Detection of demagnetization in a motor in an electric or partially electric motor vehicle

• US 6,720,792 B2
• Filed: 09/17/2001
• Issued: 04/13/2004
• Est. Priority Date: 09/17/2001
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Curran, Patrick J., Raftari, Abbas, Garg, Vijay K
• Primary Examiner(s): Cuneo, Kamand
• Assistant Examiner(s): KOBERT, RUSSELL MARC
• Application Number:
  US09/682,531
• Publication Number:
  US 20030055584A1
• Time in Patent Office: 939 Days
• Field of Search: 324/772, 324/158.1, 318/490, 318/565, 318/798, 318/799, 322/99
• US Class Current: 324/765.01
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60K 6/445 Differential gearing distribution type
• CPC Class Codes: B60L 15/2009 for braking
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2240/12 Speed
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2240/425 Temperature
• CPC Class Codes: B60L 2240/427 Voltage
• CPC Class Codes: B60L 2240/441 Speed
• CPC Class Codes: B60L 2250/10 by alarm
• CPC Class Codes: B60L 2270/145 Structure borne vibrations
• CPC Class Codes: B60L 3/0061 relating to electrical machines
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 7/14 for vehicles propelled by ac motors
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: G01R 31/343 in operation
• CPC Class Codes: H02K 11/20 for measuring, monitoring, testing, protecting or switching rectifiers H02K11/04; power electronics H02K11/33
• CPC Class Codes: H02K 11/35 Devices for recording or transmitting machine parameters, e.g. memory chips or radio transmitters for diagnosis
• CPC Class Codes: H02K 15/03 : having permanent magnets
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• 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 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y10S 903/906 : Motor or generator

Abstract

In an electric or hybrid electric vehicle, a voltage monitor (102) is directly coupled to a traction motor (38) and/or generator motor (30) to detect a permanent magnet induced voltage within the motor at a predetermined speed and no load condition. A controller (100) compares the detected permanent magnet induced voltage with an expected reference voltage that represents an expected permanent magnet induced voltage at full magnetization and the predetermined speed. The comparison includes identifying points of synchronization and using those points to determine a difference in the detected permanent magnet induced voltage that is caused by a faulty component.

Claims

1. A device for detecting permanent magnet demagnetization in a motor in a vehicle comprising:

a permanent magnet induced voltage monitor that measures a detected permanent magnet induced voltage of the motor at a predetermined speed, wherein the permanent magnet induced voltage monitor has

a sensor coil wrapped around a plurality of teeth in a plurality of slots of a stator of the motor adjacent to a rotor of the motor at an edge closest to a gap between the stator and the rotor of the motor, and wherein the sensor coil is not related to a plurality of windings of the motor, and

a voltmeter disposed in the vehicle coupled to the sensor coil of the motor, wherein the voltmeter periodically monitors of the state of magnetism of the permanent magnets in the motor during no load conditions to provide the detected permanent magnet induced voltage to a processor;

a predetermined irregularity in the motor that cooperates with the sensor coil to locate a position of each of a plurality of permanent magnets in the motor; and

a processor that;

compares the detected permanent magnet induced voltage with a reference voltage that reflects a permanent magnet induced voltage of the motor with a fully magnetized permanent magnet at the predetermined speed; and

analyzes the detected permanent magnet induced voltage with reference to the reference voltage to determine whether a characteristic of the detected permanent magnet induced voltage indicates a demagnetized permanent magnet of the motor.

2. The device of claim 1 wherein the processor analyzes the detected permanent magnet induced voltage with reference to a point of synchronization that relates to a position of a permanent magnet in the motor.

3. The device of claim 2 wherein the point of synchronization is caused by the predetermined irregularity in the motor.

4. The device of claim 3 wherein the predetermined irregularity is formed in one of a rotor and a permanent magnet.

5. The device of claim 2 wherein the point of synchronization is caused by a predetermined change in one of motor reluctance and magnetic strength.

6. The device of claim 1 wherein current to the motor is limited to an amount that prevents damage to components of the vehicle when the magnetic strength of the motor is below a predetermined first threshold.

7. The device of claim 6 wherein the processor is calibrated to force the motor to provide the torque required when the current to the motor is limited.

8. The device of claim 7 wherein operation of the motor is suspended and the motive power within the vehicle is switched to an available second motor providing an alternative motive source when a second threshold of magnetization is met.

9. A method for identifying a component that is causing permanent magnet demagnetization in a motor of a vehicle, the method comprising the steps of:

providing a sensor coil wrapped around a plurality of teeth in a plurality of slots of a stator of the motor adjacent to a rotor of the motor at an edge closest to a gap between the stator and the rotor of the motor, wherein the sensor coil is not related to a plurality of windings of the motor;

using the sensor coil to sense permanent magnet induced voltage in the motor;

providing a voltmeter disposed in the vehicle coupled to the sensor coil of the motor;

using the voltmeter to periodically monitor the state of magnetism sensed by the sensor coil of each of the plurality of permanent magnets in the motor during no load conditions;

providing a predetermined irregularity in the motor that cooperates with the sensor coil to locate a position of each of a plurality of permanent magnets in the motor;

detecting a first signal from the voltmeter that is a function of permanent magnetization of a plurality of permanent magnets in the motor;

comparing the first signal with a reference signal that represents a function of permanent magnetization of the plurality of magnets in the motor, wherein the reference signal reflects a level of magnetization that is expected where the plurality of permanent magnets in the motor are fully magnetized; and

analyzing a difference between the first signal and the reference signal to determine a demagnetized permanent magnet selected from the plurality of permanent magnets that is likely causing the difference.

10. The method of claim 9 further comprising the step of:

setting a diagnostic code indicating the demagnetized permanent magnet selected from the plurality of permanent magnets.

11. The method of claim 9 wherein the first signal is a permanent magnet induced voltage and the reference signal is a permanent magnet induced voltage.

12. The method of claim, 11 wherein the first signal is detected by inducing a voltage in the sensor coil .

13. The method of claim 9 wherein the first signal includes a point of synchronization and the reference signal includes a point of synchronization.

14. The method of claim 13 wherein the point of synchronization of the first signal is determined by the predetermined irregularity in the motor.

15. The method of claim 14 wherein the predetermined irregularity causes a change in one of motor reluctance and magnetic strength.

16. A device for identifying a permanent magnet that is demagnetized in a motor of vehicle, the device comprising:

a sensor coil wrapped around a plurality of teeth in a plurality of slots of a stator of the motor adjacent to a rotor of the motor at an edge closest to a gap between the stator and the rotor of the motor that operates to sense permanent magnet induced voltage in the motor, and wherein the sensor coil is not related to a plurality of windings of the motor;

a voltmeter disposed in the vehicle coupled to the sensor coil of the motor, wherein the voltmeter periodically monitors of the state of magnetism of the permanent magnets in the motor during no load conditions to provide the detected permanent magnet induced voltage to a processor;

a predetermined irregularity in the motor that cooperates with both the sensor coil and the processor to locate a position of each of the plurality of permanent magnets in the motor; and

a processor that;

receives a first signal that is a function of permanent magnetization of a plurality of permanent magnets in the motor;

compares the first signal with a reference signal that represents a function of permanent magnetization of the plurality of magnets in the motor, wherein the reference signal reflects a level of magnetization that is expected where the plurality of permanent magnets in the motor are fully magnetized;

analyzes a difference between the first signal and the reference signal to determine a demagnetized permanent magnet selected from the plurality of permanent magnets in the motor that is likely causing the difference.

17. The device of claim 16 further comprising the processor setting a diagnostic code indicating the demagnetized permanent magnet.

18. The device of claim 16 wherein the first signal is a permanent magnet induced voltage and the reference signal is a permanent magnet induced voltage.

19. The device of claim 18 wherein the first signal is detected by inducing a voltage in the sensor coil.

20. The device of claim 16 wherein the first signal includes a point of synchronization and the reference signal includes a point of synchronization.

21. The device of claim 20 wherein the point of synchronization of the first signal is determined by the predetermined irregularity in the motor.

22. The device of claim 21 wherein the predetermined irregularity is formed in one of a rotor and a permanent magnet of the plurality of permanent magnets.