High efficiency circulator with sensors
AssigneeTaco, Inc.
InventorsSteve Thompson, Vladislav Milchev Stakev, Robert F. Birkenstock, Jr., Douglas Bird, David E. Sweet
Life of this patent
Estimating the term…
Abstract
A highly efficient circulator system is provided, useful for hydronic systems, including both heating and cooling systems. The stand-alone circulator motor is controllable by input from certain sensors, preferably thermal sensors, which provide data enabling the controller of the brushless pump motor to vary its flow output to meet changes in systems loads. The circulator has a ceramic permanent magnet rotor, such as a ferrite, with an electronically, preferably sinusoidally, commutated, electro-magnetic stator controlling the input of electrical power.
Claims20
A stand-alone, wet rotor circulator comprising:
- a centrifugal impeller configured to move a hydronic fluid through a recirculating hydronic fluid system;
- a variable frequency DC motor operationally connected to the impeller to drive the impeller, the DC motor comprising:
- a permanent magnet rotor formed of a ferrite ceramic magnet material, and
- a system of stator coils configured to be powered by a sinusoidally variable DC current;
- a rectifier system configured to convert an AC current to a non-stepped down DC current, the rectifier system including:
- a first electrical circuit connection configured to connect the rectifier system to an AC current source, and
- a second electrical circuit connection configured to output the non-stepped down DC current from the rectifier system;
- and
- an electronic motor control system electrically connected to the second electrical circuit connection, the electronic motor control system comprising:
- a power module configured to convert the non-stepped down DC current from the rectifier system to an artificial sinusoidally variable frequency DC current output,
- an electronic variable frequency drive (VFD) electrically connected to the power module and configured to receive the artificial sinusoidally variable frequency DC current output, the VFD being configured to receive data signals from at least one thermal sensor, and
- a third electrical connection electrically connecting the electronic motor control system to the system of stator coils of the DC motor,
- wherein the VFD is configured to control a speed of the DC motor by varying the a frequency of the artificial sinusoidally variable frequency DC current output powering the system of stator coils of the DC motor in response to the data signals received from the at least one thermal sensor, and thereby control a speed of the impeller and resulting flow of the hydronic fluid in through the recirculating hydronic fluid system.
A method of operating a stand-alone, wet rotor circulator to circulate hydronic fluid through a hydronic fluid circulation system, the method comprising:
- providing a variable frequency DC motor including a system of stator coils and a rotor operationally connected to a centrifugal impeller to drive the centrifugal impeller;
- receiving, at a rectifier system, an AC current from an AC current source;
- converting, with the rectifier system, the AC current to a non-stepped down DC current;
- receiving, at an electronic motor control system, the non-stepped down DC current from the rectifier system;
- converting, at a power module of the electronic motor control system, the non-stepped down DC current to an artificial sinusoidally variable frequency DC current output;
- receiving, at an electronic variable frequency drive (VFD) of the electronic motor control system, one or more data signals from at least one thermal sensor;
- controlling, via the VFD, a speed of the DC motor by varying a frequency of the artificial sinusoidally variable frequency DC current output that is transmitted to a system of stator coils of the DC motor, the varying of the frequency being in response to the one or more data signals from the at least one thermal sensor, wherein the rotor rotates at varying speeds in response to the varying frequency of the artificial sinusoidally variable frequency DC current output transmitted to the system of stator coils, thereby controlling circulation of the hydronic fluid through the hydronic fluid circulation system.
Dependencies are inferred from the claim text.