METHODS, SYSTEMS AND APPARATUS FOR CONTROLLING OPERATION OF TWO ALTERNATING CURRENT (AC) MACHINES

• US 20100301786A1
• Filed: 05/28/2009
• Published: 12/02/2010
• Est. Priority Date: 05/28/2009
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations Incorporated (General Motors Company)
• Inventors: NAGASHIMA, JAMES M., HITI, SILVA, PERISIC, MILUN, GALLEGOS-LOPEZ, GABRIEL
• Granted Patent: US 8,115,430 B2
• Time in Patent Office: Days
• US Class Current: 318/400.02
• CPC Class Codes: B60L 15/007 Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
• CPC Class Codes: B60L 15/08 using pulses
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2210/46 with more than three phases
• CPC Class Codes: H02P 21/22 Current control, e.g. using a current control loop
• CPC Class Codes: H02P 5/74 controlling two or more ac dynamo-electric motors H02P5/46, H02P5/60 take precedence
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

A system is provided for controlling two AC machines. The system comprises a DC input voltage source that provides a DC input voltage, a voltage boost command control module (VBCCM), a five-phase PWM inverter module coupled to the two AC machines, and a boost converter coupled to the inverter module and the DC input voltage source. The boost converter is designed to supply a new DC input voltage to the inverter module having a value that is greater than or equal to a value of the DC input voltage. The VBCCM generates a boost command signal (BCS) based on modulation indexes from the two AC machines. The BCS controls the boost converter such that the boost converter generates the new DC input voltage in response to the BCS. When the two AC machines require additional voltage that exceeds the DC input voltage required to meet a combined target mechanical power required by the two AC machines, the BCS controls the boost converter to drive the new DC input voltage generated by the boost converter to a value greater than the DC input voltage.

Claims

1. A system for controlling two alternating current (AC) machines, the system comprising:

a five-phase PWM inverter module coupled to the two AC machines and being designed to generate sinusoidal voltages for the two AC machines;

a DC input voltage source that provides a DC input voltage;

a boost converter, coupled to the five-phase PWM inverter module and the DC input voltage source, and being designed to supply a new DC input voltage to the five-phase PWM inverter module having a value that is greater than or equal to a value of the DC input voltage; and

a voltage boost command control module designed to generate a boost command signal that controls the boost converter such that the boost converter generates the new DC input voltage in response to the boost command signal, wherein the boost command signal drives the new DC input voltage generated by the boost converter to a value greater than the DC input voltage when the two AC machines require additional voltage that exceeds the DC input voltage required to meet a combined target mechanical power required by the two AC machines.

2. A system according to claim 1, wherein the voltage boost command control module is further designed to:

output the voltage boost command signal with a positive value to the boost converter when the two AC machines require additional voltage that exceeds the DC input voltage, and output the voltage boost command signal with a zero value to the boost converter when the voltage required by the two AC machines is less than or equal to the DC input voltage, and

wherein the five-phase PWM inverter module generates, based on the new DC input voltage, sinusoidal voltage waveforms that drive the two AC machines at varying speeds.

3. A system according to claim 1, further comprising:

a first control loop designed to map a first torque command signal, a first speed (ω

1) of a shaft, and the new DC input voltage to a first d-axis current command signal and a first q-axis current command signal;

a second control loop designed to map a second torque command signal, a second speed (ω

2) of the shaft, and the new DC input voltage to a second d-axis current command signal and a second q-axis current command signal;

wherein the voltage boost command control module is further designed to receive a modulation index reference signal, a first modulation index from the first control loop and a second modulation index from the second control loop, and add the first modulation index to the second modulation index to generate a modulation index feedback signal input; and

subtract the modulation index reference signal input from the modulation index feedback signal input to generate a modulation index error signal.

4. A system according to claim 3, wherein the voltage boost command control module is designed to operate in conjunction with the first control loop and the second control loop and further comprises:

a voltage command controller, comprising;

a voltage controller designed to;

receive the modulation index error signal; and

generate a first output command signal based on the modulation index error signal;

a positive limiter module designed to;

receive the first output command signal, and limit the first output command signal between zero and a positive value, wherein the positive limiter module outputs the boost command signal to the boost converter, wherein the boost command signal controls the boost converter such that the boost converter supplies a voltage greater than the DC input voltage to the five-phase PWM inverter module when the two AC machines require additional voltage that exceeds the DC input voltage, and wherein the boost command signal outputs a zero value to the boost converter when the first output command signal is less than or equal to zero so that the boost converter supplies the DC input voltage to the five-phase PWM inverter module when the voltage required by the two AC machines is less than or equal to the DC input voltage.

5. A system according to claim 3, wherein the two AC machines comprise:

a first three-phase AC machine and a second three-phase AC machine, and wherein the first control loop comprises;

a first torque-to-current mapping module designed to;

receive the first torque command signal, the first speed (ω

1) of the shaft, and the new DC input voltage, and to map the first torque command signal, the first speed (ω

1) of the shaft, and new DC input voltage to the first d-axis current command signal and the first q-axis current command signal;

a first stationary-to-synchronous conversion module designed to;

receive a first resultant stator current, a second resultant stator current, a third resultant stator current that are measured phase currents from the first three-phase AC machine and the first shaft position output (θ

_r1); and

generate a first feedback d-axis current signal and a first feedback q-axis current signal based on the first resultant stator current, the second resultant stator current, the third resultant stator current and the first shaft position output (θ

_r1);

a first summing junction designed to;

receive the first d-axis current command signal and the first feedback d-axis current signal; and

subtract the first feedback d-axis current signal from the first d-axis current command signal to generate a first error d-axis current signal; and

a second summing junction designed to;

receive the first q-axis current command signal and a first feedback q-axis current signal; and

subtract the first feedback q-axis current signal from the first q-axis current command signal to generate a first error q-axis current signal.

6. A system according to claim 5, wherein the first control loop further comprises:

a first current controller module designed to;

receive the first error d-axis current signal and the first error q-axis current signal; and

generate a first d-axis voltage command signal and a first q-axis voltage command signal;

a first modulation index computation module designed to;

receive the first d-axis voltage command signal and the first q-axis voltage command signal; and

generate the first modulation index; and

a first synchronous-to-stationary conversion module designed to;

receive the first d-axis voltage command signal, the first q-axis voltage command signal and the first shaft position output (θ

_r1); and

generate a first sinusoidal voltage command, a second sinusoidal voltage command, a third sinusoidal voltage command.

7. A system according to claim 6 wherein the second control loop further comprises:

a second torque-to-current mapping module designed to;

receive a second torque command signal, a second speed (ω

2) of the shaft, and the new DC input voltage; and

map the second torque command signal, the second speed (ω

2) of the shaft, and the new DC input voltage to a second d-axis current command signal and a second q-axis current command signal;

a second stationary-to-synchronous conversion module designed to;

receive a fourth resultant stator current, a fifth resultant stator current and a sixth resultant stator current that are measured phase currents from the second three-phase AC machine and a second shaft position output (θ

_r2); and

generate a second feedback d-axis current signal and a second feedback q-axis current signal based on the fourth resultant stator current, the fifth resultant stator current, the sixth resultant stator current that are measured phase currents from the second three-phase AC machine and the second shaft position output (θ

_r2).

a third summing junction designed to;

receive the second d-axis current command signal and the second feedback d-axis current signal; and

subtract the second feedback d-axis current signal from the second d-axis current command signal to generate a second error d-axis current signal; and

a fourth summing junction designed to;

receive the second q-axis current command signal and the second feedback q-axis current signal; and

subtract the second feedback q-axis current signal from the second q-axis current command signal to generate a second error q-axis current signal.

8. A system according to claim 7, wherein the second control loop further comprises:

a second current controller module designed to;

receive the second error d-axis current signal and the second error q-axis current signal; and

generate a second d-axis voltage command signal and a second q-axis voltage command signal;

a second modulation index computation module designed to;

receive the second d-axis voltage command signal and the second q-axis voltage command signal; and

generate a second modulation index; and

a second synchronous-to-stationary conversion module designed to;

receive the second d-axis voltage command signal and the second q-axis voltage command signal; and

generate a fourth sinusoidal voltage command, a fifth sinusoidal voltage command and a sixth sinusoidal voltage command.

9. A system according to claim 1, the system further comprising:

a Space Vector (SV) PWM module, coupled to the first control loop and the second control loop and designed to receive the first sinusoidal voltage command, the second sinusoidal voltage command, the third sinusoidal voltage command, the fourth sinusoidal voltage command, the fifth sinusoidal voltage command, and the sixth sinusoidal voltage command; and

generate a first switching vector signal, a second switching vector signal, a third switching vector signal, a fourth switching vector signal, and a fifth switching vector signal;

wherein the five-phase PWM inverter module is coupled to the SVPWM module and designed to receive the first switching vector signal, the second switching vector signal, the third switching vector signal, the fourth switching vector signal, and the fifth switching vector signal, and further comprises;

a first inverter pole that outputs a first sinusoidal voltage, a second inverter pole that outputs a second sinusoidal voltage, a third inverter pole that outputs a third sinusoidal voltage, a fourth inverter pole that outputs a fourth sinusoidal voltage, and a fifth inverter pole that outputs a fifth sinusoidal voltage;

wherein the first three-phase AC machine is coupled to the five-phase PWM inverter module via the first inverter pole, the second inverter pole and the third inverter pole and designed to generate first mechanical power based on the first sinusoidal voltage, the second sinusoidal voltage and the third sinusoidal voltage, and the first shaft position output (θ

_r1);

wherein the second three-phase AC machine coupled to the five-phase PWM inverter module via the third inverter pole, the fourth inverter pole and the fifth inverter pole, and designed to generate second mechanical power based on the third sinusoidal voltage, the fourth sinusoidal voltage and the fifth sinusoidal voltage and the second shaft position output (θ

_r2); and

a first shaft coupled to and driven by the first mechanical power output by the first three-phase AC machine and a second shaft by the second mechanical power output by the second three-phase AC machine.

10. A system according to claim 3, further comprising:

a stationary-to-synchronous conversion module designed to;

receive a first resultant stator current, a second resultant stator current, a third resultant stator current, a fourth resultant stator current, a fifth resultant stator current, a first shaft position output, and a second shaft position output, and designed to generate a first feedback d-axis current signal, a first feedback q-axis current signal, a second feedback d-axis current signal and a second feedback q-axis current signal; and

a synchronous-to-stationary conversion module designed to;

receive a first d-axis voltage command signal, a first q-axis voltage command signal, a second d-axis voltage command signal and a second q-axis voltage command signal, the first shaft position output, and the second shaft position output; and

generate a first sinusoidal voltage command, a second sinusoidal voltage command, a third sinusoidal voltage command, a fourth sinusoidal voltage command, and a fifth sinusoidal voltage command.

11. A system according to claim 10, wherein the two AC machines comprise:

a first five-phase AC machine coupled to a second five-phase AC machine, and wherein the first control loop comprises;

a first torque-to-current mapping module designed to;

receive the first torque command signal, the first speed (ω

1) of the shaft, and the new DC input voltage, and to map the first torque command signal, the first speed (ω

1) of the shaft, and the new DC input voltage to the first d-axis current command signal and the first q-axis current command signal;

a first summing junction designed to;

receive the first d-axis current command signal and the first feedback d-axis current signal; and

subtract the first feedback d-axis current signal from the first d-axis current command signal to generate a first error d-axis current signal; and

a second summing junction designed to;

receive the first q-axis current command signal and the first feedback q-axis current signal; and

subtract the first feedback q-axis current signal from the first q-axis current command signal to generate a first error q-axis current signal.

12. A system according to claim 11, wherein the first control loop further comprises:

a first current controller module designed to;

receive the first error d-axis current signal and the first error q-axis current signal; and

generate a first d-axis voltage command signal and a first q-axis voltage command signal; and

a first modulation index computation module designed to;

receive the first d-axis voltage command signal and the first q-axis voltage command signal; and

generate the first modulation index.

13. A system according to claim 12, wherein the second control loop further comprises:

a second torque-to-current mapping module designed to;

receive a second torque command signal, a second speed (ω

2) of the shaft, and the new DC input voltage; and

map the second torque command signal, the second speed (ω

2) of the shaft, and the new DC input voltage to a second d-axis current command signal and a second q-axis current command signal;

a third summing junction designed to;

receive the second d-axis current command signal and the second feedback d-axis current signal; and

subtract the second feedback d-axis current signal from the second d-axis current command signal to generate a second error d-axis current signal; and

a fourth summing junction designed to;

receive the second q-axis current command signal and the second feedback q-axis current signal; and

subtract the second feedback q-axis current signal from the second q-axis current command signal to generate a second error q-axis current command signal.

14. A system according to claim 13, wherein the second control loop further comprises:

a second current controller module designed to;

receive the second error d-axis current signal and the second error q-axis current signal; and

generate a second d-axis voltage command signal and a second q-axis voltage command signal; and

a second modulation index computation module designed to;

receive the second d-axis voltage command signal and the second q-axis voltage command signal; and

generate a second modulation index.

15. A system according to claim 14, the system further comprising:

a Space Vector (SV) PWM module, coupled to the first control loop, the second control loop via the synchronous-to-stationary conversion module, and the five-phase PWM inverter module, the SVPWM module being designed to receive the first sinusoidal voltage command, the second sinusoidal voltage command, the third sinusoidal voltage command, the fourth sinusoidal voltage command, and the fifth sinusoidal voltage command; and

generate a first switching vector signal, a second switching vector signal, a third switching vector signal, a fourth switching vector signal, and a fifth switching vector signal;

wherein the five-phase PWM inverter module is coupled to the SVPWM module and designed to receive the first switching vector signal, the second switching vector signal, the third switching vector signal, the fourth switching vector signal, and the fifth switching vector signal,

wherein the five-phase PWM inverter module comprises;

a first inverter pole that outputs a first sinusoidal voltage, a second inverter pole that outputs a second sinusoidal voltage, a third inverter pole that outputs a third sinusoidal voltage, a fourth inverter pole that outputs a fourth sinusoidal voltage, and a fifth inverter pole that outputs a fifth sinusoidal voltage;

wherein the first five-phase AC machine is coupled to the five-phase PWM inverter module via the first inverter pole, the second inverter pole and the third inverter pole, the fourth inverter pole and the fifth inverter pole, and is designed to generate first through fifth machine voltages and to generate mechanical power based on first to fifth machine voltage; and

a first shaft coupled to and driven by the mechanical power output by the first five-phase AC machine,

wherein the second five-phase AC machine coupled in series to the first five-phase AC machine, and is designed to generate mechanical power based on the first through fifth machine voltages; and

a second shaft coupled to and driven by the mechanical power output by the second five-phase AC machine.

16. A system, comprising:

two alternating current (AC) machines that require a combined target mechanical power that varies during operation;

a five-phase PWM inverter module coupled to the two AC machines and being designed to generate sinusoidal voltage waveforms for the two AC machines at varying speeds;

a DC input voltage source that provides a DC input voltage;

a boost converter, coupled to the five-phase PWM inverter module and the DC input voltage source, and being designed to supply a new DC input voltage to the five-phase PWM inverter module having a value that is greater than or equal to a value of the DC input voltage, wherein the five-phase PWM inverter module generates the sinusoidal voltage waveforms that drive the two AC machines based on the new DC input voltage; and

a voltage boost command control module designed to generate a boost command signal that controls the boost converter.

17. A system according to claim 16, wherein the boost command signal generated by the voltage boost command control module controls the boost converter such that the boost converter generates the new DC input voltage in response to the boost command signal.

18. A system according to claim 17, wherein the boost command signal drives the new DC input voltage generated by the boost converter to a value greater than the DC input voltage when the two AC machines require additional voltage that exceeds the DC input voltage required to meet the combined target mechanical power required by the two AC machines.

19. A system according to claim 18, wherein the voltage boost command control module is further designed to:

output the voltage boost command signal with a positive value to the boost converter when the two AC machines require additional voltage that exceeds the DC input voltage, and output the voltage boost command signal with a zero value to the boost converter when the voltage required by the two AC machines is less than or equal to the DC input voltage.

20. A system according to claim 16, further comprising:

a first control loop; and

a second control loop, wherein the voltage boost command control module is designed to operate in conjunction with the first control loop and the second control loop, and

wherein the voltage boost command control module is further designed to receive a modulation index reference signal, a first modulation index from the first control loop and a second modulation index from the second control loop, and add the first modulation index to the second modulation index to generate a modulation index feedback signal input; and

subtract the modulation index reference signal input from the modulation index feedback signal input to generate a modulation index error signal, wherein the voltage boost command control module further comprises;

a voltage command controller, comprising;

a voltage controller designed to;

receive the modulation index error signal; and

generate a first output command signal based on the modulation index error signal;

a positive limiter module designed to;

receive the first output command signal, and limit the first output command signal between zero and a positive value, wherein the positive limiter module outputs the boost command signal to the boost converter, wherein the boost command signal controls the boost converter such that the boost converter supplies a voltage greater than the DC input voltage to the five-phase PWM inverter module when the two AC machines require additional voltage that exceeds the DC input voltage, and wherein the boost command signal outputs a zero value to the boost converter when the first output command signal is less than or equal to zero so that the boost converter supplies the DC input voltage to the five-phase PWM inverter module when the voltage required by the two AC machines is less than or equal to the DC input voltage.