System and method for preventing permanent magnet demagnetization in electrical machines

• US 10,230,321 B1
• Filed: 10/23/2017
• Issued: 03/12/2019
• Est. Priority Date: 10/23/2017
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Papini, Francesco, Bertoncelli, Tiziana, Osama, Mohamed
• Primary Examiner(s): Masih, Karen
• Application Number:
  US15/790,251
• Time in Patent Office: 505 Days
• CPC Class Codes: H02H 9/00 Emergency protective circuit arrangements for limiting excess current or voltage without disconnection
• CPC Class Codes: H02K 1/2766 having a flux concentration effect
• CPC Class Codes: H02K 1/2773 consisting of tangentially magnetized radial magnets
• CPC Class Codes: H02K 1/2791 Surface mounted magnets; Inset magnets
• CPC Class Codes: H02K 21/16 having annular armature cores with salient poles with homopolar co-operation H02K21/20
• CPC Class Codes: H02K 21/22 with magnets rotating around the armatures, e.g. flywheel magnetos
• CPC Class Codes: H02K 21/44 with armature windings wound upon the magnets
• CPC Class Codes: H02P 21/06 Rotor flux based control involving the use of rotor position or rotor speed sensors
• CPC Class Codes: H02P 21/12 Stator flux based control involving the use of rotor position or rotor speed sensors
• CPC Class Codes: H02P 21/24 Vector control not involving the use of rotor position or rotor speed sensors
• CPC Class Codes: H02P 2207/05 Synchronous machines, e.g. with permanent magnets or DC excitation
• CPC Class Codes: H02P 29/0241 the fault being an overvoltage
• CPC Class Codes: H02P 29/027 the fault being an over-current
• CPC Class Codes: H02P 29/028 the motor continuing operation despite the fault condition, e.g. eliminating, compensating for or remedying the fault
• CPC Class Codes: H02P 29/032 Preventing damage to the motor, e.g. setting individual current limits for different drive conditions
• CPC Class Codes: H02P 6/12 Monitoring commutation; Providing indication of commutation failure
• CPC Class Codes: H02P 9/006 Means for protecting the generator by using control control effected upon generator excitation circuit to reduce harmful effects of overloads or transients H02P9/10

Abstract

A motor drive for driving a permanent magnet electrical machine includes an inverter having switches that are selectively operated to control current flow and terminal voltages in the electrical machine and a controller operatively connected to the inverter to control switching of the switches to control the current flow and terminal voltages in the electrical machine. The controller receives inputs regarding at least one of currents and voltages provided to the electrical machine on one or more phases, analyzes the voltages and currents to identify a fault in the electrical machine, and controls switching of the plurality of switches in the inverter to modify current flow and terminal voltages in the electrical machine based on the identified fault, with the modified current flow and terminal voltages in the electrical machine preventing demagnetization of the permanent magnets in the electrical machine.

Claims

1. A motor drive for driving an electrical machine having one or more permanent magnets therein, the motor drive comprising:

an inverter having a plurality of switches therein that are selectively operated to control current flow and terminal voltages in the electrical machine; and

a controller operatively connected to the inverter and configured to control switching of the plurality of switches to control the current flow and terminal voltages in the electrical machine, the controller being programmed to;

analyze at least one of voltages and currents provided to the electrical machine on one or more phases to identify a fault condition in the electrical machine; and

control switching of the plurality of switches in the inverter to modify current flow and terminal voltages in the electrical machine based on the identified fault condition, so as to prevent demagnetization of the one or more permanent magnets in the electrical machine.

2. The motor drive of claim 1 wherein the one or more permanent magnets comprise ceramic permanent magnets.

3. The motor drive of claim 1 wherein, in identifying the fault condition in the electrical machine, the controller is further programmed to identify a change in a pattern of the at least one of the voltages and currents supplied to the electrical machine.

4. The motor drive of claim 1 wherein, in identifying the fault condition in the electrical machine, the controller is further programmed to:

analyze the at least one of the voltages and currents via an intelligent signature identification algorithm, so as to identify a voltage and/or current signature therefrom; and

identify a fault type in the electrical machine based on the identified voltage and/or current signature, via one or more of a lookup table, a neural network, or a deep learning technique.

5. The motor drive of claim 1 wherein, in modifying the current flow and terminal voltages in the electrical machine, the controller is further programmed to indirectly control a fault current in the electrical machine based on the modified current flow and terminal voltages.

6. The motor drive of claim 5 wherein, in modifying the current flow and terminal voltages and controlling the fault current in the electrical machine, the controller is further programmed to maintain a d-axis magnetic flux in the electrical machine above a pre-determined threshold, so as to prevent demagnetization of the permanent magnets in the electrical machine.

7. The motor drive of claim 1 wherein, in modifying the current flow and terminal voltages in the electrical machine, the controller is further programmed to maintain a torque and speed in the electrical machine at a pre-fault torque and speed level via the modified voltages and currents supplied to the electrical machine.

8. The motor drive of claim 1 wherein, in modifying the current flow and terminal voltages in the electrical machine, the controller is further programmed to minimize losses in the electrical machine via the modified current flow and terminal voltages in the electrical machine.

9. The motor drive of claim 1 wherein the identified fault comprises one or more of a turn-to-turn fault or a full phase fault.

10. The motor drive of claim 1 wherein the electrical machine driven thereby is operable as a motor and/or a generator.

11. The motor drive of claim 1 wherein the electrical machine driven thereby comprises one of a radial flux, axial flux, or transverse flux electrical machine, and wherein the electrical machine comprises one of an inner rotor, outer rotor, dual stator, or dual rotor electrical machine.

12. The motor drive of claim 1 wherein the electrical machine driven thereby comprises one of tooth wound or distributed windings, and wherein the electrical machine comprises one of formed wound or random wound coils.

13. The motor drive of claim 1 wherein the electrical machine driven thereby comprises conductors formed as solid or Litz wires or formed as hollow or non-hollow conductors.

14. The motor drive of claim 1 wherein the one or more permanent magnets of the electrical machine are located on a rotor or on a stator of the electrical machine, with a configuration of the one or more permanent magnets comprising a SPM (Surface Permanent magnet), IPM (interior permanent magnet), XPM (Inset permanent magnet), or spoke permanent magnet configuration.

15. A method for implementing a post-fault protection technique for preventing demagnetization of permanent magnets in an electrical machine, the method comprising:

monitoring, via a controller, at least one of voltages and currents supplied to the electrical machine;

analyzing, via the controller, the at least one of the voltages and currents supplied to the electrical machine to detect a fault condition in the electrical machine;

determining, via the controller, a fault type of the detected fault condition based on the analyzed at least one of the voltages and currents; and

modifying, via the controller, the voltages and currents supplied to the electrical machine on at least one phase based on the determined fault type;

wherein modifying the voltages and currents supplied to the electrical machine on the at least one phase constrains a fault current in the electrical machine, so as to control a negative d-axis magnetic flux in the electrical machine and thereby prevent demagnetization of the permanent magnets.

16. The method of claim 15 wherein detecting a fault condition in the electrical machine comprises identifying a change in a pattern of the at least one of the voltages and currents supplied to the electrical machine.

17. The method of claim 15 wherein determining the fault type of the detected fault condition comprises:

analyzing the at least one of the voltages and currents via an intelligent signature identification algorithm, so as to identify a voltage and/or current signature therefrom; and

identifying the fault type in the electrical machine based on the identified voltage and/or current signature, via one or more of a lookup table, a neural network, or a deep learning technique.

18. The method of claim 15 wherein the d-axis magnetic flux in the electrical machine is maintained above a pre-determined threshold, so as to prevent demagnetization of the permanent magnets.

19. The method of claim 15 wherein, in modifying the voltages and currents supplied to the electrical machine, the method comprises maintaining a torque and speed in the electrical machine at a pre-fault torque and speed level via the modified voltages and currents supplied to the electrical machine.

20. The method of claim 15 wherein, in modifying the voltages and currents supplied to the electrical machine, the method comprises controlling operation of a motor drive operatively connected to the electrical machine to control input voltages and currents supplied to all available phases of the electrical machine.

21. A controller configured to control operation of an inverter so as to control currents and voltages output to a permanent magnet electrical machine connected thereto, the controller having a processor programmed to:

receive inputs regarding at least one of currents and voltages provided to the permanent magnet electrical machine on one or more phases;

analyze the at least one of the voltages and currents to identify a fault in the permanent magnet electrical machine; and

upon identification of a fault, control switching of a plurality of switches in the inverter to modify the currents and voltages provided to the permanent magnet electrical machine based on a type of the identified fault;

wherein the modified currents and voltages provided to the permanent magnet electrical machine maintain a d-axis magnetic flux in the permanent magnet electrical machine at a level that prevents demagnetization of one or more permanent magnets therein.

22. The controller of claim 21 wherein the processor is programmed to determine the type of the fault by analyzing the at least one of the voltages and currents via an intelligent signature identification algorithm, so as to identify a voltage and/or current signature therefrom indicative of the fault type.

23. The controller of claim 21 wherein, in modifying the currents and voltages provided to the permanent magnet electrical machine, the processor is programmed to indirectly control a fault current in the permanent magnet electrical machine based on the modified currents and voltages, thereby maintaining the d-axis magnetic flux in the permanent magnet electrical machine at the desired level.

24. The controller of claim 21 wherein the processor is programmed to maintain a torque and speed in the permanent magnet electrical machine at a pre-fault torque and speed level via the modified voltages and currents supplied thereto.

25. The controller of claim 21 wherein the modification of the currents and voltages provided to the permanent magnet electrical machine is selectively controlled based on the fault type and the number of phases on which the fault is present.