Methods and systems for transient voltage protection

1. A method for protecting a motor controller from a transient voltage, said method comprising:

providing an electromagnetic interference (EMI) filter having at least a first input terminal, a second input terminal, a first output terminal, and a second output terminal, the EMI filter configured to suppress electromagnetic interference;

coupling a first voltage clamping device and a second voltage clamping device in series between the first output terminal and the second output terminal;

coupling a spark gap device to a ground conductor and to a shared node between the first voltage clamping device and the second voltage clamping device; and

coupling a third voltage clamping device between the first input terminal and the second input terminal of the EMI filter.

2. A method in accordance with claim 1 further comprising configuring the first output terminal for coupling to a first input of a motor controller and configuring the second output terminal for coupling to a second input of the motor controller.

3. A method in accordance with claim 2 further comprising:

configuring the first voltage clamping device and the spark gap device to prevent damage to the motor controller caused by exposure to a transient voltage between the first output terminal and the ground conductor; and

configuring the second voltage clamping device and the spark gap device to prevent damage to the motor controller caused by exposure to a transient voltage between the second output terminal and the ground conductor.

4. A method in accordance with claim 2 further comprising configuring the first voltage clamping device and the second voltage clamping device to prevent damage to the motor controller caused by exposure to a transient voltage between the first output terminal and the second output terminal by clamping the voltage between the first input and the second input of the motor controller below a predefined voltage level.

5. A method in accordance with claim 1 , wherein coupling the first voltage clamping device and the second voltage clamping device in series between the first output terminal and the second output terminal of the EMI filter, and coupling the spark gap device to a ground conductor and to the shared node between the first voltage clamping device and the second voltage clamping device, suppresses voltage ringing generated within the EMI filter.

6. A method in accordance with claim 1 , further comprising at least one of:

configuring the first input terminal of the EMI filter for coupling to a first alternating current (AC) line input;

configuring the second input terminal of the EMI filter for coupling to a second AC line input;

coupling a first intentional weak link between the first input terminal of the EMI filter and the first AC line input; and

coupling a second intentional weak link and the third voltage clamping device in series between the first input terminal and the second input terminal of the EMI filter.

7. A protective device for conditioning electricity provided by a power line to a motor controller, the power line comprising at least a first alternating current (AC) line input and a second AC line input, said protective device comprising:

an electromagnetic interference (EMI) filter for suppressing electromagnetic interference having at least a first input terminal, a second input terminal, a first output terminal, and a second output terminal, the first input terminal configured to be coupled to the first AC line input and the second input terminal configured to be coupled to the second AC line input;

a first voltage clamping device and a second voltage clamping device coupled in series between the first output terminal and the second output terminal of the EMI filter;

a spark gap device coupled between a ground conductor and a node shared by the first voltage clamping device and the second voltage clamping device; and

a third voltage clamping device coupled between the first input terminal and the second input terminal of the EMI filter, the third voltage clamping device configured to protect the EMI filter from a transient voltage between the first AC line input and the second AC line input.

8. A device in accordance with claim 7 , wherein the spark gap device, in combination with the first voltage clamping device, is configured to prevent damage to a device coupled to the EMI filter caused by exposure to a transient voltage between the first output terminal and the ground conductor.

9. A device in accordance with claim 7 , wherein the spark gap device, in combination with the second voltage clamping device, is configured to prevent damage to a device coupled to the EMI filter caused by exposure to a transient voltage between the second output terminal and the ground conductor.

10. A device in accordance with claim 7 , further comprising an intentional weak link coupled between the first input terminal and the third voltage clamping device, the intentional weak link configured to uncouple the third voltage clamping device from the first input terminal if the third voltage clamping device is damaged.

11. A device in accordance with claim 7 , wherein the first voltage clamping device, the second voltage clamping device, and the spark gap device are configured to suppress an open circuit transient voltage of at least 6000 volts.

12. A motor control system comprising:

a motor controller;

an electric motor coupled to the motor controller and configured to receive an operating signal from the motor controller;

a power source coupled to the motor controller; and

a protective device coupled between the power source and the motor controller and configured to suppress transient voltages, the protective device comprising:

an electromagnetic interference (EMI) filter having at least a first input terminal, a second input terminal, a first output terminal, and a second output terminal, the first input terminal and the second input terminal coupled to the power source;

a first voltage clamping device and a second voltage clamping device coupled in series between the first output terminal and the second output terminal of the EMI filter;

a spark gap device coupled between a ground conductor and a node shared by the first voltage clamping device and the second voltage clamping device; and

a third voltage clamping device coupled between the first input terminal and the second input terminal of the EMI filter, the third voltage clamping device configured to protect the EMI filter from a transient voltage.

13. A system in accordance with claim 12 , wherein the spark gap device, in combination with the first voltage clamping device, is configured to direct current caused by a transient voltage between the first output terminal of the EMI filter and the ground conductor to ground.

14. A system in accordance with claim 12 , wherein the spark gap device, in combination with the second voltage clamping device, is configured to direct current caused by a transient voltage between the second output terminal of the EMI filter and the ground conductor to ground.

15. A system in accordance with claim 12 , wherein the protective device further comprises at least one intentional weak link, the at least one intentional weak link coupling an AC line input of the power source to at least one of the third voltage clamping device and the first input terminal of the EMI filter.

16. A system in accordance with claim 15 , wherein the at least one intentional weak link is configured to at least one of:

uncouple the third voltage clamping device from the first input terminal if the third voltage clamping device is damaged; and

uncouple the first AC line input from the first input terminal of the EMI filter when a component coupled to at least one of the first output terminal and the second output terminal of the EMI filter is damaged.

17. A system in accordance with claim 12 , wherein the first voltage clamping device, the second voltage clamping device, and the spark gap device are configured to suppress an open circuit transient voltage of at least 6000 volts.