System and methods for dynamically allocating voltage in a compressor motor

Abstract

A system including a motor of a compressor system and a motor controller is disclosed. The controller is configured to selectively allocate voltage between a first winding and second winding of the compressor motor. Allocation of voltage biases the first winding of the compressor motor over the second winding. The controller selectively allocates voltage to bias windings in response to a command to transition the HVAC control system from the first operating mode to a second operating mode. The controller further selectively allocates voltage to bias windings in response to received sensor data, such as temperature, pressure, or time data. The controller biases voltages for one or more operating modes or load intervals of the system.

What is claimed is: 
     
         1 . A heating, ventilation, and air conditioning (HVAC) control system comprising:
 a compressor comprising a motor, the motor having a first winding and a second winding;   a motor controller comprising a microcontroller, the microcontroller programmed to:
 selectively allocate voltage between the first winding and the second winding according to a first operating mode of the HVAC control system; and 
 in response to a command to transition the HVAC control system from the first operating mode to a second operating mode, bias the first winding over the second winding by selectively allocating voltage from the second winding to the first winding. 
   
     
     
         2 . The HVAC control system of  claim 1 , wherein the microcontroller is further programmed to:
 bias the first winding over the second winding using dynamic saturation of the vector modulation pattern, such that the biasing depends on a desired motor operating point and an angle of an applied voltage.   
     
     
         3 . The HVAC control system of  claim 1  further comprising:
 one or more sensors coupled to the motor controller and configured to sense one or more parameters of the HVAC control system, 
 wherein the microcontroller is further programmed to bias the first winding over the second winding based on the one or more parameters of the HVAC control system. 
 
     
     
         4 . The HVAC control system of  claim 1  further comprising:
 one or more sensors coupled to the motor controller and configured to sense at least one of an ambient temperature and an operating temperature of a system component, 
 wherein the microcontroller is further programmed to bias the first winding over the second winding when the temperature meets one or more conditions. 
 
     
     
         5 . The HVAC control system of  claim 4 , wherein the microcontroller is further programmed to:
 bias the first winding over the second winding when the ambient temperature is above 79° F.   
     
     
         6 . The HVAC control system of  claim 4 , wherein the microcontroller is further programmed to:
 bias the first winding over the second winding when the ambient temperature is below 39° F.   
     
     
         7 . The HVAC control system of  claim 1  further comprising:
 one or more sensors coupled to the motor controller and configured to detect a system pressure of an HVAC system, 
 wherein the microcontroller is further programmed to bias the first winding over the second winding based on the system pressure. 
 
     
     
         8 . The HVAC control system of  claim 1 , wherein the microcontroller is programmed to:
 detect a time-based parameter related to the HVAC control system; and   bias the first winding over the second winding based on the time-based parameter.   
     
     
         9 . The HVAC control system of  claim 8 , wherein the time-based parameter comprises an amount of time since the compressor was last in an active operating mode, and wherein the microcontroller is further programmed to bias the first winding over the second winding based on the amount of time. 
     
     
         10 . The HVAC control system of  claim 1  further comprising:
 one or more sensors coupled to the motor controller and configured to detect a temperature of one or more electronics of an HVAC system, 
 wherein the microcontroller is further programmed to bias the first winding over the second winding based on the temperature of the one or more electronics. 
 
     
     
         11 . The HVAC control system of  claim 1 , wherein the microcontroller is further programmed to:
 determine a load point of the HVAC control system; and   bias the first winding over the second winding when the load point is higher than an achievable speed, where the achievable speed is calculated based on optimal biasing between the first winding and the second winding.   
     
     
         12 . The HVAC control system of  claim 1 , wherein the microcontroller is further programmed to:
 bias the first winding over the second winding when the compressor is in a variable speed operating mode with a commanded speed higher than an achievable speed, where the achievable speed is calculated based on optimal biasing between the first winding and the second winding.   
     
     
         13 . An air conditioning control system comprising:
 a compressor comprising a motor, the motor having a first winding and a second winding;   a motor controller comprising a microcontroller, the microcontroller programmed to:
 selectively allocate voltage between the first winding and the second winding according to a first operating mode of the air conditioning control system; and 
 in response to a command to transition the air conditioning control system from the first operating mode to a second operating mode, bias the first winding over the second winding by selectively allocating voltage from the second winding to the first winding. 
   
     
     
         14 . The air conditioning control system of  claim 13  wherein the microcontroller is further programmed to:
 bias the first winding over the second winding using dynamic saturation of the vector modulation pattern, such that the biasing depends on a desired motor operating point and an angle of an applied voltage. 
 
     
     
         15 . The air conditioning control system of  claim 14 , further comprising:
 one or more sensors coupled to the motor controller and configured to sense one or more parameters of the air conditioning control system,   wherein the microcontroller is further programmed to bias the first winding over the second winding based on one or more parameters of the air conditioning control system.   
     
     
         16 . The air conditioning control system of  claim 13 , wherein the microcontroller is further programmed to:
 bias the first winding over the second winding when the compressor is in a variable speed operating mode with a commanded speed higher than an achievable speed, where the achievable speed is calculated based on optimal biasing between the first winding and the second winding.   
     
     
         17 . A heating control system comprising:
 a compressor comprising a motor, the motor having a first winding and a second winding;   a motor controller comprising a microcontroller, the microcontroller programmed to:
 selectively allocate voltage between the first winding and the second winding according to a first operating mode of the heating control system; and 
 in response to a command to transition the heating control system from the first operating mode to a second operating mode, bias the first winding over the second winding by selectively allocating voltage from the second winding to the first winding. 
   
     
     
         18 . The heating control system of  claim 17  wherein the microcontroller is further programmed to:
 bias the first winding over the second winding using dynamic saturation of the vector modulation pattern, such that the biasing depends on a desired motor operating point and an angle of an applied voltage. 
 
     
     
         19 . The heating control system of  claim 18 , further comprising:
 one or more sensors coupled to the motor controller and configured to sense one or more parameters of the heating control system,   wherein the microcontroller is further programmed to bias the first winding over the second winding based on one or more parameters of the heating control system.   
     
     
         20 . The heating control system of  claim 17 , wherein the microcontroller is further programmed to:
 bias the first winding over the second winding when the compressor is in a variable speed operating mode with a commanded speed higher than an achievable speed, where the achievable speed is calculated based on optimal biasing between the first winding and the second winding.