Power supply apparatus capable of detecting abnormality of current flowing through drive circuit

• US 7,355,826 B2
• Filed: 06/09/2005
• Issued: 04/08/2008
• Est. Priority Date: 07/07/2004
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Yagi, Koji, Yaguchi, Hideaki, Ochiai, Kiyoe, Uechi, Tatsuyuki
• Primary Examiner(s): Donovan; Lincoln
• Assistant Examiner(s): BRANDT, MICHAEL J
• Application Number:
  US11/148,345
• Publication Number:
  US 20060007615A1
• Time in Patent Office: 1,034 Days
• Field of Search: 318/434, 361/23, 361/24, 361/28, 361/31, 363/41, 363/97
• US Class Current: 361/23
• CPC Class Codes: B60L 3/0023 Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 10/30 including control of auxiliary equipment, e.g. air-conditioning compressors or oil pumps
• CPC Class Codes: B60W 20/00 Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: B60W 20/50 Control strategies for responding to system failures, e.g. for fault diagnosis, failsafe operation or limp mode

Abstract

A current detection unit starts sampling of a motor current at the timing when the motor current has exceeded a threshold value, and holds a maximum motor current value for each prescribed operation cycle. An abnormality determination unit determines whether the maximum motor current value is greater than the threshold value, and counts the number of times that the maximum motor current value continuously exceeds the threshold value. When the count value has reached at least 3, the abnormality determination unit generates and outputs a detection signal indicating abnormality in the motor current to a relay drive unit and a notification unit. The relay drive unit in receipt of the detection signal generates a signal to turn off the system relays. The notification unit generates and outputs a signal AL to display means outside the power supply apparatus.

Claims

1. A power supply apparatus, comprising:

a CPU having prescribed operation cycles including a shortest operation cycle;

a power supply;

a drive circuit for receiving supply of power from said power supply and driving a load circuit; and

an abnormal current detection circuit for detecting abnormality in a drive current flowing through said drive circuit;

said abnormal current detection circuit including

current detection means for detecting a maximum value of said drive current for each prescribed operation cycle, and

abnormality determination means for determining whether the maximum value of said drive current exceeds a prescribed threshold value for each said prescribed operation cycle, and determining presence of abnormality in said drive current when detecting that the maximum value of said drive current exceeds said prescribed threshold value in each of n (n is a natural number of at least

     3) consecutive cycles of said prescribed operation cycles including a first operation cycle, wherein the first operation cycle is set to the shortest operation cycle of the CPU.

3. The power supply apparatus according to claim 1, wherein

said load circuit includes an AC motor,

said abnormal current detection circuit further includes mode determination means for determining a control mode of said AC motor, and

said abnormality determination means adjusts said prescribed threshold value to a threshold value suitable for the determined control mode, determines whether the detected maximum value of said drive current exceeds said suitable threshold value for each said prescribed operation cycle, and determines presence of abnormality in said drive current when detecting that the maximum value of said drive current exceeds said suitable threshold value in each of said n consecutive prescribed operation cycles.

4. The power supply apparatus according to claim 3, wherein said mode determination means determines one of control modes having different carrier frequencies.

5. The power supply apparatus according to claim 4, wherein said abnormality determination means adjusts said threshold value in accordance with the carrier frequency of said determined control mode.

6. The power supply apparatus according to claim 1, further comprising rotation number detection means for detecting a motor rotation number of said AC motor based on a rotation angle of said AC motor, wherein

said abnormality determination means determines whether the maximum value of said drive current exceeds the prescribed threshold value for each said prescribed operation cycle and whether said motor rotation number is not greater than a prescribed rotation number, and determines presence of abnormality in said drive current when detecting that the maximum value of said drive current exceeds said prescribed threshold value in each of said n consecutive prescribed operation cycles and that said motor rotation number is not greater than said prescribed rotation number.

7. The power supply apparatus according to claim 6, wherein said prescribed rotation number is set smaller than a motor rotation number detected by said rotation number detection means during a normal operation of said power supply apparatus.

8. The power supply apparatus according to claim 1, further comprising a switch for electrically connecting/disconnecting said power supply to/from said drive circuit by an opening/closing operation, wherein

said abnormal current detection circuit controls the opening/closing operation in such a manner that said power supply is electrically disconnected from said drive circuit upon detection of abnormality in said drive current.

9. The power supply apparatus according to claim 8, wherein said prescribed threshold value is set to a current level higher than said drive current flowing in said drive circuit when said power supply apparatus is in a normal operation.

10. The power supply apparatus according to claim 9, wherein a period corresponding to a total sum of said n consecutive prescribed operation cycles is set shorter than a time period causing breaking of said drive circuit when the drive current of a current level corresponding to said prescribed threshold value continuously flows in said drive circuit during the time period.

11. The power supply apparatus according to claim 10, wherein said n is set to 3.

12. The power supply apparatus according to claim 1, wherein

said abnormality determination means includes counting means,

said counting means increments a count value when it is determined that the maximum value of said drive current exceeds said prescribed threshold value and resets said count value when it is determined that the maximum value of said drive current does not exceed said prescribed threshold value in each said prescribed operation cycle, and

said abnormality determination means determines presence of abnormality in said drive current when detecting that said count value has reached a count value equal to said n.

13. The power supply apparatus according to claim 12, wherein said abnormality determination means adjusts said n in accordance with said prescribed threshold value.

14. The power supply apparatus according to claim 13, wherein said abnormality determination means adjusts said n to a smaller value as said prescribed threshold value becomes higher.

15. The power supply apparatus according to claim 12, wherein

said abnormal current detection circuit further includes temperature detection means for detecting a temperature of a circuit element of said drive circuit, and

said abnormality determination means adjusts said n in accordance with said detected temperature of the circuit element.

16. The power supply apparatus according to claim 15, wherein said abnormality determination means adjusts said n to a smaller value as said detected temperature of the circuit element becomes higher.

17. The power supply apparatus according to claim 1, wherein said prescribed operation cycle is longer than a shortest operation cycle of said abnormal current detection circuit.

18. The power supply apparatus according to claim 17, wherein said current detection means samples a drive current in said shortest operation cycle, and extracts and holds a maximum value of said drive current from among said sampled drive currents for each said prescribed operation cycle.

37. The power supply apparatus according to claim 1, further comprising an inverter used to generate a drive current from an AC motor.

2. A power supply apparatus, comprising:

a CPU having prescribed operation cycles including a shortest operation cycle;

a power supply;

a drive circuit for receiving supply of power from said power supply and driving a load circuit; and

an abnormal current detection circuit for detecting abnormality in a drive current flowing through said drive circuit;

said abnormal current detection circuit including

current detection means for starting sampling of said drive current using a prescribed threshold value as a trigger and detecting a maximum value of said drive current for each prescribed operation cycle, and

abnormality determination means for determining whether the maximum value of said drive current exceeds said prescribed threshold value for each said prescribed operation cycle, and determining presence of abnormality in said drive current when detecting that the maximum value of said drive current exceeds said prescribed threshold value in each of n (n is a natural number of at least

     3) consecutive cycles of said prescribed operation cycles including a first operation cycle, wherein the first operation cycle is set to the shortest operation cycle of the CPU.

19. A power supply apparatus, comprising:

a CPU having prescribed operation cycles including a shortest operation cycle;

a power supply;

a drive circuit for receiving supply of power from said power supply and driving a load circuit; and

an abnormal current detection circuit for detecting abnormality in a drive current flowing through said drive circuit;

said abnormal current detection circuit including

a current detection unit for detecting a maximum value of said drive current for each prescribed operation cycle, and

an abnormality determination unit for determining whether the maximum value of said drive current exceeds a prescribed threshold value for each said prescribed operation cycle, and determining presence of abnormality in said drive current when detecting that the maximum value of said drive current exceeds said prescribed threshold value in each of n (n is a natural number of at least

     3) consecutive cycles of said prescribed operation cycles including a first operation cycle, wherein the first operation cycle is set to the shortest operation cycle of the CPU.

21. The power supply apparatus according to claim 19, wherein

said load circuit includes an AC motor,

said abnormal current detection circuit further includes a mode determination unit for determining a control mode of said AC motor, and

said abnormality determination unit adjusts said prescribed threshold value to a threshold value suitable for the determined control mode, determines whether the detected maximum value of said drive current exceeds said suitable threshold value for each said prescribed operation cycle, and determines presence of abnormality in said drive current when detecting that the maximum value of said drive current exceeds said suitable threshold value in each of said n consecutive prescribed operation cycles.

22. The power supply apparatus according to claim 21, wherein said mode determination unit determines one of control modes having different carrier frequencies.

23. The power supply apparatus according to claim 22, wherein said abnormality determination unit adjusts said threshold value in accordance with the carrier frequency of said determined control mode.

24. The power supply apparatus according to claim 19, further comprising rotation number detection means for detecting a motor rotation number of said AC motor based on a rotation angle of said AC motor, wherein

said abnormality determination unit determines whether the maximum value of said drive current exceeds the prescribed threshold value for each said prescribed operation cycle and whether said motor rotation number is not greater than a prescribed rotation number, and determines presence of abnormality in said drive current when detecting that the maximum value of said drive current exceeds said prescribed threshold value in each of said n consecutive prescribed operation cycles and that said motor rotation number is not greater than said prescribed rotation number.

25. The power supply apparatus according to claim 24, wherein said prescribed rotation number is set smaller than a motor rotation number detected by said rotation number detection means during a normal operation of said power supply apparatus.

26. The power supply apparatus according to claim 19, further comprising a switch for electrically connecting/disconnecting said power supply to/from said drive circuit by an opening/closing operation, wherein

said abnormal current detection circuit controls the opening/closing operation in such a manner that said power supply is electrically disconnected from said drive circuit upon detection of abnormality in said drive current.

27. The power supply apparatus according to claim 26, wherein said prescribed threshold value is set to a current level higher than said drive current flowing in said drive circuit when said power supply apparatus is in a normal operation.

28. The power supply apparatus according to claim 27, wherein a period corresponding to a total sum of said n consecutive prescribed operation cycles is set shorter than a time period causing breaking of said drive circuit when the drive current of a current level corresponding to said prescribed threshold value continuously flows in said drive circuit during the time period.

29. The power supply apparatus according to claim 28, wherein said n is set to 3.

30. The power supply apparatus according to claim 19, wherein

said abnormality determination unit includes counting unit,

said counting unit increments a count value when it is determined that the maximum value of said drive current exceeds said prescribed threshold value and resets said count value when it is determined that the maximum value of said drive current does not exceed said prescribed threshold value in each said prescribed operation cycle, and

said abnormality determination unit determines presence of abnormality in said drive current when detecting that said count value has reached a count value equal to said n.

31. The power supply apparatus according to claim 30, wherein said abnormality determination unit adjusts said n in accordance with said prescribed threshold value.

32. The power supply apparatus according to claim 31, wherein said abnormality determination unit adjusts said n to a smaller value as said prescribed threshold value becomes higher.

33. The power supply apparatus according to claim 30, wherein

said abnormal current detection circuit further includes temperature detection means for detecting a temperature of a circuit element of said drive circuit, and

said abnormality determination unit adjusts said n in accordance with said detected temperature of the circuit element.

34. The power supply apparatus according to claim 33, wherein said abnormality determination unit adjusts said n to a smaller value as said detected temperature of the circuit element becomes higher.

35. The power supply apparatus according to claim 19, wherein said prescribed operation cycle is longer than a shortest operation cycle of said abnormal current detection circuit.

36. The power supply apparatus according to claim 35, wherein said current detection unit samples a drive current in said shortest operation cycle, and extracts and holds a maximum value of said drive current from among said sampled drive currents for each said prescribed operation cycle.

20. A power supply apparatus, comprising:

a CPU having prescribed operation cycles including a shortest operation cycle;

a power supply;

a drive circuit for receiving supply of power from said power supply and driving a load circuit; and

an abnormal current detection circuit for detecting abnormality in a drive current flowing through said drive circuit;

said abnormal current detection circuit including

a current detection unit for starting sampling of said drive current using a prescribed threshold value as a trigger and detecting a maximum value of said drive current for each prescribed operation cycle, and

an abnormality determination unit for determining whether the maximum value of said drive current exceeds said prescribed threshold value for each said prescribed operation cycle, and determining presence of abnormality in said drive current when detecting that the maximum value of said drive current exceeds said prescribed threshold value in each of n (n is a natural number of at least

     3) consecutive cycles of said prescribed operation cycles including a first operation cycle, wherein the first operation cycle is set to the shortest operation cycle of the CPU.