Method for producing voltage waveforms in a PWM motor controller of a PM DC brushless motor

• US 20070222403A1
• Filed: 03/23/2006
• Published: 09/27/2007
• Est. Priority Date: 03/23/2006
• Status: Active Grant

• Current Assignee: BWI Company Limited SA (Shougang Corporation)
• Original Assignee: Delphi Technologies, Inc. (Aptiv PLC)
• Inventors: Crabill, Monty, Disser, Robert
• Granted Patent: US 7,402,969 B2
• Time in Patent Office: Days
• US Class Current: 318/400.130
• CPC Class Codes: H02P 6/15 Controlling commutation time

Abstract

A method produces PWM voltage waveforms in a PWM motor controller of a three phase PM DC brushless motor, wherein the motor controller has first, second and third half H-bridge transistor pairs to generate the voltage waveforms to electronically commutate the motor. The first transistor pair is always assigned to the first phase for every commutation state requiring a voltage waveform from the first transistor pair. The second and third transistor pair are similarly assigned. The first method also includes always starting a voltage waveform generated by the first transistor pair substantially at the beginning of the PWM period when a commutation state requires a voltage waveform from the first transistor pair but delaying starting a voltage waveform generated by the second transistor pair by substantially ⅓ of the PWM period and delaying starting a voltage waveform generated by the third transistor pair by substantially ⅔ of the PWM period.

Claims

1. A method for producing PWM voltage waveforms in a PWM motor controller of a PM DC brushless motor, wherein the motor has commutation states and first, second and third phases, wherein the voltage waveforms have a PWM period for each commutation state, wherein the motor controller has first, second and third half H-bridge transistor pairs to generate the voltage waveforms to electronically commutate the motor, and wherein the method comprises:

a) always assigning the first transistor pair to the first phase for every commutation state requiring a voltage waveform from the first transistor pair;

b) always assigning the second transistor pair to the second phase for every commutation state requiring a voltage waveform from the second transistor pair;

c) always assigning the third transistor pair to the third phase for every commutation state requiring a voltage waveform from the third transistor pair;

d) always starting a voltage waveform generated by the first transistor pair substantially at the beginning of the PWM period for a commutation state when a commutation state requires a voltage waveform from the first transistor pair;

e) always delaying starting a voltage waveform generated by the second transistor pair by substantially ⅓

of the PWM period for a commutation state when a commutation state requires a voltage waveform from the second transistor pair; and

f) always delaying starting a voltage waveform generated by the third transistor pair by substantially ⅔

of the PWM period for a commutation state when a commutation state requires a voltage waveform from the third transistor pair.

2. The method of claim 1, wherein each commutation state requires voltage waveforms from exactly two of the first, second and third transistor pairs.

3. The method of claim 2, wherein each voltage waveform has a duty cycle which can be adjusted from a first duty cycle equal to a desired duty cycle and a second duty cycle equal to a 100% duty cycle, and wherein the desired duty cycle is greater than a predetermined duty cycle required for the motor controller to sample current in the motor.

4. The method of claim 2, wherein each voltage waveform has a duty cycle which can be adjusted from a first duty cycle equal to a predetermined minimum duty cycle required for the motor controller to sample current in the motor and a second duty cycle equal to the predetermined minimum duty cycle plus a desired duty cycle, and wherein the desired duty cycle is less than the predetermined minimum duty cycle.

5. The method of claim 4, wherein the commutation states consist of rotationally sequential first, second, third, fourth, fifth and sixth commutation states, wherein the motor has a first winding for the first phase, a second winding for the second phase and a third winding for the third phase, wherein for the first commutation state the first transistor pair has a duty cycle equal to the second duty cycle, the second transistor pair has a duty cycle equal to the first duty cycle, the voltage waveform from the first transistor pair is applied to the first winding and the voltage waveform from the second transistor pair is applied, opposite in sign, to the second winding, and wherein current flows from the first winding to the second winding.

6. The method of claim 5, wherein for the second commutation state the first transistor pair has a duty cycle equal to the second duty cycle, the third transistor pair has a duty cycle equal to the first duty cycle, the voltage waveform from the first transistor pair is applied to the first winding and the voltage waveform from the third transistor pair is applied, opposite in sign, to the third winding, and wherein current flows from the first winding to the third winding.

7. The method of claim 6, wherein for the third commutation state the second transistor pair has a duty cycle equal to the second duty cycle, the third transistor pair has a duty cycle equal to the first duty cycle, the voltage waveform from the second transistor pair is applied to the second winding and the voltage waveform from the third transistor pair is applied, opposite in sign, to the third winding, and wherein current flows from the second winding to the third winding.

8. The method of claim 7, wherein for the fourth commutation state the second transistor pair has a duty cycle equal to the second duty cycle, the first transistor pair has a duty cycle equal to the first duty cycle, the voltage waveform from the second transistor pair is applied to the second winding and the voltage waveform from the first transistor pair is applied, opposite in sign, to the first winding, and wherein current flows from the second winding to the first winding.

9. The method of claim 8, wherein for the fifth commutation state the third transistor pair has a duty cycle equal to the second duty cycle, the first transistor pair has a duty cycle equal to the first duty cycle, the voltage waveform from the third transistor pair is applied to the third winding and the voltage waveform from the first transistor pair is applied, opposite in sign, to the first winding, and wherein current flows from the third winding to the first winding.

10. The method of claim 9, wherein for the sixth commutation state the third transistor pair has a duty cycle equal to the second duty cycle, the second transistor pair has a duty cycle equal to the first duty cycle, the voltage waveform from the third transistor pair is applied to the third winding and the voltage waveform from the second transistor pair is applied, opposite in sign, to the second winding, and wherein current flows from the third winding to the second winding.

11. A method for producing PWM voltage waveforms in a PWM motor controller of a PM DC brushless motor, wherein the motor has commutation states and first, second and third phases, wherein the voltage waveforms have a PWM period for each commutation state, wherein the motor controller has first, second and third half H-bridge transistor pairs to generate the voltage waveforms to electronically commutate the motor, and wherein the method comprises:

a) always assigning the first transistor pair to the first phase for every commutation state requiring a voltage waveform from the first transistor pair;

b) always assigning the second transistor pair to the second phase for every commutation state requiring a voltage waveform from the second transistor pair;

c) always assigning the third transistor pair to the third phase for every commutation state requiring a voltage waveform from the third transistor pair;

d) always starting a voltage waveform generated by the first transistor pair substantially at the beginning of the PWM period for a commutation state when a commutation state requires a voltage waveform from the first transistor pair;

e) always delaying starting a voltage waveform generated by the second transistor pair by substantially ⅓

of the PWM period for a commutation state when a commutation state requires a voltage waveform from the second transistor pair;

f) always delaying starting a voltage waveform generated by the third transistor pair by substantially ⅔

of the PWM period for a commutation state when a commutation state requires a voltage waveform from the third transistor pair; and

g) operating the motor in all four quadrants of a motor torque versus motor speed diagram.

12. The method of claim 11, wherein each commutation state requires voltage waveforms from exactly two of the first, second and third transistor pairs.

13. The method of claim 12, wherein each voltage waveform has a duty cycle which can be adjusted from a first duty cycle equal to a desired duty cycle and a second duty cycle equal to a 100% duty cycle, and wherein the desired duty cycle is greater than a predetermined duty cycle required for the motor controller to sample current in the motor.

14. The method of claim 12, wherein each voltage waveform has a duty cycle which can be adjusted from a first duty cycle equal to a predetermined minimum duty cycle required for the motor controller to sample current in the motor and a second duty cycle equal to the predetermined minimum duty cycle plus a desired duty cycle, and wherein the desired duty cycle is less than the predetermined minimum duty cycle.

15. The method of claim 14, wherein the commutation states consist of rotationally sequential first, second, third, fourth, fifth and sixth commutation states, wherein the motor has a first winding for the first phase, a second winding for the second phase and a third winding for the third phase, wherein for the first commutation state the first transistor pair has a duty cycle equal to the second duty cycle, the second transistor pair has a duty cycle equal to the first duty cycle, the voltage waveform from the first transistor pair is applied to the first winding and the voltage waveform from the second transistor pair is applied, opposite in sign, to the second winding, and wherein current flows from the first winding to the second winding.

16. The method of claim 15, wherein for the second commutation state the first transistor pair has a duty cycle equal to the second duty cycle, the third transistor pair has a duty cycle equal to the first duty cycle, the voltage waveform from the first transistor pair is applied to the first winding and the voltage waveform from the third transistor pair is applied, opposite in sign, to the third winding, and wherein current flows from the first winding to the third winding.

17. The method of claim 16, wherein for the third commutation state the second transistor pair has a duty cycle equal to the second duty cycle, the third transistor pair has a duty cycle equal to the first duty cycle, the voltage waveform from the second transistor pair is applied to the second winding and the voltage waveform from the third transistor pair is applied, opposite in sign, to the third winding, and wherein current flows from the second winding to the third winding.

18. The method of claim 17, wherein for the fourth commutation state the second transistor pair has a duty cycle equal to the second duty cycle, the first transistor pair has a duty cycle equal to the first duty cycle, the voltage waveform from the second transistor pair is applied to the second winding and the voltage waveform from the first transistor pair is applied, opposite in sign, to the first winding, and wherein current flows from the second winding to the first winding.

19. The method of claim 18, wherein for the fifth commutation state the third transistor pair has a duty cycle equal to the second duty cycle, the first transistor pair has a duty cycle equal to the first duty cycle, the voltage waveform from the third transistor pair is applied to the third winding and the voltage waveform from the first transistor pair is applied, opposite in sign, to the first winding, and wherein current flows from the third winding to the first winding.

20. The method of claim 19, wherein for the sixth commutation state the third transistor pair has a duty cycle equal to the second duty cycle, the second transistor pair has a duty cycle equal to the first duty cycle, the voltage waveform from the third transistor pair is applied to the third winding and the voltage waveform from the second transistor pair is applied, opposite in sign, to the second winding, and wherein current flows from the third winding to the second winding.

21. A method for producing PWM voltage waveforms in a PWM motor controller of a PM DC brushless motor, wherein the motor has commutation states and first, second and third phases, wherein the voltage waveforms have a PWM period for each commutation state, wherein the motor controller has first, second and third half H-bridge transistor pairs to generate the voltage waveforms to electronically commutate the motor, and wherein the method comprises:

a) always assigning the first transistor pair to the first phase for every commutation state requiring a voltage waveform from the first transistor pair;

b) always assigning the second transistor pair to the second phase for every commutation state requiring a voltage waveform from the second transistor pair;

c) always assigning the third transistor pair to the third phase for every commutation state requiring a voltage waveform from the third transistor pair;

d) always starting a voltage waveform generated by the first transistor pair substantially at the beginning of the PWM period for a commutation state when a commutation state requires a voltage waveform from the first transistor pair;

e) always delaying starting a voltage waveform generated by the second transistor pair by substantially ⅓

of the PWM period for a commutation state when a commutation state requires a voltage waveform from the second transistor pair;

f) always delaying starting a voltage waveform generated by the third transistor pair by substantially ⅔

of the PWM period for a commutation state when a commutation state requires a voltage waveform from the third transistor pair; and

g) operating the motor in all four quadrants of a motor torque versus motor speed diagram,

wherein each commutation state requires voltage waveforms from exactly two of the first, second and third transistor pairs,

wherein each voltage waveform has a duty cycle which can be adjusted from a first duty cycle equal to a predetermined minimum duty cycle required for the motor controller to sample current in the motor and a second duty cycle equal to the predetermined minimum duty cycle plus a desired duty cycle, and wherein the desired duty cycle is less than the predetermined minimum duty cycle, and

wherein for each commutation state the voltage waveform of one of the two transistor pairs has a duty cycle equal to the second duty cycle and the other of the two transistor pairs has a duty cycle equal to the first duty cycle.

22. The method of claim 21, wherein the motor has a winding for each phase, wherein the voltage waveform of the one transistor pair is applied to one winding when a commutation state requires a voltage waveform from the one transistor pair, wherein the voltage waveform of the other transistor pair is applied, opposite in sign, to an other winding when a commutation state requires a voltage waveform from the other transistor pair, and wherein current flows from the one winding to the other winding.