`Patent 7,626,349
`
`
`IN THE UNITED STATES PATENT AND TRADEMARK OFFICE
`BEFORE THE PATENT TRIAL AND APPEAL BOARD
`
`
`
`
`
`
`
`Zhongshan Broad Ocean Motor Co.,
`Ltd.; Broad Ocean Motor LLC; and
`Broad Ocean Technologies, LLC
` Petitioners
` v.
`Nidec Motor Corporation
` Patent Owner
`
`Case IPR2014-01121
`Patent 7,626,349
`
`
`
`DECLARATION BY MARK E. CARRIER
`
`I, Mark E. Carrier, am one of the joint inventors named in U.S. Patent
`
`1.
`
`No. 7,626,349 (the “’349 patent”), which is the subject of the above-referenced
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`inter partes review proceeding. I am presently the Vice President of New Product
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`Development at Nidec Motor Corporation.
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`Work Experience
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`2.
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`I have been working as an engineer and researching and developing
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`new products concerning electric motors and controls for almost 35 years. I have a
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`B.S. in Electrical Engineering and a Masters degree in Engineering Management.
`
`3.
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`From 1983 until 1997 I worked at Philips Technologies or its
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`affiliated entities
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`in Cheshire, Connecticut and The Netherlands. My
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`- 1 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 1
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`Case IPR2014-01121
`Patent 7,626,349
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`responsibilities included testing stepping motor products, testing on brushless
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`permanent magnet motors, and design and implementation of controllers for BPM
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`motors.
`
`4.
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`From 1997 until 2001 I worked at Nidec America Corporation as a
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`Senior Development Engineer. While at Nidec America I developed motors for
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`disk drives and analyzed a magnetic design for BPM motors for the industrial
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`control industry.
`
`5.
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`From July 2001 until October 2010 I worked at Emerson Electric Co.
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`(“Emerson”) in St. Louis, Missouri in Emerson’s motors and controls division.
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`Nidec Corporation acquired Emerson’s motors and controls division in the fall of
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`2010, which later became Nidec Motor Corporation. While at Emerson and then at
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`Nidec Motor Corporation, I have worked in St. Louis, Missouri and had various
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`job titles and had numerous job responsibilities. For instance, at Nidec Motor
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`Corporation, from October 2010 until the present, I was first a Director of New
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`Product Development and now am Vice President of New Product Development.
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`While at Nidec Motor Corporation, I have managed many engineers and have had
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`substantial involvement in the research, development, and implementation of
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`electric motors and controls intended for use in the HVAC market. I will refer to
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`- 2 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 2
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`Case IPR2014-01121
`Patent 7,626,349
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`Emerson and Nidec Motor Corporation collectively as “Nidec” in this declaration.
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`6.
`
`During my time at Nidec, I have gained extensive experience
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`designing and developing various electric motors and controls for electric motors,
`
`including motor controls like those described and claimed in the ’349 patent. As a
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`co-inventor of the ’349 patent, I know about HVAC system design and constituent
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`components that are described and claimed in the ’349 patent. I am also
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`knowledgeable about commercial embodiments of the subject matter described and
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`claimed in the ’349 patent by Nidec.
`
`7.
`
`Beginning in 2003 I became a program manager at Nidec and
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`participated in meetings with all tier 1 and tier 2 HVAC customers. Tier 1
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`customers are those who have the highest volume, and tier 2 have lower volume
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`purchases. I have consistently participated since 2003 in meetings to sell our ECM
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`products to all potential major customers.
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`8.
`
`I am making this declaration to describe the development of the
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`subject matter described and claimed in the ’349 patent, the commercial benefits
`
`attributable to the subject matter claimed in the ’349 patent, and the associated
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`commercial success Nidec realized as a result of the invention claimed in the ’349
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`patent.
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`- 3 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 3
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`Case IPR2014-01121
`Patent 7,626,349
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`The Market for Electric Motors And Features Desired by Customers
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`9.
`
`Through my work experience described above, I have gained
`
`significant experience researching, designing, and marketing electric motors and
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`motor controls. Nidec markets and sells its variable speed electric motors and
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`controls to the original equipment manufacturer (“OEM”) HVAC market and
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`through several large distributors who sell into the aftermarket. The OEM HVAC
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`market includes well-known companies like Trane, Goodman, JCI, Rheem,
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`Lennox, Carrier and others. These OEM customers install and service full HVAC
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`systems to businesses and homeowners across the globe.
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`10. The OEM HVAC market for variable speed electric motors and
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`controls is highly price sensitive and feature driven. The market is highly price
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`sensitive because OEMs require substantial volumes of electric motors and
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`controls, so costs can quickly accumulate with volume purchases that are necessary
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`for OEMs to service their respective markets. Moreover, end-consumers—the
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`businesses and homeowners—that purchase and require service of their HVAC
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`systems are incredibly price sensitive and want inexpensive units that will
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`effectively and efficiently condition their work and living spaces.
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`11. Additionally, OEMs desire feature-rich motors and controllers that
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`- 4 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 4
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`Case IPR2014-01121
`Patent 7,626,349
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`can be used in many different environments and circumstances. OEMs want to
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`easily incorporate electric motors and controllers into their systems to minimize
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`any engineering or other requirements that may increase their costs to end
`
`consumers.
`
`12. The most important features of variable speed HVAC motors and
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`controls are:
`
`a.
`
`Constant Airflow Leading to Improved Comfort and Efficiency
`
`of the HVAC System: An HVAC’s job is to condition the air in a work or
`
`living space. Conditioning air requires the air to move across elements of the
`
`HVAC to remove or add heat to the air, which is then recirculated through
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`the work or living space to maintain a desired temperature and/or humidity
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`level. The ability to accurately and efficiently control the flow of air with a
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`variable speed electric motor over the HVAC heat exchanger is of
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`paramount importance. Accordingly accurately and easily controlling the
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`flow rate of air—measured in cubic feet per minute (“CFM”)—is vitally
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`important for an electric motor in an HVAC system to assure consistent
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`conditioning and comfort to the consumer. Constant CFM also improves the
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`life of the heat exchanger and A-coil of the system.
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`- 5 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 5
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`Case IPR2014-01121
`Patent 7,626,349
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`b.
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`Quiet Operation: HVAC systems often operate in or near the
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`environments they are designed to condition air. In central heating and
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`cooling systems,
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`the ductwork communicates noise and vibrations
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`throughout the system. Vibrations generated by the motor may be heard
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`directly by the consumer or be transmitted or even amplified via the
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`ductwork to the conditioned space. Because of this, it is important that the
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`variable speed electric motors operate quietly. End-consumers do not like
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`loud or noisy HVAC systems because they are distracting and obtrusive.
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`Consequently, it is extremely important to OEMs and their customers alike
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`that variable speed electric motors operate as quietly as possible.
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`c.
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`Performance When Voltage Drops: Low-voltage situations can
`
`exist on a power grid. For instance, when a customer is located on the
`
`periphery of a service area, voltage drops can occur as power is consumed or
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`anomalies occur across the grid. It is important to maintain motor operation
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`when these voltage drops occur so that interruptions in HVAC systems are
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`unnoticeable or minimized. Maintaining motor operation during low line
`
`voltage situations maintains airflow and is important because it minimizes
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`perceived HVAC problems by end-consumers and helps with comfort in the
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`- 6 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 6
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`Case IPR2014-01121
`Patent 7,626,349
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`conditioned space.
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`The Invention Claimed in The ’349 Patent
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`13. The invention of the ’349 Patent is directed to a HVAC system
`
`including a system controller, a motor controller, an air-moving component, and a
`
`permanent magnet motor. Importantly, the “motor controller is configured for
`
`performing sinewave commutation, using independent values of Q and d axis
`
`currents, in response to one or more control signals received from the system
`
`controller to produce continuous phase currents in the permanent magnet motor for
`
`driving the air-moving component.” (See, e.g., Ex. 1001, claim 1).
`
`14. With brushless electric motors, there are permanent magnets on the
`
`rotor (the rotating elements of the motor) and windings on the stator (the stationary
`
`part of the motor) that are energized to create electromagnets on the stator. In a
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`conventional brushless motor, the windings on the stator may be arranged around
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`the periphery of the rotors. In operation, the motor controller cycles electrical
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`current through the different windings in a specific order and manner to generate
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`magnetic fields that in turn cooperatively pull and push the electric motor’s rotors
`
`to drive the electric motor.
`
`15. Before the invention claimed in the ’349 patent, the pulse width
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`- 7 -
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`Nidec Motor Corporation
`IPR2014-01121
`
`Exhibit 2033 - 7
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`Case IPR2014-01121
`Patent 7,626,349
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`modulated electrical signals applied to the groups of stator windings in HVAC
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`electric motors had a square wave form. (Prior art square waveform technology is
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`equivalent to trapezoidal waveform control–the only difference being whether
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`voltages or currents are being described and depicted). For example, the square
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`waveforms for a 3-phase electric motor could look like this:
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`
`
`(Ex. 1001, Fig. 1).
`
`16. The square waves resulted in discontinuous phase currents on stator
`
`electromagnets, which resulted in high torque ripple, which in turn leads to
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`undesirable noise and vibration in the motor and HVAC systems in which the
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`motor is used. (Ex. 1001, Col. 1, ll. 47-67).
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`17. With sine wave commutation, the pulse width modulated signals
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`applied to the stator electromagnets are continuously varied to form a sinusoidal
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`- 8 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 8
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`Case IPR2014-01121
`Patent 7,626,349
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`waveform. Rather than square waveforms, the sinusoidal wave forms could
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`resemble this:
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`
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`(Ex. 1001, Fig. 5). Unlike square-wave forms, a sinusoidal waveform signal
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`gradually varies the current so that current smoothly builds up and ramps down in
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`the stator. There are no discontinuous phase changes in the current waveform and
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`consequent torque ripple. Accordingly, a designer has more control over the
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`current build up and ramp down. With the increased control, the motor is more
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`efficiently used to generate accurate torque and the continuous wave currents result
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`in operating torque that is substantially free of torque-ripple and its undesirable
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`noise-generating effects. (Ex. 1001, Co. 4, l. 66 – Col. 5, l. 19).
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`18. Additionally, because of our decision to use sine wave commutation,
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`- 9 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 9
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`Case IPR2014-01121
`Patent 7,626,349
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`the start-up of the motor is smoother. A smoother start means the motor is much
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`quieter when it is first energized. So, sine wave commutation leads to quieter start-
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`up noise and less noise throughout the operation of the motor.
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`19. Another advance claimed in the ’349 patent is the use of independent
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`Q and d axis currents. Even with sine wave commutation, without the use of
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`independent Q and d axis currents, achieving accurate torque in the electric motor
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`can be challenging because of the opposing back-electromotive force (EMF). Back
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`EMF is voltage that opposes the current that causes it. In fact, back EMF arises in
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`any electric motor when there is relative motion between the current-carrying
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`stator and the external magnetic field. As the rotor spins (with or without power
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`applied to the windings) the mechanical rotation generates a voltage – so, in effect,
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`becomes a generator. At the time of our invention, developing Q and d axis
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`currents independently permitted us to account for the back EMF and more easily
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`and accurately control the operating torque generated by the motor.
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`Motors and Controllers Sold By Nidec Within the Scope of the ’349 Patent
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`20. Nidec sells motors and control for use in HVAC systems that practice
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`the invention claimed in the ’349 patent.
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`21.
`
`I am familiar with the document shown in Exhibit 2004. Exhibit 2004
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`- 10 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 10
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`Case IPR2014-01121
`Patent 7,626,349
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`comprises a true and accurate copy of a Nidec presentation entitled “Goodman
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`Business Alignment & Technology Review” which, among other things, describes
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`the various features and benefits of Nidec’s electric motors and controllers offered
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`for sale by Nidec in 2012. This presentation was prepared by Nidec employees as
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`marketing material to identify and explain the various features and benefits of
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`Nidec’s various electric motors and controllers to OEM customers, specifically
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`Goodman. The descriptive text in Exhibit 2004 fairly and accurately describes
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`features and benefits of Nidec’s various electric motors and controllers. The
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`presentation was kept in the course of regularly conducted business activities of
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`Nidec and was prepared as a regular practice and custom of Nidec to identify and
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`explain the various features and benefits of Nidec’s electric motors and controllers
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`to OEM customers like Goodman. The presentation was created by Nidec
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`employees whose job responsibilities at Nidec include creating presentations like
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`that shown in Exhibit 2004 in collaboration with engineers such as myself. Exhibit
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`2004 was presented to Goodman personnel under a non-disclosure agreement.
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`22.
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` I am familiar with the document shown in Exhibit 2005. Exhibit 2005
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`comprises a true and accurate copy of a Nidec presentation entitled “Variable
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`Speed Motor Program Update” which, among other things, describes the various
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`- 11 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 11
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`Case IPR2014-01121
`Patent 7,626,349
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`features and benefits of Nidec’s electric motors and controllers before first offered
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`for sale by Nidec in 2007. This presentation was prepared by Nidec employees to
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`identify and explain the various features and benefits of Nidec’s various electric
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`motors and controllers to OEM customers, specifically Trane. The descriptive text
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`in Exhibit 2005 fairly and accurately describes features and benefits of Nidec’s
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`various electric motors and controllers. The presentation was kept in the course of
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`regularly conducted business activities of Nidec and was prepared as a regular
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`practice and custom of Nidec to identify and explain the various features and
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`benefits of Nidec’s electric motors and controllers to OEM customers like Trane.
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`The presentation was created by Nidec employees whose job responsibilities at
`
`Nidec include creating presentations like that shown in Exhibit 2005 in
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`collaboration with engineers such as myself. Exhibit 2005 was presented to Trane
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`personnel under a non-disclosure agreement.
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`23. The electric motors and controllers described in Exhibits 2004 and
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`2005, include Nidec electric motors and controllers sold under the names
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`PerfectSpeed, EcoTech, 16X4W, EcoApex48, Rescue Select, and SelecTech.
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`These products all practice the invention claimed in the ’349 patent and I will
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`collectively refer to them in this declaration as the “Practicing Nidec Motors.”
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`- 12 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 12
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`Case IPR2014-01121
`Patent 7,626,349
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`24.
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`I am familiar with the Practicing Nidec Motors and they practice the
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`invention claimed in the ’349 Patent as set forth in the exemplary claim chart
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`below:
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`’349 Patent Claim 1
`
`Observations
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`A heating, ventilating
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`and/or
`
`air
`
`The Practicing Nidec Motors are
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`conditioning
`
`(HVAC)
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`system
`
`designed and intended to be used with
`
`comprising
`
`HVAC systems.
`
`a system controller,
`
`A system controller communicates with
`
`the controller of a Practicing Nidec
`
`Motor.
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`a motor controller,
`
`The Practicing Nidec Motors include a
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`motor controller comprising a digital
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`signal
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`processor
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`and
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`associated
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`programming.
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`an air-moving component,
`
`The Practicing Nidec Motors are
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`designed and intended to drive air-
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`moving components.
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`and a permanent magnet motor having a The Practicing Nidec Motors include a
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`- 13 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 13
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`Case IPR2014-01121
`Patent 7,626,349
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`stationary assembly,
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`permanent magnet motor having a
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`stationary assembly, such as a stator.
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`a
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`rotatable assembly
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`in magnetic
`
`The Practicing Nidec Motors include a
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`coupling
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`relation
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`to
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`the stationary
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`rotatable assembly in magnetic coupling
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`assembly,
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`relation to the stationary assembly, such
`
`as a rotor.
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`and a shaft coupled to the air-moving
`
`The Practicing Nidec Motors include a
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`component,
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`shaft.
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`wherein
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`the motor
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`controller
`
`is
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`The Practicing Nidec Motors include
`
`configured for performing sinewave
`
`motor controllers comprising a digital
`
`commutation, using independent values
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`signal processor that performs sinewave
`
`of Q and d axis currents, in response to
`
`commutation using independent Q and d
`
`one or more control signals received
`
`axis currents. The motor controllers
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`from the system controller to produce
`
`receive command signals from
`
`the
`
`continuous phase currents
`
`in
`
`the
`
`system controller and using sinewave
`
`permanent magnet motor for driving the
`
`commutation and independent Q and d
`
`air-moving component.
`
`axis currents produce continuous phase
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`currents in the permanent magnet motor
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`- 14 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 14
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`Case IPR2014-01121
`Patent 7,626,349
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`for driving the air-moving component.
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`Notably, the Practicing Nidec Motor controllers “are configured for
`
`performing sinewave commutation, using independent values of Q and d axis
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`currents, in response to one or more control signals received from the system
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`controller to produce continuous phase currents in the permanent magnet motor for
`
`driving the air-moving component.” I know this because:
`
`a.
`
`Sine wave commutation: Having directly participated in the
`
`development of these products, I know we designed them this way. Additionally, I
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`have from time to time examined the currents produced by the system controllers
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`of the Practicing Nidec Motors by observing the output from a calibrated and
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`properly operating oscilloscope. An oscilloscope is a well-known tool in the
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`electrical engineering arts for showing electrical signals in a graphical format. In
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`my long experience electrical engineers regard oscilloscopes as a reliable
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`mechanism for graphically displaying electrical signals. Using the oscilloscope is
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`particularly useful to show the Practicing Nidec Motor controllers perform sine
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`wave commutation because it can confirm that the current waveforms supplied to
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`the Practicing Nidec Motors are sine waves. If the graphs generated by the
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`oscilloscope look like a square waveform (See ¶ 15, above), then the Practicing
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`- 15 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 15
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`Case IPR2014-01121
`Patent 7,626,349
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`Nidec Motors are not performing sine wave commutation as claimed. But, if the
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`graphs generated by the oscilloscope look like sine waves (See ¶ 17, above), then
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`we know the Practicing Nidec Motors are performing sine wave commutation
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`because the waves generated look like sine waves. I examined the waveforms
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`generated by the controllers of current Practicing Nidec Motors under different
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`loads and speeds. The motor phase currents are observed by placing the
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`oscilloscope probes on the motor phase leads. The motor controller delivers
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`current to the motor through the phase leads. True and accurate depictions of the
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`images shown by the oscilloscope from the Practicing Nidec Motors under
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`different loads are provided in Exhibit 2026 and reproduced below:
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`- 16 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 16
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`Case IPR2014-01121
`Patent 7,626,349
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`These images show sine waves produced by the controller. These sine waves are
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`produced in response to control signals received from a system controller and
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`produce continuous phase currents in the permanent magnet motor controlled by
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`the controller to drive the air-moving component. All Practicing Nidec Motors
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`operate this way because they are designed and programmed to do so. I have
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`personal knowledge that all Practicing Nidec Motors employ sine wave
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`commutation.
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`b.
`
`Independent Q and d axis currents: Engineers at Nidec use, among
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`other things, a software package based on auto-code generation tools from
`
`MathWorks including Simulink, Stateflow, and RealTime Workshop (collectively
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`“Simulink tools”) to generate the code for the digital signal processors used in the
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`motor controllers of Practicing Nidec Motors. Simulink is a graphical environment
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`in which block diagrams are used to model and simulate a system. The Simulink
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`tools can then compile the Simulink model using auto code generation into the
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`code that ultimately results in a program used by digital signal processors. I have
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`- 17 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 17
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`Case IPR2014-01121
`Patent 7,626,349
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`examined the Simulink model applied to and implemented by the motor controllers
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`of the Practicing Nidec Motors. Exhibit 2027 is a true and accurate excerpt from
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`the Simulink model used to code the digital signal processors of the Practicing
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`Nidec Motors showing how the values of Q and d axis currents are developed. The
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`Simulink model shown in Exhibit 2027 was created by Nidec engineers when
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`developing the motor controllers for the Practicing Nidec Motors. The model in
`
`Exhibit 2027 was created by Nidec engineers in the course of regularly conducted
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`business activities of Nidec and is maintained by Nidec to apply to Practicing
`
`Nidec Motors. The engineers who developed the model in Exhibit 2027 had
`
`knowledge of and a business duty to create the model. Indeed, the model shown in
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`Exhibit 2027 is applied to the motor controllers of all Practicing Nidec Motors.
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`Exhibit 2027 clearly shows that the Q and d axis currents are developed
`
`independently. Notably, the Q axis current is developed by the top portion of the
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`block diagram and shows torque _demand _out (From 6), iq_blocked _filter _lim
`
`(From 14), iq_temp _lim (From 10), and iq_power _lim (From 11) as inputs on the
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`left side. The d axis current is developed by the bottom portion of the block
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`diagram and shows vdc, and power out (From 12) as inputs to a look-up table that
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`stores values of id_dem_out, which is the output from the look-up table. The
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`- 18 -
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`Nidec Motor Corporation
`IPR2014-01121
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`Exhibit 2033 - 18
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`Case IPR2014-01121
`Patent 7,626,349
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`id_dem_out values in the look-up table are based upon empirical data from testing
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`Practicing Nidec Motors. I understand that in this proceeding the phrase “using
`
`independent values of Q and d axis currents” means Q and d axis current values are
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`developed independently of each other, without relying on one to derive the other.
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`The diagram shown in Exhibit 2027 shows both Q and d axis currents are
`
`developed separately from each other and neither relies on the other. Neither the
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`top portion (Q axis) nor the bottom portion (d axis) has the other portion as their
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`respective inputs.
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`The Invention of the ’349 Patent Achieves Features Important to Customers
`
`25. The claimed invention, most notably sine wave commutation and
`
`independent Q and d axis current control, helped Nidec achieve incredibly
`
`important functionality in Nidec’s variable speed electric motors.
`
`26. Constant Airflow Leading to Improved Comfort and Efficiency of
`
`the HVAC System: Sine wave commutation allows much better control flexibility
`
`of the motor. For instance, assuming everything else is equal, sine wave control of
`
`a motor achieves better efficiency over square wave control. (Ex. 1001, Col. 2, ll.
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`1-3; See also Col. 4., l. 66 – Col. 5, l. 2). Likewise, utilizing independent Q and d
`
`axis currents facilitates easier and more accurate motor torque control. Enhanced
`
`
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`- 19 -
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`Nidec Motor Corporation
`IPR2014-01121
`
`Exhibit 2033 - 19
`
`
`
`Case IPR2014-01121
`Patent 7,626,349
`
`torque control of the motor enables constant flow rate control (“Constant CFM”).
`
`Maintaining Constant CFM is important in HVAC applications to ensure that the
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`proper amount of air is moving across the heat exchanger or A-coil to obtain
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`efficient conditioning of the air. If the flow rates are inconsistent, inconsistent air
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`conditioning occurs, which yields inefficient and potentially uncomfortable living
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`and work spaces.
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`27. Nidec conducted tests of its variable speed electric motors having sine
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`wave and independent Q and d axis current control against a variable speed electric
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`motor offered by Regal Beloit using square wave control. The results, shown in the
`
`chart below, demonstrate Nidec’s technology achieves excellent Constant CFM:
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`
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`- 20 -
`
`Nidec Motor Corporation
`IPR2014-01121
`
`Exhibit 2033 - 20
`
`
`
`Case IPR2014-01121
`Patent 7,626,349
`
`
`
`
`(Ex. 2004, at 101; Ex. 2005, at 20). Nidec conducted the testing following an
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`industry standard protocol that is established by the American Society of Heating,
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`Refrigeration and Air- Conditioning Engineers. The protocol is identified as
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`ANSI/ASHRE 37. This standard describes and defines testing that was used to
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`develop the data shown on the chart above and in Exhibit 2004 and 2005. A true
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`and accurate copy of the 2005 ANSI/ASHRE 37 standard is submitted as Exhibit
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`2028. Nidec has technicians whose job is to perform this testing according to these
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`standards. They generated the data shown in the chart above following the
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`standard.
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`
`- 21 -
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`Nidec Motor Corporation
`IPR2014-01121
`
`Exhibit 2033 - 21
`
`
`
`Case IPR2014-01121
`Patent 7,626,349
`
`
`28.
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`In the figure above the black lines on the chart correspond to CFM of
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`Nidec’s technology embodied in its Practicing Nidec Motors. The red lines
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`correspond to the CFM of Regal Beloit’s square wave technology. Constant CFM
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`is exhibited if the lines are near vertical. A comparison of the black lines (Nidec)
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`with the red lines (Regal Beloit) demonstrates the technology claimed in the ’349
`
`patent achieves better constant CFM characteristics as compared to prior
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`technology, particularly at higher flow rates.
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`29. Quiet Operation: Unlike with square wave control, which exhibits
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`motor torque ripple as a result of discontinuities in phase currents, sine wave
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`control effectively nullifies torque ripple in the motor. (See Ex. 1001, Col. 4., l. 66
`
`– Col. 5, l. 6). For instance, torque output from a variable speed electric motor
`
`using square wave control may look like this:
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`(Ex. 2004, at 102; Ex. 2005, at 9). The variation in the torque output graph
`
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`- 22 -
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`
`
`Nidec Motor Corporation
`IPR2014-01121
`
`Exhibit 2033 - 22
`
`
`
`Case IPR2014-01121
`Patent 7,626,349
`
`represents torque ripple that results from the current phase discontinuities present
`
`with square wave control. Torque ripple produces undesirable vibrations and, thus,
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`noise within the variable speed electric motor. The noise generated from torque
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`ripple propagates throughout an HVAC system through its ducting and can lead to
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`undesirable loud, obtrusive noises. While square wave controls like those of the
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`Regal Beloit motor may use damping material on the motor shaft to try and reduce
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`the vibration and noise, those dampers increase cost and can fail over time. (See
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`Ex. 1001, Col. 1, ll. 57 – 67).
`
`30.
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`In contrast, sine wave control claimed in the ‘349 patent and
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`implemented in the Practicing Nidec Motors have torque output that is
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`approximated by the following graph:
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`(Ex. 2004, at 102; Ex. 2005, at 9). The sine wave control results in no phase
`
`
`- 23 -
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`
`
`Nidec Motor Corporation
`IPR2014-01121
`
`Exhibit 2033 - 23
`
`
`
`Case IPR2014-01121
`Patent 7,626,349
`
`current discontinuities, which eliminates torque ripple and enables constant torque
`
`output from the variable speed electric motor. Consequently, no noise is generated
`
`in the Practicing Nidec sine wave motor that can be propagated through the HVAC
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`system. Thus, no mechanical dampers are necessary.
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`31. Nidec has tested the noise characteristics of its Practicing Nidec
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`Motors in comparison with competitive Regal Beloit offerings using square wave
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`control. We have observed that Practicing Nidec Motors are typically 2 decibels
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`quieter than the competition that uses square wave control. (Ex. 2004, at 103). Of
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`course, since sound is measured in decibels on a logarithmic scale, a decrease in 3
`
`decibels equates to about half the noise energy of the closest competition using
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`square wave control:
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`
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`- 24 -
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`Nidec Motor Corporation
`IPR2014-01121
`
`Exhibit 2033 - 24
`
`
`
`Case IPR2014-01121
`Patent 7,626,349
`
`
`
`
`(Ex. 2004, at 103). The data for the chart above is found on page 103 of Exhibit
`
`2004. It was generated by alternately placing a Practicing Nidec Motor and a
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`Regal Beloit ECM 3.0 motor in a reverberation chamber at Nidec that Nidec uses
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`as a diagnostic tool. The reverberation chamber contains an array of microphones
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`that capture sound pressure output by each system. We were able to evaluate the
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`relative amount of sound pressure generated by the Practicing Nidec Motor as
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`compared to the Regal Beloit ECM 3.0 motor. The results were reported in the
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`data and the chart reproduced above.
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`32.
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`In addition, as described above, feeding in sine wave commutated
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`
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`- 25 -
`
`Nidec Motor Corporation
`IPR2014-01121
`
`Exhibit 2033 - 25
`
`
`
`Case IPR2014-01121
`Patent 7,626,349
`
`currents during start-up as compared to the competitors starting routine leads to
`
`lower noise at start-up. In one test in which a Practicing Nidec Motor was
`
`compared against a Regal Beloit motor, Nidec was found to be quieter on startup:
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`NIDEC Startup Noise Profile
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`Regal Beloit Startup Noise Profile
`
`
`
`
`
`
`(Id., at 104).
`
`33. Performance When Voltage Drops: HVAC systems can also
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`encounter adverse operating conditions, such as low voltage, when a system is
`
`installed on the edge of a power grid or when voltage drops occur on a power grid.
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`When these events occur, variable speed electric motors designed for normal line
`
`voltage may not function properly. In low voltage situations, back-emf effects on
`
`the motor are more prominent, not properly adjusting for those effects could cause
`
`variable speed electric motors to stop working altogether or work inefficiently.
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`
`
`- 26 -
`
`Nidec Motor Corporation
`IPR2014-01121
`
`Exhibit 2033 - 26
`
`
`
`Case IPR2014-01121
`Patent 7,626,349
`
`However, with independent Q and d axis current control Practicing Nidec Motors
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`were designed to inject “d axis current” independent of torque demand or Q axis
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`current that allows Practicing Nidec Motors to continue operating while torque
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`demand is calculated independently of d axis current to maintain constant CFM.
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`Additionally, if abnormal transient conditions occur, injection of independent d
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`axis currents maintains motor operation. In essence, Nidec’s design of independent
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`Q and d axis current control permits defluxing of the motor to counteract the
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`voltage drop and maintain proper motor operation. Consequently, when line
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`voltage drops occur, other motors may fail or stop working efficiently whereas
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`Practicing Nidec Motors can continue operating closer to peak efficiency as
`
`compared to other variable speed electric motors. Nidec touted this feature when
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`discussing the benefits of Practicing Nidec Motors with customers. (Ex. 2005, at
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`19).
`
`34. Nidec touted each of the aforementioned features to its OEM
`
`c