Electronic commutation method and related apparatus

• US 7,573,224 B2
• Filed: 08/26/2005
• Issued: 08/11/2009
• Est. Priority Date: 08/26/2005
• Status: Active Grant

• Current Assignee: BWI Company Limited SA (Shougang Corporation)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Crabill, Monty L., Disser, Robert J.
• Primary Examiner(s): Benson; Walter
• Assistant Examiner(s): MCCLOUD, RENATA D
• Application Number:
  US11/212,952
• Publication Number:
  US 20070046234A1
• Time in Patent Office: 1,446 Days
• Field of Search: None
• US Class Current: 318/599
• CPC Class Codes: H02P 6/15 Controlling commutation time

Abstract

A method and apparatus for electronic commutation of a pulse width modulation (PWM) controlled motor involves temporarily increasing the frequency of one or more PWM drive signals applied to the motor upon the occurrence of an asynchronous commutation event.

Claims

1. A method of controlling an electronically commutated motor having multiple phase windings by applying PWM drive signals in accordance with a series of commutation states, where a commutation event occurs when a rotor moves from a position associated with one commutation state to a position associated with another commutation state, the method comprising the steps of:

(a) applying PWM drive signals at a set frequency on a cyclical basis;

(b) responsive to occurrence of a commutation event that is asynchronous with and occurs during an ongoing PWM drive signal cycle at the set frequency, increasing the frequency of PWM drive signals applied during the ongoing PWM drive signal cycle to a frequency above the set frequency in order to reach the end of the ongoing PWM drive signal cycle more quickly than without such a frequency increase; and

wherein the set frequency is X, in step (b), the frequency is increased to a frequency Y and, after completion of the ongoing PWM drive signal cycle at frequency Y, the frequency is subsequently decreased to a frequency Z, which is greater than X and less than Y.

2. The method of claim 1, wherein in step (b), the frequency Y is an integer multiple of the set frequency X.

3. The method of claim 1, wherein in step (b), the frequency Y is a non-integer multiple of the set frequency X.

4. The method of claim 1 wherein the electronically commutated motor is one of a rotary motor or a linear motor.

5. A motor arrangement including the electronically commutated motor of claim 1, comprising:

a motor control system associated with the electronically commutated motor of claim 1 and operating to carry out method steps (a) and (b) of claim 1.

6. A method for operating a motor control system in which motor phase windings are energized by PWM drive signals in accordance with a series of commutation states, where a commutation event occurs when a rotor moves from a position associated with one commutation state to a position associated with another commutation state, the method comprising the steps of:

(a) detecting a commutation event that is asynchronous with an ongoing PWM drive signal of an initial frequency being applied to a motor phase winding; and

(b) responsive to detection step (a), at least temporarily increasing the frequency of the ongoing PWM drive signal to a frequency above the initial frequency in order to reach an end of cycle of the ongoing PWM drive signal more quickly than without such a frequency increase; and

wherein the initial frequency of the ongoing PWM drive signal is X, in step (b) the frequency of the ongoing PWM drive signal is increased to a frequency Y and, after the end of cycle of the ongoing PWM drive signal at frequency Y, frequency of a next PWM drive signal is decreased to a frequency Z, which is greater than X and less than Y.

7. The method of claim 6 wherein upon completion of the cycle for the next PWM drive signal at frequency Z, frequency of a next PWM drive signal is set back to frequency X.

8. The method of claim 6 wherein the electronically commutated motor is one of a rotary motor or a linear motor.

9. A motor arrangement including the electronically commutated motor of claim 6, comprising:

a motor control system associated with the electronically commutated motor of claim 6 and operating to carry out method steps (a) and (b) of claim 6.

10. A motor control system comprising:

a motor having multiple phase windings and a movable rotor, the position of the rotor defines multiple commutation states for the phase windings;

a sensor arrangement for indicating the occurrence of commutation events when the rotor moves from a position associated with one commutation state to a position associated with another commutation state; and

a controller for selectively energizing the phase windings with PWM drive signals, the controller operatively connected with the sensor arrangement and operable, upon occurrence of a commutation event that is asynchronous to an ongoing PWM drive signal of an initial frequency, to increase the frequency of the ongoing PWM drive signal to a frequency above the initial frequency in order to reach an end of cycle for the ongoing PWM drive signal more quickly than without such a frequency increase; and

wherein the initial frequency of the ongoing PWM drive signal is X, the increased frequency of the ongoing PWM drive signal is Y, and at the end of cycle of the ongoing PWM drive signal at frequency Y, a next PWM drive signal cycle is initiated at a frequency Z, where Z is between X and Y.

11. The motor control system of claim 10, wherein each phase winding is driven by a complementary pair of electronic switching devices associated with the controller.

12. The motor control system of claim 11, wherein each complementary pair of electronic switching devices comprise HI side device and a LO side device.

13. The motor control system of claim 10, wherein the sensor arrangement outputs rotor position signals to the controller.

14. The motor control system of claim 13, wherein a change in output from the sensor arrangement acts as an interrupt to the controller, causing the controller to increase the frequency of the ongoing PWM drive signal.

15. The motor control system of claim 13, wherein the controller determines, based upon receipt of said motor position signals, when an asynchronous commutation event occurs.

16. The motor control system of claim 10, wherein the motor comprises one of a rotary motor and a linear motor.

17. The motor control system of claim 10, wherein upon completion of the cycle for the next PWM drive signal at frequency Z, frequency of a next PWM drive signal is set back to frequency X.