Abstract:
A variable speed power converter controls the speed of a load in a material handling system as a function of the torque required to move the load. While the power converter is running, the torque being produced in the motor is determined. The power converter then determines the maximum rotational speed of the motor as a function of the torque currently being produced and of the torque-speed curve of the motor. The power converter then commands the motor to rotate at this maximum rotational speed. The power converter periodically monitors the torque being produced and adjusts the maximum rotational speed of the motor throughout the run.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The subject matter disclosed herein relates to variable speed control of a motor. More specifically, the subject matter disclosed herein relates to a method and apparatus for controlling the speed of a motor used in a material handling system as a function of the load applied to the motor. 
         [0002]    Material handling systems are widely used to lift heavy loads, weighing up to hundreds of tons. A typical material handling system includes at least one motor used to raise and lower the load and at least one additional motor to position the material handling system over the load to be moved. Common applications include manufacturing facilities, in which large components may be positioned for assembly and/or the final assembly may be moved for shipping. In the shipping industry, containers are loaded and unloaded between storage facilities, trucks, trains, and ships. Such material handling systems typically include a hook block, connected by a cable to a drum, which is, in turn, connected directly or indirectly through a gearbox, to the motor. The hook may be directly connected to a lifting point on the object or indirectly connected to the object via another lifting apparatus such as chains, slings, or custom structures. The motor then rotates in one direction to raise the load and in the other direction to lower the load. 
         [0003]    Still other material handling systems are designed to handle application specific requirements of certain loads. For example, bulk materials such as sand or salt may require a bucket, or clam shell, attachment. The clam-shell is lowered in an open position and closed to scoop up a load of the bulk material. Scrap yards and recycling facilities may utilize a magnet attachment which, when energized, may be used to pick up ferrous metals. Still other attachments are used as dictated by the application requirements. As described above, it is apparent that material handling systems are an integral part of many manufacturing processes. As a result, the efficiency of the material handling system impacts the efficiency of the manufacturing process. 
         [0004]    It is known that electric motors are capable of producing rated torque up to rated speed and at least a portion of rated torque when operating above rated speed. The portion of rated torque the motor is capable of producing decreases the further above rated speed the motor operates. Therefore, in order to increase the efficiency of the material handling system, it is desirable to operate the motor at the maximum speed at which the motor can operate and still produce sufficient torque to control the load being moved. 
         [0005]    Historically, it is known that the weight of the load may be determined by including a load sensor or by detecting the magnitude of the current in the motor. Such systems either weigh the load prior to operating the motor or detect a current once the motor is operating at constant speed. The maximum operating speed is then determined once during the initial operation of the motor and a maximum speed is set for the duration of the run. Such a system may be suitable for applications in which the load is constant; however, material handling systems may experience applications in which the load is changing. If the load decreases during operation, the motor no longer operates at peak efficiency, and if the load increases during operation, the motor may not be able to produce sufficient torque at the current speed to maintain control of the load. 
         [0006]    Thus, it would be desirable to provide a system to improve productivity of material handling systems in which the load changes during operation. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0007]    The subject matter disclosed herein describes a variable speed power converter controlling the speed of a load in a material handling system as a function of the torque required to move the load. The torque produced in the motor is determined as the power converter is running. The power converter then determines a maximum rotational speed of the motor as a function of the torque currently being produced and of the torque-speed curve of the motor. The power converter then commands the motor to rotate at this maximum rotational speed. The power converter periodically monitors the torque being produced and adjusts the maximum rotational speed of the motor throughout the run. 
         [0008]    According to a first embodiment of the invention, a motor drive for controlling rotation of a motor in a material handling system includes a memory device storing a series of processor executable instructions and a processor in communication with the memory device. The processor is configured to periodically execute the instructions to perform the following steps while rotating the motor: obtain a signal corresponding to a magnitude of torque produced by the motor, determine a maximum operating speed of the motor as a function of the magnitude of torque produced in the motor, and control the motor to rotate at the maximum operating speed. The signal obtained may be a current feedback signal, an estimated current value, or a value derived from either the current feedback signal or the estimated current value. 
         [0009]    Thus, it is a feature of the invention that the maximum operating speed is periodically recalculated during the course of a run. Consequently, if the load changes during the run, the motor continues to run at the maximum operating speed at which it is capable of producing the torque required to control the load. 
         [0010]    As another aspect of the invention, the maximum operating speed is a function of the direction of rotation of the motor. The signal corresponding to the magnitude of torque produced by the motor is filtered prior to determining the maximum operating speed. Additionally, the maximum operating speed is a function of a torque-speed characteristic of the motor, and the maximum operating speed is determined at least two times between starting and stopping the motor. 
         [0011]    According to another embodiment of the invention, a power converter controls the rotation of a motor which, in turn, rotates a drum around which a cable is wound. The cable is alternately let out or wound in according to the direction of rotation of the drum to raise or lower a load in a material handling system. The power converter includes a processor and an input. The input is configured to receive a run command and to transmit the run command to the processor. The power converter also includes a sensor providing a feedback signal to the processor corresponding to a magnitude of the load, and a control module executing on the processor to periodically determine a maximum operating speed of the motor as a function of the feedback signal when the run command is present at the input. 
         [0012]    As still another aspect of the invention, the control module further executes to output a new speed command to the motor as a function of the maximum operating speed. The processor may also execute a series of instructions to convert the feedback signal, corresponding to the magnitude of the load, to a torque feedback signal. A filter may receive either the feedback signal or the torque feedback signal as an input and generate a filtered output signal. 
         [0013]    The power converter may also include a memory device in communication with the processor, and a plurality of parameters corresponding to a torque-speed curve of the motor. The maximum operating speed may be determined as a function of the filtered output signal and the plurality of parameters corresponding to the torque-speed curve of the motor. At least one input of the power converter may be configured to receive a command signal indicating the direction of rotation of the motor, and the maximum operating speed may also be a function of the direction of rotation of the motor. 
         [0014]    As yet another aspect of the invention, the power converter may also include an input configured to receive a speed feedback signal corresponding to a rotational speed of the motor. The control module further executes to periodically compare the speed feedback signal to a predetermined threshold, and if the speed feedback signal is greater than the predetermined threshold, the motor drive indicates a fault condition and stops rotation of the motor, but if the speed feedback signal is less than the predetermined threshold, the motor drive continues to rotate the motor at the new speed command. 
         [0015]    According to yet another embodiment of the invention, a method of controlling a motor used to selectively raise or lower a load in a material handling system with a motor drive receives a command signal at the motor drive to begin rotation of the motor to either raise or lower the load. At a periodic interval, the following steps are repeated while the command signal is present at the motor drive. A magnitude of torque produced by the motor during rotation of the motor is obtained from a signal in the motor drive. A maximum rotational speed of the motor is determined as a function of the magnitude of torque produced by the motor, and the speed of the motor is controlled with the motor drive to rotate at the maximum rotational speed. Rotation of the motor is stopped when the command signal is removed from the motor drive. The measured torque in the motor drive may be filtered prior to determining the maximum rotational speed of the motor, and the maximum rotational speed of the motor may further be a function of the direction of rotation of the motor. 
         [0016]    As another aspect of the invention, the method may also retrieve a torque-speed profile prior to determining the maximum rotational speed, and the maximum rotational speed may also be a function of the torque-speed profile. Initially, a torque-speed profile for the motor may be stored in the motor drive, and the maximum rotational speed may be selected at a speed less than the speed indicated by the torque-speed profile. 
         [0017]    As still another aspect of the invention, a speed feedback signal is received at the motor drive, which corresponds to the rotational speed of the motor. At a periodic interval, the speed feedback signal is compared to a predetermined threshold stored in the motor drive. The predetermined threshold is a function of the maximum rotational speed, and if the speed feedback signal is greater than the predetermined threshold, the motor drive indicates a fault condition, stopping rotation of the motor. However, if the speed feedback signal is less than the predetermined threshold, the motor drive continues to rotate the motor. 
         [0018]    These and other objects, advantages, and features of the invention will become apparent to those skilled in the art from the detailed description and the accompanying drawings. It should be understood, however, that the detailed description and accompanying drawings, while indicating preferred embodiments of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING(S) 
         [0019]    Various exemplary embodiments of the subject matter disclosed herein are illustrated in the accompanying drawings in which like reference numerals represent like parts throughout, and in which: 
           [0020]      FIG. 1  is a partial schematic representation of a grapple crane, illustrating an exemplary environment incorporating the present invention; 
           [0021]      FIG. 2  is a block diagram of a controller for the exemplary environment of  FIG. 1 ; 
           [0022]      FIG. 3  is a block diagram representation of the motor drive of  FIG. 2 ; 
           [0023]      FIG. 4  is an exemplary torque-speed curve for a motor according to the present invention; and 
           [0024]      FIG. 5  is a flowchart illustrating the steps of the present invention. 
       
    
    
       [0025]    In describing the preferred embodiments of the invention which are illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific terms so selected and it is understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the word “connected,” “attached,” or terms similar thereto are often used. They are not limited to direct connection but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0026]    The various features and advantageous details of the subject matter disclosed herein are explained more fully with reference to the non-limiting embodiments described in detail in the following description. 
         [0027]    Turning initially to  FIG. 1 , a grapple crane  10  includes a boom  20  from which the grapple  30  is suspended. The grapple  30  is suspended by a cable  26  which is secured to, and wound around, one or more drums  24 . As illustrated, the cable  26  passes through two pulleys  34  mounted on an upper portion of a frame  32  of the grapple  30 . The jaws  36  are pivotally mounted to a lower portion of the frame  32  and may be selectively opened or closed to release or grab a load, L, respectively. As is known in the art, many configurations of grapples  30  exist with, for example, varying frames  32 , numbers of pulleys  34 , or numbers and styles of jaws  36 . 
         [0028]    As illustrated, the drums  24  are rigidly mounted to the boom  20 . Optionally, the drums  24  may be mounted remotely from the boom, for example, near the base of the crane, and the cables  26  may be routed around additional pulleys and up through the boom  20 . The drums are rotated by a motor  28 , which may be connected to the drums  24  directly or via a gearbox, according to the system requirements. The motor  28  is controlled by a motor drive  40 , see  FIG. 2 , which is typically contained in an enclosure  22 . The boom  20  may be connected to a mobile crane, such as a truck-mounted or track-mounted crane. Optionally, the boom  20  may be rigidly mounted across a work zone and the motor  28  and drums  24  may be mounted to a trolley, not shown, which travels along the boom  20 . As still another option, the boom  20  may also be movably mounted to a pair of rails, not shown, allowing the boom  20  to travel along the rails in a first direction and the trolley to travel in a second direction, generally perpendicular to the first direction. It is contemplated that still other configurations of the boom  20 , motor  28 , and drums  24  may be used according to the system requirements. 
         [0029]    Further, the exemplary embodiment is not intended to be limiting. The present invention may be incorporated into material handling systems utilizing other load handling members, including but not limited to overhead material handling systems incorporating a block and hook, a bucket, a clam-shell attachment, or a magnet. Similarly, the present invention may be incorporated into winch-type applications which may spool out and reel in a cable along a more horizontal plane, including but not limited to a winch, a dredge, an anchor, or other side-pull systems. In each of the exemplary environments, the potential exists for the load, L, to vary during the course of a run. 
         [0030]    The following definitions will be used to describe exemplary material handling systems throughout this specification. As used herein, the terms “raise” and “lower” are intended to denote the operations of letting out or reeling in a cable connectable to a load handling member of a material handling system and are not limited to moving a load in a vertical plane. The load handling member may be any suitable device for connecting to or grabbing a load, including, but not limited to, a hook block, a bucket, a clam-shell, a grapple, or a magnet. While an overhead crane may lift a load vertically, a winch may pull a load from the side. Further, an appropriately configured load handling member may allow a load to spool out cable or be reeled in at any desired angle between a horizontal plane and a vertical plane. 
         [0031]    The “cable,” also known as a “rope,” may be of any suitable material. For example, the “cable” may be made from, but is not limited to, steel, nylon, plastic, other metal or synthetic materials, or a combination thereof, and may be in the form of a solid or stranded cable, chain links, or any other combination as is known in the art. 
         [0032]    A “run” is one cycle of operation of the motor drive  40 . The motor drive  40  controls operation of the motor  28 , rotating the motor  28  to cause the cable  26  to wind around or pay out from the drum  24 . A “run” may include multiple starts and stops of the motor and, similarly it may require multiple “runs” to let the cable  26  reel fully out or wind completely around the drum  24 . Further, the cable  26  need not be fully let out or wound up before reversing direction of rotation of the motor  28 . In addition, direction of rotation of the motor  28  may be reversed within a single run. 
         [0033]    Referring next to  FIG. 2 , a controller  38 , such as an industrial joystick, provides a command signal  46  to the motor drive  40  via an electrical connection. Optionally, the command signal  46  may be transmitted via a wireless connection. The motor drive  40  receives input power  42  which may be a single or multiple phase alternating current (AC) or direct current (DC) power source  42 . The motor drive converts the input power  42  to a desired output power  44  to the motor  28 , which may similarly be a single or multiple phase AC or DC output power  44  according to the application requirements. The motor  28  may include a position sensor  48  connected to the motor drive  40  via an electrical connection to provide a position feedback signal  50  corresponding to the angular position of the motor  28 . 
         [0034]    Referring next for  FIG. 3 , the motor drive  40  receives the input power  42  at a rectifier section  52 . The rectifier section  52  may be either passive, such as a diode bridge, or active, including controlled power electronic devices such as transistors. Preferably, the input power  42  is converted to a DC voltage present on a DC bus  54 . The DC bus  54  may include a bus capacitance  56  connected across the bus  54  to smooth the level of the DC voltage present on the bus. As is known in the art, the bus capacitance may include a single or multiple capacitors arranged in serial, parallel, or a combination thereof according to the power ratings of the motor drive  40 . An inverter section  58  converts the DC voltage to the desired output power  44  for the motor  28  according to switching signals  64 . The switching signals  64  may be determined by an application specific integrated circuit  63  receiving reference signals from a processor  60  or, optionally, directly by the processor  60  executing in the motor drive  40 . The processor  60  is also connected to a memory  62 . The memory  62  may be a single or multiple electronic devices, including static memory, dynamic memory, or a combination thereof. The memory  62  preferably stores operating parameters of the motor drive  40  and one or more programs, which include instructions executable on the processor  60 . 
         [0035]    Referring next to  FIG. 4 , a torque-speed curve  80  describes the magnitude of torque that the motor  28  is capable of producing as a function of the speed at which the motor  28  is rotating. One or more default torque-speed curves  80  may be preconfigured and stored in memory  62 . Preferably, the motor drive  40  includes parameters configurable to define at least one point on the torque-speed curve  80 . Motors  28  are designed to output rated torque up to rated speed. Beyond rated speed, the amount of torque the motor  28  is capable of producing is reduced as described by the torque-speed curve  80 . A first set point  82  is defined by a first torque parameter  84  indicating the torque the motor  28  is capable of producing at a first speed  86 , and a second set point  88  is defined by a second torque parameter  90  indicating the torque the motor  28  is capable of producing at a second speed  92 . Additional set points may be interpolated between known points and, optionally, additional set points may be defined by additional parameters. 
         [0036]    In operation, the processor  60  executes to command rotation of the motor  28  up to a maximum speed as a function of the load, L, present on the material handling system. Referring next to  FIG. 5 , the motor drive  40  receives a command signal  46  to begin a run at step  100 . The motor drive  40  monitors operation of the motor  28  during the run, including determining the amount of torque required by the motor  28  to maintain control of the load, L, at the commanded speed. At step  102 , the processor  60  obtains a signal corresponding to the size of the load, L, being moved during the run. This signal may be a feedback signal input to the drive from a current sensor external to the drive or a load, L, weighing system installed on the material handling system. Optionally, the signal may also be a signal internal to the drive. The internal signal may be a measured signal from, for example, a current sensor internal to the drive  40  or a calculated signal derived from either a commanded or a measured signal. At step  104 , the processor  60  determines a maximum speed at which the motor  28  can operate as a function of the size of load, L. Preferably, the maximum speed is determined at a point during the run when the torque is generally constant, for example near base speed. The speed reference is set to the maximum speed at step  106 . At step  108 , the processor  60  checks the command signal  46  to determine whether the run is complete. If the run is complete, the motor drive  40  brings the motor  28  to a controlled stop. If the run is not complete, the processor  60  again obtains the signal corresponding to the size of the load, L, being moved during the run and the steps are repeated. Steps  102 - 108  are periodically repeated throughout the course of the run. 
         [0037]    In some material handling systems, the potential exists for the load, L, to change during the course of the run. Referring again to  FIG. 1 , the potential exists for the grapple  30  to be positioned other than at the center of the load, L. Further, the load, L, illustrated as a group of logs is often not uniformly distributed. Consequently, one end of the load, L, may remain on the ground, vehicle, or pile of other logs as the load, L, is raised. Further, due to the length of the logs and depending on the position of the grapple  30  along the length of the load, L, one end may remain on the ground for a significant portion of the run. The potential also exists for a log to fall from the grapple  30  if grasped too close to the end of the log. As a result of these potential loading conditions, the load, L, may vary, gradually or suddenly, during the course of a run. 
         [0038]    In some material handling systems, the cable  26  itself may cause the motor  28  to experience a change in load, L, during the course of a run. Depending on the rated torque of the motor  28  and the length of the cable  26 , the weight of the cable  26  may need to be factored into the weight of the load, L. As additional cable  26  is unwound from the drum  24 , the weight of the load, L, applied to the motor increases, and as the cable  26  is wound back around the drum  24 , the weight of the load, L, decreases. Further, the length of the cable  26  may be significant with respect to the width of the drum  24 . As illustrated in  FIG. 1 , the cable  26  may be required to be wound back upon itself, also known as overwrap. In certain material handling systems, such as winches, the number of times which the cable  26  is wound about itself may be significant. The combined diameter of the cable  26  and drum  24  increases as more cable  26  is wound around the drum  24  and decreases as the cable  26  is unwound from the drum  24 . The change in diameter may be significant enough, having a similar effect as changing gears in a gearbox, such that the torque applied to the load, L, changes if the speed of the motor  28  remains constant. Thus, the length of the cable  26  may result in a changing load, L, either due to changing weight or changing diameter on the drum  24 , during the course of a run of a material handling system. 
         [0039]    Material handling systems may be subject to changing loads, L, during the course of a run for still other factors. According to one embodiment, the material handling system may be mounted on a ship and be subject to wave motion. The ship on which the crane is mounted, the load, L, being raised by the crane, or both may rise or fall along with the crests and troughs of the waves. This motion alternately reduces or increases the tension in the cable  26  and, consequently, reduces or increases the torque required to control the load, L. According to another embodiment, the material handling system may include an electromagnetic attachment. The lifting force of the electromagnetic attachment may be varied during the course of a run by adjusting the strength of the electric field in the attachment. As the strength of the magnetic field increases or decrease, the size of the load attracted to the electromagnetic attachment similarly increases and decreases. 
         [0040]    If the load, L, changes during the course of a run, the potential exists for the motor  28  to either operate at less than its maximum speed, reducing efficiency, or at a speed at which the motor  28  is no longer capable of producing sufficient torque to control the load, L. Periodically recalculating the maximum speed during the run permits the motor drive  40  to adjust the operating speed of the motor  28  to compensate for changes in the load, L, during the course of a run. It is desirable to perform the calculation at a frequent enough interval such that the motor drive  40  may respond to a change in load, L, without operating with insufficient torque to control the load, L. However, it is also undesirable to perform the calculation too often such that excessive bandwidth of the processor  60  is consumed by the calculation. According to one embodiment of the invention, the processor  60  recalculates the maximum speed at intervals from about 1 to about 20 ms. 
         [0041]    Material handling systems are often subject to harsh operating environments. The potential exists for electrical noise to be present either in radiated or conducted emissions. Further, even in environments with minimal electrical noise, the motor drive itself may produce such emissions. As a result, the signal detecting the size of the load may be subject to such electrical noise resulting in frequent changes or erroneous spikes of significant magnitude in the feedback signal. Frequent changes or sudden large changes in the commanded speed may result in instability in the motor drive  40  or undesirable performance, such as vibrations, in the material handling system. Consequently, the signal corresponding to the size of the load, L, is preferably filtered to reduce the potential for changing the commanded speed too frequently. It is contemplated that any suitable filter may be employed, for example analog filtering on the feedback signal prior to being received at the motor drive  40  or digital filtering within the motor drive  40  after sampling the feedback signal. 
         [0042]    The motor drive  40  may also be receiving a speed feedback signal  50  from a position sensor  48  mounted on the motor  28 . The speed feedback signal  50  corresponds to the rotational speed of the motor  28 . The motor drive  40  may further include fault detection algorithms, detecting, for example, an overspeed condition of the motor  28 . During an overspeed condition, the actual speed of the motor  28  exceeds a preset speed, typically a small percentage above the rated speed of the motor  28 . If the processor  60  determines that the motor  28  may operate at a maximum speed above the current preset speed at which an overspeed condition may be detected, the processor  60  preferably determines a new preset speed as a function of the maximum speed, and stores the new preset speed in memory  62 . Thus, the maximum operating speed calculation preferably interacts with fault condition detection to prevent inadvertent fault detection from occurring. 
         [0043]    It should be understood that the invention is not limited in its application to the details of construction and arrangements of the components set forth herein. The invention is capable of other embodiments and of being practiced or carried out in various ways. Variations and modifications of the foregoing are within the scope of the present invention. It also being understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention.