Electronic throttle/brake control system for motorized wheel hub

• US 6,690,127 B2
• Filed: 01/29/2002
• Issued: 02/10/2004
• Est. Priority Date: 11/07/2000
• Status: Expired due to Fees

• Current Assignee: D&V Electronics, Ltd. (Motorcar Parts of America Incorporated)
• Original Assignee: Orville J. Birkestrand, William A. Peterson
• Inventors: Birkestrand, Orville J., Peterson, William A.
• Primary Examiner(s): Masih, Karen
• Application Number:
  US10/059,725
• Publication Number:
  US 20020135330A1
• Time in Patent Office: 742 Days
• Field of Search: 318/139, 318/9, 318/14, 318/254, 318/138, 318/439, 318/515, 318/528, 318/501, 318/375, 318/376, 388/824, 388/81, 388/827, 388/829, 388/840
• US Class Current: 318/139
• 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 15/2009 for braking
• CPC Class Codes: B60L 2200/12 Bikes
• CPC Class Codes: B60L 2220/14 Synchronous machines
• CPC Class Codes: B60L 2220/44 Wheel Hub motors, i.e. integrated in the wheel hub
• CPC Class Codes: B60L 2240/12 Speed
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 50/20 using propulsion power generated by humans or animals
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 7/14 for vehicles propelled by ac motors
• CPC Class Codes: B62M 6/40 Rider propelled cycles with auxiliary electric motor
• CPC Class Codes: B62M 6/45 Control or actuating devices therefor
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

An electronic motor control system includes a brushless DC machine having an armature and a stator with at least three phase windings, a commutation circuit including a DC power supply and switching devices associated with the windings to supply current two selected pairs of the windings and anti-parallel unidirectional current devices which provide current paths to dissipate energy stored in each windings after the supply of current through the associated switching device has terminated, a programmable commutation logic circuit responsive to the current signals in the windings for providing switching signals to the commutation circuit to cause rotation of the armature, a current sensor in circuit with the power supply for sensing the supply current and producing current signals, a controller responsive to the current signals, an additional unidirectional current device connected between each winding and the power supply, the direction of conduction therethrough being opposite to that of the first-mentioned unidirectional current devices and a switch for interrupting the connection between the additional unidirectional current devices and the power supply.

Claims

1. A motor-drive circuit that includes a plurality of drive terminals adapted for coupling to respective phase terminals of a polyphase DC machine, the motor-drive circuit comprising:

a DC source having positive and negative source electrodes;

a separate source current path associated with each drive terminal and extending between that drive terminal and the positive source electrode;

a separate sink current path associated with each drive terminal and extending between that drive terminal and the negative source electrode;

a separate source switch associated with and interposed in each source current path and operable by application of switch-control signals thereto to switch between an open state, in which it prevents current flow through that source current path, and a closed state, in which it permits current flow therethrough;

a separate sink switch associated with and interposed in each sink current path and operable by application of switch-control signals thereto to switch between an open state, in which it prevents current flow through that sink current path, and a closed state, in which it permits current flow therethrough;

a separate source shunt unidirectional device associated with each source switch and so connected and oriented as, when that source switch is open, to shunt current around the associated source switch in the direction toward the positive source electrode but not in the direction away from it;

a separate sink shunt unidirectional device associated with each sink switch and so connected and oriented as, when that sink switch is open, to shunt current around the associated sink switch in the direction away from the negative source electrode but not in the direction toward it, all source or all sink shunt unidirectional devices also being denominated shorting-path shunt unidirectional devices;

a separate shorting electrical path associated with each drive terminal and extending therefrom to the other drive terminals through the shorting-path shunt unidirectional devices associated with those other drive terminals;

a separate shorting unidirectional device so interposed and oriented in each shorting electrical path as to permit current flow therethrough only in the direction from the drive terminal with which it is associated to each other drive terminal;

a shorting switch interposed in each shorting electrical path and operable by switch-control signals applied thereto between a closed state, in which it permits current flow therethrough, and an open state, in which it prevents current flow therethrough, and

a control circuit that, when the drive terminals are coupled to respective phase terminals of a polyphase DC machine having a rotor rotating at least at a minimum speed and stator windings terminating in the phase terminals, is operable;

in a motor mode, in which it applies;

to each shorting switch, switch-control signals that keep each shorting switch open, and

to the source and sink switches, switch-control signals that open and close the source and sink switches in such a phase relationship with the rotor'"'"'s rotation as to make the stator windings cause magnetic fields that drive the rotor in its direction of motion, and

in a generator mode, in which it applies;

to each source and sink switch, switch-control signals that keep that source or sink switch open, and

to each shorting switch, switch-control signals that keep that shorting switch closed during portions of the rotor'"'"'s cycle that start when the current flowing in the source and sink current paths is relatively low and open during portions of a rotor'"'"'s cycle that start when the current flowing in the source and sink current paths is relatively high.

2. A motor-drive circuit as defined in claim 1 wherein the shorting-path shunt unidirectional devices are the sink shunt unidirectional devices.

3. A motor-drive circuit as defined in claim 1 further including a common shorting-path segment included in every shorting electrical path.

4. A motor-drive circuit as defined in claim 3 wherein every shorting switch is the same, common shorting switch, which is interposed in the common shorting-path segment.

5. A motor-drive circuit as defined in claim 3 wherein:

the motor-drive circuit further includes a current sensor that generates a current-sensor output indicative of the current flowing through the drive terminals, and

the control circuit is responsive to the current-sensor output in applying switch-control signals to each shorting switch.

6. A motor-drive circuit as defined in claim 5 wherein the current sensor is interposed in the common shorting-path segment.

7. A motor-drive circuit as defined in claim 3 wherein the negative source electrode is coupled into the common shorting-path segment.

8. A motor-drive circuit as defined in claim 1 wherein:

the motor-drive circuit further includes a current sensor that generates a current-sensor output indicative of the current flowing through the drive terminals, and

the control circuit is responsive to the current-sensor output in applying switch-control signals to each shorting switch.

9. A motor-drive circuit as defined in claim 8 wherein the control circuit, when it is in its generator mode, establishes first and second hysteresis thresholds representing respective current values and so applies switch-control signals to each shorting switch as thereby to:

open the shorting switch when the magnitude of the current represented by the current-sensor output rises from below that represented by the first hysteresis threshold to above that represented by the second hysteresis threshold, and

close the shorting switch when the magnitude of the current represented by the current-sensor output falls from above the second hysteresis threshold to below the first hysteresis threshold.

10. A motor-drive circuit as defined in claim 9 wherein the control circuit is responsive to a torque-command signal representing a torque value corresponding to a stator-current value to assign the hysteresis thresholds values that define a hysteresis range containing the stator-current value.

11. A motor-drive circuit as defined in claim 8 wherein the control circuit includes:

a commutation circuit that generates, for respective source and sink switches, commutation signals whose values indicate which states of the source and sink switches are in such a phase relationship with the rotor'"'"'s rotation as to make the stator windings cause magnetic fields that drive the rotor in its direction of rotation;

gates that receive respective ones of the commutation signals and are responsive to a gating signal to generate, as respective ones of the switch-control signals, output signals that open the source and sink signals when the gating signal has a first, disabling value but are determined by the respective commutation signals when the gating signal has a second, enabling value, and

a gating-signal generator, responsive to the current-sensor output and a torque-command signal that assumes values that extend from a motor range through a generator range, that generates the gating signal, to which it gives;

the disabling value when the torque-command signal assumes a value in its generator range, and

one of the enabling value and the disabling value selected in accordance with a comparison of the current-sensor output and the torque-command signal when the torque-command signal assumes a value in its motor range.

12. A motor-drive circuit as defined in claim 11 wherein the control circuit, when it is in its generator mode, establishes first and second hysteresis thresholds representing respective current values and so applies switch-control signals to each shorting switch as thereby to:

open the shorting switch when the magnitude of the current represented by the current-sensor output rises from below that represented by the first hysteresis threshold to above that represented by the second hysteresis threshold, and

close the shorting switch when the magnitude of the current represented by the current-sensor output falls from above the second hysteresis threshold to below the first hysteresis threshold.

13. A motor-drive circuit as defined in claim 12 wherein the control circuit is responsive to a torque-command signal representing a torque value corresponding to a stator-current value to assign the hysteresis threshold values that define a hysteresis range containing the stator-current value.

14. A motor drive circuit as defined in claim 1 and further including a polyphase DC machine connected to said drive terminals.