Engine starting system utilizing multiple controlled acceleration rates

• US 5,430,362 A
• Filed: 05/12/1993
• Issued: 07/04/1995
• Est. Priority Date: 05/12/1993
• Status: Expired due to Term

• Current Assignee: Sundstrand Corporation (Rtx Corporation)
• Original Assignee: Sundstrand Corporation (Rtx Corporation)
• Inventors: Maddali, Vijay K., Markunas, Albert L., Rozman, Gregory I., Cook, Alexander, Rinaldi, Mario R., Hanson, Michael J., McArthur, Malcolm J., Nuechterlein, Paul E., Weber, Leland E., Nguyen, Vietson, Shippling, James A., Carr, Kenneth R.
• Primary Examiner(s): Shoop, Jr., William M.
• Assistant Examiner(s): Sircus, Brian
• Application Number:
  US08/063,166
• Time in Patent Office: 783 Days
• Field of Search: 318/1, 318/6, 318/8, 318/778, 318/779, 318/270, 318/139, 378/842-844
• US Class Current: 318/779
• CPC Class Codes: F02N 11/04 the motors being associated with current generators
• CPC Class Codes: F05B 2220/50 for auxiliary power units (APU's)
• CPC Class Codes: H02P 9/302 Brushless excitation

Abstract

A control for operating an electromagnetic machine in a starting mode of operation wherein the main armature winding of the machine receives electrical power from a controllable power source during the starting mode of operation, comprises a circuit for detecting a magnitude of a parameter of power applied to the main armature winding relative to a stationary frame of reference, a position sensor for detecting rotor position of the electromagnetic machine, a converter responsive to angular position indication for converting the detected parameter magnitude into field and torque producing components relative to a rotating frame of reference, and a circuit responsive to the field and torque producing components for controlling the power source during operation in the starting mode. This control includes an igniter for igniting a prime mover. Further, the control is operable during a first phase prior to ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a first predetermined rate, is operable during a second phase subsequent to the first phase so as to accelerate the prime mover at a second predetermined rate, is operable during this second phase for providing fuel to the prime mover to facilitate ignition thereof, and is operable during a third phase subsequent to the ignition of the prime mover so as to accelerate the prime mover at a third predetermined rate to a self-sustaining speed.

Claims

1. A control for operating an electromagnetic machine in a starting mode of operation wherein the electromagnetic machine includes a motive power shaft coupled to a rotor, a permanent magnet generator (PMG) having a set of armature phase windings at which a set of PMG phase outputs are produced and a main generator portion having a main armature winding, wherein the main armature winding receives electrical power from a controllable power source during the starting mode of operation, comprising:

means for detecting a magnitude of a parameter of power applied to the main armature winding relative to a stationary frame of reference;

a position sensor for detecting rotor position of the electromagnetic machine including a shaft pulse encoder which develops a cycle pulse once per revolution of the motive power shaft, means coupled to the PMG armature phase windings for deriving a number of interval pulses per revolution of the motive power shaft from the PMG phase outputs, means coupled to the developing means for measuring time periods between adjacent interval pulses and means coupled to the measuring means and responsive to the cycle pulse for transforming the measured time periods into an indication of the angular position of the motive power shaft;

a converter coupled to the position sensor and responsive to the angular position indication for converting the detected parameter magnitude into field and torque producing components relative to a rotating frame of reference; and

means coupled between the converter and the power source and responsive to the field and torque producing components for controlling the power source during operation in the starting mode such that the rotor is rotated.

2. The control of claim 1, wherein the control includes means for igniting a prime mover and the electromagnetic machine is operated to bring the prime mover up to self-sustaining speed and further including

first means operable during a first phase prior to ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a first predetermined rate,

second means operable during a second phase subsequent to said first phase for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a second predetermined rate which is less than said first predetermined rate,

means operable during said second phase for providing fuel to the prime mover to facilitate ignition thereof and

third means operable during a third phase subsequent to the ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a third predetermined rate.

3. A control for operating an electromagnetic machine in a starting mode of operation wherein the electromagnetic machine includes a motive power shaft coupled to a rotor and a main generator portion having a set of main armature windings, wherein the set of main armature windings receives AC power from a controllable power source and developing a back EMF voltage during the starting mode of operation, comprising:

means for detecting a magnitude of a parameter of power applied to the set of main armature windings relative to a stationary frame of reference;

a position sensor for detecting rotor position of the electromagnetic machine including means coupled to the set of main armature windings and responding to the AC power for producing a back EMF estimate signal representing an estimate of the back EMF voltage and means for transforming the back EMF estimate signal into an indication of angular position of the motive power shaft;

a converter coupled to the position sensor and responsive to the angular position indication for converting the detected parameter magnitude into field and torque producing components relative to a rotating frame of reference; and

means coupled between the converter and the power source and responsive to the field and torque producing components for controlling the power source during operation in the starting mode such that the rotor is rotated.

4. The control of claim 3, wherein the control includes means for igniting a prime mover and the electromagnetic machine is operated to bring the prime mover up to self-sustaining speed and further including

first means operable during a first phase prior to ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a first predetermined rate,

second means operable during a second phase subsequent to said first phase for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a second predetermined rate which is less than said first predetermined rate,

means operable during said second phase for providing fuel to the prime mover to facilitate ignition thereof and

third means operable during a third phase subsequent to the ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a third predetermined rate.

5. A control for operating an electromagnetic machine in a starting mode of operation wherein the electromagnetic machine includes a motive power shaft coupled to a rotor, a permanent magnet generator (PMG) having a set of PMG armature phase windings disposed in a stator of the electromagnetic machine and at which a set of PMG phase outputs are produced, an exciter having an exciter field winding disposed in the stator and an exciter armature winding disposed on the rotor and a main generator portion having a main field winding disposed on the rotor and coupled to the exciter armature winding and a main armature winding disposed in the stator, wherein the main armature winding and the exciter field winding receive electrical power from first and second controllable power sources, respectively, during the starting mode of operation, comprising:

means for detecting a magnitude of a parameter of power applied to the main armature winding relative to a stationary frame of reference;

a converter responsive to the detecting means for converting the detected parameter magnitude into field and torque producing components relative to a rotating frame of reference;

first means coupled between the converter and the first controllable power source and responsive to the field and torque producing components for controlling the first controllable power source during operation in the starting mode such that the first power source provides a first AC waveform at a first frequency to the main generator portion armature winding; and

second means for controlling the second power source during operation in the starting mode such that the second power source provides a second AC waveform at a second frequency to the exciter field winding at the beginning of a start sequence and such that the second AC waveform changes to a third frequency less than the second frequency after the beginning of the start sequence.

6. The control of claim 5, wherein the control includes means for igniting a prime mover and the electromagnetic machine is operated to bring the prime mover up to self-sustaining speed and further including

first means operable during a first phase prior to ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a first predetermined rate,

second means operable during a second phase subsequent to said first phase for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a second predetermined rate which is less than said first predetermined rate,

means operable during said second phase for providing fuel to the prime mover to facilitate ignition thereof and

third means operable during a third phase subsequent to the ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a third predetermined rate.

7. A control for operating an electromagnetic machine in a starting mode of operation wherein the electromagnetic machine includes a motive power shaft coupled to a rotor, a permanent magnet generator (PMG) having a set of PMG-armature phase windings disposed in a stator of the electromagnetic machine and at which a set of PMG phase outputs are produced, an exciter having an exciter field winding disposed in the stator and an exciter armature Winding disposed on the rotor and a main generator portion having a main field winding disposed on the rotor and coupled to the exciter armature winding and a main armature winding disposed in the stator, wherein the main armature winding and the exciter field winding receive electrical power from first and second controllable power sources, respectively, during the starting mode of operation, comprising:

means for detecting a magnitude of a parameter of power applied to the main armature winding relative to a stationary frame of reference;

a converter responsive to the detecting means for converting the detected parameter magnitude into field and torque producing components relative to a rotating frame of reference;

first means coupled between the converter and the first controllable power source and responsive to the field and torque producing components for controlling the first controllable power source during operation in the starting mode such that the first power source provides AC power to the main generator portion armature winding; and

second means for controlling the second power source during operation in the starting mode such that the second power source provides AC and DC power simultaneously to the exciter field winding during operation in the starting mode.

8. The control of claim 7, wherein the control includes means for igniting a prime mover and the electromagnetic machine is operated to bring the prime mover up to self-sustaining speed and further including

first means operable during a first phase prior to ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a first predetermined rate,

second means operable during a second phase subsequent to said first phase for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a second predetermined rate,

means operable during said second phase for providing fuel to the prime mover to facilitate ignition thereof and

third means operable during a third phase subsequent to the ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a third predetermined rate.

9. A control for operating an electromagnetic machine in a starting mode of operation wherein the electromagnetic machine includes a motive power shaft coupled to a rotor, a permanent magnet generator (PMG) having a set of armature phase windings at which a set of PMG phase outputs are produced and a main generator portion having a main armature winding, wherein the main armature winding receives electrical power from a controllable power source during the starting mode of operation, comprising:

means for detecting a magnitude of a parameter of power applied to the main armature winding relative to a stationary frame of reference;

a position sensor for detecting rotor position of the electromagnetic machine including a shaft pulse encoder which develops a cycle pulse once per revolution of the motive power shaft, means coupled to the PMG armature phase windings for deriving a number of interval pulses per revolution of the motive power shaft from the PMG phase outputs, means coupled to the developing means for measuring time periods between adjacent interval pulses and means coupled to the measuring means and responsive to the cycle pulse for transforming the measured time periods into an indication of the angular position of the motive power shaft;

a converter coupled to the position sensor and responsive to the angular position indication for converting the detected parameter magnitude into field and torque producing components relative to a rotating frame of reference;

means coupled to the converter for obtaining field and torque producing commands from the field and torque producing components; and

means operable during the starting mode for controlling the power source in accordance with the field producing command during a first period of time and in accordance with the torque producing command during a second period of time exclusive of the first period of time such that the rotor is rotated.

10. The control of claim 9, wherein the control includes means for igniting a prime mover and the electromagnetic machine is operated to bring the prime mover up to self-sustaining speed and further including

first means operable during a first phase prior to ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a first predetermined rate,

second means operable during a second phase subsequent to said first phase for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a second predetermined rate which is less than said first predetermined rate,

means operable during said second phase for providing fuel to the prime mover to facilitate ignition thereof and

third means operable during a third phase Subsequent to the ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a third predetermined rate.

11. A control for operating an electromagnetic machine in a starting mode of operation wherein the electromagnetic machine includes a motive power shaft coupled to a rotor and a main generator portion having a set of main armature windings, wherein the set of main armature windings receives AC power from a controllable power source and developing a back EMF voltage during the starting mode of operation, comprising:

means for detecting a magnitude of a parameter of power applied to the set of main armature windings relative to a stationary frame of reference;

a position sensor for detecting rotor position of the electromagnetic machine including means coupled to the set of main armature windings and responding to the AC power for producing a back EMF estimate signal representing an estimate of the back EMF voltage and means for transforming the back EMF estimate signal into an indication of angular position of the motive power shaft;

a converter coupled to the position sensor and responsive to the angular position indication for converting the detected parameter magnitude into field and torque producing components relative to a rotating frame of reference;

means coupled to the converter for obtaining field and torque producing commands from the field and torque producing components; and

means operable during the starting mode for controlling the power source in accordance with the field producing command during a first period of time and in accordance with the torque producing command during a second period of time exclusive of the first period of time such that the rotor is rotated.

12. The control of claim 11, wherein the control includes means for igniting a prime mover and the electromagnetic machine is operated to bring the prime mover up to self-sustaining speed and further including

first means operable during a first phase prior to ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a first predetermined rate,

second means operable during a second phase subsequent to said first phase for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a second predetermined rate which is less than said first predetermined rate,

means operable-during said second phase for providing fuel to the prime mover to facilitate ignition thereof and

third means operable during a third phase subsequent to the ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a third predetermined rate.

13. A control for operating an electromagnetic machine in a starting mode of operation wherein the electromagnetic machine includes a motive power shaft coupled to a rotor, a permanent magnet generator (PMG) having a set of PMG armature phase windings disposed in a stator of the electromagnetic machine and at which a set of PMG phase outputs are produced, an exciter having an exciter field winding disposed in the stator and an exciter armature winding disposed on the rotor and a main generator portion having a main field winding disposed on the rotor and coupled to the exciter armature winding and a main armature winding disposed in the stator, wherein the main armature winding and the exciter field winding receive electrical power from first and second controllable power sources, respectively, during the starting mode of operation, comprising:

means for detecting a magnitude of a parameter of power applied to the main armature winding relative to a stationary frame of reference;

a converter responsive to the detecting means for converting the detected parameter magnitude into field and torque producing components relative to a rotating frame of reference;

means coupled to the converter for obtaining field and torque producing commands from the field and torque producing components;

means operable during the-starting mode for controlling the first controllable power source in accordance with the field producing command during a first period of time and in accordance with the torque producing command during a second period of time exclusive of the first period of time such that the first power source provides a first AC waveform at a first frequency to the main generator portion armature winding; and

second means for controlling the second power source during operation in the starting mode such that the second power source provides a second AC waveform at a second frequency to the exciter field winding at the beginning of a start sequence and such that the second AC waveform changes to a third frequency less than the second frequency after the beginning of the start sequence.

14. The control of claim 13, wherein the control includes means for igniting a prime mover and the electromagnetic machine is operated to bring the prime mover up to self-sustaining speed and further including

first means operable during a first phase prior to ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a first predetermined rate,

second means operable during a second phase subsequent to said first phase for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a second predetermined rate which is less than said first predetermined rate,

means operable during said second phase for providing fuel to the prime mover to facilitate ignition thereof and

third means operable during a third phase subsequent to the ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a third predetermined rate.

15. A control for operating an electromagnetic machine in a starting mode of operation wherein the electromagnetic machine includes a motive power shaft coupled to a rotor, a permanent magnet generator (PMG) having a set of PMG armature phase windings disposed in a stator of the electromagnetic machine and at which a set of PMG phase outputs are produced, an exciter having an exciter field winding disposed in the stator and an exciter armature winding disposed on the rotor and a main generator portion having a main field winding disposed on the rotor and coupled to the exciter armature winding and a main armature winding disposed in the stator, wherein the main armature winding and the exciter field winding receive electrical power from first and second controllable power sources, respectively, during the starting mode of operation, comprising:

means for detecting a magnitude of a parameter of power applied to the main armature winding relative to a stationary frame of reference;

a converter responsive to the detecting means for converting the detected parameter magnitude into field and torque producing components relative to a rotating frame of reference;

means coupled to the converter for obtaining field and torque producing commands from the field and torque producing components;

means operable during the starting mode for controlling the first controllable power source in accordance with the field producing command during a first period of time and in accordance with the torque producing command during a second period of time exclusive of the first period of time such that the first power source provides AC power to the main generator portion armature winding; and

second-means for controlling the second power source during operation in the starting mode such that the second power source provides AC and DC power simultaneously to the exciter field winding during operation in the starting mode.

16. The control of claim 15, wherein the control includes means for igniting a prime mover and the electromagnetic machine is operated to bring the prime mover up to self-sustaining speed and further including

first means operable during a first phase prior to ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a first predetermined rate,

second means operable during a second phase subsequent to said first phase for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a second predetermined rate,

means operable during said second phase for providing fuel to the prime mover to facilitate ignition thereof and

third means operable during a third phase subsequent to the ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a third predetermined rate.

17. A starting system control for controlling an electromagnetic machine having a rotor and a set of main armature windings to start a prime mover which is connected to the electromagnetic machine by a motive power shaft, comprising:

means for sensing a terminal voltage of the electromagnetic machine to determine a back EMF voltage induced within one of the armature windings;

means coupled to the sensing means for developing an indication of rotor speed and an indication of rotor position in accordance with the back EMF voltage;

means for determining the direction of rotation of the motive power shaft;

means responsive to the indications of the rotor speed and the rotor position and further responsive to the determined direction of rotation of the motive power shaft for operating the electromagnetic machine in one of a plurality of operating modes including a braking mode, a plugging mode and a motoring mode to bring the prime mover up to a self-sustaining speed;

first means operable during a first phase of the motoring mode prior to ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a first predetermined rate;

second means operable during a second phase of the motoring mode subsequent to said first phase for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a second predetermined rate which is less than said first predetermined rate;

means operable during said second phase of the motoring mode for providing fuel to the prime mover to facilitate ignition thereof; and

third means operable during a third phase of the motoring mode subsequent to the ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a third predetermined rate.

18. A control for operating an electromagnetic machine as a motor wherein the electromagnetic machine includes a rotatable rotor and a set of armature phase windings each of which has a reluctance associated therewith and develops back EMF when the machine is operated as a motor, comprising:

first sensing means for sensing the reluctance associated with the armature windings;

second sensing means for sensing the back EMF developed by the armature windings;

third sensing means responsive to the first and second sensing means for sensing rotor position based upon the sensed reluctance when the machine rotor is rotating below a certain speed and based upon the sensed back EMF when the machine rotor is rotating above the certain speed; and

controlling means for controlling electrical power applied to the armature windings in dependence upon the sensed rotor position.

19. The control of claim 18, wherein the control includes means for igniting a prime mover and the electromagnetic machine is operated to bring the prime mover up to self-sustaining speed and further including

first causing means operable during a first phase prior to ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a first predetermined rate,

second causing means operable during a second phase subsequent to said first phase for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a second predetermined rate which is less than said first predetermined rate,

providing means operable during said second phase for providing fuel to the prime mover to facilitate ignition thereof and

third causing means operable during a third phase subsequent to the ignition of the prime mover for causing the electromagnetic machine to provide motive power to the prime mover so as to accelerate the prime mover at a third predetermined rate.

20. The control of claim 18, wherein the electrical power is developed by a controllable power source comprising an inverter, a DC link connected to said inverter, said DC link providing a DC link current to said inverter during the starting mode of operation and a controller coupled to said DC link for controlling the magnitude of the DC link current provided to said inverter by said DC link.