BACKGROUND OF THE INVENTION

[0001] Embodiments of the invention relate generally to primary transformers such as a motor and, more particularly, to measuring current flowing through a primary transformer for use in detecting motor operational status.

[0002] In general, three-phase induction motors consume a large percentage of all generated electrical capacity. Many applications for this "workhorse" of industry are fan and pump industrial applications. Due to the prevalence of motors in industry, it is paramount that the three-phase motor be reliable. Industry reliability surveys suggest that motor failures typically fall into one of four major categories. Specifically, motor faults typically result from bearing failure, stator turn faults, rotor bar failure, or other faults/failures. Within these four categories: bearing, stator, and rotor failure account for a majority of all motor failures.

[0003] Detection devices have been designed that generate feedback regarding an operating motor. The feedback is then monitored to determine the operating conditions of the motor. A common industrial practice is to measure current using the same principles as a transformer. A magnetic field is induced around a conductor as current is passed through the conductor. This magnetic field may be induced into a magnetic coil looped around the conductor. This method is similar to an air core transformer and is commonly referred to as a current transformer. The amount of magnetically induced current into the coil is dependent on the number of coil loops and the amount of signal current desired. The current signal, therefore, should be proportional to the actual current in the conductor of interest. A scale is developed to read the coupled current signal value in the conductor as an actual current signal.

[0004] The output of the current transformer may be used to sense an overcurrent condition in the motor by sensing a high current passing through the conductor, for example. Once detected, the overcurrent condition may be set up to drive an overload relay to shut off the motor. Sensing a high current for overcurrent protection includes sensing a wide range of current that may pass through the conductor. The sensing circuit may have to provide feedback for a range of up to six times the normal operating range of the motor for overcurrent protection such as, for example, 750 amps.

[0005] Often, the sensed current is converted from an analog signal to a digital signal. Sensing and converting such a wide range of current to a digital signal results in a large step size between each digital value. For a circuit providing overcurrent protection, such a coarse digital step size scale is often adequate to provide motor protection prior to conditions leading to motor failure. However, besides sensing the motor current for purposes of overcurrent protection, it may be desirable to sense the currents flowing through the motor while the motor is operating in its steady-state mode of operation. In this case, the coarse digital step size of the scale set up for overcurrent protection is often too large to provide reliable accurate information when used for both overcurrent feedback as well as steady-state operation feedback.

[0006] Typically, current transformers that are used in sensing the motor current through the conductor are costly, heavy, and occupy a large amount of space within the system. Accordingly, simply adding an additional current transformer with associated sensing circuit into a system for each desired current sensing range is prohibitive.

[0007] It would therefore be desirable to have a system for sensing primary transformer current that provides multiple sensing ranges.

BRIEF DESCRIPTION OF THE INVENTION

[0008] According to an aspect of the invention, a current monitoring system comprises a current sensor configured to sense a first current passing through a conductor and a voltage conversion device coupled to the current sensor and configured to receive a second current from the current sensor and convert the second current into a first voltage. A first scaling circuit is coupled to the voltage conversion device and configured to convert the first voltage to a second voltage proportional to the first current based on a first scaling factor, and a second scaling is circuit coupled to the voltage conversion device and configured to convert the first voltage to a third voltage proportional to the first current based on a second scaling factor, wherein the second scaling factor is different from the first scaling factor.

[0009] According to another aspect of the invention, a method of manufacturing a current-to-voltage conversion system comprises coupling a current sensor to a conductor configured to pass a current therethrough and coupling a voltage conversion device to the current sensor, the voltage conversion device configured to generate a sensor voltage proportional to the current passing through the conductor. The method also comprises coupling a first scaling circuit to the voltage conversion device and coupling a second scaling circuit to the voltage conversion device. The first scaling circuit is configured to convert the sensor voltage to a first scaled voltage using a first scaling factor, and the second scaling circuit is configured to convert the sensor voltage to a second scaled voltage using a second scaling factor distinct from the first scaling factor.

[0010] According to yet another aspect of the invention, a motor current detection system comprises a motor comprising a primary winding, an electrical conductor electrically coupled to the primary winding and configured to carry a primary current passing through the primary winding, and a current transformer inductively coupled to the electrical conductor and configured to inductively generate a secondary current proportional to the primary current. The system also comprises a current-to-voltage converter configured to convert the secondary current to a first voltage and a pair of scaling circuits coupled to the current-to-voltage converter, each scaling circuit configured to scale the first voltage to a unique scaling voltage via a unique scaling factor.

[0011] Various other features and advantages of the present invention will be made apparent from the following detailed description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The drawings illustrate preferred embodiments presently contemplated for carrying out the invention.

[0013] In the drawings:

[0014] FIG. 1 is a block diagram of a primary transformer current monitoring system according to an embodiment of the invention.

[0015] FIG. 2 is a schematic illustration of the primary transformer current monitoring system of FIG. 1 according to an embodiment of the invention.

DETAILED DESCRIPTION

[0016] FIG. 1 illustrates a block diagram of the motor current monitoring system 10 according to an embodiment of the invention. Monitoring system 10 includes a current sensing device 12 positioned to sense a transformer primary current of a primary transformer 14 such as a soft starter or other industrial motor. In one embodiment, current sensing device 12 is a current transformer inductively coupled to a conductor 16 leading to or from primary transformer 14. A secondary current 18 representative of the primary current passing through primary transformer 14 is output from current sensing device 12 and is converted to a voltage via a current-to-voltage device 20 such as a resistor. The voltage, which is representative of the current passing through primary transformer 14, is supplied to multiple scaling circuits 22, 24, which, according to embodiments of the invention, provide voltages to monitoring systems 26 designed to monitor the operational status of primary transformer 14. Scaling circuits 22, 24 and thus configured to output respective voltages that are proportional to the primary transformer current and that are scaled differently.

[0017] Scaling circuit 22 includes a block 28 that provides DC offset and EMC filtering functions to scaling circuit 22. In this manner, the voltage provided to scaling circuit 22 from current-to-voltage device 20 is filtered and provided to a scaling block 30 having a gain or attenuation configured to scale the filtered voltage according to a scale desired for a first monitoring system 32, which converts the scaled voltage from an analog signal into a digital signal. According to one embodiment, scaling circuit 22 may be designed to monitor the operation of primary transformer 14 within its normal steady-state operation parameters, which may include monitoring primary transformer currents within the range of 5% of motor nominal FLA to 120% motor FLA. Preferably, the scaling output of scaling circuit 22 is adjusted to provide the maximum dynamic range to first monitoring system 32 when monitoring the normal operating range of primary transformer 14.

[0018] Scaling circuit 24 includes a block 34 that provides DC offset and EMC filtering functions to scaling circuit 24. In this manner, the voltage provided to scaling circuit 24 from current-to-voltage device 20 is filtered and provided to a scaling block 36 having a gain or attenuation configured to scale the filtered voltage according to a scale desired for a second monitoring system 38, which converts the scaled voltage from an analog signal into a digital signal. According to one embodiment, scaling circuit 24 may be designed to monitor the operation of primary transformer 14 for an overload condition, which may include monitoring primary transformer currents within the range of 120% motor FLA to 800% motor FLA. The scaling output of scaling circuit 24 may thus be adjusted to provide a Volts/Amp gain that is a fraction of the monitoring channel so that an entire overload range can be sensed.

[0019] Additional scaling circuits (not shown) may also be included and coupled to current-to-voltage device 20. The additional scaling circuits may each have distinct scaling corresponding to a particular range of primary transformer current operation and may each provide distinct monitoring voltages to respective monitoring system. In this manner, scaling circuits that are proportional to specific dynamic current ranges can be used to pinpoint specific current ranges that may benefit from increased current sensitivity.

[0020] Thus, according to embodiments of the invention, monitoring system 10 provides multiple scaled outputs of a primary transformer operation from a single current measurement. In this manner, the resolution for various ranges of monitored primary transformer current may be tailored such that the analog-to-digital conversion thereof may have a high resolution for a fine current monitor, a lower resolution for a coarse current monitor, or an intermediate resolution for an intermediate current monitor. For example, the fine current monitor range can provide an output with a much greater volts/amp transfer function than the coarse current monitor range.

[0021] FIG. 2 illustrates a schematic illustration of the primary transformer current monitoring system 10 of FIG. 1 according to an embodiment of the invention. Similar components discussed in connection with the embodiments shown in FIGS. 1 and 2 have been designated with similar reference numerals [0022] As shown in FIG. 2, current sensing device 12 includes a coil 40 looped around conductor 16. In one embodiment, coil 40 has multiple turns looped around conductor 16. Accordingly, a current from primary transformer 14 passing through coil 40 along conductor 16 inductively generates a current in coil 40 that is converted to a voltage via current-to-voltage device 20, which is a resistor as shown. The current induced in coil 40 and, hence, the voltage generated across resistor 20 is proportional to the current passing to or from primary transformer 14 along conductor 16. The proportional voltage is available at a node 42 coupled to scaling circuits 22, 24 and to other additional scaling circuits (not shown) as described above.

[0023] Scaling circuit 22 includes an amplifier 44 having a pair of power terminals 46, 48 electrically coupled to a positive DC voltage bus 50 and to a ground bus 52, respectively. A single, positive DC power supply 54 is coupled between positive DC voltage bus 50 and ground bus 52 and provides single-source power to energize amplifier 44. A positive voltage input 56 of amplifier 44 is configured to receive a first DC offset voltage 58 designed, in one embodiment, based on a combination (e.g., multiplication) of the median of a desired output voltage range of scaling circuit 22 with an inverse of the scaling factor of scaling circuit 22. The scaling factor of scaling circuit 22 may be determined by a pair of resistors 60, 62 coupled to node 42 and between a negative voltage input 64 of amplifier 44 and a scaled voltage output 66 of amplifier 44. A capacitor 68 is also coupled to negative voltage input 64 and helps provide EMC filtering of the voltage at negative voltage input 64. First monitoring system 32 includes an analog-to-digital converter 70 according to an embodiment of the invention.

[0024] Scaling circuit 24 includes an amplifier 72 having a pair of power terminals 74, 76 electrically coupled to positive DC voltage bus 50 and ground bus 52, respectively A positive voltage input 78 of amplifier 72 is configured to receive a second DC offset voltage 80 designed, in one embodiment, based on a combination (e.g., multiplication) of the median of a desired output voltage range of scaling circuit 24 with an inverse of the scaling factor of scaling circuit 24. The scaling factor of scaling circuit 24 may be determined by a pair of resistors 82, 84 coupled to node 42 and between a negative voltage input 86 of amplifier 72 and a scaled voltage output 88 of amplifier 72. A capacitor 90 is also coupled to negative voltage input 86 and helps provide EMC filtering of the voltage at negative voltage input 86. Second monitoring system 38 includes an analog-to-digital converter 92 according to an embodiment of the invention.

[0025] In one embodiment, analog-to-digital converters 70 and 92 are distinct converters and may be dedicated to their respective scaling circuits 22 and 24. According to another embodiment, analog-to-digital converters 70 and 92 correspond with the same converter, and the analog-to-digital conversion of the voltages output from scaling circuits 22 and 24 is alternately performed. When the analog-to-digital conversion according to either embodiment occurs using a common bit conversion process, the conversion of the smaller range output from scaling circuit 22 results in a higher resolution step size in the digital data than the conversion of the larger range output from scaling circuit 24.

[0026] As described above, additional scaling circuits (not shown) may also be included and may coupled to node 42. The additional scaling circuits may each have distinct scaling corresponding to a particular range of primary transformer current operation and may each provide distinct monitoring voltages to respective monitoring system. Similar to scaling circuits 22 and 24, the scaling of the additional circuits may be designed via setting the parameters of the pair of resistors as well as the DC offset voltage of each circuit.

[0027] According to embodiments of the invention, primary transformer operational status may be monitored by multiple monitoring circuits using a relatively minimum number of components per circuit in conjunction with a single, positive power supply. In this manner, a high level of immunity to external interference is provided as well as the monitoring capability of a plurality of monitoring circuits each having an optimal resolution and accuracy of the sensed primary transformer current particular to a desired monitoring system. Accordingly, multiple levels of primary transformer current status may be monitored for a wide current range without maxing out the monitoring capability of certain current ranges and while maintaining accuracy throughout the entire current monitoring range.

[0028] Therefore, according to one embodiment of the invention, a current monitoring system comprises a current sensor configured to sense a first current passing through a conductor and a voltage conversion device coupled to the current sensor and configured to receive a second current from the current sensor and convert the second current into a first voltage. A first scaling circuit is coupled to the voltage conversion device and configured to convert the first voltage to a second voltage proportional to the first current based on a first scaling factor, and a second scaling is circuit coupled to the voltage conversion device and configured to convert the first voltage to a third voltage proportional to the first current based on a second scaling factor, wherein the second scaling factor is different from the first scaling factor.

[0029] According to another embodiment of the invention, a method of manufacturing a current-to-voltage conversion system comprises coupling a current sensor to a conductor configured to pass a current therethrough and coupling a voltage conversion device to the current sensor, the voltage conversion device configured to generate a sensor voltage proportional to the current passing through the conductor. The method also comprises coupling a first scaling circuit to the voltage conversion device and coupling a second scaling circuit to the voltage conversion device. The first scaling circuit is configured to convert the sensor voltage to a first scaled voltage using a first scaling factor, and the second scaling circuit is configured to convert the sensor voltage to a second scaled voltage using a second scaling factor distinct from the first scaling factor.

[0030] According to yet another embodiment of the invention, a motor current detection system comprises a motor comprising a primary winding, an electrical conductor electrically coupled to the primary winding and configured to carry a primary current passing through the primary winding, and a current transformer inductively coupled to the electrical conductor and configured to inductively generate a secondary current proportional to the primary current. The system also comprises a current-to- voltage converter configured to convert the secondary current to a first voltage and a pair of scaling circuits coupled to the current-to-voltage converter, each scaling circuit configured to scale the first voltage to a unique scaling voltage via a unique scaling factor.

[0031] Embodiments of the present invention have been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.