compensate for different temperature conditions.

The drive control module (having an integrated battery management function) may be communicatively coupled to the integrated battery and configured to monitor and control battery operation in accordance with operating mode and associated related parameters, as described in more detail below.

In fig. 3 is a flowchart of operation of the battery control module and illustrates a method for controlling the battery.

The battery control flowchart begins at step 100, at which a subsequent charging process may be initiated and at which the module is turned on or the battery is brought out of the standby state.

After starting the process at step 102, the drive control module checks the condition of the battery according to the following parameters:

Charge level;

Temperature;

Malfunctions:

Low voltage;

Overvoltage and

Overheat; And

Item condition and/or service/repair requests.

The drive control module selects an event and action mode based on the current state of the grid power level, whether the battery is safe to use, whether the drive is safe to start, and whether the battery requires charging. Thus, at step 104, the actuator control module checks whether the mains power connected to the valve actuator is valid (ie, sufficient to drive the motor, perform auxiliary functions of the valve actuator, and, if necessary, charge the battery).

If or when it is determined that the current mains power is acceptable, the battery is safe to use and fully charged, and the actuator is safe to start, the valve actuator will operate as a normal engine driven valve actuator, which is defined herein as normal events. operation, powered from the existing mains, with the battery in a standby state (and configured to provide the required uninterrupted operation of the valve in the event of a corresponding command, loss of power and/or failure of the actuator).

If mains power is determined to be unacceptable (i.e. missing or below a certain level) and/or a valid failsafe command is received, but the battery is safe to use, the drive is safe to start and there is sufficient battery charge (i.e. sufficient charge to complete at least two battery disconnect events), the drive control module will trigger a battery disconnect event. In this mode, the battery-powered actuator moves to a specified position or limit immediately or after a configurable timeout.

If the present utility power is determined to be valid (i.e., present and above a specified level) and a valid shutdown command is received, the drive control module will trigger a utility shutdown event. In this mode, the actuator moves to a specified position or to a specified limit while energized from mains power, with the battery in standby mode (if mains power is detected as invalid, it may trigger an automatic battery shutdown event) immediately or after a pre-set period. configured wait time.

During a battery disconnect event, the battery powered valve actuator

will move from any position until the full open limit is reached, stopping at the load limit (i.e. torque and/or thrust) or at the limit position;

will move from any position until the full closing limit is reached, stopping at the load limit or at the limit position; and/or

will move from any position to any other middle position.

When valid mains power returns, the drive will re-enter normal operating mode (whether normal mode, battery activated or stand-alone mode), provided (or when) the battery is sufficiently charged to tolerate at least one more battery shutdown event.

If it is determined at step 104 that utility power is acceptable (and it is determined at step 102 that the battery is safe to use but requires charging), the drive control module at step 106 begins charging the battery. During the battery charging cycle, the drive control module checks the utility power again at step 108 and also checks again to see if all battery safety checks have passed at step 110. If the utility power remains normal and the battery passes all safety checks, the battery is charging. goes to step 112.

At step 112, the drive control module receives data from the temperature sensor indicative of the temperature of and around the battery cells. It then compares the measured temperature with a specified upper limit. If the battery temperature is determined to be too high compared to the predetermined upper limit, the drive control module reduces the battery charging current at step 114. This part of the process is iterative and can be repeated in stages until the battery temperature is determined to be below the upper limit and/or within a specified range.

Next, at step 116, the drive control module compares the current battery temperature with the predetermined primary lower limit. If the battery temperature is determined to be too low compared to the predetermined primary lower limit, the drive control module is actuated at step 118 to turn on the battery heater. Once again, this portion of the process may be iterative, and is repeated until the battery temperature is determined to be within a temperature range between the upper limit and the primary lower limit.

In accordance with embodiments of the invention, the charging mode can be adapted according to the age/degree of degradation of the battery. Thus, in step 119a, the battery life log is periodically updated. At step 119b, the control module compares the life log with predetermined benchmarks. If, at step 119c, it is determined that the battery is not close to the beginning of its service life, it is charged at a predetermined low voltage (step 119d), but if it is determined that it is no longer close to the beginning of its service life, it is charged at a predetermined high voltage (step 119d). step 119e).

While charging the battery at step 121, the control module receives data from the voltmeter and/or ammeter indicative of the measured charge level of the battery, such as a voltage and/or charge measurement value. The control module then compares these measurement values with the first set charge threshold. The first charge threshold is the charge level required to perform at least two battery shutdown events, such as moving the actuator at least twice to the fail-safe position when powered by the battery alone. In other words, the battery is capable of performing at least two shutdown events when powered by the battery alone. When the actuator moves a valve, the uninterrupted position may be the normally open or normally closed position of the valve.

If the measured charge level is equal to or greater than the first predetermined charge threshold, the control module sets a system flag (referred to as a double buffer flag) that indicates the battery status for the rest of the system (step 127).

The first shutdown event typically occurs when the control module detects a loss of utility power. The system then switches from mains operation to battery activation to perform a battery disconnect event. A battery disconnect event may cause the actuator to move to the fail-safe position when powered by battery alone. When the double buffer flag is present, after the first shutdown event, the control module determines when utility power has been restored and is safe to use, and then restarts utility operation. At this point, the battery will still have enough charge to complete at least one more battery shutdown event if required (for example, in the event of a subsequent mains power failure).

Simultaneously with the resumption of mains operation, the battery can also begin to charge from the mains. The system does not have to wait until the battery is fully charged before resuming normal drive operation. Typically, batteries can take tens of minutes or hours to charge, and during this time there is usually no drive operation. The ability to perform at least two shutdown events on battery power alone means that after the first shutdown event there is no need to wait for the battery to recharge until it is ready to perform the next shutdown operation. This helps reduce downtime, which in turn can help minimize any production and financial losses that typically occur during downtime.

Additionally, since the battery will have enough charge to complete at least a second shutdown event when operation resumes on utility power, concurrent battery charging may occur at a much slower/lower rate. As stated above, it is possible to quickly recharge the battery after a shutdown event, but this comes at the cost of reducing battery life and limiting its operating temperature range. In addition, if the battery is outside the optimal temperature range, concurrent charging of the battery may be delayed until the battery is within the optimal temperature range. Slower charging rates, as well as delaying charging until the battery is in the optimal temperature range, can help preserve and extend battery life, and also allow operation in more extreme temperature ranges. As such, the drive and battery of the present invention can be used in a much wider range of environmental conditions.

If it is determined at step 121 that there is insufficient battery power to complete at least two shutdown events, all previous double buffer flags set by the control module are cleared (step 129). This tells the system that there is only enough charge for one shutdown event, and if a battery shutdown event occurs, there will not be enough charge left in the battery to handle subsequent shutdown events.

The control module also compares the measured charge level with a second preset charge threshold. The second charge threshold represents the level of charge required to complete one battery shutdown event when powered by battery power alone. If the mains power is valid and determined to be safe for use, and the measured charge level is less than the second predetermined charge level, such that the battery charge level is below that at which even one battery shutdown event can be tolerated, the control module may be configured to decide whether to: resume normal operation of the drive when on mains power, or prevent operation of the drive until the battery has been recharged from mains power to at least the first specified level.

The charging and temperature sensing/control process described above is repeated until a charge completion signal is received from the charging circuit at step 120. The drive control module is configured to stop charging the battery at step 122 at this point and check again at step 123 whether the power supply is normal. The process also checks at step 124 whether the battery is discharged, and if so, the process returns to step 106 and the drive control module begins charging the battery.

Thus, to summarize, after checking the condition of the battery in step 102, if there is no fault in the battery (ie, the battery is safe to use), the drive control module will decide the next step depending on the requirement determined by the current operating mode. If the battery requires charging, the drive control module will turn on a constant current/constant voltage source to charge the battery according to that need. The voltage charge level is determined and controlled depending on the age of the battery cells, and the current level is determined by temperature and the charge power set by the user.

The user may be informed of any faults detected in the battery pack at step 125 via the drive display or the drive's own status relays or a network system (wired and/or wireless) connected to the drive. In addition, the drive control module can decide whether to continue operation based on the above measured parameters and the user's preset configuration.

While charging the battery and subsequently, the drive will operate normally without being tied to the battery unless the following occurs:

a) the battery will report a critical failure (in this case, the drive control module terminates the process and generates an error signal to be output/displayed); or

b) valid mains power is lost or a valid shutdown command is received and power is removed; or a valid trip command will be received, where mains power will be present and the drive will be configured to preferentially operate on battery power (in which case the drive control module will enter the trip mode of operation described above).

During charging, the drive control module's battery management function will monitor whether the battery is safe to use and whether the drive is safe to start. If any of these checks fail, an error will be generated. The drive control module also monitors whether valid utility power has been lost and/or a valid trip command has been received, and if either of these conditions is met, the drive control module enters the shutdown mode described above.

Finally, charging is complete when the battery reaches a specified current limit at a specified voltage level, resulting in a charge completion signal. The specified voltage level may be changed depending on the age of the battery and the ambient temperature. At this point, the battery management function checks the steady-state voltage of the battery and, if it is within a specified range, the battery enters the aforementioned standby state until it is determined that it requires charging. If this criterion is not met, the battery management function returns to step 106 and resumes the charging process.

Charging is completed when, as before, the battery reaches the specified limit voltage, which may vary depending on the age of the battery. As before, at this stage the battery management function checks the steady-state battery voltage.

If this meets the predetermined criteria, the battery will enter the aforementioned standby state until it is determined to require charging. If the criteria are not met, the battery management function returns to step 106 and resumes the charging process.

Each time the battery is activated at step 126, or when a battery disconnect event occurs, or when a battery activation event occurs, the battery management function starts the discharging process. During this process, the drive control module again monitors the battery temperature, but in this case only compensates for low temperatures, i.e. below the primary low limit (eg 0°C) and the secondary low limit (eg -30°C). At step 132, the battery management function checks to see if the temperature has dropped below the primary lower limit. If so, then at step 134 it causes the heater to turn on. It then determines the impedance of the cells in the battery. If so, then at step 130 it isolates the battery and stops discharging. If not, the flow returns to step 126 and use of the battery can continue.

Of course, another significant advantage of the battery and the associated active battery management process is the fact that the battery can operate in a selected one of many operating modes, rather than the single passive shutdown mode or fail-safe mode that is provided in the above conventional valve actuators with a built-in battery.

In trip mode, the drive operates as a normal mains-powered electric drive until the mains power drops below a preset threshold and/or a valid trip command is received. There may or may not be a configurable time delay between the event and the shutdown action as described above. The drive will then decide, based on the grid power level and/or the nature of the shutdown command, to initiate a grid shutdown event or a battery shutdown event as described above.

In Battery Activation mode, utility power (mains or renewable energy) is used to operate the auxiliary drive systems and charge the battery. When the valve needs to be moved, the battery is discharged to power the drive motor and then recharged between movements. This will be further described as a battery activation event. With this configuration, the drive can initiate the next battery shutdown event if the grid power drops below a configured threshold and/or a valid shutdown command is received. This can be with or without a configurable time delay between the event and the trip action as described above, and with or without mains power.

The offline mode described below is similar to the battery activation mode in many respects; In order to achieve direct optimized power supply from a renewable energy source, additional equipment is used to enable the connection of additional auxiliary elements such as sensors. The energy collected from the solar panel is typically used to operate auxiliary drive systems and charge the battery. This is called an autonomous event. When the valve needs to be moved, the battery is discharged to power the drive motor and then recharged between movements. This is further described as battery activation. With this configuration, the drive can optionally trigger a battery shutdown event if the grid power drops below a specified threshold and/or a valid shutdown command is received and/or the battery discharges to a specified level. This may be with or without a configurable time delay between the event and the shutdown action as described above.

These additional modes of operation are described in more detail below.

In Battery Activation mode, the actuator control module can operate the valve using a power supply that is less powerful than the power required to operate the electromechanical actuator. Mains power supply (from the mains or from a renewable energy source) is used to operate auxiliary systems and charge the battery. When the valve needs to be moved, the battery is discharged at step 126 to operate the actuator, which is described herein as a battery activation event. In this mode of operation, a so-called deep sleep mode (as described below) can be used to maximize the charge supplied to the battery, with an automatic wake-up signal generated when the drive motor needs to be driven. If it is determined at step 128 that the battery voltage is below the set cut-off voltage, the drive control module at step 130 isolates the battery and issues an error message.

To enable a battery activation event, the charge mode battery management function will use available grid power to charge the battery, with the battery being used to move the actuator in all cases. In this case, when there is a need to start the drive, the drive control module checks:

a) whether there is sufficient battery charge;

b) whether the drive is awakened from deep sleep mode;

c) is the battery safe to use and c!) is it safe to start the drive.

If all these conditions are met, the actuator will move from any specified position to any other specified position. Acceptable input signals are digital, analog level, or network command.

If a battery or drive error occurs, an error message is issued and the drive decides whether it is severe enough to prevent operation. If the battery is insufficiently charged, operation will stop until there is sufficient charge.

To charge the battery, and while the battery is not being used to move the actuator, the process returns to steps 102 and 104. If there is sufficient mains power, the battery is safe to use, the actuator is safe to start, and the battery requires charging, drive control module to step 106 will begin charging the battery. While charging the battery, if configured appropriately, the drive will enter a power saving (or deep sleep) mode and the battery will not be used until a valid move command is received. The battery will charge unless the battery reports a critical failure (in which case an error message is displayed and the system will not start), valid utility power is removed (in which case the system will trigger the battery disconnect event described above), or valid utility power is not accepted. move command (in this case the actuator will move from any set position to any other set position as described above). These parameters are monitored throughout the charging process.

The above-described battery activation mode can be used in a grid-powered system and/or in a system powered by a renewable energy source, such as solar, wind and/or hydropower. Thus, a so-called off-line operation is also provided, which is described in more detail below. Offline operation is very similar to Battery Activation mode, and the Battery Activation and Battery Off events are identical in operation. The key differences are the power supply and the ability to make process decisions from a local sensor powered by the actuator and/or transmit information wirelessly back to the control center to receive a motion command in response that will be sent wirelessly to the actuator.

In off-grid operation, the valve actuator can be powered by an intermittent power supply, such as solar panels or wind generators. Electrical power from these sources can be supplied directly to the drive and can be used in place of mains power in applications where adequate mains power cannot be provided. The drive control module controls the energy input and stores energy in the battery. The drive power input starts the auxiliary system and charges the battery when sufficient power is available, then the battery powers the drive motor and other systems when commanded and/or when there is insufficient power. As described above, the battery management feature can force the battery into what is called a deep sleep mode to maximize the charge going to the battery, waking up only when needed. As with all other modes, status can be reported visually, wired, or wirelessly, in which case the device may be able to connect directly to third-party sensors and process the information based on user-specified values.

The power source can be solar radiation through third party solar panels. The drive will be able to monitor and optimize, by monitoring electrical input, the performance of solar panels or other sources and feed the resulting electricity into the drive's battery. The main advantage of this system is that the solar panel system does not need to be able to directly drive the drive motor, so the battery will be used as a battery to drive the motor and bridge interruptions in sunlight caused by darkness or shade. The operation method will correspond to the battery activation mode.

In terms of functionality, in addition to the usual wired commands and networks, the actual signal will be received wirelessly. The drive can respond with status information via the same wireless connection. This allows for a completely autonomous solution.

The final aspect of this is the connection of external sensors, such as pressure sensors. This allows the drive to make internal process decisions and change its own setpoint with or without the central reference setpoint. If the process goes outside the set parameters, the drive can send a warning message via wired or wireless communication to the control system.

In the event of a complete loss of power, for example due to solar panel failure, the actuator, in accordance with the described battery disconnect event, will move from any position to the specified non-stop position and generate an alarm, wired or wireless.

One skilled in the art will appreciate from the foregoing description that modifications and changes may be made to the described embodiments without departing from the scope of the invention as defined by the appended claims.

Claims (66)

1. A drive device driven by a motor, comprising: - drive motor; - control module (12); - input for receiving external power supply; And - an electrically connected battery (14) for selectively driving the drive motor, configured to be electrically connected to an external power supply so as to be charged from the external power supply; in this case, when the battery (14) is charged from an external power supply, the control module (12) is configured to: - receive data characterizing the measured charge level of the battery (14); - compare the measured charge level with a predetermined charge level required to complete at least two battery disconnect events, wherein the battery disconnect event includes the transition of the drive device to a specified uninterruptible operation position when powered by battery power alone; And, - if the measured charge level is equal to or greater than the specified charge level, indicate the battery status to other internal components associated with the drive device; wherein the control module (12) during subsequent operation of the drive device is configured to: - detect and determine the validity of the external power supply and, if the external power supply is determined to be invalid, issue an instruction for a battery disconnect event causing the battery (14) to discharge, while the battery (14) will still have enough charge to complete the at least one more battery disconnect event; And - subsequently detect when the external power supply becomes acceptable and resume operation of the drive device from the external power supply while simultaneously recharging the battery (14) to at least a predetermined charge level; And - prevent operation of the drive device if the measured charge level is less than a second predetermined charge level required to complete one battery shutdown event when powered by battery alone. 2. The drive device of claim 1, wherein the data indicative of the measured battery charge level includes voltage and/or electrical charge measurement values. 3. The drive device according to any of the previous paragraphs, in which the control module (12) is configured to: - receive data characterizing the state of the external power supply; - receive data characterizing the level and/or state of charge of the battery (14); And - cause the battery (14) to be charged from an external power supply when the external power supply is determined to be valid and present and the battery (14) requires charging. 4. The drive device according to any of the preceding claims, further comprising at least one temperature measuring device associated with the battery (14). 5. The drive device according to claim 4, in which the control module (12) while charging the battery (14) is additionally configured to: - receive from said at least one temperature measuring device data characterizing the measured temperature associated with the battery (14); - compare the measured temperature with the first set limit temperature; And, - if the measured temperature is higher than the first set limit temperature, cause a reduction in the charging current supplied from the external power supply to the battery (14) in order to extend the service life of the battery (14). 6. The drive device according to claim 5, wherein the control module (12) is configured to cause a decrease in the charging current supplied from the external power supply to the battery (14) until the measured temperature reaches the first predetermined limit temperature or will not go lower if the measured temperature is higher than the first set temperature. 7. The drive device according to claim 5 or 6, further comprising at least one heating device associated with the battery (14); wherein the control module (12) while charging the battery (14) is additionally configured to: - compare the measured temperature with the second specified limit temperature; And, - if the measured temperature is less than the second set limit temperature, cause at least one heating device to turn on until the measured temperature reaches the second set limit temperature or rises above. 8. The drive device according to any of the previous paragraphs, additionally containing a built-in control module (12), configured to: - control selective actuation of the drive motor in accordance with a given control process; And - receive data from a remote location, the configuration of which provides the ability to update and/or change the control process. 9. The drive device according to any of the preceding paragraphs, in which the control module (12) is configured to transmit to the user information about the battery charge level, condition and/or malfunctions of the battery; wherein the battery charge level, condition and/or faults of the battery are presented to the user on a local display forming part of the drive device and/or transmitted digitally to a remote location via a network and/or via discrete signals for monitoring. 10. The drive device as claimed in any one of the preceding claims, wherein the control module (12) is configured to operate in a plurality of operating modes, events and actions in addition to a battery disconnection event, wherein the plurality of operating modes, events and operating actions include battery activation mode and offline mode; as well as power outage and battery activation events. 11. The drive device according to claim 10, wherein the control module (12) is configured to prevent operation of the drive device if the control module (12) detects a fault condition in the battery (14). 12. Drive device according to any one of paragraphs. 10 or 11, in which the control module (12) in the battery activation mode is configured to cause operation from an external power supply of any auxiliary systems of the drive device, including causing charging of the battery (14) from an external power supply until a transition command will be received; and wherein, in response to a transition command, the control module (12) is configured to cause a transition of the drive device powered by the battery (14) in the form of a battery activation event, which results in the battery (14) being discharged. 13. The drive device according to any of the preceding claims, further comprising a drive housing, wherein one or more of the following: a drive motor, a control module (12) and a battery (14) are located in the drive housing. 14. A battery management system for a drive device driven by an engine, comprising: - battery control module (12); - drive motor; - input for receiving external power supply and - an electrically connected battery (14) for selectively driving the drive motor and configured to be electrically connected to an external power supply so as to be charged from the external power supply; - in this case, when the battery (14) is charged from an external power supply, the battery control module (12) is configured to: receive data characterizing the measured charge level of the battery (14); - compare the measured charge level with a predetermined charge level required to complete at least two battery disconnect events, wherein the battery disconnect event includes the transition of the drive device to a specified uninterruptible operation position when powered by battery power alone; And, - if the measured charge level is equal to or greater than the specified charge level, indicate the battery status to other internal components associated with the drive device; wherein the battery control module (12) during subsequent operation of the drive device is configured to: - detect and determine the validity of the external power supply and, if the external power supply is determined to be invalid, issue an instruction for a battery disconnect event causing the battery (14) to discharge, while the battery (14) will still have enough charge to complete the at least one more battery disconnect event; And - subsequently detect when the external power supply becomes acceptable and resume operation of the drive device from the external power supply while simultaneously recharging the battery (14) to at least a predetermined charge level; And - prevent operation of the drive device if the measured charge level is less than a second predetermined charge level required to complete one battery shutdown event when powered by battery alone. 15. The battery management system of claim 14, wherein the data indicative of the measured charge level of the battery includes voltage and/or electrical charge measurement values. 16. Battery management system according to any one of paragraphs. 14, 15, in which the battery control module (12) is additionally configured to: - receive data characterizing the state of the external power supply; - receive data characterizing the level and/or state of charge of the battery (14); And - cause the battery (14) to be charged from an external power supply when the external power supply is determined to be valid and present and the battery (14) requires charging. 17. Battery management system according to any one of paragraphs. 14-16, in which the drive device further comprises at least one temperature measuring device associated with the battery (14). 18. The battery management system according to claim 17, in which the battery control module (12) during charging of the battery (14) is additionally configured to: - receive from said at least one temperature measuring device data characterizing the measured temperature associated with the battery (14); - compare the measured temperature with the first set limit temperature and, - if the measured temperature is higher than the first set limit temperature, cause a reduction in the charging current supplied from the external power supply to the battery (14) in order to extend the service life of the battery (14). 19. Battery management system according to any one of paragraphs. 14-18, wherein the battery control module (12) may be configured to operate in a selected one of a plurality of operating modes, events, and actions in addition to a battery disconnection event; while many modes, events and actions during operation include battery activation mode and offline mode; as well as power outage and battery activation events. 20. Battery management system according to any one of paragraphs. 14-19, in which the battery control module (12) during charging of the battery (14) is configured to receive data characterizing the measured service life and impedance of the battery cell (14), compare this data with a given performance profile and, if the measured cell impedance is greater than the specified profile, causing the charge voltage to decrease. 21. Battery management system according to any one of paragraphs. 14-20, in which the battery control module (12) during discharging of the storage battery (14) is configured to receive data characterizing a measured temperature associated with the storage battery (14), compare the measured temperature with a predetermined limit temperature and, if the measured temperature below the specified limit temperature, cause a decrease in the lower limit of the discharge voltage. 22. Battery management system according to any one of paragraphs. 14-21, in which the battery control module (12), during discharging of the storage battery (14), is configured to receive data characterizing a measured temperature associated with the storage battery (14), compare the measured temperature with a predetermined second limit temperature and, if the measured temperature temperature is less than the set temperature, cause the heating device connected to the battery (14) to turn on. 23. Battery management system according to any one of paragraphs. 14-22, in which the battery control module (12) is configured to detect and determine the acceptability of an external power supply and: (i) if the external power supply is valid and a valid shutdown command has been received, cause a shutdown event powered by the external power supply; A (ii) if the external power supply is invalid or is determined to be invalid, and/or a valid shutdown command is received, and/or a mains shutdown event occurs, switch from a shutdown event powered by the external power supply to a battery shutdown event causing discharging the battery (14) such that there is still enough charge left in the battery (14) to complete at least one more battery disconnect event. 24. Battery management system according to any one of paragraphs. 14-23, in which the battery control module (12) is configured to ensure normal operation of the drive device driven by the engine, while the battery (14) is either in a standby state or in a charging state, unless an external power supply is determined to be invalid and/or a valid shutdown command is not received, so that a shutdown event powered by external power supply or a battery shutdown event is accordingly enabled.