Phase angle control for synchronous machine control

• US 20050073279A1
• Filed: 09/30/2004
• Published: 04/07/2005
• Est. Priority Date: 10/01/2003
• Status: Active Grant

• Current Assignee: J.L. Behmer Corporation
• Original Assignee: J.L. Behmer Corporation
• Inventors: Fenley, Thomas D.
• Granted Patent: US 7,064,513 B2
• Time in Patent Office: Days
• US Class Current: 318/717
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60K 6/52 Driving a plurality of drive axles, e.g. four-wheel drive
• CPC Class Codes: B60W 2520/26 Wheel slip
• CPC Class Codes: B60W 2520/28 Wheel speed
• CPC Class Codes: F02D 29/06 peculiar to engines driving electric generators
• CPC Class Codes: F02D 41/009 using means for generating position or synchronisation signals
• CPC Class Codes: F02D 41/0205 using an auxiliary engine speed control engine speed control per se F02D31/00
• CPC Class Codes: F02D 41/083 taking into account engine load variation, e.g. air-conditionning
• CPC Class Codes: H02P 2101/30 for aircraft
• CPC Class Codes: H02P 2101/45 for motor vehicles, e.g. car alternators
• CPC Class Codes: H02P 6/15 Controlling commutation time
• CPC Class Codes: H02P 9/04 Control effected upon non-electric prime mover and dependent upon electric output value of the generator
• CPC Class Codes: H02P 9/48 Arrangements for obtaining a constant output value at varying speed of the generator, e.g. on vehicle H02P9/04 - H02P9/46 take precedence
• CPC Class Codes: Y02T 10/62 Hybrid vehicles

Abstract

A synchronous machine control device for a polyphase synchronous machine includes a phase detection sensor and a control circuit. The phase detection sensor is set to 90° advanced. The control circuit includes phase detection, commutation driver and time delay circuits. The phase detection circuit is coupled to the phase detection sensor and is configured to determine electrical phase of the machine. The commutation driver circuit is coupled to the phase detection circuit and has high-side and low-side outputs for selectively and alternately controlling commutation of the machine. The time delay circuit is coupled to the phase detection sensor, the phase detection circuit and the commutation driver circuit. The time delay circuit provides a control output to the commutation driver circuit based upon an adjustable setpoint compared to a speed of the machine as measured by the phase detection circuit.

Claims

1. A control device for a polyphase synchronous machine, the synchronous machine having a field coil, a rotor and polyphase windings, the control device comprising:

(a) a machine frequency detection sensor that detects machine frequency, the detection sensor set to 90°

advanced electrically with respect to the rotor of the synchronous machine; and

(b) a control circuit including;

(i) a machine frequency detection circuit coupled to the machine frequency detection sensor and configured to generate pulses corresponding to the detected machine frequency;

(ii) a commutation driver circuit coupled to the machine frequency detection circuit and having a high-side output coupled to the windings and a low-side output coupled to the windings, the commutation driver circuit selectively and alternately controlling the high-side and low-side outputs to control commutation of the synchronous machine.

(iii) a time delay circuit coupled to the machine frequency detection sensor, the machine frequency detection circuit and the commutation driver circuit, the time delay circuit providing a control output to the commutation driver circuit based upon an adjustable setpoint compared to a speed of the machine as measured by the machine frequency detection circuit.

2. The control device according to claim 1, wherein the control circuit further includes:

(iv) a stator current control circuit, the stator current control circuit selectively overriding control of the commutation driver circuit to at least the high-side output.

3. The control device according to claim 2, wherein the stator current control circuit uses pulse width modulation (PWM) to selectively override the control of the high-side output.

4. The control device according to claim 1, wherein the control circuit further includes:

(iv) a field coil voltage control circuit, the field coil voltage control circuit selectively modulating the voltage to the field coil to control back electromagnetic field (EMF).

5. The control device according to claim 4, wherein the field coil voltage control circuit uses pulse width modulation (PWM) to selectively modulate the voltage to the field coil.

6. The control device according to claim 1, wherein the control circuit is configured to control phase angle or torque with a linear voltage independently of frequency while simultaneously, by way of superposition, controlling torque with pulse width modulation (PWM) of stator current.

7. The control device according to claim 1, wherein the machine frequency detection circuit generates the commutation output when the synchronous machine is advanced and ceases the commutation output when the synchronous machine is lagging by a predetermined amount of phase.

8. The control device according to claim 1, wherein the control circuit is configured to control field weakening directly as a function of frequency to increase speed by reduction of back electromagnetic field (EMF).

9. The control device according to claim 1, wherein the control circuit further includes a setpoint amplifier having inverting and non-inverting inputs, a voltage representative of the speed of the machine as measured by the machine frequency detection circuit being applied to the inverting input of the setpoint amplifier as feedback.

10. The control device according to claim 1, wherein the machine frequency detection circuit is configured to determine when the phase of the stator flux vector of the machine is delayed beyond an in-phase condition of rotor position by a predetermined amount.

11. The control device according to claim 1, wherein the time delay circuit controls the phase of commutation from an advanced condition to an in-phase condition in an analog manner.

12. The control device according to claim 1, wherein the control circuit is configured to automatically switch control of the machine from motor control to generator control when the machine frequency detection circuit detects a predetermined amount of delay beyond an in-phase condition of the machine.

13. The control device according to claim 1, wherein the control circuit is at least partially implemented in a microprocessor.

14. The control device according to claim 1, wherein the control circuit further includes a one time false pulse circuit that provides a one-shot output when the machine is being started up from a zero-speed condition or when the control circuit has not been reset since commutation control has ceased.

15. The control device according to claim 1, wherein the control circuit further includes:

(iv) a power transistor-driver bridge having two high-side and two low-side power transistors for each phase of the polyphase synchronous machine, the two high-side power transistors being electrically connected in parallel between the windings and a power source and the two low-side power transistors being electrically connected in parallel between the windings and ground, the high-side outputs of the commutation driver circuit activating and deactivating the two high-side power transistors and the low-side outputs of the commutation driver circuit alternately, with respect to the high-side power transistors, activating and deactivating the two low-side power transistors.

22. The control device according to claim 1, wherein the control circuit further includes:

(iv) a phase detection circuit that detects when the machine is lagging and leading with respect to electrical phase angle, the phase detection circuit generating a commutation output when the machine is leading, the commutation output being coupled to the commutation driver circuit to allow commutation.

23. The control device according to claim 22, wherein the control circuit further includes:

(iv) a phase detection circuit that detects when the machine is lagging and leading with respect to electrical phase angle, the machine frequency detection circuit ceasing the commutation output when the machine is lagging.

26. The control device according to claim 15, wherein low-side inputs of the commutation driver circuit, when on, deactivate high-side inputs of the commutation driver circuit and the low-side inputs of the commutation driver circuit, when off, activate the high-side inputs of the commutation driver circuit.

16. A hybrid vehicle having a frame and at least two wheels, the at least two wheels being movably coupled to the frame, the vehicle comprising:

(a) a power source that supplies polyphase electrical power and direct current (DC) power;

(b) at least one battery coupled to the power source to charge using DC power;

(c) an inverter coupled to the at least one battery to convert DC voltage to a polyphase voltage;

(d) a drive-wheel polyphase synchronous machine coupled to the inverter to receive polyphase voltage when operating as a motor, the drive-wheel polyphase synchronous machine having a stator and a rotor, one of the stator and rotor being fixed to the frame of the hybrid vehicle and the other of the stator and rotor being mechanically coupled to one of the at least two wheels to provide drive power thereto in a driving mode and to receive power therefrom in a coasting or a braking mode, the drive-wheel polyphase synchronous machine controlling acceleration and deceleration of the wheel coupled thereto; and

(e) a drive-wheel rectifying circuit that receives polyphase voltage from the drive-wheel polyphase synchronous machine and converts the polyphase voltage to a direct current voltage to charge the at least one battery when the drive-wheel polyphase synchronous machine is operating as a generator.

17. The hybrid vehicle of claim 16, wherein the power source includes:

(i) an internal combustion engine having an output shaft;

(ii) a power-system polyphase synchronous machine that converts mechanical input power to the polyphase electrical power being supplied, the power-system polyphase synchronous machine having a rotor and a stator, the output shaft being mechanically coupled to one of the rotor and the stator of the power-system polyphase synchronous machine; and

(iii) a power-system rectifying circuit that receives polyphase voltage from the power-system polyphase synchronous machine and converts the polyphase voltage to a DC voltage to charge the at least one battery.

21. The polyphase synchronous machine according to claim 16, further comprising:

(d) a step-down circuit formed by connecting a step-down sub-combination of the plurality of stator winding leads and by separately connecting a step-down sub-combination of the plurality of rotor winding leads, whereby the synchronous machine is configured as an electromechanical step-down transformer.

18. A hybrid vehicle having a frame, the vehicle comprising:

(a) a power source that supplies polyphase electrical power and direct current (DC) power;

(b) at least one battery coupled to the power source to charge using DC power;

(c) an inverter coupled to the at least one battery to convert DC voltage to a polyphase voltage;

(d) four drive wheels movably coupled to the frame of the vehicle;

(e) four drive-wheel control devices, each drive-wheel control device comprising;

(i) a drive-wheel polyphase synchronous machine coupled to the inverter to receive polyphase voltage when operating as a motor, the drive-wheel polyphase synchronous machine having a stator and a rotor, one of the stator and rotor being fixed to the frame of the hybrid vehicle and the other of the stator and rotor being mechanically coupled to a respective one of the four drive-wheels to provide drive power thereto in a driving mode and to receive power therefrom in a coasting or a braking mode, the drive-wheel polyphase synchronous machine controlling acceleration and deceleration of the wheel coupled thereto;

(ii) a drive-wheel control circuit that measures and controls the speed of the drive-wheel polyphase synchronous machine; and

(iii) a drive-wheel rectifying circuit that receives polyphase voltage from the drive-wheel polyphase synchronous machine and converts the polyphase voltage to a direct current voltage to charge the at least one battery when the drive-wheel polyphase synchronous machine is operating as a generator; and

(f) an anti-slip detection circuit that compares the speed of each drive-wheel polyphase synchronous machine to the speed of the other drive-wheel polyphase synchronous machines, the anti-slip detection circuit determining when the speed of one of the drive-wheel polyphase synchronous machines is greater than or less than one or more of the other drive-wheel polyphase synchronous machines by a predetermined amount.

19. An electrical generator comprising:

(a) an internal combustion engine having an output shaft; and

(b) polyphase synchronous machine mechanically coupled to the output shaft of the internal combustion engine, the synchronous machine having a field coil, a rotor and polyphase windings, the synchronous machine including;

(ii) a machine frequency detection sensor set to 90°

advanced electrically;

(iii) a machine frequency detection circuit coupled to the machine frequency detection sensor and configured to control electrical phase of the synchronous machine independent of frequency;

(iv) a commutation driver circuit coupled to the machine frequency detection circuit and having a high-side output coupled to the windings and a low-side output coupled to the windings, to the commutation driver circuit controlling the commutation of the synchronous machine only when the machine frequency detection circuit provides the commutation output; and

(v) a time delay circuit coupled to the machine frequency detection sensor, the machine frequency detection circuit and the commutation driver circuit, the time delay circuit providing a control output to the commutation driver circuit based upon an adjustable setpoint compared to a speed of the machine as measured by the machine frequency detection circuit, wherein control of the control output is independent of frequency.

20. A polyphase synchronous machine comprising:

(a) a stator having a plurality of stator windings, each stator winding having a plurality of stator winding leads;

(b) a rotor having a plurality of rotor windings, each rotor winding having a plurality of rotor winding leads, the rotor windings being inductively coupled to the stator windings by proximity and causing electrical power to be induced in the stator windings when the polyphase synchronous machine is being operated as a generator or receiving electromotive force from the stator windings when the polyphase synchronous machine is being operated as a motor; and

(c) a step-up circuit formed by connecting a step-up sub-combination of the plurality of stator winding leads and by separately connecting a step-up sub-combination of the plurality of rotor winding leads, whereby the synchronous machine is configured as an electro-mechanical step-up transformer.

24. An internal combustion engine-powered synchronous machine comprising:

(a) an internal combustion engine having a motor speed and an output shaft;

(b) a fuel flow control device that controls the flow of fuel to the internal combustion engine;

(c) a synchronous machine coupled to the output shaft of the internal combustion engine, the synchronous machine having an electrical load;

(d) a control circuit that measures the electrical load of the synchronous machine and continuously controls the fuel flow control device in order to control the motor speed of the internal combustion engine based upon the measured electrical load from an idle speed to a maximum speed so as to achieve an optimal fuel efficiency with respect to electrical load.

25. The internal combustion engine-powered synchronous machine of claim 24, wherein the control circuit momentarily shifts electrical load, when there is a sudden electrical load increase at low engine speed, from the generator to the battery in order to prevent engine stall.