Abstract:
This invention is for incrementally controlling energizing and de-energizing of at least two electrical motors in which motor armatures are mechanically coupled to a single mechanical member and in which motor stators are mechanically referenced to a second mechanical member. By energizing and deenergizing two or more electric motors of different force and torque capability coupled in this manner it is possible to provide increments of force and torque as small as the incremental capability of the smallest motor and to provide a large number of force and torque increments which can approximate a smooth control of force and torque in forward and reverse directions. The type of motor used for this invention is a multiple-two-node-open-circuit-armature-winding motor as disclosed in the referenced patents. This type of motor offers various levels of energizing the motor to the full force and torque capability.

Description:
This application for patent is a continuation-in-part of Ser. No. 07/746,602 filed Aug. 19, 1991, now U.S. Pat. No. 5,293,518, which is a continuation-in-part of Ser. No. 06/804,588 filed Mar. 20, 1986, now U.S. Pat. No. 5,077,509, which is a continuation-in-part of Ser. No. 188,000 filed Sep. 17, 1980, now abandoned. 
    
    
     SUMMARY OF THE INVENTION 
     This invention is of controllers for several multiple open-circuit-armature windings electrical motors and two-node, open-circuit-armature-windings electrical motors as are described in U.S. Pat. No. 4,305,027 and U.S. Pat. Re. No. 32,674 which is the reissue of U.S. Pat. No. 4,305,027; these patents are incorporated herein by this reference. A prior U.S. Pat. No. 5,077,509 titled Multiple Windings Electrical Motors Controllers is incorporated herein by this reference. 
     The present invention provides for multiple increments in control of force and torque generated between an armature-commmon mechanical member, mechanically coupled to respective armatures of separate, multiple windings electrical motors, and a stator-common mechanical member, mechanically coupled to respective stators of the separate, multiple windings electrical motors; the multiple increments can be a large number of small increments by having the separate, multiple windings electrical motors with different force-and-torque-generating capability. By sequencing switches which energize and de-energize various such respective motors, or potions of such respective motors, increases and decreases of force or torque between the armature-common member and the stator-common member can be achieved to the various additive levels of force or torque available from combining multiples of such motors. As described and claimed in the reference patent, the various levels of force or torque in a respective multiple two-node windings electrical motor are obtained by operating electrical switches which energize various numbers of force or torque generating winding sets within the motor and by positioning a brush holder in the motor. The means of energizing and de-energizing these winding sets are individual electrical switches, which can be sequentially operated by means disclosed in reference U.S. Pat. No. 5,077,509. The multiple windings electrical motor is uniquely controllable; the multiple windings electrical motor has multiple brushes in two groups contacting the commutator which provide multiple electrical control points. Each of these brushes can be energized, either directly or in series with a stator winding or portion thereof, through an electrical switch with electrical energy derived from an electrical energy source. Thus, by operating respective electrical switches for respective motors, the magnitude of force or torque generated by respective, multiple-two-node-windings-electrical motors can be controlled. Another aspect of the multiple-two-node-windings-electrical-motor control is use of the position of the brush holder to control the positions of the groups of brushes and thereby control the direction and magnitude of force or torque generation. This invention includes the sequential operation of individual electrical switches to proceed in increments to any desired force or torque generation within the capabilities of at-least-two such motors. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention is related to motor speed and torque controllers for both positive and negative torques, and to motor starters, and power output controllers. This invention is related to such controllers for brush-type and brushless machines, and more particularly, to controllers for brush-type and brushless electrical machines of the types disclosed in the referenced patents. This invention is related to controllers of conventional, brush-type and brushless motors in groups of two or more. 
     2. Background Art 
     Previous brush-type electrical machine controllers have used series resistance to control speed and torque and current, especially the excessive currents caused during the starting of series motors. The control of these brush-type machines is very important in considering the application of these motors. There has been a lack of a reliably-operating, efficient controller for brush-type machines. The speed and torque of a series motor energized from a constant potential supply can be controlled by inserting resistance in series with the supply line. Speed control for shunt and compound motors can be obtained by inserting resistance in series with the armature circuit only. The stator field flux of shunt motors can be varied to control the speed of these motors, although special care is required to prevent overspeeding of the motor if the shunt stator field flux becomes very weak. The speed of DC motors can be varied by varying the voltage applied to the motors; the Ward Leonard system of speed control is an example of varying the voltage applied to the DC motor. In the Ward Leonard system the adjustable output voltage from a motor-generator set is applied to the motor. Electric vehicle motor controllers use semiconductor chopper controllers as well as electromechanical switches to connect resistors and batteries in various combinations to regulate electrical power input to the motor, which thereby control the motor output torque. Alternating current induction motors are being controlled for powering other electric vehicles. 
     DISCLOSURE OF THE INVENTION 
     This invention is for controlling the energizing and de-energizing of two or more electrical motors which are mechanically coupled to the same output member and which are mechanically referenced to another member. By energizing and de-energizing two, multiple two-node windings electric motors of different force and torque capability coupled in this manner, it is possible to provide increments of force and torque as small as the incremental capability of the smallest motor and to provide a large number of force and torque increments. One objective of this invention is to smooth changes between torque levels of the larger motor and to add the torque capability of the smaller motor to that of the larger motor. 
     The type of motor used for this invention is a multiple-two-node-open-circuit-armature-winding motor as disclosed in the referenced patents. This type of motor has various levels of energizing the motor to the full force and torque capability of the motor. The controller of this invention uses at least two such motors. 
     This invention uses at least two, multiple-two-node-open-circuit-armature-windings electrical motors of different force and torque capability. In each of these motors, various conditions of control are used according to the number of force and torque levels available in each motor. The smaller motor introduces smaller torque increments or steps which provides smoother force or torque control. This invention allows smoother control by having two sizes of motors. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 shows a linear representation of a controller for two, two-pole, multiple-two-node-armature-windings electrical motors in which each such electrical motor has three force or torque generating winding sets and the force or torque may be varied between zero and maximum in fifteen discrete steps by operating six, two-pole, single throw switches. The multiple, two-node-armature-windings electrical motor linear representation uses the same drawing simplifications used in the reference patents and adds a brush holder. To simplify FIG. 1 and represent two, multiple-two-node-armature-windings motors in one view, the commutators 51 and 94, with respective commutator segments 26 through 33 and 70 through 77, and respective brushes 18 through 25 and 62 through 69, and connecting circuits and respective brush holders 52 and 95 and respective brush springs, ones designated 61 and 104, are shown in enlarged air gaps between the stator magnetic poles 2 and 3 and the magnetic armature 105 and the stator magnetic poles 4 and 5 and the magnetic armature 106. The preferred and practical electrical machines constructions in accord with the reference patents and parent application and the present application is to remove these elements from these fictitious but simplifying air gaps placements and place them adjacent to stator magnetic yokes 107 and 108 and armature magnetic members 105 and 106, respectively. Several figures showing the practical placement of a commutator and brush holder with brushes in a rotary multiple windings electrical machine and in a rotary, multiple, two-node windings electrical motor are shown in the reference U.S. Pat. No. 4,305,027. In FIG. 1 dotted lines are used to represent stator or armature windings as the windings pass behind stator or armature magnetic members respectively. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Consider two, two-pole multiple windings electrical motors as represented in linear fashion in FIG. 1. If it is assumed that the smaller motor is controlled by switches 6 through 11 and the larger motor is controlled by switches 12 through 17, and that the force and torque generated by energizing one winding set of the larger motor is one and one third times the total force and torque capability of the smaller motor, then, the force and torque delivered to the armature-common mechanical member 48, assuming stator-common mechanical member 103 as the reference, can be varied in force and torque increments of approximately one-third of the smaller-motor-maximum force and torque capability by energizing or de-energizing the split-stator windings of both motors in a fifteen-step sequence. Thus, if the smaller motor has a total capability of one foot-pound of torque and the larger motor has a total capability of four foot-pounds of torque, the combined torque from both motors will be five foot-pounds of torque and the torque will be controllable in fifteen increments of one-third foot-pound each. The fifteen step sequence is as follows. 
     In FIG. 1, the first step of this sequence is to energize in stator 107 the stator winding 53-42 and stator winding 56-45 from unidirectional voltage source 60 by closing electrical switches 6 and 9. The stator windings 53-42 and 56-45 connect to first and second brushes group brushes 18 and 22 respectively, which connect through various segments of the commutator 5 at various armature positions to energize open circuit armature windings once removed contrary to the direction of force and torque generation from the brush vacancies 21 and 25, and from which the armature 105 and open circuit armature windings will move in the forward direction of force and torque generation--armature 105 and armature-common member 48 movement to the left in FIG. 1. 
     In FIG. 1, the second step of this sequence is to continue the first step and additionally energize in stator 107 the stator winding 54-43 and stator winding 57-46 from unidirectional voltage source 60 by closing electrical switches 7 and 10. The stator windings 54-43 and 57-46 connect to first and second brushes group brushes 19 and 23 respectively, which connect through various segments of the commutator 51 at various armature positions to energize open circuit armature windings twice removed contrary to the direction of force and torque generation from the brush vacancies 21 and 25, and from which the armature 105 and open circuit armature windings will move in the forward direction of force and torque generation--armature 105 and armature-common member 48 movement to the left in FIG. 1. 
     In FIG. 1, the third step of this sequence is to continue the second step and additionally energize in stator 107 the stator winding 55-44 and stator winding 58-47 from unidirectional voltage source 60 by closing electrical switches 8 and 11. The stator windings 55-44 and 58-47 connect to first and second brushes group brushes 20 and 24 respectively, which connect through various segments of the commutator 51 at various armature positions to energize open circuit armature windings thrice removed contrary to the direction of force and torque generation from the brush vacancies 21 and 25, and from which the armature and open circuit armature windings will move in the forward direction of force and torque generation--armature 105 and armature-common member 48 movement to the left in FIG. 1. 
     In FIG. 1, the fourth step of this sequence is to simultaneously de-energize all the stator windings of stator 107 by opening switches 6 through 11, and to energize, in stator 108, stator windings 96-86 and 99-89 from the unidirectional voltage source 60 by closing electrical switches 12 and 15. The stator windings 96-86 and 99-89 connect to first and second brushes group brushes 62 and 66 respectively, which connect through various segments of the commutator 94 at various armature positions to energize open circuit armature windings once removed contrary to the direction of force and torque generation from the brush vacancies 65 and 69, and from which the armature 106 and open circuit armature windings will move in the forward direction of force and torque generation--armature 106 and armature-common member 48 movement to the left in FIG. 1. 
     In FIG. 1, the fifth step of this sequence is to continue with switches 12 and 15 closed to generate the armature 106 force and torque contribution, and additionally energize, in stator 107, stator windings 53-42 and 56-45 from the unidirectional voltage source 60 by closing electrical switches 6 and 9. The stator windings 53-42 and 56-45 connect to first and second brushes group brushes 18 and 22 respectively, which connect through various segments of the commutator 51 at various armature positions to energize open circuit armature windings once removed contrary to the direction of force and torque generation from the brush vacancies 21 and 25, and from which the armature 105 and open circuit armature windings will move in the forward direction of force and torque generation--armature 105 and armature-common member 48 movement to the left in FIG. 1. 
     In FIG. 1, the sixth step of this sequence is to continue the fifth step and additionally energize, in stator 107, stator windings 54-43 and 57-46 from the unidirectional voltage source 60 by closing electrical switches 7 and 10. The stator windings 54-43 and 57-46 connect to first and second brushes group brushes 19 and 23 respectively, which connect through various segments of the commutator 51 at various armature positions to energize open circuit armature windings twice removed contrary to the direction of force and torque generation from the brush vacancies 21 and 25, and from which the armature 105 and open circuit armature windings will move in the forward direction of force and torque generation--armature 105 and armature-common member 48 movement to the left in FIG. 1. 
     In FIG. 1, the seventh step of this sequence is to continue the sixth step and additionally energize, in stator 107, stator windings 55-44 and 58-47 from the unidirectional voltage source 60 by closing electrical switches 8 and 11. The stator windings 55-44 and 58-47 connect to first and second brushes group brushes 20 and 24 respectively, which connect through various segments of the commutator 51 at various armature positions to energize open circuit armature windings thrice removed contrary to the direction of force and torque generation from the brush vacancies 21 and 25, and from which the armature 105 and open circuit armature windings will move in the forward direction of force and torque generation--armature 105 and armature-common member 48 movement to the left in FIG. 1. 
     In FIG. 1, the eighth step of this sequence is to simultaneously de-energize all the stator windings of stator 107 by opening switches 6 through 11, and to additionally energize, in stator 108, stator windings 97-87 and 100-90 from the unidirectional voltage source 60 by closing electrical switches 13 and 16; the switches 12 and 15 remaining closed. The stator windings 97-87 and 100-90 connect to first and second brushes group brushes 63 and 67 respectively, which connect through various segments of the commutator 94 at various armature positions to energize open circuit armature windings twice removed contrary to the direction of force and torque .generation from the brush vacancies 65 and 69, and from which the armature 106 and open circuit armature windings will move in the forward direction of force and torque generation--armature 106 and armature-common member 48 movement to the left in FIG. 1. 
     In FIG. 1, the ninth step of this sequence is to continue with switches 12, 15, 13 and 16 closed to generate the armature 106 force and torque contribution and to additionally energize, in stator 107, stator windings 53-42 and 56-45 from the unidirectional voltage source 60 by closing electrical switches 6 and 9. The stator windings 53-42 and 56-45 connect to first and second brushes group brushes 18 and 22 respectively, which connect through various segments of the commutator 51 at various armature positions to energize open circuit armature windings once removed contrary to the direction of force and torque generation from the brush vacancies 21 and 25, and from which the armature 105 and open circuit armature windings will move in the forward direction of force and torque generation--armature 105 and armature-common member 48 movement to the left in FIG. 1. 
     In FIG. 1, the tenth step of this sequence is to continue the ninth step and to additionally energize, in stator 107, stator windings 54-43 and 57-46 from the unidirectional voltage source 60 by closing electrical switches 7 and 10. The stator windings 54-43 and 57-46 connect to first and second brushes group brushes 19 and 23 respectively, which connect through various segments of the commutator 51 at various armature positions to energize open circuit armature windings twice removed contrary to the direction of force and torque generation from the brush vacancies 21 and 25, and from which the armature 105 and open circuit armature windings will move in the forward direction of force and torque generation--armature 105 and armature-common member 48 movement to the left in FIG; 1. 
     In FIG. 1, the eleventh step of this sequence is to continue the tenth step and to additionally energize, in stator 107, stator windings 55-44 and 58-47 from the unidirectional voltage source 60 by closing electrical switches 8 and 11. The stator windings 55-44 and 58-47 connect to first and second brushes group brushes 20 and 24 respectively, which connect through various segments of the commutator 51 at various armature positions to energize open circuit armature windings thrice removed contrary to the direction of force and torque generation from the brush vacancies 21 and 25, and from which the armature 105 and open circuit armature windings will move in the forward direction of force and torque generation--armature 105 and armature-common member 48 movement to the left in FIG. 1. 
     In FIG. 1, the twelfth step of this sequence is to simultaneously de-energize all the stator windings of stator 107 by opening electrical switches 6 through 11, and to additionally energize, in stator 108, stator windings 98-88 and 101-91 from the unidirectional voltage source 60 by closing electrical switches 14 and 17; the electrical switches 12, 15, 13 and 16 remaining closed. The stator windings 98-88 and 101-91 connect to first and second brushes group brushes 64 and 68 respectively, which connect through various segments of the commutator 94 at various armature positions to energize open circuit armature windings thrice removed contrary to the direction of force and torque generation from the brush vacancies 65 and 69, and from which the armature 106 and open circuit armature windings will move in the forward direction of force and torque generation--armature 106 and armature-common member 48 movement to the left in FIG. 1. 
     In FIG. 1, the thirteenth step of this sequence is to continue with electrical switches 12 through 17 closed to generate the armature-106 force and torque contribution, and to additionally energize, in stator 107, stator windings 53-42 and 56-45 from the unidirectional voltage source 60 by closing electrical switches 6 and 9. The stator windings 53-42 and 56-45 connect to first and second brushes group brushes 18 and 22 respectively, which connect through various segments of the commutator 51 at various armature positions to energize open circuit armature windings once removed contrary to the direction of force and torque generation from the brush vacancies 21 and 25, and from which the armature 105 and open circuit armature windings will move in the forward direction of force and torque generation--armature 105 and armature-common member 48 movement to the left in FIG. 1. 
     In FIG. 1, the fourteenth step of this sequence is to continue the thirteenth step and to additionally energize, in stator 107, stator windings 54-43 and 57 -46 from the unidirectional voltage source 60 by closing electrical switches 7 and 10. The stator windings 54-43 and 57-46 connect to first and second brushes group brushes 19 and 23 respectively, which connect through various segments of the commutator 51 at various armature positions to energize open circuit armature windings twice removed contrary to the direction of force and torque generation from the brush vacancies 21 and 25, and from which the armature 105 and open circuit armature windings will move in the forward direction of force and torque generation--armature 105 and armature-common member 48 movement to the left in FIG. 1. 
     In FIG. 1, the fifteenth step of this sequence is to continue the fourteenth step and to additionally energize, in stator 107, stator windings 55-44 and 58-47 from the unidirectional voltage source 60 by closing electrical switches 8 and 11. The stator windings 55-44 and 58-47 connect to first and second brushes group brushes 20 and 24 respectively, which connect through various segments of the commutator 51 at various armature positions to energize open circuit armature windings thrice removed contrary to the direction of force and torque generation from the brush vacancies 21 and 25, and from which the armature 105 and open circuit armature windings will move in the forward direction of force and torque generation--armature 105 and armature-common member 48 movement to the left in FIG. 1.