Patent Abstract:
A motor drive is provided that includes a control circuit or board and a one or more functional circuits or option boards coupled to the control board, and a profile that includes a configuration for the option board. A method of operating a motor drive that includes loading a profile for a option board coupled to a control board of the controller, wherein the profile comprises a configuration for the option board. A tangible machine-readable medium implementing the method is also provided.

Full Description:
BACKGROUND 
       [0001]    The present invention relates generally to the field of power electronic devices, and particularly to a hardware architecture for motor control drives to provide interfaces for communication and control of motors and processes. 
         [0002]    A wide variety of applications exist for power electronic devices, such as switching devices and systems. In such systems, multiple components may be combined and interconnected for a wide range of functionality. For example, in traditional switchgear applications, such as motor drives, an enclosure is generally provided into which power is routed, along with network signals, sensor inputs, actuator outputs, and so forth. Components within the enclosure are interconnected with external circuitry, and can be interconnected with one another to provide for control, monitoring, circuit protection, and a multitude of other functions. Such conventional approaches, however, require a substantial number of terminations of various conductors, routing of conductors, mounting of various components, and so forth. 
         [0003]    In other types of packaging, components may be associated with one another in mounting areas or bays, which are electrically coupled to buses for routing power to the various components. Examples of this type of packaging may be found in conventional motor control drives, in which various control, monitoring and protective circuits are mounted and interconnected with one another via wiring harnesses, cables, and so forth. In other applications, particularly where power levels are much lower, it has become conventional to provide a “backplane” to which components may be coupled, such as via plug-in connections. Such backplanes are currently in use throughout industrial applications, as for providing data and control signals to and from programmable logic controllers, computer components and peripherals, and so forth. The use of such backplanes, through which data and control signals can be easily routed, presents substantial advantages from the point of view of ease of assembly, replacement, servicing and expansion of overall systems incorporating a large number of interfaced components. 
         [0004]    However, for backplanes using multiple components receiving any number of signals, the routing and timing of such signals to the motor control drive may present hardware and software challenges. The signaling must operate in such a way so that each signal reaches the main processing unit of the motor control drive and may be processed quickly enough to ensure a timely response. Additionally, where synchronization of multiple motors is required, synchronization of the signals of multiple motors and sensors also presents additional challenges. 
       BRIEF DESCRIPTION 
       [0005]    The present invention provides a novel approach to configuration and management of motor drives and synchronization of signals of such drives. The approach includes a motor drive having a control board and one or more option boards physically connected to the motor drive via a backplane. The motor drive may load a profile for the option board that includes a configuration for the option board. The profile may include a unique identifier and one or more interrupts for the option board. 
         [0006]    Methods, devices, and computer programs are all supported for performing these and other functions of the invention. 
     
    
     
       DRAWINGS 
         [0007]    These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: 
           [0008]      FIG. 1  is a perspective view of a motor drive in accordance with an embodiment of the present invention; 
           [0009]      FIG. 2  is a block diagram of a motor drive system in accordance with an embodiment of the present invention; 
           [0010]      FIG. 3  is a schematic diagram of the power electronic switching circuitry of  FIG. 2  in accordance with an embodiment of the present invention; 
           [0011]      FIG. 4  is a block diagram of multiple motors and drives controlling a process in accordance with an embodiment of the present invention; 
           [0012]      FIG. 5  is a perspective view of a pod and backplane in accordance with an embodiment of the present invention; 
           [0013]      FIG. 6  is a cutaway perspective view of the pod and backplane of  FIG. 5  in accordance with an embodiment of the present invention; 
           [0014]      FIGS. 7-10  are perspective views of option boards configured to be used with the pod and backplane of  FIGS. 5 and 6  in accordance with an embodiment of the present invention; 
           [0015]      FIG. 11  is a block diagram illustrating connections between a control board and various option boards in accordance with an embodiment of the present invention; 
           [0016]      FIG. 12  depicts an interrupt scheme utilizing a “Control Event” signal and “System Event” signal for synchronized operation of a control board and option boards in accordance with an embodiment of the present invention; 
           [0017]      FIG. 13  depicts a process for operation of a control board and option board using a profile in accordance with an embodiment of the present invention; 
           [0018]      FIGS. 14 and 15  depict screenshots a user interface for configuring a control board and option board in accordance with an embodiment of the present invention; and 
           [0019]      FIG. 16  is a diagrammatical representation of a pair of motor drives, illustrating how multiple drives may be synchronized down to a functional circuit level. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    Beginning now with  FIG. 1 , a perspective view of a motor drive  100  is depicted. In one embodiment, the motor drive  100  may be a PowerFlex drive manufactured by Rockwell Automation of Milwaukee, Wis. The motor drive  100  may include a housing  102  having cooling vents  104  on one or more sides of the drive  100 . To facilitate interacting with the motor drive  100 , the motor drive  100  may include a human-machine interface (HMI)  106 . The HMI  106  may include a display  108 , such as an LCD or other display and a keypad  110  allowing input by a user. Additionally, the HMI  106  may be removable and dockable in a receptacle  114  in the housing  102 . 
         [0021]    As described further below, the motor drive is adapted to receive three-phase power from a power source, such as the electrical grid and to convert the fixed frequency input power to controlled frequency output power. The motor drive  100  may manage both application of electrical power to the loads, typically including various machines or motors. The drive may also collect data from the loads, or from various sensors associated with the load or the machine system of which the load is part. Such data may be used in monitoring and control functions, and may include parameters such as current, voltage, speed, rotational velocity, temperatures, pressures, and so forth. The motor drive  100  may be associated with a variety of components or devices (not shown) used in the operation and control of the loads. Exemplary devices contained within the motor drive  100  are motor starters, overload relays, circuit breakers, and solid-state motor control devices, such as variable frequency drives, programmable logic controllers, and so forth. As discussed further below, the motor drive  100  may include expandable functionality through the addition of option boards installed in a backplane inside the motor drive  100 . Additionally, the motor drive  100  may be used in conjunction with other motor drives, such that a plurality of motor drives may be used to control one or more processes. As also discussed below, functions within the drive are synchronized, and the drive (and its internal functions) may be synchronized with other drives in an overall machine system. 
         [0022]      FIG. 2  is a block diagram  200  illustrating various internal components of the drive  100  and other devices in the system  200 . For example, the drive  100  may include control circuitry  202 , driver circuitry  204 , and power electronic switching circuitry  206 . The power electronic switching circuitry  206  may receive three-phase power  212 , and output three phase power  214  to a motor  216 . To facilitate control of the motor drive  100 , a remote control monitor  208  may be connected to the motor drive  100 . Additionally, other drives  210  may also be connected to the motor drive  100  and the remote control monitor  208 , such as via a network. Remote control and monitoring functions, and coordinated operation of the drive may be performed via such network connections. Moreover, such networks and network connections may be based on any known or subsequently developed standard, including standard industrial protocols, Ethernet protocols, Internet protocols, wireless protocols, and so froth. 
         [0023]    The control circuitry  202  and driver circuitry  204  may include a control circuit board and various optional function circuits, referred to herein as “option boards”, in accordance with an embodiment of the present invention, as discussed further below. The driver circuitry  204  signals the switches of the power electronic switching circuitry  206  to rapidly close and open, resulting in a three phase waveform output across the output terminals  218 ,  220 , and  222 . The driver circuitry  204  is controlled by the control circuitry  202 , which may operate autonomously, or which may respond to command inputs from the remote control monitor  208  through a network. Similarly, operation of the driver circuitry may be coordinated, via the control circuitry, with that of other drives. Many different control schemes and functions may be implemented by the control circuitry, and programs for such operation may be stored on the control board, such as for closed loop speed control, closed loop torque control, among many others. 
         [0024]      FIG. 3  is a schematic diagram of power electronic switching circuitry  206 . As mentioned above, the power electronic switching circuitry will typically receive as an input three phase power  214 , such as from the power grid. The three phase power source is electrically coupled to a set of input terminals  226 ,  228 , and  230  that provide three phase AC power of constant frequency to rectifier circuitry  232 . The rectifier circuitry  232  includes components, such as diodes  234  that perform full wave rectification of the three phase voltage waveform. After rectification, all phases of the incoming power are combined to provide DC power to the low side  236  to the high side  238  of a DC bus. Inductors  240  may be coupled to both the high and low sides of the DC bus and act as chokes for smoothing the rectified DC voltage waveform. One or more filter capacitors  242  may link the high side  238  and low side  236  of the DC bus and are also configured to smooth the rectified DC voltage waveform. Together, the inductors and capacitors serve to remove most of the ripple from the waveform, so that the DC bus carries a waveform closely approximating a true DC voltage. It should be noted that the three-phase implementation described herein is not intended to be limiting, and the invention may be employed on single-phase circuitry, as well as on circuitry designed for applications other than motor drives. 
         [0025]    An inverter  244  is coupled to the DC bus and generates a three phase output waveform at a desired frequency for driving a motor  216  connected to the output terminals  218 ,  220 , and  222 . In the illustrated embodiment, within the inverter  244 , for each phase, two insulated gate bipolar transistors (IGBT&#39;s)  246  are coupled in series, collector to emitter, between the high side  238  and low side  236  of the DC bus. Three of these transistor pairs are then coupled in parallel to the DC bus, for a total of six transistors  246 . Each of the output terminals  218 ,  220 , and  222  is coupled to one of the outputs between one of the pairs of transistors  246 . The driver circuitry  204  signals the transistors  246  to rapidly close and open, resulting in a three phase waveform output across output terminals  218 ,  220 , and  222 . The driver circuitry  204  is controlled by the control circuitry  202 . 
         [0026]    In some embodiments, multiple motor drives and motors may be used to control a process. For example, as illustrated in  FIG. 4 , a process  302  may be controlled by multiple motors  304  such as a first motor M 1 , a second motor M 2 , a third motor M 3 , and a fourth motor M 4 . Each motor  304  may be controlled by a respective motor drive  306 . For example, the motor M 1  may be controlled by motor drive D 1 , the motor M 2  may be controlled by motor drive D 2 , the motor M 3  may be controlled by motor drive D 3 , and the motor M 4  may be controlled by the motor drive D 4 . The motor drives  306  may be connected together via a network  308 , such as a network employing a known standard communications protocol, such as industrial DeviceNet, ControlNet, or Ethernet. A remote control and monitoring station  310  may be connected to the motor drives by the network  308  to provide for control and monitoring of the drives  306 , the motors  304  and the process  302 . 
         [0027]    As discussed above, in some embodiments a motor drive may add functionality, connections, or both through the addition of option boards installed in the motor drive. The option boards may be in communication with other motor drives, motors, sensors, or other devices. As discussed above with respect to  FIG. 4 , for example, multiple drives and motors may be used to control a process. In accordance with an embodiment of the present invention, a motor drive may provide one or more serial interfaces for the addition of option boards. Additionally, to facilitate control of highly synchronized drives and motors, the dedicated serial interface may provide synchronization between each of the option boards and the control board or circuitry of the respective motor drive through the use of synchronized interrupts. Additionally, the communication and synchronization between the option boards and the control board may be selected and configured by user, such that different communication speeds may be enabled while maintaining the synchronization. Further, some embodiments may include profiles to select and configure the communication and synchronization of the option boards. 
         [0028]    To facilitate addition of the option cards, a motor drive may include a “pod”  400  having a chassis  402  as shown in  FIG. 5 . The pod  400  may be mounted inside a motor drive, and acts as a modular card rack for the option boards discussed below. The pod  400  may include a control board  404 , which may manage and process signals received from the option boards, as discussed further below. The control board  404  may include one or more processors  406 , (which may include microprocessors, CPU&#39;s, field programmable gate arrays, etc.) to provide applications, management and processing. The processor  406  may include or be associated with a memory having applications for operating the control board  404 , the option boards in the pod  400 , or any other device in the motor drive. For example, the processor  406  may include applications such as an interface, torque control, vector control, drive logic, Ethernet logic, etc. The control board  404  may also include a field programmable gate array for communication and simple processing tasks. For example, in an embodiment the field programmable gate array may perform transfer, size, and CRC frame adders and receive frame stripping, CRC verification, error handling and communication status without processor intervention. Additionally, the control board  404  may include additional interfaces for connection to other motor drives or devices in accordance with certain data exchange standards, such as IEEE 1588, Ethernet, etc. 
         [0029]    The pod chassis  402  may include a one or more backplanes  408 , which generally support and provide the physical interconnect between the control board  404  and various option boards. The backplanes  408  may include a printed circuit board having any number of slots, plugs, connectors, or other interface structures. The backplane  408  provides for distribution of power and data signals, and enables the option cards to be interfaced with a network. For example, as shown in  FIG. 5 , the backplane  408  includes a plurality of slots  410 , configured to receive various option boards as described further below. In one embodiment, the pod  400  may include two backplanes  408  having six slots  410  each. 
         [0030]    The pod chassis  402  may also include additional features to increase reliability and performance. The chassis  402  may include one or more fans  412  and one or vents  414  on any portion of the chassis  402  to allow for airflow and heat dissipation. 
         [0031]      FIG. 6  is a cutaway view of the pod  400  illustrating the pod  400  and backplanes  408  in further detail. The backplanes  408  may include a bus board  416  providing the interface slots  410  and the necessary bus routing to the control board  404 . The backplane  408  may also include one or more communication ports, such as a multi-pin communication port  418  and an Ethernet port  420 . In one embodiment, the backplanes  408  may have six interface slots and may receive up to six option boards. The backplanes  408  may include one or more receptacles  422  configured to receive one or more screws or other fastener to secure an option board, as discussed below. Of course, any number of such option board slots may be provided, depending upon the range of options contemplated for the system. 
         [0032]      FIGS. 7-10  illustrate various option boards configured to mate with the interface slots  410 . It should be appreciated that some embodiments may include options board not illustrated below that include any number of processors, memory, interfaces, inputs and/or outputs. The options boards may provide any desired functionality, including: input and output; signal conditioning; isolation; data conversion; safety; analog-to-digital (A/D) conversion or other data conversion; and communication via standard protocols such as DeviceNet, ControlNet, and/or Ethernet. As explained further below, various option boards may also include one or more of the following components: processor, FPGA, memory, logic registers, clock, terminals, input/output ports, etc. In the presently contemplated embodiment, special option boards may be developed from time to time to address particular system and application needs, to perform particular types of data processing, interfacing with legacy systems, and so forth. 
         [0033]    For example, beginning with  FIG. 7 , a first option board  500  may include a processor  502  and an FPGA  503 . To engage an interface slot  410 , the option board  500  may include a bus interface  504 . As mentioned above, in one embodiment the bus interface  504  may be a 6-pin PCI-E interface. Additionally, the option board  500  may have one or more connectors  506  or terminals  508  for connection to various inputs and outputs used by the option board  500 . To secure the option board  500  to the pod  400 , and the receptacles  418 , the option board  500  may include one or more screws  510 , such as thumbscrews. In some embodiments, other mechanisms may be used to secure the option board  500 , such as clips or other fasteners. 
         [0034]      FIG. 8  depicts another option board  514  also having a bus interface  516  for insertion into the interface slots  410 . The option board  514  includes capacitors  518 , and a processor or FPGA  520 . Additionally, the option board  514  includes input-output terminals  522 , and may include one or more screws  524 .  FIG. 9  depicts another option board  528  having a bus interface  530  and one or more screws  532  having functions as described above. 
         [0035]    Finally,  FIG. 10  illustrates an option board  536  configured to allow use of a “legacy” option board. For example, the option board  536  includes a legacy board  538  mounted to the option board  536 , such as by one or more screws  540 . In such an embodiment, the legacy board may connect to the option board  536  via any interface suitable for communication with both the option board  536  and the legacy board  538 . The option board  536  may provide any emulation, translation, or other processing necessary for communication with the legacy board  538 . The option board  536  may also include a bus interface (not shown) for communication with the interface slots  410  and may also include one or more screws  540  to secure the option board  536  to the pod  400 . Communication from the legacy board  538  may be routed through the option board  526  and the bus interface for communication to the control board. Advantageously, the control board backplanes  408  and option boards described above allow connection of option boards without wiring or other internal cable connections. 
         [0036]      FIG. 11  is a block diagram  600  illustrating the connections between a control board  602  and a plurality of option boards  604 . The option boards  604  may be connected to the control board by dedicated dual channel full duplex serial interfaces  606 . As discussed above, each option board  604  may include a clock that controls the timing of signaling on the respective serial interface  606 . In some embodiments, the control board  602  and option boards  604  may also include a CAN (DPI) channel. As described further below, each channel may carry different signals, such coordinated by an interrupt scheme based on a “Control Event” on a first channel  608  and a “System Event” on a second channel  610 , and the timing of the signals may be controlled by the clock on the option boards  604 . By using the dedicated serial interfaces  606 , the control board  602  allows transfer for serial communication of information from the option boards simultaneously and in parallel. Additionally, as dictated by the timing of the “Control Event,” the data transfer from each option board  604  may be synchronized. 
         [0037]    As described above, in some embodiments the pod  400  may have two (or more) backplanes, as indicated by a dashed regions  612  and  614 . In the illustrated embodiment, because each backplane  612  and  614  may include three interface slots, which in one embodiment may be PCI-E interface slots, three dedicated serial buses are provided on each backplane. In addition to communication with the control board  602 , the option boards  604  may communicate with each other via a network  616 . By using the network  616 , the option boards  604  may communicate with each other without first routing the communication through the control board  602 . In other embodiments, the option boards  604  may route communication to other options boards on the same backplane or an adjacent backplane via the control board  602 . 
         [0038]    As described above, in a presently contemplated embodiment, each channel of the dual channel full duplex serial interfaces  606  may transmit a specific signal. In this embodiment, the signal processing may be implemented by means of an FPGA on the control board  602 . In other embodiments the signal processing may be implemented in software and may use a processor on the control board  602 .  FIG. 12  depicts the signals defining the interrupt scheme in further detail, such as a “Control Event” (CTRL) signal  700  and a “System Event” (SYS) signal  702 . In one embodiment, the Control Event signal  700  may be used to coordinate the transfer and collection of data at very short intervals, such as data needed for commutation or generation of the output waveform, while the System Event signal  702  may be used to coordinate transfer and collection of less time-critical data, such as multiple types of system level messages, such as general feedback, communications, I/O, and so forth. 
         [0039]    To ensure synchronization, regardless of the clock timing of each option board, each signal  700  and  702  may have a data acquisition interval and a transfer interval. For example, the Control Event signal may include a data acquisition window  704  and a transfer interval  706 . In one embodiment, the data acquisition window  704  for the Control Event signal may about 6 μs, and the transfer interval may be about 128 μs to about 256 μs. At the end of the data acquisition window, a processor on the control board is interrupted, e.g., via an IRQ, to ensure no wasted idle or wait time is consumed by the CPU. By providing a data acquisition window  704 , the control board is ensured of receiving all data from the option boards in the pod. Thus, in a presently contemplated embodiment, the rising edge  708  of the Control Event signal, the option boards may shift their register to the control board within the 6 μs window. The clock rate of the option boards may be set at the appropriate level to ensure this data is transferred in the data acquisition window. The clock rate may be standardized at 32 MHz, although other rates may be employed. Advantageously, this ensures that all registers (signals) from the options boards will be synchronized. That is, no matter when each option board acquired its data, all options board must report to the control board by the end of the data acquisition window. In one embodiment, the Control Event signal may be referred to as a “Control Event Primary” signal and may be used for control task (commutation) data acquisition from the option cards, such as for such data as torque references, encoder feedback, etc. Further, to facilitate communication with the serial interface, the option boards may include a shift register interface having a 32-bit length, and the transfer rate may controlled by a clock on the option board. 
         [0040]    Similarly, in a presently contemplated embodiment, the System Event signal  702  may include a data acquisition interval  710  and a transfer interval  712 . In such an embodiment, the data acquisition window  710  for the System Event signal  702  may be about 20 μs and the transfer interval may be about 1-2 ms to about 256 μs. In some embodiments, the System Event signal  702  may provide for both a primary and secondary message sent on the data acquisition interval and transfer interval respectively. In such an embodiment, the secondary message must be completed prior to the end of transfer interval. In one embodiment, the primary message may be referred to as a “System Event Primary” and have a 64 byte storage limit, and the secondary message may be referred to as “Secondary Event Continuous” and have a 512 byte storage limit. 
         [0041]    It should be noted that the particular speed, data acquisition interval length, interrupt spacing, and so forth used in the drive may be different from that set forth in the present discussion. For example, the timing of the deterministic interrupt scheme is set based upon such factors as the amount of data to be transferred from the option boards (or from the control circuit to the option boards), and the duration of the data acquisition interval desired, as compared to the duration of the processing window needed. That is, the processing circuitry of the control board will collect and process the data received, and perform the control functions for operation of the motor coupled to the drive, and will need some time to perform such functions. The data acquisition window may be set to a duration that is a function of the anticipated processing time, such as 10%. Such considerations may result in design choices within the ambit of those skilled in the art. 
         [0042]    It will be appreciated that the use of dedicated serial interfaces for each functional circuit (option board), and the interrupt scheme for transfer and collection of data from all such circuits provides a deterministic, synchronous interrupt structure that permits very fast data transfer rates. The serial interfaces essentially function as bit shift registers for the transfer of data without the need for traffic control between the circuits. Similarly, it should be noted that while the rate of transfer of data from the functional circuits may be set, such as at 32 MHz, this rate is actually configurable. Thus, where less data is to be delivered in the available time, a slower data transfer rate from the functional circuit may be set (e.g., as low as 2 MHz), while for more demanding data transfer, even higher rates may be set (e.g., 64 MHz). Moreover, the rates of data transfer from the different option boards, even within a single drive, need not be the same. Different rates may be set for different option boards, while still maintaining synchronization in operation by virtue of the dedicated serial interfaces and deterministic interrupt scheme. Similarly, different data transfer rates may be used for different channels for each board, and these rates may be changed over time. In certain applications the use of different data transfer rates may aid in reducing harmonic distortion or interference between the interfaces and channels. 
         [0043]    The System Event Primary may be used for a “login” function on the serial interface such that each option card may use this signal to log on to the control board and establish communication. The System Event Primary may be used for system task data acquisition, such as analog I/O, digital I/O, feedback, communications, etc. Additionally, in one embodiment the System Event Continuous signal may provide additional communication such as transfer of large data blocks. 
         [0044]    To facilitate communication and interfacing of a control board with the option boards, the control board and/or option boards may use profiles to assist with the “log on” of the option boards.  FIG. 13  depicts a process  800  for operation of a control board and option board using a profile in accordance with an embodiment of the present invention. Initially, upon startup of a motor drive having a backplane with a control board as described above, an installed option board is also powered on (block  802 ). The option board sends data to the control board during the data acquisition window of the “System Event” signal (block  804 ), as described above. In response, the control board references a locally stored database (block  806 ) that may store profiles for the various option boards. The control board reads “log on” info received in the data from the option board (block  808 ) that may provide identification information and the state for of option board. The control board then loads the appropriate profile for the option board from the database (block  810 ) and begins communication with the option board (block  812 ). 
         [0045]    In one embodiment, the HMI on a motor drive may provide a user interface for accessing, managing, and configuring the option boards installed in a pod of the motor drive. As mentioned above, the user interface may be provided on a processor and a memory of the control board. In many applications, however, the initial configuration of the drive will be performed by coupling the drive to a workstation, which may include a conventional programmed computer (e.g., personal computer). Screen views provided by software on the workstation, or served by the drive to the workstation facilitate in selecting parameter settings, units of measure, parameter names, and so forth. The profile for each option board, moreover, greatly facilitates this process, and each profile may already preconfigure certain of the settings for the option board, or may reduce the set of options presented to the installer or system integrator to those available or appropriate to that option board and selected system setup. The profiles may thus be part of an automatic device configuration scheme, streamlining setup of the drives by reducing the information presented to the installer and guiding the installer though the setup. It is presently contemplated that such individual profiles may be stored on the option boards (i.e., each option board including its respective profile), and fed to the control board, or a library of profiles may be stored on the control board, and an appropriate profile used for configuration of a specific option board if it is recognized as present in the drive by the control board. Such profiles may also be downloaded to the drive from a library, such as via the network connection provided to the drive, or upon initial installation. Certain of these options may allow for expansion of the number and types of functional circuits available over time. 
         [0046]      FIGS. 14 and 15  depict screenshots of such a user interface in accordance with an embodiment of the present invention.  FIG. 13  depicts a first screen  900  having a left hand navigation pane  902  and a right hand parameter pane  904 . As illustrated in  FIG. 14 , the navigation pane  902  includes list of the control boards and associated option boards for a motor drive. The control boards may be listed as nodes in the navigation pane and may include any number of collapsible parameters and device underneath. For example, a first node  908  (Node  1 ) corresponds to the “PowerFlex 755” control board. Underneath the first node  908  various parameters  910  are listed. The option boards  912  may also be listed underneath the first node  908 . In one embodiment, the option boards  912  may be arranged according to the interface slots occupied by the option board. For example, a first option board  914  (LCD Module) may be listed in slot  1 , a second option board  916  (20-COMM-E-Ethernet/IP) may be listed in slot  2 , etc. 
         [0047]    By selecting a node  908 , e.g., a control board  908 , or an option board  912 , a user may display the parameters associated with that control board or option board. For example, the right hand pane  904  a list of parameters is displayed, such as the speed parameters  914 . The right hand pane  904  may display information about each item listed, including a node column  916 , a slot column  918 , and a parameter number  920 , with each column displaying the node, slot and parameter respectively of each item. To configure a node, a user may select a parameter, as illustrated by the selected parameter  922  (Speed Ref A Set, e.g., a speed reference). 
         [0048]    As shown in  FIG. 15 , the second screen  924  illustrates a pop-up window  926  that displays after selection of a parameter. The pop-up window  926  corresponds to the selected parameter  922  and provides a number of selections. As shown, a first tab  928  (List Selection) displays the port  930 , the parameter  938 , the value  940  and the internal value  942 . Additionally, a minimum value  944 , a maximum value  946 , and a default value  948  may also be set. The port  930  may display a drop down box corresponding to the port or slot selectable by the user. To configure the parameter  922  for a specific port, a user may select the port from the drop down menu  950 , such as selecting port (node)  0 , port  4 , port  5 , etc. After the port  930  is selected, the parameter  938  may be configured by entering a new value. Additional tabs in the pop-window  926  may include additional functionality, such as a “Numeric Edit” tab  952  and an “Advanced tab”  954 . The “Numeric Edit” tab  952  may allow direct editing of numeric parameters, and the “Advanced tab”  954  may include additional configuration operations for the selected parameter  922 . In this manner, a user may configure of any option boards coupled to the backplane of a motor drive. It should be noted that any number of drives may be configured in a similar manner, particularly where numerous drives are networked together in a system. Thus, the system integrator may navigate to a specific drive for its configuration, then to other drives for configuration of the overall system. 
         [0049]    The interrupt scheme described above permits synchronization of all functions within the motor drive, including the acquisition of data from all functional circuits supported on the option boards. That is, because all data is received serially from all of the option board functional circuits and in response to the Command and System interrupts, all of the data is assured of being received by the control circuitry at the same time. Once received, the data can be acted upon by the processing capabilities of the control circuitry in the interim between interrupts. For data that directly affects motor control, sometimes referred to as communication data, the data acquisition is particularly fast, with little time between the interrupts. For other data, the intervals may be more widely spaced in time. 
         [0050]    The same interrupt scheme, and close synchronization of data acquisition can also allow for very accurate synchronization between drives linked to one another via a network. For example,  FIG. 16  illustrates a system  1000  in which two motor drives  1002  and  1004  are interconnected to maintain synchronization. Drive  1002  includes a control circuit  1006  of the type described above, coupled to functional circuits  1008 . As in the embodiments described above, the control circuit will typically be supported separately from the functional circuits, such as on a control board, while the functional circuits are supported on option boards. The number and type of such option boards may vary depending upon the system requirements, the type of control to be performed, and so forth. Also as described above, the control circuit communicates with the functional circuits via dedicated serial interfaces, and coordinates the transfer and collection of data from the functional circuits by interrupts, thus maintaining precise synchronization of all drive operations down to the option board level. The control circuit utilizes data collected from the functional circuits to provide control signals to drive circuit  1010 , which powers solid state switches to produce output power for a motor  1012 , as described above. 
         [0051]    Drive  1004  is similarly configured. It includes a control circuit  1014  and a series of functional circuits  1016  that communicate with the control circuit  1014  via dedicated serial interfaces, with data transfer again being coordinated via interrupts as described above. The control circuit  1018  similarly produces control signals that are applied to drive circuit  1018  for driving motor  1020 . 
         [0052]    In system  1000 , the operation of motors  1012  and  1020  is coordinated and synchronized, such as for “multi-axis” control. Such coordinated control is extremely useful in many applications, such as integrated machines in which motors handle product in continuous processes. Examples may include printing applications, paper making applications, product handling applications, and so forth, to mention only a few. 
         [0053]    To permit such high degree of synchronization, a synchronization counter  1022 , or similar device, is included in each drive, and synchronizes the clock of the control circuit for that drive with that of other drives interconnected in the system. In a presently contemplated embodiment, the drives are interconnected via a network connection  1024 , which utilizes an Ethernet communications protocol, although other protocols may be used. The coordination of the synchronization counters is performed in accordance with IEEE 1588 standards. 
         [0054]    It has been found that the use of such clock synchronization between drives, in conjunction with the use of dedicated serial interfaces for functional circuits, and the interrupt scheme for transfer and collection of data from the functional circuits permits an unprecedented degree of coordination and synchronization of the drives. That is, in the overall system, all functional circuits (e.g., input/output circuits, communications circuits, encoders, parameter estimation/calculation circuits, etc.) of all drives can be precisely coordinated insomuch as the interrupts for transfer and collection of data from all such circuits occurs at the same time, as coordinated by synchronization of the clocks of all drives. Such coordination allows the drives to be used in applications and with a degree of precision that was heretofore unavailable in similar production equipment. 
         [0055]    While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.

Technology Classification (CPC): 7