Method and apparatus for motor control

• US 6,936,991 B2
• Filed: 05/30/2003
• Issued: 08/30/2005
• Est. Priority Date: 06/03/2002
• Status: Expired due to Term

• Current Assignee: Vitesco Technologies USA, LLC (Continental AG)
• Original Assignee: Ballard Power Systems Corporation (Superior Plus Corporation)
• Inventors: Stella, Stephen, Chen, Li, Tesch, Tod R., Davis, Roy I.
• Primary Examiner(s): Martin, David
• Assistant Examiner(s): COLON SANTANA, EDUARDO
• Application Number:
  US10/449,824
• Publication Number:
  US 20040036434A1
• Time in Patent Office: 823 Days
• Field of Search: 318700-724, 318/138, 318/254, 318/439, 318/811, 318/802, 318/805, 318432-434, 318/798, 318/799, 318/723, 318/716, 318/812
• US Class Current: 318/700
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: H02P 21/0089 using field weakening
• CPC Class Codes: H02P 21/06 Rotor flux based control involving the use of rotor position or rotor speed sensors
• CPC Class Codes: H02P 21/22 Current control, e.g. using a current control loop
• CPC Class Codes: H02P 6/08 Arrangements for controlling the speed or torque of a single motor H02P6/10, H02P6/28 take precedence

Abstract

A closed-loop permanent magnet motor control method and system optimally partitions torque and flux-weakening currents to produce a desired torque without exceeding the capability of the DC source. A maximum limit for allowable torque current and a minimum threshold for the maximum torque current are determined, and the flux current is varied based at least in part on whether the maximum torque current limit is above or below the minimum threshold while operating in a flux-weakening region to compensate for the variability of the DC source voltage.

Claims

1. A method for controlling motor torque of a motor in a vehicle, comprising:

determining a maximum torque current that a DC source can supply to the motor;

determining a present flux weakening current;

determining a minimum threshold for the determined maximum torque current, below which a commanded torque current should not fall;

increasing a flux current to the motor if a commanded torque requires higher current than the determined maximum torque current that the DC source can supply, by adding to the flux current the output of a first proportional-plus-integral controller operating on a difference between the commanded torque current and the determined maximum torque current that the DC source can supply; and

further increasing the flux current to the motor if the determined maximum torque current that the DC source can supply is less than the minimum threshold for the determined maximum torque current, by adding to the flux current the output of a second proportional-plus-integral controller operating on a difference between the determined maximum torque current that the DC source can supply and the determined minimum threshold for the determined maximum torque current.

2. The method of claim 1 wherein the maximum torque current that the DC source can supply to the motor is determined via the following formula:

$i_q^{\mathrm{Max}}=\sqrt{{\left(\frac{V_{D<br><br>\text{\hspace{1em}<br><br>}<br><br>C}}{{\mathrm{\omega <br><br>}}_r<br><br>L_q}\right)}^2-{\left(\frac{L_d}{L_q}\right)}^2<br><br>{\left(i_d^{*}+\frac{{\mathrm{\lambda <br><br>}}_{\mathrm{PM}}}{L_d}\right)}^2},$

where i_q^Max is the maximum torque current, V_DC is the DC source voltage, ω

_r is a synchronous speed, L_q is a q-axis stator inductance, L_d is a d-axis stator inductance, i_d* is a commanded flux current, and λ

_PM is a permanent magnet flux.

3. A method to control a motor powered at least in part by a DC source, the method comprising:

determining a maximum torque current that the DC source can supply to the motor under a present set of operating parameters;

determining a minimum threshold for the maximum torque current;

determining whether the determined maximum torque current is greater than the determined minimum threshold for the maximum torque current;

determining a torque current limit based on an outcome of the determination of whether the determined maximum torque current is greater than the determined minimum threshold for the determined maximum torque current;

determining whether a demanded torque current exceeds the determined torque current limit; and

adjusting a flux current supplied to the motor based on an outcome of the determination of whether the demanded torque current exceeds the determined torque current limit.

4. The method of claim 3 wherein the maximum torque current that the DC source can supply to the motor under the present set of operating parameters is determined as:

$i_q^{\mathrm{Max}}=\sqrt{{\left(\frac{V_{D<br><br>\text{\hspace{1em}<br><br>}<br><br>C}}{{\mathrm{\omega <br><br>}}_r<br><br>L_q}\right)}^2-{\left(\frac{L_d}{L_q}\right)}^2<br><br>{\left(i_d^{*}+\frac{{\mathrm{\lambda <br><br>}}_{\mathrm{PM}}}{L_d}\right)}^2},$

where i_q^Max is the maximum torque current, V_DC is the DC source voltage, ω

_r is a synchronous speed, L_q is a q-axis stator inductance, L_d is a d-axis stator inductance, i_d* is a commanded flux current, and λ

_PM is a permanent magnet flux.

5. The method of claim 3 wherein determining a torque current limit based on an outcome of the determination of whether the determined maximum torque current is greater than the minimum threshold for the determined maximum torque current includes increasing the flux current supplied to the motor if the determined maximum torque current is not greater than the minimum threshold for the determined maximum torque current.

6. The method of claim 3 wherein determining a torque current limit based on an outcome of the determination of whether the determined maximum torque current is greater than the minimum threshold for the determined maximum torque current includes increasing the flux current supplied to the motor based on an output of a first proportional-plus-integral controller if the determined maximum torque current is not greater than the minimum threshold for the determined maximum torque current.

7. The method of claim 3 wherein determining a torque current limit based on an outcome of the determination of whether the determined maximum torque current is greater than the minimum threshold for the determined maximum torque current includes maintaining the flux current supplied to the motor based on an output of a first proportional-plus-integral controller if the determined maximum torque current is greater than the minimum threshold for the determined maximum torque current.

8. The method of claim 3 wherein adjusting a flux current supplied to the motor based on an outcome of the determination of whether the demanded torque current exceeds the determined torque current limit includes increasing the flux current supplied to the motor.

9. The method of claim 3 wherein adjusting a flux current supplied to the motor based on an outcome of the determination of whether the demanded torque current exceeds the determined torque current limit includes increasing the flux current supplied to the motor based on an output of a proportional-plus-integral controller if the demanded torque current exceeds than the determined torque current limit.

10. The method of claim 3 wherein determining a torque current limit based on an outcome of the determination of whether the maximum torque current is greater than the minimum threshold for the maximum torque current includes increasing the flux current supplied to the motor if the maximum torque current is not greater than the minimum threshold for the maximum torque current, and wherein adjusting a flux current supplied to the motor based on an outcome of the determination of whether the demanded torque current exceeds the determined torque current limit includes further increasing the flux current supplied to the motor.

11. The method of claim 3 wherein determining a torque current limit based on an outcome of the determination of whether the maximum torque current is greater than the minimum threshold for the maximum torque current includes increasing the flux current supplied to the motor based on an output of a first proportional-plus-integral controller if the maximum torque current is not greater than the minimum threshold for the maximum torque current, and wherein adjusting a flux current supplied to the motor based on an outcome of the determination of whether the demanded torque current exceeds the determined torque current limit includes further increasing the flux current supplied to the motor based on an output of a second proportional-plus-integral controller if the demanded torque current is greater than the determined torque current limit.

12. A method for controlling a motor powered at least in part by a DC source, the method comprising:

determining a torque current and a flux current according to a peak torque per ampere algorithm;

determining whether the motor is operating in one of a constant torque region and a constant power region;

supplying the determined torque current and the determined flux current to the motor if the motor is operating in the constant torque region;

determining an adjusted flux current according to a flux-weakening algorithm, if the motor is operating in the constant power region; and

supplying the adjusted flux current to the motor, if the motor is operating in the constant power region, wherein the determining an adjusted flux current comprises;

determining a maximum torque current that the DC source can supply to the motor;

determining a minimum threshold for the determined maximum torque current;

increasing the flux current supplied to the motor if a torque demand requires higher current than the determined maximum torque current that the DC source can supply; and

further increasing the flux current supplied to the motor if the determined maximum torque is less than the determined minimum threshold for the determined maximum torque current.

13. The method of claim 12 wherein determining a maximum torque current that the DC source can supply to the motor comprises:

determining the maximum torque current according to;

$i_q^{\mathrm{Max}}=\sqrt{{\left(\frac{V_{D<br><br>\text{\hspace{1em}<br><br>}<br><br>C}}{{\mathrm{\omega <br><br>}}_r<br><br>L_q}\right)}^2-{\left(\frac{L_d}{L_q}\right)}^2<br><br>{\left(i_d^{*}+\frac{{\mathrm{\lambda <br><br>}}_{\mathrm{PM}}}{L_d}\right)}^2},$

where i_q^max is the maximum torque current, V_DC is the DC source voltage, ω

_r is a synchronous speed, L_q is a q-axis stator inductance, L_d is a d-axis stator inductance, i_d* is a commanded flux current, and λ

_PM is a permanent magnet flux.

14. A system for controlling motor torque of a motor in an electric vehicle having at least one DC source, comprising:

means for computing a maximum torque current that can be supplied to the motor by the DC source;

means for computing a present flux weakening current of the motor;

means for setting a minimum threshold of the computed maximum torque current, below which a commanded torque current should not fall;

means for increasing a flux current if the commanded torque current requires a higher current than the computed maximum torque current that the DC source can supply to the motor by subtracting from the flux current an output of a first proportional-plus-integral controller operating on the difference between the commanded torque current and the determined maximum torque current that the DC source can supply; and

means for increasing the flux current further, if the determined maximum torque current that the DC source can supply is less than the minimum threshold of the maximum torque current, by subtracting from the flux current an output of a second proportional-plus-integral controller operating on the difference between the determined maximum torque current that the DC source can supply and the minimum threshold of the determined maximum torque current.

15. The system of claim 14 wherein the means for computing a maximum torque current that that the DC source can supply to the motor includes control logic for calculating the maximum torque current as:

$i_q^{\mathrm{Max}}=\sqrt{{\left(\frac{V_{D<br><br>\text{\hspace{1em}<br><br>}<br><br>C}}{{\mathrm{\omega <br><br>}}_r<br><br>L_q}\right)}^2-{\left(\frac{L_d}{L_q}\right)}^2<br><br>{\left(i_d^{*}+\frac{{\mathrm{\lambda <br><br>}}_{\mathrm{PM}}}{L_d}\right)}^2},$

where i_q^Max is the maximum torque current, V_DC is the DC source voltage, ω

_r is a synchronous speed, L_q is a q-axis stator inductance, L_d is a d-axis stator inductance, i_d* is a commanded flux current, and λ

_PM is a permanent magnet flux.

16. A motor control system to control a torque current and a flux current supplied to a permanent magnet motor from a DC power source, the motor control system comprising:

a maximum torque current subsystem to adjust a maximum torque current limit when a maximum torque current that the DC power source can supply to the motor is below a minimum limit of the maximum torque current;

a flux current command subsystem coupled to receive the maximum torque current limit from the maximum torque current subsystem and to provide a flux current command in response; and

a reference d-q voltage subsystem coupled to receive the flux current command from the flux current command subsystem and a torque voltage reference and a flux voltage reference.

17. The motor control system of claim 16, further comprising:

a torque command subsystem to produce a torque demand value; and

a torque current command subsystem coupled to receive the torque demand value from the torque command subsystem and to supply a torque current command to the reference d-q voltage subsystem.

18. The motor control system of claim 16 wherein the maximum torque current subsystem includes a controller coupled to the flux current command subsystem to increase the flux current command when the maximum torque current that the DC source can supply is below the minimum limit of the maximum torque current.

19. The motor control system of claim 16 wherein the flux current command subsystem includes a controller coupled to increase the flux current command when a demanded torque current exceeds the maximum torque current limit.

20. The motor control system of claim 16 wherein the flux current command subsystem includes a first controller coupled to increase the flux current command when a demanded torque current exceeds the maximum torque current limit, and wherein the maximum torque current subsystem includes a second controller coupled to the flux current command subsystem to increase the flux current command when the maximum torque current that the DC source can supply is below the minimum limit of the maximum torque current.

21. The motor control system of claim 16 wherein the motor control system takes the form of at least one of an analog circuit, a digital circuit and a programmed microprocessor.

22. A system for an electric vehicle, comprising:

a permanent magnet traction motor; and

a motor control system to control a torque current and a flux current supplied to the permanent magnet traction motor from a DC power source, the motor control system including;

a maximum torque current subsystem to adjust a maximum torque current limit when a maximum torque current that the DC power source can supply to the permanent magnet motor is below a minimum limit of the maximum torque current;

a flux current command subsystem coupled to receive the maximum torque current limit from the maximum torque current subsystem and to provide a flux current command in response; and

a reference d-q voltage subsystem coupled to receive the flux current command from the flux current command subsystem and a torque voltage reference and a flux voltage reference.

23. The system of claim 22 wherein the motor control system further includes:

a torque command subsystem to produce a torque demand value; and

a torque current command subsystem coupled to receive the torque demand value from the torque command subsystem and to supply a torque current command to the reference d-q voltage subsystem.

24. The system of claim 22 wherein the flux current command subsystem includes a first controller coupled to increase the flux current command when a demanded torque current exceeds the maximum torque current limit, and wherein the flux current command subsystem includes a second controller coupled to the maximum torque current subsystem to increase the flux current command when the maximum torque current that the DC source can supply is below the minimum limit of the maximum torque current.

25. The system of claim 22 wherein the permanent magnet traction motor is a surface permanent magnet motor.

26. The system of claim 22 wherein the permanent magnetic motor is an interior permanent magnetic motor.

27. A vehicle, comprising:

at least one drive wheel;

a DC power source;

a permanent magnet motor coupled to drive the at least one drive wheel; and

a motor control system coupled between the DC power source and the permanent magnet motor, the motor control system having control logic that causes a torque current and a flux current to be supplied to the permanent magnet motor from the DC power source, by;

determining a maximum torque current that the DC source can supply to the motor under a present set of operating parameters;

determining a minimum threshold for the maximum torque current;

determining whether the maximum torque current is greater than the minimum threshold for the maximum torque current;

determining a torque current limit based on an outcome of the determination of whether the maximum torque current is greater than the minimum threshold for the maximum torque current;

determining whether a demanded torque current exceeds the determined torque current limit; and

adjusting the flux current supplied to the motor based on an outcome of the determination of whether the demanded torque current exceeds the determined torque current limit.

28. The vehicle of claim 27 wherein the control logic determines a torque current limit based on an outcome of the determination of whether the maximum torque current is greater than the determined minimum threshold for the determined maximum torque current by increasing the flux current supplied to the motor if the determined maximum torque current is not greater than the determined minimum threshold for the determined maximum torque current, and wherein the control logic adjusts the flux current supplied to the motor based on an outcome of the determination of whether the demanded torque current exceeds the determined torque current limit by further increasing the flux current supplied to the motor.

29. The vehicle of claim 27 wherein the DC power source is at least one of a battery, a fuel cell system and a super-capacitor.

30. The vehicle of claim 27, further comprising:

an internal combustion engine.