System and method for transient-based motor speed estimation with transient excitation

• US 7,227,326 B1
• Filed: 04/24/2006
• Issued: 06/05/2007
• Est. Priority Date: 04/24/2006
• Status: Active Grant

• Current Assignee: Rockwell Automation, Inc., Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Nondahl, Thomas A., Lu, Haihui, Messersmith, David M.
• Primary Examiner(s): Ro; Bentsu
• Application Number:
  US11/379,887
• Time in Patent Office: 407 Days
• Field of Search: 318461-465, 318/490, 318/727, 318798-805, 318807-811, 324160-166, 324177-180
• US Class Current: 318/461
• CPC Class Codes: H02P 23/20 Controlling the acceleration or deceleration
• CPC Class Codes: H02P 6/182 using back-emf in windings
• CPC Class Codes: H02P 6/185 using inductance sensing, e.g. pulse excitation

Abstract

AC motor control systems and speed controllers are presented, including a transient-based speed estimation system that provides a rotor speed estimate based on a measured speed-related motor transient signal, and a transient excitation system which selectively modifies at least one switch control signal to excite the measured motor transient. The measured speed-related transient may include a phase error signal, a phase lag signal, a peak current signal, a voltage integral signal, a motor winding voltage signal, a switching device voltage, and a voltage zero crossing signal, and the switching signal modification can comprise removal of select pulse(s) from a switching control pulse stream or selective modification of spacings between pulses to re-excite the motor transient.

Claims

1. An AC motor control system for operating an AC induction motor, the motor control system comprising:

a switching system including a plurality of switching devices coupled between an AC power source and an induction motor, the individual switching devices operative to selectively couple a corresponding motor lead to the AC power source according to a corresponding switch control signal;

a motor controller providing a motor controller output to control the motor speed during starting or stopping according to a desired speed profile and according to a rotor speed estimate;

a switch control system providing a plurality of switch control signals to control operation of the switching devices of the switching system during starting or stopping of the motor according to the controller output;

a transient excitation system operatively coupled with the switch control system to selectively modify at least one switch control signal to excite a motor transient; and

a transient-based speed estimation system operatively coupled with the switching system and the motor speed control system, the transient-based speed estimation system receiving at least one feedback signal or value from the switching system and providing the rotor speed estimate at least partially according to the feedback signal or value.

2. The motor control system of claim 1, wherein the transient-based speed estimation system measures at least one transient speed-related signal in the at least one feedback signal or value, the transient speed-related signal being associated with the motor transient, the transient-based speed estimation system determining the rotor speed estimate at least partially according to the transient speed-related signal, and wherein the transient speed-related signal is one of a phase error signal, a phase lag signal, a peak current signal, a voltage integral signal, a motor winding voltage signal, a switching device voltage, and a voltage zero crossing signal.

3. The motor control system of claim 1, wherein the at least one switching control signal comprises a series of pulses for controlling a corresponding one of the switching devices, and wherein the transient excitation system selectively removes individual pulses from the switching control signal to excite the motor transient.

4. The motor control system of claim 1, wherein the at least one switching control signal comprises a series of pulses for controlling a corresponding one of the switching devices, and wherein the transient excitation system selectively modifies spacings between select pulses in the switching control signal to excite the motor transient.

5. The motor control system of claim 1, wherein the at least one switching control signal comprises a series of pulse pairs for controlling a corresponding one of the switching devices, and wherein the transient excitation system selectively removes select pulse pairs from the switching control signal to excite the motor transient.

6. The motor control system of claim 1, wherein the at least one switching control signal comprises a series of pulse pairs for controlling a corresponding one of the switching devices, and wherein the transient excitation system selectively removes one pulse from select pulse pairs of the switching control signal to excite the motor transient.

7. The motor control system of claim 1, wherein the at least one switching control signal comprises a series of pulse pairs for controlling a corresponding one of the switching devices, and wherein the transient excitation system selectively modifies spacings between pulses of select pulse pairs in the switching control signal to excite the motor transient.

8. The motor control system of claim 7, wherein the transient excitation system selectively increases spacings between pulses of select pulse pairs in the switching control signal to excite the motor transient.

9. The motor control system of claim 7, wherein the transient excitation system selectively decreases spacings between pulses of select pulse pairs in the switching control signal to excite the motor transient.

10. The motor control system of claim 1, wherein the at least one switching control signal comprises a series of pulse pairs for controlling a corresponding one of the switching devices, and wherein the transient excitation system selectively modifies spacings between pulses of consecutive pulse pairs in the switching control signal to excite the motor transient.

11. The motor control system of claim 10, wherein the transient excitation system selectively increases and decreases spacings between pulses of consecutive pulse pairs in the switching control signal based at least partially on the rotor speed estimate to excite the motor transient.

12. The motor control system of claim 10, wherein the transient excitation system selectively increases and decreases spacings between pulses of consecutive pulse pairs in the switching control signal based at least partially on a modulation waveform to excite the motor transient.

13. The motor control system of claim 12, wherein the modulation waveform is one of a sine wave, a square wave, or a sawtooth wave.

14. The motor control system of claim 1, further comprising a rotor flux initialization system operatively coupled with the switch control system to selectively initialize rotor flux in the motor during starting prior to activating the transient excitation system.

15. The motor control system of claim 14, wherein the motor is a three phase motor and wherein the rotor flux initialization system causes the switch control system to selectively activate select ones of the switching devices such that voltage is applied to only two of the motor phases for several power cycles to selectively initialize rotor flux in the motor during starting prior to activating the transient excitation system.

16. The motor control system of claim 1, wherein the transient excitation system periodically modifies the at least one switch control signal to excite a motor transient.

17. The motor control system of claim 1, wherein the transient-based speed estimation system measures at least one transient speed-related signal in the at least one feedback signal or value, the transient speed-related signal being associated with the motor transient, and wherein the transient excitation system selectively modifies at least one switch control signal to excite a motor transient at least partially according to an amplitude of the measured transient speed-related signal.

18. A motor speed control system operatively coupled with a switching system of a motor controller to control a driven motor speed during starting or stopping, the motor speed control system comprising:

a motor controller providing a motor controller output to control the motor speed during starting or stopping according to a desired speed profile and according to a rotor speed estimate;

a switch control system providing a plurality of switch control signals to control operation of a plurality of switching devices of the switching system during starting or stopping of the motor according to the controller output;

a transient excitation system operatively coupled with the switch control system to selectively modify at least one switch control signal to excite a motor transient; and

a transient-based speed estimation system receiving at least one feedback signal or value from the switching system and providing the rotor speed estimate to the motor controller at least partially according to the feedback signal or value.

19. The motor speed control system of claim 18, wherein the transient-based speed estimation system measures at least one transient speed-related signal in the at least one feedback signal or value, the transient speed-related signal being associated with the motor transient, the transient-based speed estimation system determining the rotor speed estimate at least partially according to the transient speed-related signal, and wherein the transient speed-related signal is one of a phase error signal, a phase lag signal, a peak current signal, a voltage integral signal, a motor winding voltage signal, a switching device voltage, and a voltage zero crossing signal.

20. The motor speed control system of claim 18, further comprising a rotor flux initialization system operatively coupled with the switch control system to selectively initialize rotor flux in the motor during starting or stopping prior to activating the transient excitation system.

21. The motor speed control system of claim 20, wherein the motor is a three phase motor and wherein the rotor flux initialization system causes the switch control system to selectively activate select ones of the switching devices such that voltage is applied to only two of the motor phases for several power cycles to selectively initialize rotor flux in the motor during starting prior to activating the transient excitation system.

22. The motor speed control system of claim 18, wherein the transient excitation system periodically modifies the at least one switch control signal to excite a motor transient.

23. The motor speed control system of claim 18, wherein the transient-based speed estimation system measures at least one transient speed-related signal in the at least one feedback signal or value, the transient speed-related signal being associated with the motor transient, and wherein the transient excitation system selectively modifies the at least one switch control signal to excite a motor transient at least partially according to an amplitude of the measured transient speed-related signal.

24. A method for controlling the speed of an AC motor during starting or stopping, the method comprising:

providing a plurality of switch control signals to a switching system for selective coupling of motor leads to an AC power source to control the motor speed during starting or stopping according to a desired speed profile and according to a rotor speed estimate;

selectively modifying at least one of the switch control signals to excite a motor transient;

measuring a transient speed-related signal associated with the motor transient; and

providing the rotor speed estimate at least partially according to the transient speed-related signal.

25. The method of claim 24, wherein the measured transient speed-related signal is one of a phase error signal, a phase lag signal, a peak current signal, a voltage integral signal, a motor winding voltage signal, a switching device voltage, and a voltage zero crossing signal.

26. The method of claim 24, wherein the switching control signal is provided as a series of pulses, and wherein selectively modifying at least one of the switch control signals comprises selectively removing individual pulses from the switching control signal to excite the motor transient.

27. The method of claim 24, wherein the switching control signal is provided as a series of pulses, and wherein selectively modifying at least one of the switch control signals comprises modifying spacings between select pulses in the switching control signal to excite the motor transient.

28. The method of claim 24, wherein the switching control signal is provided as a series of pulse pairs, and wherein selectively modifying at least one of the switch control signals comprises removing select pulse pairs from the switching control signal to excite the motor transient.

29. The method of claim 24, wherein the switching control signal is provided as a series of pulse pairs, and wherein selectively modifying at least one of the switch control signals comprises removing one pulse from select pulse pairs of the switching control signal to excite the motor transient.

30. The method of claim 24, wherein the switching control signal is provided as a series of pulse pairs, and wherein selectively modifying at least one of the switch control signals comprises modifying spacings between pulses of select pulse pairs in the switching control signal to excite the motor transient.

31. The method of claim 24, wherein the switching control signal is provided as a series of pulse pairs, and wherein selectively modifying at least one of the switch control signals comprises modifying spacings between pulses of consecutive pulse pairs in the switching control signal to excite the motor transient.

32. The method of claim 24, further comprising selectively initializing rotor flux in the motor during starting prior to selectively modifying at least one of the switch control signals.

33. The method of claim 24, wherein selectively modifying at least one of the switch control signals comprises periodically modifying the switch control signal to excite a motor transient.

34. The method of claim 24, wherein selectively modifying at least one of the switch control signals comprises selectively modifying at least one of the switch control signals at least partially according to an amplitude of the measured transient speed-related signal.