Direct power control for constant airflow control with advanced motor system modeling
09732976 · 2017-08-15
Assignee
Inventors
- Jizhong Wang (Bolingbrook, IL, US)
- Zheng Zhang (Saint Joseph, MI, US)
- Yiqiao Zhou (Naperville, IL, US)
- Yong Zhao (Zhongshan, CN)
Cpc classification
F24F2140/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/77
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/88
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/62
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D27/004
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D27/001
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02B30/70
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
F04D27/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24F11/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Systems and methods for providing constant airflow based on direct motor power control and advanced motor system modeling are described. A power and speed of a motor may be determined based on static pressure in the system. A target airflow rate for the system may be obtained, and a target motor power that yields the target airflow rate in the system may be determined based on the determined speed of the motor and the obtained target airflow rate for the system. A determination of whether the determined motor power is approximately equal to the target motor power may be made, and the power of the motor may be adjusted when the motor power is not approximately equal to the target motor power.
Claims
1. A method for providing constant airflow with a variable speed motor in a Heating, Ventilation, and Air Conditioning (HVAC) system, comprising: (a) determining a power and speed of a motor; (b) obtaining a target airflow rate for the HVAC system; (c) determining a target motor power that yields the target airflow rate in the HVAC system, wherein determining the target motor power comprises calculating the target motor power based on an equation, wherein the equation comprises the target motor power being set to equal a natural exponential function, and wherein an exponent of the natural exponential function is a non-linear higher-order polynomial function of at least the determined speed, the obtained target airflow rate for the HVAC system, and motor operation parameters, and wherein the non-linear higher-order polynomial function includes a product of at least one of: the obtained target airflow rate and the determined speed; and the determined speed and the determined speed; (d) determining whether the determined motor power is approximately equal to the target motor power; and (e) adjusting the power of the motor when the motor power is not approximately equal to the target motor power, wherein the motor power is adjusted until the motor power is approximately equal to the target motor power.
2. The method of claim 1, further comprising determining the motor operation parameters based, at least in part, on a minimization of a percent error yielded from the natural exponential function.
3. The method of claim 1, wherein adjusting the power comprises adjusting the speed of the motor when the motor power is not approximately equal to the target motor power until the motor power is approximately equal to the target motor power.
4. The method of claim 1, further comprising maintaining constant the motor power when the motor power is approximately equal to the target motor power.
5. The method of claim 1, further comprising repeating steps (a)-(e) such that the motor provides constant airflow in the HVAC system.
6. The method of claim 1, wherein the motor is a permanent magnet motor.
7. The method of claim 1, wherein the non-linear higher-order polynomial function that is the exponent of the natural exponential function that is set to equal the target motor power comprises the following polynomial:
k.sub.0 +k.sub.1*CFM +k.sub.2*speed +k.sub.3*CFM*speed +k.sub.4*speed.sup.2, wherein speed is the determined speed, CFM is the obtained target airflow rate, and k.sub.0, k.sub.1, k.sub.2, k.sub.3, and k.sub.4 are the motor operation parameters.
8. The method of claim 1, wherein the non-linear higher-order polynomial function that is the exponent of the natural exponential function that is set to equal the target motor power comprises five or fewer parameters.
9. An apparatus for providing constant airflow in a Heating, Ventilation, and Air Conditioning (HVAC) system, comprising: a variable speed motor; and a motor controller coupled to the variable speed motor and configured to control the operation of the variable speed motor, the motor controller comprising a processor configured to perform the steps of: (a) determining a power and speed of a motor; (b) obtaining a target airflow rate for the HVAC system; (c) determining a target motor power that yields the target airflow rate in the HVAC system, wherein determining the target motor power comprises calculating the target motor power based on an equation, wherein the equation comprises the target motor power being set to equal a natural exponential function, and wherein an exponent of the natural exponential function is a non-linear higher-order polynomial function of at least the determined speed, the obtained target airflow rate for the HVAC system, and motor operation parameters, and wherein the non-linear higher-order polynomial function includes a product of at least one of: the obtained target airflow rate and the determined speed; and the determined speed and the determined speed; (d) determining whether the determined motor power is approximately equal to the target motor power; and (e) adjusting the power of the motor when the motor power is not approximately equal to the target motor power, wherein the motor power is adjusted until the motor power is approximately equal to the target motor power.
10. The apparatus of claim 9, wherein the processor is further configured to perform the step of determining the motor operation parameters based, at least in part, on a minimization of a percent error yielded from the natural exponential function.
11. The apparatus of claim 9, wherein the processor being configured to perform the step of adjusting the power comprises adjusting the speed of the motor when the motor power is not approximately equal to the target motor power until the motor power is approximately equal to the target motor power.
12. The apparatus of claim 9, wherein the processor is further configured to perform the step of maintaining constant the motor power when the motor power is approximately equal to the target motor power.
13. The apparatus of claim 9, wherein the processor is further configured to perform the step of repeating steps (a)-(e) such that the motor provides constant airflow in the HVAC system.
14. The apparatus of claim 9, wherein the motor is a permanent magnet motor.
15. The apparatus of claim 9, wherein the non-linear higher-order polynomial function that is the exponent of the natural exponential function that is set to equal the target motor power comprises the following polynomial:
k.sub.0 +k.sub.1*CFM +k.sub.2*speed +k.sub.3*CFM*speed +k.sub.4*speed.sup.2, wherein speed is the determined speed, CFM is the obtained target airflow rate, and k.sub.0, k.sub.1, k.sub.2, k.sub.3, and k.sub.4 are the motor operation parameters.
16. The apparatus of claim 9, wherein the non-linear higher-order polynomial function that is the exponent of the natural exponential function that is set to equal the target motor power comprises five or fewer parameters.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE INVENTION
(23) This invention is described for further detail through examples combined with the appended drawings. One embodiment of the present invention is shown in
(24) As shown in
(25) 2) The motor controller includes a microprocessor, which may be a single chip or DSP electronic board conducting motor control. Part of the power source provides power to each circuit that is part of the controller, and the power source sets up a DC bus voltage and current. Therefore, the motor control will conduct power transmission. The motor controller that is made with low costs and mass production usually uses a parallel resistance circuit as current and voltage sensing hardware, and a feedback system to control the motor drive carrying out motor control, such as vector control, direct torque control, and other types of sensor based or sensorless controls. As is known to those skilled in the art, the variation of any electronic component's operating parameters impacts testing accuracy and durability.
(26) 3) The PM motor rotor includes a magnet body and structure, and multiphase windings at the stator slots. When the temperature changes, the resistance of the windings will change, which may lead to a variation in motor control. Motor manufacturing processes often also create some variation to a certain degree. The aging of the motor and whether the motor is a new motor or an old motor are also contributing factors that affect accuracy and durability, such as the lifespan of the motor. Moreover, the magnet or the magnetic flux of the motor may be affected by temperature changes, demagnetization, etc. In addition, the motor shaft failure, the security of the system, and the detection or real-time monitoring of parameters is also impacted by temperature changes and variation.
(27) 4) The blower is installed on the motor shaft, and causes air to flow at a certain speed. Installation position may affect the operation, may increase the friction, cause low flow, or even cause rotation in a wrong direction.
(28) 5) The filter should be replaced and receive maintenance service periodically. But this can be forgotten over a long period of time tracking, which can increase the friction and impact the air pressure.
(29) 6) Pipeline control: pipeline system may change due to dust, a broken duct, regional control, and on/off wind port system pressure changes. A system performing constant airflow control may have a lot of unstable factors as a result of the foregoing pipeline system changes.
(30) As shown in
EXAMPLE 1
(31) As shown in
(32) In
(33) Step A) starting a motor controller;
(34) Step B) receiving or presetting a target airflow volume value IN-CFM;
(35) Step C) obtaining a function P=ƒ(n) according to the target airflow value IN-CFM, where n is speed and P is the input power of the PM motor;
(36) Step D) entering a direct power control mode for constant airflow control, wherein the motor is controlled so that the motor speed starts at zero and increases along the control path specified by the function P=ƒ(n) to reach a stable working point (pt, nt), wherein Pt, nt are located on the input power and speed pair trajectory specified by the constant airflow control function P=ƒ(n);
(37) Step E) maintaining the direct power control mode for constant airflow control according to the motor operation parameters comprising P.sub.i, wherein P.sub.i is the calculated real-time input power;
(38) Step F) computing a power increment value ΔP, wherein if the power increment value ΔP is less than a set value Pset, then the current working point is maintained;
(39) Step G) if the power increment value ΔP is greater than or equal to the set value Pset, then power and speed control logic is executed to calculate a speed loop operating time to be reached, wherein if the operating time of the speed loop is not reached, then the current working point is maintained; and
(40) Step H) if the speed loop operating time is reached, then speed control circuitry is entered according to a regulated speed ni, which is the real-time speed of the motor, to realize a new working point on the input power and speed pair trajectory (Pi, ni), wherein Pt equals Pi, nt equals ni, and operation returns to step D).
(41) According to an embodiment, the above-described function of P=ƒ(n) is obtained by collecting original data for a plurality of target air volumes by adjusting the static pressure from low static pressure to high static pressure. The range of static pressures may span the actual static pressure range experienced by the motor, and while the static pressure is adjusted the motor speed n and real-time input power Pi may be adjusted to keep airflow at a target air volume. The motor speed n and corresponding real-time input power Pi may be recorded for a plurality of target air volumes to produce a plurality of original data pairs of real-time input power Pi and speed n for the motor, wherein a function P=ƒ(n) is determined for a plurality of target airflow values by curve fitting the corresponding recorded original data pairs of real-time input power Pi and speed ni of the motor for the target airflow.
(42) According to another embodiment, if the external input target airflow value IN-CFM is not approximately equal to one of the determined target airflow functions P=ƒ(n), then interpolation fitting may be used to calculate a new function P=ƒ(n) corresponding to the external input target airflow value IN-CFM, wherein the new function P=ƒ(n) may be used to perform the constant airflow control.
(43) According to another embodiment, the above mentioned function relation formula P=ƒ(n) is a polynomial function: P=C.sub.mn.sup.m−1+ . . . +C.sub.2n+C.sub.1, where C.sub.1, C.sub.2, . . . , and C.sub.m are the coefficients and n is the motor speed value, and wherein each target airflow corresponding to a set of coefficients C.sub.1, C.sub.2, . . . , and C.sub.m is stored, and wherein the microprocessor obtains the corresponding set of C.sub.1, C.sub.2, . . . , and C.sub.m coefficients based on the input target airflow value IN-CFM and one of a look-up table that includes the determined target airflow functions P=ƒ(n) and the new function P=ƒ(n) calculated using the interpolation fitting.
(44) According to another embodiment, the above-mentioned function relation formula P=ƒ(n) is a quadratic function: P=C.sub.3n.sup.2+C.sub.2n+C.sub.1.
(45) The development of the control method of the present invention for constant airflow controlled by a direct-power controlled PM motor and the establishment of a mathematical model for the control method may be described as follows: generally, in a ventilation system, a fan driven by a PM motor produces airflow under a steady state. A constant airflow control may be realized through control of the speed and power of the motor at a static pressure, as shown in the following formula: CFM=F (P, speed, pressure), wherein CFM is airflow in Cubic Feet per Minute (CFM), P is the power, speed is rotation speed, pressure is static pressure. When the static pressure changes, the constant CFM is maintained, for example, within about plus or minus 5 percent, by the control of power and speed. When the static pressure is increased, the power and speed are varied. A cluster of constant airflow CFM curves can be tested, as shown in
(46) In
F(A,B,C)=Σ.sub.i.sup.m(Y.sub.i(C.sub.3n.sub.i.sup.2+C.sub.2n.sub.i+C.sub.1)).sup.2,
where F(A, B, C) is minimized by solving the equations ∂F/∂A=0, ∂F/∂B=0, and ∂F/∂C=0.
(47) The process of curve fitting includes the selection of curves of polynomials based on the least-squares method. In general, the function P=C.sub.mn.sup.m−1+ . . . +C.sub.3n.sup.2+C.sub.2n+C.sub.1 can be used to model the pairs of power and speed data as a curve. In one embodiment, the functional relationship between P and n may be a quadratic function: P=C.sub.3n.sup.2+C.sub.2n+C.sub.1, wherein C.sub.1, C.sub.2, and C.sub.3 are the coefficients, n is the motor speed value, and any a target airflow corresponds to a set of coefficients C.sub.1, C.sub.2, and C.sub.3 stored among a plurality of target airflows. In some embodiments, the microprocessor may obtain a set of corresponding coefficients C.sub.1, C.sub.2, and C.sub.3 based on the input target airflow value IN-CFM through the use of a look-up table method. Thus, the functional relationship formula P=ƒ(n) may be obtained, wherein every target airflow corresponds to a set of coefficients C.sub.1, C.sub.2, and C.sub.3 among any load, and they are shown in Table 1 below.
(48) TABLE-US-00001 TABLE 1 CFM C.sub.1 C.sub.2 C.sub.3 150 0.338 −0.151 0.0458 300 0.4423 −0.2113 0.0765 450 ∘ ∘ ∘ ∘ ∘ ∘ ∘ ∘ ∘ 600 ∘ ∘ ∘ ∘ ∘ ∘ ∘ ∘ ∘ 750 ∘ ∘ ∘ ∘ ∘ ∘ ∘ ∘ ∘ 900 ∘ ∘ ∘ ∘ ∘ ∘ ∘ ∘ ∘
(49)
(50) Table 2 shows an example of the test data results. The motor speed in table 2 ranges from 200 to 1400 RPM, and the static pressure of the system ranges from 0.1 to 1 in HO.sub.2. Maintaining the preset constant airflow CFM output constant, for example, within about plus or minus 5 percent, a series of motor input power values are obtained, and a database is formed based on the obtained power values as shown in
(51) TABLE-US-00002 TABLE 2 150 CFM 300 CFM 450 CFM 600 CFM 750 CFM airflow airflow airflow airflow airflow Speed Power Speed Power Speed Power Speed Power Speed Power 385.3 3.6% 452.2 6.9% 590.1 14.8% 693.6 26.6% 822.9 45.6% 385.9 3.6% 577.7 10.6% 680.6 19.6% 763.9 31.6% 878.1 50.4% 531 6.0% 700.3 14.6% 778.5 24.7% 839.3 37.2% 936 56.4% 637.3 8.6% 787.5 18.4% 858.4 29.8% 905 43.2% 997.9 63.9% 737.4 11.6% 861.2 22.2% 940.5 35.2% 987.8 50.6% 1056 70.5% 818.4 14.4% 932.6 26.2% 1015 41.0% 1051 57.0% 1115 77.1% 891 17.4% 997.9 30.5% 1078 45.6% 1127 64.1% 1176 83.3% 970.3 21.5% 1053 34.2% 1146 51.6% 1184 70.2% 1173 83.2% 1029 24.8% 1119 39.7% 1197 56.6% 1245 75.0% 1100 28.3% 1165 43.1% 1252 61.6% 1163 32.4%
(52) Each preset CFM airflow may correspond to a quadratic function of power and speed that is obtained using a standard calculation process that applies the least-squares method. Equations (3) through (7) define a pair of power and speed working points for any system working point at a specific static pressure.
(53)
(54) According to an embodiment, when an airflow input IN-CFM is input, the motor system may use a corresponding power and speed pair quadratic function to define a working point trajectory to follow during motor operation to maintain constant the preset airflow CFM value. In general, equations (3) to (7) can be expressed as a standard equation P(CFM)=C.sub.3n.sup.2+C.sub.2n+C.sub.1 (Equation 8), where C.sub.1, C.sub.2, and C.sub.3 are constants, n is speed, and P is power.
(55) Equations (3) to (7) define five modeling curves that provide working point trajectories for several constant airflow CFM options. As shown in
(56)
(57) For the pair of power points (p.sub.1i, p.sub.2i) at a selected speed, a linear weighted interpolation can be used to calculate the p.sub.i value, as shown below.
p.sub.i=p.sub.2i+w.Math.(p.sub.1i−p.sub.2i) (9)
(58) In equation (9) above, i=1, 2, and 3, and w is the weighted coefficient that can be calculated as:
(59)
(60) Noticing that CFM2≦CFM≦CFM1, and so 0≦w≦1, the following matrix equations can be calculated as,
(61)
(62) By solving the matrix equation, the coefficients of equation 8, C.sub.1, C.sub.2, and C.sub.3 can be calculated such that the function P=C.sub.3n.sup.2+C.sub.2n+C.sub.1 corresponding to the IN-CFM=P=525 CFM can be obtained. Therefore, the power equation of any requesting input airflow command IN-CFM can be obtained. Because the process may be completed in the MCU initialization, the MCU does not need to consume much CPU calculation power.
(63) Motor real-time input power Pi may be filtered by a digital low-pass filter. Assume that samples of the input and output are taken at a sampling cycle, separated by Δt time (PWM switching frequency). The power inputs may be represented by the sequence (P.sub.in1, . . . , P.sub.inn) and the outputs may be represented by the sequence (P.sub.out1, . . . , P.sub.outn), which correspond to the same points in time, then the low-pass filter can be given as
(64)
where T is the time constant. Rearranging the terms above gives the recurrence relation, and the discrete-time low-pass filter can be expressed as the exponentially-weighted moving average, given as P.sub.outi=α.Math.P.sub.ini(1−α).Math.P.sub.out where
(65)
(66) By definition, the smoothing factor relationship is 0≦α≦1. If α=0.5, then the time constant
(67)
becomes equal to the sampling period. If α<<0.5, then time constant T is significantly larger than the sampling interval. For power filtering in direct power control, α≦0.01. So Δt≈α.Math.T.
(68) The change from one filter output to the next is proportional to the difference between the previous output and the next input. This exponential smoothing property matches the exponential decay in the continuous-time system. As expected, as the time constant T increases, the discrete-time smoothing factor α decreases, and the output samples (P.sub.out1, . . . , P.sub.outn), respond more slowly to a change in the input sample (P.sub.in1, . . . , P.sub.inn), hence the system has more inertia.
(69) This filter technique can also be applied to the DC bus voltage and DC bus current in scalar control, where the DC bus power is calculated by processing both signals on the DC bus.
(70) It can be seen that Direct Power Control (DPC) may achieve power control by speed control. The function of the power/speed control logic may be to coordinate the power/speed loop time constant to ensure the stability of the system. Power calculations can also be calculated more precisely by motor control than by torque calculation. In addition, speed control to implement power control can be precisely controlled by motor controls using either scalar or vector control in comparison with the torque control.
(71) The direct power control may be achieved by speed control because of the unique power and speed characteristic of blower load. As speed increases, the power increases simultaneously. Therefore, as the motor speed goes from zero speed to high speed, so does the power. The motor speed may rise until reaching a working point pair of power and speed that associates with the static pressure of the load condition, such as stable working point “A” in
(72) In implementation, the power fluctuation that results from the sudden changes in pressure can be reduced by using a restricted power increment control. As shown in
(73)
(74)
(75) The motor real-time input power value P.sub.i may be computed based on the DC bus voltage/current fed back to the MCU. Then, based on the air volume specified via the external input IN-CFM and the corresponding power/speed data, the target motor input power Pt may be calculated. A comparison of the calculated target motor input power value Pt and the motor real-time power P.sub.i may be performed to obtain the power difference ΔP. The power of the motor may be adjusted until P.sub.i approximately equals Pt, for example, within about plus or minus 5 percent. While the power is adjusted, the power differential ΔP may be limited to a maximum to avoid power differentials ΔP that are too large. Power difference ΔP may be output using the power/speed control logic, speed loop control, and PWM inverter speed control, as shown in
EXAMPLE 2
(76) The greatest difference between this example and example 1 is that in example 1 the motor real-time input power value P.sub.i is calculated based on the real-time bus current and the real-time bus voltage based on scalar control. In contrast, in example 2, the PM motor employs sensorless vector control, wherein the calculation of the motor real-time input power P.sub.i is more complicated.
(77) As shown in
(78)
(79) In vector control, such as in the vector control systems shown in
(80)
(81) In some embodiments, motor operating parameters may experience significant variation, which may reduce the precision with which the motor can be controlled. As a result, the motor may operate with a level of uncertainty. Also causing reduction in the precision with which the motor can be controlled may be the complexity associated with an HVAC system that may be a result of the numerous complex components that make up an HVAC system. According to one embodiment, advanced motor system modeling may be employed to mathematically model operating parameters of the motor system. As a result, a target power determined for the motor to produce constant airflow in the HVAC system may account for the variability, and hence be more precise.
(82)
(83) In some embodiments, the motor power may be determined based, at least in part, on instantaneous values of a DC bus voltage and a DC bus current on an inverter coupled to the motor. For example, in one embodiment, when scalar control is utilized for the motor control system, such as is illustrated in
(84) In another embodiment, the motor power may be determined based, at least in part, on DC bus voltage on an inverter coupled to the motor and phase currents of the motor, wherein the phase currents may correspond to the currents on a plurality of phase windings of a stator of the motor. For example, in one embodiment, when vector control is utilized for the motor control system, such as is illustrated in
(85) Returning to
(86) Method 2100 may include, at block 2106, determining a target motor power that yields the target airflow rate in the HVAC system, wherein the target motor power may be determined based, at least in part, on the determined speed of the motor and the obtained target airflow rate for the HVAC system. In some embodiments, determining the target motor power that yields the target airflow rate in the HVAC system may include calculating the target motor power based, at least in part, on an exponential non-linear higher-order function of at least the determined speed, the obtained target airflow rate for the HVAC system, and motor operation parameters.
(87) For example, as noted previously, the airflow rate can be modeled as a function of the power and speed of the motor and the static pressure in the HVAC system. Similarly the power may be modeled as a function of the airflow rate, motor speed, and the static pressure in the HVAC system. As an example, for any airflow rate, as the static pressure in the system changes, a pair of motor power and motor speed can be determined to compensate for the static pressure change and control the motor to maintain the airflow rate constant. In some embodiments, the changes in the system's static pressure can be represented by a change in the motor's speed. Therefore, the motor power may be modeled as a function of the airflow rate and the motor speed such that Power=ƒ(CFM, Speed), where CFM is the target airflow rate and the motor speed, Speed, is a function of the static pressure in the system.
(88) In some embodiments, to develop the functional relationship illustrated in
(89) According to the embodiment of
ƒ(x,y,k)=k.sub.0+k.sub.1.Math.x+k.sub.2.Math.y+k.sub.3.Math.x.Math.y+k.sub.4.Math.y.sup.2 (12)
z.sub.i=ƒ(x.sub.i,y.sub.i,k), i=1, 2, . . . m, (13)
where z=motor power, x=airflow rate, y=fan speed, which may be equivalent to the rotational speed of the motor's rotor, and k.sub.j=a vector k of parameters j=0, 1, . . . , n, where n=4 in equation (12). According to an embodiment, the two non-linear terms x.Math.y=airflow rate.Math.speed and y.sup.2=speed.sup.2 may improve the regression precision.
(90) Equations (12) and (13) show that determining the target motor power that yields the target airflow rate in the HVAC system, such as at block 2106, may include calculating the target motor power based, at least in part, on a non-linear higher-order polynomial function of at least the determined speed, the obtained target airflow rate for the HVAC system, and motor operation parameters. In addition, equations (12) and (13) show that the non-linear higher-order polynomial function of at least the determined speed, the obtained target airflow rate for the HVAC system, and motor operation parameters includes a product of at least one of: the obtained target airflow rate and the determined speed; and the determined speed and the determined speed.
(91) Because in equation (12) the airflow rate and the speed are known variables, only the vector k of parameters may need to be determined to calculate the target motor power z. According to an embodiment, the vector k of parameters may be determined by minimization of an error function for the power function described in equation (12).
(92) In many industrial applications, specifications may define precision as the percentage error, as opposed to a specific error value, of a parameter that must be met across the entire operating range for the system. For example, if airflow rate is the system parameter for which error is to be minimized and the HVAC system has a typical airflow rate that ranges from 700 CFM to 1,500 CFM, then error may be specified as 5% across the entire range from 700 CFM to 1,500 CFM, rather than 50 CFM. Otherwise, a discrepancy of 50 CFM may yield an error of 7.1% when the system is desired to be operating with an airflow rate of 700 CFM and may yield an error of 3.3% when the system is desired to be operating with an airflow rate of 1500 CFM. Therefore, precision with which the system operates may be reduced when an error value is monitored instead of the percentage error because the percentage error may vary depending on the target airflow rate for the system. Accordingly, in some embodiments, in order to operate the system with a high level of precision, the error function for the power function described in equation (12) may be a percentage error function.
(93) In some embodiments, the power model function defined in equations (12) and (13) may be defined as an exponential power function to make use of popular exponential function characteristics. As example, and not limitation, in one embodiment, the power model function defined in equation (13) may be redefined as:
z.sub.i=e.sup.ƒ(x.sup.
(94) The popular exponential function characteristics may be summarized as:
(95)
(96) where Z is the measured value and {circumflex over (Z)} is the predicted value. Equation (15) shows that the difference between the natural log of the predicted value and the natural log of the measured value yields the percentage error between the predicted value and the measured value. According to one embodiment, the exponential characteristics shown in equation (15) may be utilized to minimize the percentage error for the calculated target power, which may improve the modeling precision.
(97) The power defined as a non-linear exponential function as shown in equation (14) may be transformed into a linear model by taking the natural log of both sides of equation (14) so that the functional relationship may be defined as below:
ln(z.sub.i)=ƒ(x.sub.i,y.sub.i,k) (16)
(98) The sum of the squares may subsequently be defined as:
E=Σ.sub.i=1.sup.n[ƒ(x.sub.i,y.sub.i,k)−ln(z.sub.i)].sup.2. (17)
(99) As shown in equation (17), the errors may be multiplicative and log-normally distributed. In addition, errors on ln(z) may be different regardless of the experimental errors on z. Moreover, with multiplicative errors that are log-normally distributed, using exponential model functions may yield unbiased and consistent parameter estimates with minimal to no outliers. According to an embodiment, the minimum value of E defined in equation (17) may occur when the gradient is zero. Because the model contains n parameters, n gradient equations may exist and can be defined as:
(100)
(101) According to one embodiment, the parameters of the vector k can be found by solving the standard matrix equation in equation (18). Upon determining the parameters of the vector k, the power, as defined in equations (14) and (16), may be completely defined. As shown in equations (14) through (18), in some embodiments, the motor operation parameters, e.g., the vector k of parameters, may be determined based, at least in part, on minimization of percent error of the exponential non-linear higher-order polynomial function of at least the determined speed, the obtained target airflow rate for the HVAC system, and motor operation parameters.
(102) To summarize the model development described with equations (12)-(18), in some embodiments, the motor power may be expressed as:
Power=e.sup.ƒ(x,y,k) (19)
where ƒ(x, y, k) can, in some embodiments, be defined as:
ƒ(x,y,k)=k.sub.0+k.sub.1.Math.CFM+k.sub.2.Math.speed+k.sub.3.Math.speed+k.sub.4.Math.speed.sup.2 (20)
(103) According to one embodiment, parameters of the vector k in equation (20) can be pre-calculated from experimental tests. In general, more data points obtained from the experimental tests to determine the parameters of the vector k may yield more accurate airflow rate control. In some embodiments, equally-spaced data points may not be necessary, although it may be preferred in some embodiments.
(104) As shown in the embodiment illustrated in
(105) In some embodiments, the power functions disclosed herein as mathematical models may provide universal and high precision control of motor power to deliver constant airflow in HVAC systems. In addition, the universal and high precision control schemes disclosed herein may standardize motor control modeling and simplify the implementation to meet industrial requirements.
(106) In some embodiments in which the power is defined as in equation (13), the error function to be minimized may be the sum of residual error squares. For example, consider a set of m data points, (x.sub.1, y.sub.1, k.sub.1), (x.sub.2, y.sub.z, k.sub.2), . . . , (x.sub.m, y.sub.m, k.sub.m), and a modeling function z=ƒ(x, y, k) that in addition to the variables, x and y, also depends on the n parameters, k=(k.sub.1, k.sub.2, . . . , k.sub.n), where m>n. The vector k of parameters may be calculated so that the model best fits to the given data in the least squares sense. For example, the error function to be minimized may be the sum of residual error squares defined as:
(107)
The parameters of the vector k can be found by solving the standard matrix equation in equation (18), and upon determining the parameters of the vector k, the power, as defined in equation (13), may be completely defined. As shown in equations (12), (13), and (21), in some embodiments, the motor operation parameters, e.g., the vector k of parameters, may be determined based, at least in part, on minimization of absolute error of the non-linear higher-order polynomial function of at least the determined speed, the obtained target airflow rate for the HVAC system, and motor operation parameters.
(108) Returning to
(109) At block 2110, method 2100 may include adjusting the power of the motor when the motor power is not approximately equal to the target motor power, wherein the motor power is adjusted until the motor power is approximately equal to the target motor power. For example, as discussed with reference to the embodiments illustrated in
(110) According to some embodiments, the motor power may be maintained constant when the motor power is approximately equal to the target motor power. For example, as discussed previously, in some motor control systems, such as those disclosed in
(111) The schematic flow chart diagrams of
(112) Those of skill would appreciate that the various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the disclosure herein may be implemented as electronic hardware, computer software stored on a computing device and executed by one or more processing devices, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the disclosure.
(113) In some embodiments, the techniques or steps of a method described in connection with the aspects disclosed herein may be embodied directly in hardware, in software executed by a processor, or in a combination of the two. In some aspects of the disclosure, any software module, software layer, or thread described herein may comprise an engine comprising firmware or software and hardware configured to perform aspects of the described herein. In general, functions of a software module or software layer described herein may be embodied directly in hardware, or embodied as software executed by a processor, or embodied as a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium may be coupled to the processor such that the processor can read data from, and write data to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC. The ASIC may reside in a user device. In the alternative, the processor and the storage medium may reside as discrete components in a user device.
(114) If implemented in firmware and/or software, the functions described above may be stored as one or more instructions or code on a computer-readable medium. Examples include non-transitory computer-readable media encoded with a data structure and computer-readable media encoded with a computer program. Computer-readable media includes physical computer storage media. A storage medium may be any available medium that can be accessed by a computer. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer. Disk and disc includes compact discs (CD), laser discs, optical discs, digital versatile discs (DVD), floppy disks and blu-ray discs. Generally, disks reproduce data magnetically, and discs reproduce data optically. Combinations of the above should also be included within the scope of computer-readable media.
(115) While the aspects of the disclosure described herein have been described with reference to numerous specific details, one of ordinary skill in the art will recognize that the aspects of the disclosure can be embodied in other specific forms without departing from the spirit of the aspects of the disclosure. Thus, one of ordinary skill in the art would understand that the aspects described herein are not to be limited by the foregoing illustrative details, but rather are to be defined by the appended claims.
(116) Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the present invention, disclosure, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.