Power supply systems and methods that can enable an electromagnetic device to ride-through variations in a supply voltage

[00002] The present invention relates generally to the field of power supply systems, and, more particularly, to systems and methods that can improve the response of electrical contactor power supply systems to variations in a supply voltage, such as voltage sags and voltage dropouts.

[00003] Power line disturbances can produce serious problems for continuous process industries. In particular, voltage sags and dropouts can be some of the most troublesome events. Events lasting less than one-half second can shut down a facility and halt production for several hours, which can result in a substantial cost to the manufacturer due to loss of product. Industrial equipment reacts to voltage sags in a variety of ways. In some cases, the best solution may be to protect the entire facility from the voltage sag with a device such as a dynamic voltage restorer. In other cases, it may be more economical to identify particularly susceptible components and protect them alone.

[00004] Electrical contactors are often used as a safety device in industrial settings to provide a switch between a machine and the power supply that drives the machine. A typical electrical contactor is a form of a solenoid switch that can be used to connect and disconnect electrical circuits to and from each other. In particular, an electrical contactor is operated by applying an electric potential to an electromagnetic coil, which generates a current flow in the coil that induces a magnetic field to close two or more electrical contacts typically held open via a spring. When the electric potential is removed from the coil, the magnetic field that holds the electrical contacts closed is removed allowing the contacts to spring under tension from the spring. Many production facilities use electrical contactors to control one or more motors. While the motors often have enough inertia to ride-through power line disturbances, contactors may be particularly susceptible to voltage sags. For example, “[o]ne manufacturer has provided data that indicates their line of motor contactors will drop out at 50% voltage if the condition lasts for longer than one cycle. This data should be expected to vary among manufacturers, and some contactors can drop out at 70% normal voltage or even higher.” (McGranaghan et al., “Voltage Sags in Industrial Plants,” IEEE Transactions on Industry Applications, Vol. 29, no. 2, March/April, 1993, quoting M. Sauter, “Voltage fluctuations on Power Systems,” Westinghouse Electric Utility Engineering Reference Book, Distribution Systems, p. 362, 1965).

[00005] One approach to addressing the problem of contactor dropout is described in U.S. Pat. No. 5,734,543 to Turner (hereinafter the '543 patent). The '543 patent describes “a mechanism for improving the performance of a solenoid device during a lapse in power quality to the solenoid device from an alternating current (AC) power source. The mechanism comprises a wave shaping device configured to introduce a direct current (DC) component to an alternating current signal provided by the alternating current power source and to output at least part of the alternating current signal modified by the direct current component to the solenoid device.” (The '543 patent at col. 1, line 65 through col. 2, line 6).

[00006] Moreover, the mechanism described in the '543 patent is designed to “provide an AC electrical contactor having improved voltage sag ride through capability.” (The '543 patent at col. 1, lines 62-64). Unfortunately, the '543 patent does not address the problem of electrical contactor ride-through in response to a complete dropout of the AC power source (i.e., the AC power source voltage falls to zero for a fraction of a cycle or longer).

[00007] Consequently, there is a need for power supply systems and methods that can improve the ride-through capability of an electromagnetic device, such as an electrical contactor, particularly under voltage dropout conditions.

[00008] It is therefore an object of the present invention to provide power supply systems and methods that can improve the ride-through capability of an electromagnetic device.

[00009] It is another object of the present invention to provide power supply systems and methods that can allow an electromagnetic device, such as an electrical contactor, to ride-through a voltage dropout.

[00010] These and other objects, advantages, and features of the present invention are provided by power supply systems and methods that can enable an electromagnetic device, such as an electrical contactor, to ride-through both voltage sags and dropouts by converting an AC supply voltage to a DC input voltage. The DC input voltage is supplied to an electromagnetic device to operate the electromagnetic device therefrom. By converting the AC supply voltage to a DC input voltage and using the DC input voltage to energize an electromagnetic device, the electromagnetic device can withstand or ride-through lapses in the AC supply voltage.

[00011] In an illustrative embodiment of the present invention, a rectifier is used to generate a DC input voltage from an AC supply voltage. An interface circuit supplies the DC input voltage to an electrical contactor to provide the necessary power for operating the contactor. An electrical contactor that is intended to operate from an AC voltage typically operates equally well from a lower magnitude DC voltage. The interface circuit uses this difference in magnitudes between the AC voltage source and an operationally equivalent DC voltage source to maintain the DC input voltage at a desired level even if the AC voltage source sags below its normal operating level.

[00012] In accordance with an aspect of the invention, an energy storage device is used to store at least some of the DC input voltage. When a sag or dropout occurs in the AC voltage source, the interface circuit is able to maintain the operation of the electrical contactor for a period of time by using the stored DC input voltage as a power source. The energy storage device thus provides a power reservoir that can be accessed during severe voltage sags or even dropouts to ensure continuous operation of the electrical contactor. In a preferred embodiment of the invention, the energy storage device is a capacitor.

[00013] In accordance with another aspect of the invention, the interface circuit includes a timer that generates a periodic control signal, which is related to the magnitude of the DC input voltage. The periodic control signal is used to operate a switch that electrically connects the DC input voltage to the electrical contactor. In particular, the control signal causes the switch to connect the DC input voltage to the electrical contactor for a period of time that is inversely proportional to the magnitude of the DC input voltage.

[00014] Accordingly, the power supply systems and methods in accordance with the present invention can be useful in protecting critical equipment in continuous process industries from voltage sags and dropouts, which have the potential to be costly events in terms of both product loss and/or production downtime.

[00026] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit the invention to the particular forms disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the claims. Like reference numbers signify like elements throughout the description of the figures.

[00027] With reference to FIG. 1A, a conventional electrical contactor power supply system 12 includes a contactor 15 that comprises a contactor coil 14, which is represented as an inductor L in series with a resistor R_c, and contacts 16. The contactor coil 14 is powered from an AC voltage source that generates an AC supply voltage v_C(ac), which has a root mean square (RMS) value denoted by V_C(ac), and a frequency f_ac=1/T_ac, where T_ac is the period of one cycle of the AC supply voltage. The contactor coil 14 draws an AC current i_C(ac), which has a RMS value denoted by I_C(ac). When current is drawn through the inductor L, a magnetic force is induced that causes the contacts 16 to close thereby connecting the AC power source to the motor or machine. For purposes of illustration, only one set of contacts 16 is shown. It is not uncommon, however, to use multiple sets of contacts 16 to control a motor. For example, a three-phase motor may use three sets of contacts 16.

[00028] FIG. 1B illustrates electrical contactor power supply systems and methods 20 in accordance with the present invention. The electrical contactor power supply 20 is similar to that illustrated in FIG. 1A, but further includes a voltage regulator 22 that provides an interface between the AC supply voltage v_C(ac) and the contactor coil 14. The voltage regulator 22 draws a current i_R from the AC supply voltage source and generates a DC voltage v_C(dc) having an average value denoted by V_C(dc) that is applied to the contactor coil 14. The contactor coil 14 draws a DC current i_C(dc), which has an average value denoted by I_C(dc). Start and stop switches for the electrical contactor power supply system 20 may be incorporated into the AC supply voltage source v_C(ac).

[00029] FIG. 1C illustrates a laboratory configuration for testing the electrical contactor power supply systems and methods 20 of FIG. 1B. In particular, a resistor R_T and a 15V DC power supply are wired to the contacts 16 to generate a test signal v_T that indicates whether the contacts 16 are open or closed. The test results for this configuration are discussed in detail hereinafter.

[00030] It will be understood that while the principles and concepts of the present invention are described herein in connection with an electrical contactor 15, the present invention is generally applicable to electromagnetic devices whose operation involves the use of electromagnetic force.

[00031] The use of the voltage regulator 22 in the electrical contactor power supply system 20 is based on a recognition that electrical contact terminals or electrical contactors that are intended to operate from an AC voltage will typically operate equally well from a lower magnitude DC voltage. This recognition is examined in more detail hereafter.

[00032] When operated from an AC supply voltage source, as shown in FIG. 1A, the contactor coil 14 current i_C(ac) can be determined using only v_C(ac) and (2πf_ac)L because 2πf_acL>>R_C. The RMS value of the contactor coil 14 current I_C(ac) is therefore given by Equation 1: $\begin{array}{cc}{I}_{C\left(\mathrm{ac}\right)}=\frac{V_{C\left(\mathrm{ac}\right)}}{\sqrt{{\left[\left(2\pi f_{\mathrm{ac}}\right)L\right]}^2+R_C^2}}=\frac{V_{C\left(\mathrm{ac}\right)}}{\left(2\pi f_{\mathrm{ac}}\right)L}& \mathrm{EQ}.1\end{array}$
The time waveform for the contactor coil 14 current i_C(ac) is given by Equation 2:
i_C(ac)=√{square root over (2)}I_C(ac)sin(2πf_ac)t  EQ. 2
The contactor coil 14 current i_C(ac) exerts a time-varying, pulsating force on the contactor 15 armature that depends on the current amplitude, but not on its polarity. The armature has sufficient inertia so that the contacts 16 remain closed even as the current goes through zero twice each cycle. The average force exerted by the AC current is proportional to the average current in a half-cycle, which is expressed below as Equation 3: $\begin{array}{cc}{I}_{C\left(h-c-\mathrm{avg}\right)}=\frac{1}{\frac{T_{\mathrm{ac}}}{2}}{\int }_0^{\frac{T_{\mathrm{ac}}}{2}}i_{C\left(\mathrm{ac}\right)}dt=\frac{2\sqrt{2}}{\pi }{I}_{C\left(\mathrm{ac}\right)}& \mathrm{EQ}.3\end{array}$
Substituting the expression from Equation 1 for the contactor coil 14 current I_C(ac) into Equation 3 allows the average current in a half-cycle to be expressed in terms of the AC supply voltage v_C(ac) and frequency f_Fac as set forth in Equation 4: $\begin{array}{cc}{I}_{C\left(h-c-\mathrm{avg}\right)}=\frac{2\sqrt{2}}{\pi }\frac{V_{C\left(\mathrm{ac}\right)}}{\left(2\pi f_{\mathrm{ac}}\right)L}=\frac{\sqrt{2}{V}_{C\left(\mathrm{ac}\right)}}{{\pi }^2{f}_{\mathrm{ac}}L}& \mathrm{EQ}.4\end{array}$

[00037] Referring now to FIG. 1B, when the contactor coil 14 is operated from a DC voltage v_C(dc) having an average value V_C(dc), the impedance provided by the inductor L falls to zero (i.e., (2πf_ac)L=0). Accordingly, the average DC current I_C(dc) in the contactor coil 14 is given by Equation 5: $\begin{array}{cc}{I}_{C\left(\mathrm{dc}\right)}=\frac{V_{C\left(\mathrm{dc}\right)}}{R_C}& \mathrm{EQ}.5\end{array}$
The DC current I_C(dc) exerts a constant force on the contacts 16 through the armature. Therefore, to ensure that the DC current I_C(dc) achieves the same average force on the contactor 15 armature as provided by the AC current I_C(ac), Equations 4 and 5 are equated to obtain a ratio of the DC voltage V_C(dc) to the AC voltage V_C(ac) in Equation 6: $\begin{array}{cc}\frac{V_{C\left(\mathrm{dc}\right)}}{V_{C\left(\mathrm{ac}\right)}}=\frac{\sqrt{2}{R}_C}{{\pi }^2{f}_{\mathrm{ac}}L}& \mathrm{EQ}.6\end{array}$
For many contactors, V_C(dc) is approximately 10% of V_C(ac). For example, a contactor with a nominal 120V AC coil typically operates equally well from a 12V DC source. The voltage regulator 22 can use this difference between the available AC supply voltage and the operationally equivalent DC contactor coil voltage to maintain the contactor coil current even when the AC supply voltage drops.

[00040] Referring now to FIG. 2, the voltage regulator 22 preferably comprises several functional blocks including a rectifier circuit with energy storage 24, a switch circuit 26, an internal power supply circuit 28, a timer circuit that comprises a constant off-time control circuit 32 and a pull-in control circuit 34, a gate driver circuit 36, and a power up delay circuit 38. Each of these functional blocks will be discussed in detail hereinafter.

[heading-00041] Rectifier Circuit with Energy Storage

[00042] As shown in FIG. 2, the rectifier circuit 24 preferably comprises a full-wave bridge rectifier U₂ that converts the AC supply voltage v_C(ac) to a relatively ripple free DC input voltage v_O that has an average value V_o approximately equal to the peak value of v_C(ac). The average value of the DC input voltage V_o can also be expressed in terms of the RMS value of the AC supply voltage as set forth in Equation 7:
V_o=√{square root over (2)}V_C(ac)  EQ. 7
For V_C(ac) values of 120V, 240V, and 480V, V_O is approximately 170V, 340V and 680V, respectively. An electrolytic capacitor C₁ is connected to the DC input voltage V_o and is used to store the energy that may be used to keep the contacts 16 closed during power line sags and dropouts. The value of capacitor C₁ generally determines the length of time during which the contactor coil 14 current i_C(dc) is maintained during a complete dropout of the AC supply voltage v_C(ac). Because contactor coils generally require very little energy, the value of capacitor C₁ is typically small. As shown in FIG. 2, a small ceramic capacitor C₂ is arranged in parallel with capacitor C₁ and is preferably used for high-frequency bypass. A metal-oxide varistor (MOV) is connected across the input terminals to the full-wave bridge rectifier U₂ to prevent transient surges in the AC supply voltage source from damaging the voltage regulator 22. It should be understood that while a capacitor is used as an energy storage means in a preferred embodiment of the present invention, other forms of energy storage, such as a battery, inductor, or other suitable energy storage circuit or device could also be used.
Switch Circuit

[00046] The switch circuit 26 preferably includes a power switch transistor Q₂ and a diode D₃, which form a buck converter (also called a chopper) that reduces the relatively high DC input voltage v_O to the lower DC voltage V_C(dc) used to energize the contactor coil 14. Transistor Q₂ comprises a metal-oxide-semiconductor field-effect transistor (MOSFET) in an exemplary embodiment of the present invention. Nevertheless, transistor Q₂ may also be implemented using a bipolar junction transistor (BJT) or an insulated gate bipolar transistor (IGBT). Zener diode D₄ acts as a clamp to protect the relatively fragile gate-to-source oxide of transistor Q₂ from damage due to overvoltage. Transistor Q₂ operates as a switch that is represented by an on-time T_ON and an off-time T_OFF. During the on-time T_ON, transistor Q₂ effectively connects the DC input voltage v_O to the contactor coil 14 and conducts the contactor coil 14 current i_C(dc) through its drain terminal. Conversely, during the off-time T_OFF, transistor Q₂ effectively disconnects the DC input voltage v_O from the contactor coil 14. Inasmuch as the contactor coil 14 current i_C(dc) does not drop instantaneously to zero when transistor Q₂ turns off, a “flyback” diode D₃ is used to conduct the contactor coil 14 current i_C(dc) during the T_OFF interval until the current is dissipated through the resistor R_C. Transistor Q₂ operates with a period T_S given by Equation 8:
T_S=T_ON+T_OFF1/f_S  EQ. 8
Preferably, a value for f_S is chosen that is above the normal range of human hearing. The duty cycle d of transistor Q₂ is given by Equation 9:
$\begin{array}{cc}d=\frac{T_{\mathrm{ON}}}{T_S}& \mathrm{EQ}.9\end{array}$
While the time waveform of the voltage v_C(dc) applied to the contactor coil 14 switches between almost v_O during T_ON and almost zero during T_OFF, the average voltage V_C(dc) applied to the contactor coil 14 is given by Equation 10:
V_C(dc)=dV_O  EQ. 10
For example, from an AC supply voltage V_C(ac) of 120V (RMS), the rectifier circuit 24 may generate an average DC input voltage V_O of 170 V. Thus, a duty cycle d of 0.07 results in a contactor coil 14 voltage V_C(dc) of 12V. As will be explained in detail hereinafter, when the AC supply voltage v_C(ac) and consequently the DC input voltage v_O drop during a power line sag or dropout, the voltage regulator 22 operates to increase the duty cycle d to a value necessary to maintain the contactor coil 14 voltage V_C(dc). The voltage regulator 22 is able to maintain the contactor coil 14 voltage V_C(dc) until the DC input voltage V_O drops to a level at which the duty cycle d equals one. Beyond this point, the contactor coil 14 voltage V_C(dc) is no longer maintained by the voltage regulator 22 and the contacts 16 open or drop out.
Internal Power Supply Circuit

[00054] The internal power supply circuit 28 generates an internal power supply voltage V_CC of approximately 15V from the DC input voltage v_O. The internal power supply voltage V_CC is used to power the constant off-time control circuit 32, the pull-in control circuit 34, the gate driver circuit 36, and the power up delay circuit 38. Transistor Q₁ and resistor R₁₀ are a linear series pass voltage regulator that use resistor R₁ and Zener diode D₁ as a reference to regulate the voltage at the base of transistor Q₁. Resistor R₂ ensures proper operation of the internal power supply circuit 28 by drawing a minimum load current. Resistor R₁₁ and capacitors C₃ and C₉ provide ripple filtering and bypass for the internal power supply voltage V_CC.

[heading-00055] Constant Off-Time Control Circuit

[00056] The constant off-time control circuit 32 and the pull-in control circuit 34 each occupy one half of the dual timer integrated circuit U₁ as shown in FIG. 2. As used herein, a “high” voltage or signal means that the voltage or signal is approximately equal to the internal power supply voltage V_CC. Similarly, a “low” voltage or signal means that the voltage or signal is approximately zero volts. In a preferred embodiment, the dual timer U₁ is a conventional type 555 timer integrated circuit.

[00057] The constant off-time control circuit 32 is used to adjust the duty cycle d of the transistor Q₂. The constant off-time control circuit 32 does this by setting T_OFF to a constant value and making T_ON inversely proportional to the DC input voltage V_O. Therefore, as the DC input voltage V_O drops due to a power line sag or dropout, the duty cycle d is increased to keep the contactor coil 14 voltage V_C(dc) constant.

[00058] With reference to FIG. 2, pin 5 of the dual timer U₁ drives a control signal that determines whether transistor Q₂ is turned on or turned off. When the control signal from pin 5 is pulled low, transistor Q₂ is turned off. The time duration T_OFF that transistor Q₂ remains in the off state is determined by the time constant of capacitor C₈ and resistor R₈. During the T_OFF interval, capacitor C₈ is discharged through R₈ into pin 5. The voltage developed across capacitor C₈ appears at pin 6, which serves as a trigger input to the dual timer U₁. When the voltage across capacitor C₈ falls below one-third of the internal power supply voltage V_CC, pin 5 is driven high, which terminates the T_OFF interval. Diode D₂ ensures that capacitor C₈ quickly recharges to V_CC in anticipation of the next T_OFF interval by providing a bypass to resistor R₈.

[00059] In a similar manner, the time duration T_ON that transistor Q₂ remains in the on state is determined by the time constant of resistor R₉ and capacitor C₇. The voltage developed across capacitor C₇ appears at pin 2, which serves as a threshold signal to terminate the T_ON interval by pulling pin 5 low when capacitor C₇ charges beyond two-thirds of the internal power supply voltage V_CC. Instead of being charged from the constant internal power supply voltage V_CC, however, capacitor C₇ is charged from the DC input voltage V_O, which changes depending on the AC supply voltage V_C(ac). Therefore, a drop in the DC input voltage V_O due to a sag or dropout of the AC supply voltage V_C(ac) means that the capacitor C₇ will charge more slowly, which results in a longer T_ON interval.

[00060] This is an example of what is commonly known as “voltage feedforward.” Note that there is no closed-loop feedback in FIG. 2 so that it may be unnecessary to sense either the contactor coil 14 voltage V_C(dc) or current I_C(dc). Furthermore, by providing an open loop, concerns with closed-loop stability can be reduced or, preferably, eliminated. Advantageously, this design improves both the practicality and the affordability of the voltage regulator 22.

[00061] Capacitor C₇ is also connected to pin 1 of the dual timer U₁, which discharges capacitor C₇ during the T_OFF interval in preparation for the subsequent T_ON interval. Zener diode D₅ acts as a clamp on the voltage across capacitor C₇ to ensure that the DC input voltage V_O does not overcharge capacitor C₇, which may damage the dual timer U₁.

[heading-00062] Pull-In Control Circuit

[00063] Contactors typically require a relatively large current to pull in the contactor armature initially and a relatively small current to maintain the contacts in a closed position during normal operation. The pull-in control circuit 34, which comprises the second half of the dual timer U₁, performs this function by modifying the operation of the constant off-time control circuit 32 for a brief time during start up. The pull-in control circuit 34 is a “one shot” or monostable circuit, which generates an output pulse having a duration corresponding to the time constant set by resistor R₆ and capacitor C₆. Before start up, capacitor C₆ has discharged due to the absence of the internal power supply voltage V_CC. When the AC supply voltage v_C(ac) is first applied to the voltage regulator 22, capacitor C₆ behaves as a short circuit causing the trigger pin 8 to be pulled up to the internal power supply voltage V_CC. During this start up period, discharge pin 13 is low causing resistor R₅ and capacitor C₅ to be placed in parallel with the capacitor C₇, which increases the C₇R₉ time constant associated with the T_ON interval. The normal duty cycle d of transistor Q₂ is made longer in proportion to the value of the capacitor C₅, which increases both the DC voltage v_C(dc) applied to the contactor coil 14 and the contactor coil 14 current i_C(dc). As capacitor C₆ is charged from the internal power supply voltage V_CC through resistor R₆, the voltage applied to trigger pin 8 will eventually fall below one-third of the internal power supply voltage V_CC, which causes discharge pin 13 to become open circuited. As a result, exclusive control of the interval T_ON is restored to the constant off-time control circuit 32 where the duration of T_ON is determined by the DC input voltage V_O, and the time constant associated with resistor R₉ and capacitor C₇ as described hereinbefore.

[heading-00064] Gate Driver Circuit

[00065] The current provided from pin 5 of dual timer U₁ may not be sufficient to drive the gate electrode of the switch circuit 26 transistor Q₂. In this circumstance, a gate driver circuit 36 can be used to generate the necessary current. As shown in FIG. 2, the gate driver circuit 36 preferably comprises transistors Q₄ and Q₅ and resistors R₇ and R₁₂, which form a totem-pole gate drive for transistor Q₂. For applications involving small contactors 15, a transistor having a relatively low current rating can be used to implement transistor Q₂ thereby allowing the gate driver circuit 36 to be eliminated to save cost.

[heading-00066] Power Up Delay Circuit

[00067] The power up delay circuit 38 is used to ensure that the constant off-time control circuit 32 and the pull-in control circuit 34 do not begin operation until the internal power supply voltage V_CC has stabilized. The collector terminal of transistor Q₃ is connected to the reset pins 4 and 10 of dual timer U₁. When the reset pins 4 and 10 are driven low, dual timer U₁ is disabled, which also disables the off-time control circuit 32 and the pull-in control circuit 34. Capacitor C₄ and resistor R₄ are used to delay activation of the dual timer U₁ during the start up interval after an AC supply voltage v_C(ac) has been applied to the voltage regulator 22. Before start up, capacitor C₄ is discharged due to the absence of the internal power supply voltage V_CC. When the AC supply voltage v_C(ac) is first applied to the voltage regulator 22, capacitor C₄ applies the internal power supply voltage V_CC to the base of Q₃. This turns transistor Q₃ on, which drives its collector terminal low thereby disabling the dual timer U₁. The current into the base terminal of transistor Q₃ drops as capacitor C₄ charges. Eventually, the voltage across capacitor C₄ rises to the internal power supply voltage V_CC level at a rate controlled by the time constant R₄C₄. As the voltage developed across capacitor C₄ increases, the base current into transistor Q₃ decreases until it eventually drops to zero and transistor Q₃ is turned off. When transistor Q₃ is turned off, there is no voltage drop across resistor R₃ thus driving the collector terminal of Q₃ high and enabling operation of the dual timer U₁.

[00068] Preferred embodiments of each of the circuit blocks of FIG. 2 have been discussed. It will be understood, however, that many other circuit designs may be used for each of these blocks. Moreover, one or more of the blocks need not be included.

[heading-00069] Component Values

[00070] Table I set forth hereafter provides component values for six embodiments of the electrical contactor power supply system 20. These embodiments were developed as prototypes for experimental laboratory testing, experimental field trials, or both. As demonstrated by the entries in Table I, a near universal design can be used for a variety of contactors.

[00002]

TABLE I
COMPONENT VALUES
	Laboratory Tests		Field Trials
	No. 1	No. 2		No. 3	No. 4	No. 5	Both
	NEMA 2	NEMA 3		NEMA 4	NEMA 4	Control Relay	No. 6
	Square D	Westinghouse		Square D	Furnas	Square D	IECA to C
R1	910 kΩ
R2	150 kΩ
R3	100 kΩ
R4	274 kΩ
R5	1 MΩ
R6	200 kΩ
R7	10 kΩ
R8	100 kΩ
R9	100 kΩ ½ W
R10	18 kΩ
R11	100 kΩ
R12	12 kΩ
C1	43 μF	22 μF	33 μF
C2	0.22 μF
C3	10 μF
C4	0.1 μF
C5	5.6 nF
C6	0.47 μF		0.33 μF	0.47 μF
C7	100 pF		27 pF	100 pF
C8	560 pF	820 pF	470 pF	220 pF	330 pF	470 pF
C9	0.1 μF
D1	16 V Zener, 0.5 W
D2	1N914 - low leakage
D3	HBR 105, 400 V, 1 A, tTT = 50 ns
D4	15 V Zener
D5	15 V Zener
MOV	130 VAC
Q1	FZT658CT NPN, 400 V, 0.5 A
Q2	NTB2374, 200V, 18A, rds(on) = 0.18Ω
Q3	2N3904
Q4	2N3904
Q5	2N3906
U1	Harris, ICM7556 IPD
U2	Bridge Rectifier, 700 V, 1 A

Laboratory Test Results

[00072] A series of experimental tests were performed on different prototype embodiments of the electrical contactor power supply 20 to observe the behavior under AC supply voltage sags and complete dropouts. Specifically, three prototype designs corresponding to Nos. 1, 2, and 6 from Table I were subjected to laboratory testing. The test results for design No. 6 in which an International Electrotechnical Commission IEC-C contactor was used will now be described.

[00073] The test environment included a signal generator and a power amplifier to provide the AC supply voltage v_C(ac). The signal generator was programmed to provide sags and dropouts of varying degree and duration. A Tektronix 11401 digitizing oscilloscope was used to capture time waveforms of various signals, which were transferred to a computer over an IEEE-488 bus and plotted in a graphical format. Several of these signal graphs are included herein as FIGS. 3A-3B, 4A-4D, 5A-5D, and 6A-6D.

[00074] Referring now to FIG. 3A, two cycles of both the contactor coil 14 voltage v_C(ac) and current i_C(ac) are shown for the configuration of FIG. 1A in which the AC supply voltage v_C(ac) is connected directly to the contactor coil 14 without using the voltage regulator 22. FIG. 3B shows the AC supply voltage v_C(ac) and voltage regulator 22 current i_R when the voltage regulator 22 is used as shown in FIG. 1B. Note that the voltage regulator 22 current i_R is nonsinusoidal due to the action of the full-wave bridge rectifier U₂ in the rectifier circuit 24 (see FIG. 2). Table II shows a comparison of the peak and RMS values of i_C(ac) and i_R from FIGS. 3A and 3B.

[00002]

TABLE II
CONTACTOR COIL CURRENT COMPARED WITH VOLTAGE
REGULATOR CURRENT
		Coil - iC(ac) (mA)	Regulator - iR (mA)
	RMS value	53	30
	Peak value	85	105

While the peak value of i_R is greater than the peak value of i_C(ac), the RMS value of i_R is only 60% of the RMS value of i_C(ac). Therefore, based on these results, the addition of the voltage regulator 22 may reduce the volt-amperes (VA) required to operate the contactor coil 14.

[00076] Although not systematically investigated, the transient performance of the conventional electrical contactor power supply system shown in FIG. 1A was evaluated and found to be sensitive to minor sags and dropouts in the AC supply voltage lasting two to three cycles. Accordingly, the need for an electrical contactor power supply system in accordance with the present invention is apparently well justified.

[00077] The remainder of the laboratory transient performance testing was performed with the voltage regulator 22 installed as shown in FIG. 1C. FIGS. 4A-4D show the contactor coil 14 operation when the AC supply voltage v_C(ac) sags to 10% of its steady state level for a duration of approximately 4.2 seconds. The sag in the AC supply voltage v_C(ac) is shown in FIG. 4A where V_C(ac) drops from 120V to 12V. The DC input voltage v_O developed across energy storage capacitor C₁ takes about 0.5 seconds to decay from its initial value of approximately 170 V down to 17 V as shown in FIG. 4B. Despite the ten-to-one reduction in the AC supply voltage v_C(ac), FIG. 4C shows that the DC current i_C(dc) through the contactor coil 14 remains substantially constant. Referring now to FIG. iC, the voltage drop v_T across resistor R_T can be measured to determine the status of the contacts 16. Accordingly, FIG. 4D shows the test signal v_T remaining stable at approximately 15V, which indicates that the contacts 16 remained closed during this transient voltage sag. Although the AC supply voltage v_C(ac) is restored after approximately 4.2 seconds, the contactor 15 can operate indefinitely at the reduced voltage.

[00078] This test highlights the ability of the electrical contactor power supply system 20 to maintain the contactor coil 14 current i_C(dc) despite a 90% drop in the AC supply voltage V_C(ac). Nevertheless, such a wide operability range may not be desirable in all cases. The minimum AC source voltage value V_C(ac)−min and the corresponding DC input voltage value V_O−min, obtained from Equation 7, for which the voltage regulator 22 indefinitely maintains the contactor coil 14 current i_C(dc) are set by resistor R₁₀ of the internal power supply circuit 28. Increasing the value of resistor R₁₀ increases V_C(ac)−min and V_O−min by preventing the internal power supply circuit 28 from producing the internal power supply voltage V_CC. Referring again to FIG. 2, increasing the value of resistor R₁₀ results in a larger voltage drop between the DC input voltage v_O and the collector terminal of transistor Q₁. If the voltage drop across resistor R₁₀ is too great, the voltage at the emitter terminal of transistor Q₁ may be too small to generate a sufficient voltage level for the internal power supply voltage V_CC. As a result, the constant off-time control circuit 32 and the pull-in control circuit 34 will be disabled through the disabling of the dual timer U₁, which turns transistor Q₂ off in the switch circuit 26.

[00079] FIGS. 5A-5D show a complete dropout of the AC supply voltage v_C(ac) lasting approximately 0.5 seconds. FIG. 5A shows the AC supply voltage v_C(ac) dropping to zero and then reappearing after approximately 0.5 seconds. FIG. 5B shows the DC input voltage v_O across the energy storage capacitor C₁ decaying due to the absence of the AC supply voltage v_C(ac) and the current drain into the contactor coil 14. FIG. 5C shows that the voltage regulator 22 maintains the contactor coil 14 current i_C(dc) for almost the entire 0.5 seconds. In addition, FIG. 5C illustrates the operation of the pull-in control circuit 34, which is triggered at approximately the 0.5 second mark when the AC supply voltage v_C(ac) is restored. Specifically, the pull-in control circuit 34 causes an increase in contactor coil 14 current i_C(dc) to close the contactor armature, which, in this specific example, is not necessary because the voltage regulator 22 was able to maintain the contactor coil 14 current i_C(dc) throughout the dropout. FIG. 5D shows that the contacts 16 remained closed during the 0.5 second dropout.

[00080] For given values of the minimum AC supply voltage V_C(ac)−min and the minimum DC input voltage V_O−min, the energy storage capacitor C₁ directly sets the duration of the dropout through which the voltage regulator 22 can keep the contacts 16 closed. Doubling the value of C₁ doubles the ride-through time while halving the value of C₁ halves the ride-through time.

[00081] FIGS. 6A-6D show a complete dropout of the AC supply voltage v_C(ac) lasting approximately 1.0 second. FIG. 6A shows the AC supply voltage v_C(ac) dropping to zero and then reappearing after approximately 1.0 second. FIG. 6B shows the DC input voltage v_O dropping to zero as capacitor C₁ is completely discharged. FIG. 6C shows the voltage regulator 22 maintaining the coil current i_C(dc) for as long as the DC input voltage v_O is available at an adequate magnitude. Finally, the contacts 16 open or drop out as shown in FIG. 6D.

[00082] FIGS. 6A-6D also show the waveforms that occur upon startup of the voltage regulator 22 at the end of the one second dropout. The DC input voltage v_O across energy storage capacitor C₁ rises to the peak value of v_C(ac) (see FIG. 6B) and the contactor coil 14 startup current closes the contacts 16 (see FIG. 6C).

[00083] As stated in the foregoing, a small IEC-C contactor was used to generate the test waveforms of FIGS. 3B, 4A-4D, 5A-5D, and 6A-6D. Much larger contactors-a Square D NEMA 2 and a Westinghouse NEMA 3-were used in longer-term laboratory tests using the designs identified in Table I as No. 1 and No. 2. While a rigorous long-term reliability study has not yet been completed, these designs were used to study the possibility of “infant mortality” failures. The voltage regulators and associated contactors were operated continuously for about a month in an unventilated metal enclosure that was approximately one foot on each side. No failures occurred during these tests.

[heading-00084] Field Trial Test Results

[00085] In addition to the laboratory testing, several embodiments of the electrical contactor power supply system 20 were also subjected to experimental testing in a field setting. A plant had been experiencing repeated shut down of refrigeration equipment located at the end of a distribution feeder due to contactor dropout. The contactors control a refrigerator compressor motor that must be in continuous operation. Loss of refrigeration for only 15 to 20 minutes may cause the refrigerator temperature to exceed an acceptable limit resulting in a substantial loss of product. This was a problem during normal work hours because the plant engineer had to continually restart the compressors manually. The problem was even worse outside of normal work hours because the plant engineer had to be called in from home to restart the compressors.

[00086] A field trial of the electrical contactor power supply system 20 was initiated to evaluate the efficacy of the electrical contactor power supply system 20 in combating this problem. The installation proceeded in two phases: For the first installation, voltage regulators were designed and fabricated for one Square D NEMA 4 contactor and four Square D control relays. These designs are identified in Table I as No. 3 and No. 5, respectively. These voltage regulators were designed to ride-through a power line disturbance lasting one second. Two of the relay coils were connected in parallel and could be served by one voltage regulator, while the remaining two relay coils were each served by a dedicated voltage regulator.

[00087] A BMI 8800 was installed to monitor the nominal 120V AC supply voltage to the voltage regulator, the nominal 480V supply to the motor, and the current in phase-B of the motor. Numerous power line disturbances were captured during the trial. FIG. 7A shows the voltage applied to the contactor coil for a representative event. Starting from a nominal 120V, the contactor coil voltage sagged to approximately 70 V for a duration of approximately 0.4 seconds. FIG. 7B shows the voltage applied to the motor and the phase-B motor current. The voltage applied to the motor experienced a sag proportional to the voltage applied to the contactor coil. During this event, the motor current sagged with the voltage and then surged slightly as the AC supply voltage was restored. The refrigeration continued to operate normally during this sag. By comparison, this sag disrupted the operation of every other piece of electrical equipment in the plant, including the computing equipment.

[00088] The voltage regulators solved the problem with contactor dropout on the refrigerator compressor motors. Due to the success of the first installation, the field trial was expanded with a second installation. The first installation was replicated for two additional refrigerator compressor motors for a total of three.

[00089] Contactor dropout was also a problem on a motor driving an air compressor. To address this problem, voltage regulators were designed for a Fumas NEMA 4 contactor, an IEC-C contactor, and an additional Square D control relay, identified in Table I as designs No. 4, No. 5, and No. 6, respectively. The voltage regulators performed as desired. Unfortunately, the electronic device operating the control relay was subject to dropout as well. This experience demonstrates that generally every control device in the chain must be able to ride-through the line disturbances for the electrical contactor power supply system to be effective.

[00090] A decision was made not to pursue the air compressor problem and the voltage regulators were subsequently removed. The voltage regulators installed on the contactors for the refrigerator compressor motors remain in operation for long term evaluation of their performance.

[00091] The principles of the invention have been illustrated herein as they are applied to an electrical contactor power supply system that includes a voltage regulator. From the foregoing, it can readily be seen that the electrical contactor power supply systems and methods can solve an important piece of the power quality puzzle by addressing the problem of contactor ride-through. The voltage regulator can be mechanically compatible with many contactors and may be easily retrofitted into existing installations. In addition, very small circuit changes may be needed to adapt the voltage regulator to a variety of contactor coils.

[00092] It should be understood, however, that the electrical contactor power supply system could cause a hazard if installed in the wrong location. For example, inasmuch as the voltage regulator introduces a delay in the operation of the contactor, the electrical contactor power supply system should be installed only on equipment designed for continuous operation and not on equipment where this time delay could be dangerous. It is envisioned, however, that the electrical contactor power supply could be modified to include an emergency stop button that opens the contactor immediately.

[00093] It must also be noted that concerns have also been expressed about the possibility of motor damage caused by holding the contactor closed during a power line disturbance. While no damage has been observed so far during the field trial discussed above, the possibility of accumulated damage appearing in the future cannot be discounted. Nevertheless, the cost of replacing a motor every few years may be inconsequential compared to the cost of lost production over that same time period.

[00094] In concluding the detailed description, it should be noted that many variations and modifications can be made to the preferred embodiments without substantially departing from the principles of the present invention. All such variations and modifications are intended to be included herein within the scope of the present invention, as set forth in the following claims.