Motor for fans or blowers, pumps or compressors, method for operating such a motor and blower system having one or more motor(s)/blower(s)

A motor for a fan, a ventilator, a pump or a compressor includes integrated motor electronics and at least one sensor unit for pressure or volume flow control. The at least one sensor unit may be a module that can be plugged onto or into the integrated motor electronics or may be at least partly integrated into the motor electronics. The motor may be an electronically commutated motor. The integrated motor electronics may be configured to supply the at least one sensor unit with energy.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention concerns a motor for fans or ventilators, pumps or compressors, in particular, an electronically commutated motor (EC motor), with integrated motor electronics and at least one sensor unit for direct or indirect pressure/volume flow control. It is essential that the sensor unit can be used as a pure measuring unit and transmits the pressure or pressure values to an external control system. The regulation/control can also be integrated.

Furthermore, the invention concerns a process for the operation of such a motor and a fan system with one, two or more such motors or fans.

2. Description of the Related Art

Motors or fans of the generic type are well-known from practice. Merely by way of example, reference is made to GB 2 512 043 A. From this publication, a ventilation system with corresponding fans is known, in which an air volume measurement takes place in the housing. The relevant electronics is located in the housing, but outside the motor, and is also supplied with current/voltage from outside the motor. There is no provision for an integrated regulation. With regard to the data transmission of setpoint and actual values, the known system is complex, since no bus connection is provided.

Nowadays, speed-controlled fans with electronically commutated motors (EC fans) are used in modern air-conditioning units. They serve as a supply air/air extraction fan. In order to control the air volume as required, it is necessary to measure the air pressure and, if necessary, the temperature at different points in the air handling unit. Pressure and differential pressure sensors are used regularly. The output signal of the differential pressure sensor is usually fed to a separate control unit and processed there. The control unit calculates a speed setpoint and transmits it, for example, via an analog signal (e. g. 0 to 10 volts) or via a bus system (e. G. via a Modbus) to a higher-level controller/control system or to the fan. The pressure sensor, control unit, power supply and fan must be mounted in or on the air conditioner and wired together. This requirement is, however, costly in terms of time.

SUMMARY OF THE INVENTION

The invention is based on the task of designing and developing a motor of the generic type in such a way that it is particularly suitable for the driving fans, pumps, compressors, etc., with the least possible effort in switching and control engineering.

The foregoing task is solved by the fact that the sensor unit is designed as a module that can be plugged onto the motor electronics or plugged into the motor electronics, or at least partially integrated into the motor electronics and is supplied with energy via the motor electronics, i. e. internally.

A process in accordance with the invention serves to operate a motor in accordance with the invention, using a special control algorithm.

A fan system according to the invention comprises at least one motor or fan according to the invention.

It is essential for the invention-oriented motor, fan or ventilator that the sensor unit, comprising the sensor and the required electronics of the sensor, is either pluggable as a module onto the motor electronics or pluggable into the motor electronics. Alternatively, the sensor unit is completely integrated into the motor electronics. In both cases, the sensor unit is supplied with electrical energy via the motor electronics and the sensor unit is directly connected to the motor electronics.

In the first variant, i. e. when designing the sensor unit as a plug-in or plug-in module, corresponding motors or fans can be retrofitted. In addition, all known motor technologies are possible, such as asynchronous motors, permanent magnet synchronous motors, synchronous reluctance motors, etc.

In the following, the invention is described using the example of a centrifugal fan, whereby the description serves as an example for the discussion of the teaching in accordance with the invention, but does not restrict this to one fan type. Other fan types such as axial/diagonal fans are also possible.

As already explained, the term “sensor unit” is to be understood in the broadest sense. It comprises the actual sensor and, for example, a printed circuit board with electronic components.

The sensor unit can be the only sensor to include a pressure sensor that detects a local pressure via at least one hose or a pressure difference of the pressure at two locations via two hoses. An analog or digital signal corresponding to the pressure or pressure difference is fed to a microprocessor, which can be an integral part of the sensor unit.

Furthermore, it is conceivable that the sensor unit may also include other sensors that are connected to the sensor unit and whose measured values can be read in. It is also conceivable that additional internal or external sensor units equipped with corresponding sensors may be provided.

In any case, it is essential that the hose (pressure hose) or the hoses (at differential pressure) are connected directly to the motor/fan. The integrated sensor unit records the pressure and transmits a measured value corresponding to this pressure via an analog or digital signal to a microprocessor system. As an option, further measured variables can be determined via external sensors and their measured values can be transmitted to the sensor unit and read. Temperature sensors, humidity sensors, air quality sensors, etc. can be provided for this purpose.

The sensor unit communicates directly in an advantageous way with the motor controller unit via bus system. If several motors/fans are used, it is advantageous if an external, higher-level control is provided, which preferably sets a setpoint value via a bus system, e. g. via a Modbus. The higher-level control system is designed for data exchange with the integrated motor control and the sensor unit, among other things. It is also conceivable that the interface used for data exchange uses a method for the dynamic addressing of slave units, e. g. according to EP 2 287 689 B1. A common communication protocol with a uniform protocol set is a particular advantage.

The innovative process uses a control algorithm of a microprocessor system, taking into account a pre-set pressure setpoint and, if necessary, taking into account further setpoints for additional sensors. A speed setpoint value of the respective motor is calculated and the integrated motor electronics is controlled accordingly in such a way that a certain speed of the motor results.

As described above, the addressable unit can perform a pressure measurement, pressure control and, using the fan-dependent K-factor, a volumetric flow measurement or volume flow control.

Advantages of the invention-oriented technology can be seen in the fact that the sensor unit is supplied with voltage/current directly in the motor or fan. Accordingly, complex mounting and wiring of the sensor in the climate control unit is no longer necessary.

Hoses for pressure sensing are connected directly to the fan or to the pressure connections provided there, which are connected to the sensor unit.

If required, the fan can apply the pressure measurement, pressure control or also the volumetric flow measurement or volumetric flow control. An external control unit and its wiring can be omitted in such a design.

External power supplies of the pressure sensor are not required due to the internal power supply. In addition, only a Modbus address and a common bus description protocol are required, since the pressure sensor and motor or fan are integrated as one unit in a possibly external control system.

The sensor unit can be integrated in the motor electronics and connected to the micro-controller system of the motor.

An inventive fan system, in particular an air-conditioning unit, uses at least one motor/fan in accordance with the invention as described above. At the same time, a state-of the-art motor/fan can be provided or combined with motors/fans in accordance with the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG.1ashows an example of an application of the teaching according to the invention, namely a radial fan1with integrated differential pressure measurement. Motor2, which includes the integrated differential pressure measurement, can be used to drive different fans or compressors.

FIG.1aclearly shows a housing3for the motor electronics, whereby a pressure connection4with two nozzles5for external pressure hoses for differential pressure measurement are provided in housing3. The pressure connection4is part of a passage6shown inFIG.4, which is screwed into the housing3. Electrical connections7are also provided.

FIG.1bshows the housing3of the centrifugal fan1fromFIG.1ain enlarged view.FIG.1bclearly shows the pressure connection4with the two nozzles5.

FIG.2shows the centrifugal fan shown inFIG.1in a tilted diagram with the components discussed above. The housing3has a cover8, which is fastened to the housing3by means of screws9.

FIGS.3aand3bshow the centrifugal fan1as shown inFIG.2, but with open housing3. The cover8not shown inFIGS.3aand3bhas been removed after loosening the screws9.

According toFIG.3b, the motor electronics in the housing3is indicated, where only the terminals10, which are part of the motor electronics, are visible. The actual motor electronics is covered by an inner cover8a, which serves as a touch protection.

The modular sensor unit11is inserted into the motor electronics, in the area of a recess in the inner cover8a, or inserted in/on the printed circuit board of the motor electronics and contacted there. The two internal hoses12are visible. They extend from the modular sensor unit11to passage6and can be connected from outside the housing3via the sockets5to external hoses which are not shown. Pressures from any location can be communicated to the sensor unit11, i.e. by means of a flow connection created in this way.

FIG.4shows a schematic view of passage6with internal connection piece13, from which relatively thin hoses lead to sensor unit11(seeFIG.3b). The external connection pieces5are used to connect external pressure hoses in accordance with the previous versions.

FIG.5ashows the sensor unit11in a plan view, which is housed in a housing made preferably of plastic. In addition to other electronic components, the actual pressure sensor (17), which is connected to the internal hoses12by a flow, is located on a printed circuit board (PCB)15.

Furthermore, connection terminals (18) are provided for (Modbus) communication with the outside world.

FIG.5bshows the modular sensor unit11from below, i. e. in a lower view of the circuit board15provided there, which is provided with a contacting16for power supply directly from the main circuit board of the motor electronics and for the internal communication connection to the processor, etc.

FIG.6shows two radial fans1and an external, higher-level control19, which preferably sets a setpoint value via a bus system, e. g. via a Modbus. The higher-level control system19is designed for data exchange with the integrated motor control and the sensor unit11of each radial fan1, among other things. It is also conceivable that the interface used for data exchange uses a method for the dynamic addressing of the radial fans1as slave units1.

REFERENCE LIST