Rhey W. Hedges, Mellin Industries, Inc. & Jerry Drew, Xencom Communications Inc.
Energy Economizer Technology (EET) introduces a new approach to motor control. 50 granted USA and International patents say it provides power management that is truly different from familiar old-technology motor-control processes. The vital role AC electric motors play in profit return on investment is universal. They are the "motive resource" that turn the wheels of productivity in every industry; the Petroleum Industry's dependency on motors is a prime example. When pump motors stop, profit stops and "downtime" costs begin. This condition spans the globe. It is as true in developing countries as it is in Texas. Every country depends on electric motors for internal operations and growth by export dollars. As is true with other resources, motors that are managed are the most productive. Unmanaged motors start with avoidable electro-mechanical stress and full voltage is applied during light loads where a lesser current would reduce energy waste, life-shortening heat damage and increase production "uptime." A large percentage of "downtime" cost could be avoided by supervisors who turn power off to protect motors and conserve energy by making manual adjustments. Manual control for hundreds of millions of motors by "human" supervisors is not feasible. Most AC motors waste some energy as life shortening heat and rely on thermal devices or fuses for protection. Even though such means prevent single-event catastrophic failures, some motor damage inevitably occurs with each over-current fault; especially with mechanical locked-rotor events. Controlling power is an improvement over direct-on-line operation. But familiar voltage ramp "soft" starters, even new ones upgraded with the latest microprocessors, are limited by the "design approach" that earned the name: Motor Controller. The old familiar approaches literally control power to the motor. Prior technology relies on measurements compared to arbitrary software or hardware references the designer believes will control motor performance under conditions that are "anticipated". The motor becomes a "design-controlled" item. Energy Economizer Technology relies on natural properties of standard induction motors as the controlling elements of a "power management system" that: (1) commands start acceleration, (2) adjusts run torque in proportion to work demand and (3) includes diagnostics that protectively respond to electro-mechanical faults. The EET approach empowers THE MOTOR to command current in response to conditions and work of a moment without comparison to programmable, arbitrary references; "designer anticipation" of such conditions is not a performance factor. A novel communications and power control system are united by the EET process.