Motor drive system

• US 7,893,637 B2
• Filed: 10/26/2006
• Issued: 02/22/2011
• Est. Priority Date: 10/27/2005
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Suhama, Masayoshi, Sato, Eiji, Okamura, Masaki
• Primary Examiner(s): Benson; Walter
• Assistant Examiner(s): Dinh; Thai
• Application Number:
  US12/091,892
• Publication Number:
  US 20090243522A1
• Time in Patent Office: 1,580 Days
• Field of Search: 318/400.02, 318/400.15, 318/400.3, 318/711, 318/714, 318/717, 318719-722, 318/366, 318/375, 318/376, 318/434, 180/271, 180/275, 180/65.1, 180/65.3, 180/309, 180/68.5
• US Class Current: 318/376
• CPC Class Codes: B60L 15/02 characterised by the form of the current used in the control circuit
• CPC Class Codes: B60L 15/025 using field orientation; Vector control; Direct Torque Control [DTC]
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 50/13 using AC generators and AC motors
• CPC Class Codes: B60L 50/15 with additional electric power supply with capacitors charged by engine-driven generators B60L50/40; with batteries charged by engine-driven generators B60L50/61
• CPC Class Codes: B60L 7/16 for vehicles comprising converters between the power source and the motor
• CPC Class Codes: H02P 21/00 Arrangements or methods for the control of electric machines by vector control, e.g. by control of field orientation
• CPC Class Codes: H02P 21/06 Rotor flux based control involving the use of rotor position or rotor speed sensors
• CPC Class Codes: H02P 21/20 Estimation of torque
• CPC Class Codes: H02P 2201/09 Boost converter, i.e. DC-DC step up converter increasing the voltage between the supply and the inverter driving the motor general aspects of plural converters in cascade H02M
• CPC Class Codes: H02P 2205/05 Torque loop, i.e. comparison of the motor torque with a torque reference
• CPC Class Codes: H02P 29/0241 the fault being an overvoltage
• CPC Class Codes: H02P 3/18 for stopping or slowing an ac motor
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• 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

Abstract

In a drive system of an AC motor in which a motor current is feedback-controlled, a motor current command is produced in a normal operation according to a torque command value on an optimum efficiency characteristic line so as to select an optimum current phase maximizing an output torque with a constant motor current amplitude. Conversely, when the AC motor produces an excessively generated power exceeding a regeneratable power quantity of the AC motor, a consuming operation is performed for intentionally increasing the power loss in the AC motor. In the consuming operation, the motor current command is produced according to the torque command value on a loss increase characteristic line to change the current phase from the above optimum value. Thereby, the power loss in the AC motor can be increased to consume the surplus power without causing instability in the motor control.

Claims

1. A motor drive system for driving an AC motor, comprising:

a motor drive circuit being capable of bidirectionally supplying and receiving a power to and from the AC motor, and supplying a drive power to said AC motor; and

motor control means for controlling an operation of said motor drive circuit, wherein

said motor control means performs a consuming operation of consuming a surplus power determined depending on a state of said motor drive system by said AC motor, and performs a follow-up operations of causing an output torque to follow changes in torque command value while keeping said consuming operation when said torque command value to said AC motor changes during said consuming operation.

2. The motor drive system according to claim 1, wherein

said motor control means drives said AC motor with a current phase relatively lowering drive efficiency of said AC motor according to increase in the determined surplus power in said consuming operation.

3. The motor drive system according to claim 1, wherein

said motor control means has power estimating means for estimating a power generated by said AC motor based on the a rotation angular speed of said AC motor and said torque command value, and determines said surplus power consumed by said consuming operation according to the generated power estimated by said power estimating means.

4. The motor drive system according to claim 1, wherein

said motor drive circuit is capable of bidirectionally supplying and receiving the power to and from a rechargeable DC power supply,

said motor drive system further comprises a voltage detector detecting a voltage on an interconnection electrically connecting said motor drive circuit and said DC power supply together, and

said motor control means determines said surplus power consumed by said consuming operation according to the voltage detected by said voltage detecting means.

5. The motor drive system according to claim 1, wherein

said AC motor is mounted on a vehicle, and an output shaft of said AC motor is connected to a wheel of said vehicle for torque transmission, and

said motor control means determines said surplus power to be consumed by said consuming operation according to a braking force required in said vehicle.

6. The motor drive system according to claim 1, wherein

said motor control means has characteristic storing means for storing in advance a correlation between said torque command value and a current command corresponding to said surplus power consumption of the same magnitude in said AC motor, and produces said current command according to said torque command value and the determined surplus power based on said correlation stored in said characteristic storing means.

7. The motor drive system according to claim 1, wherein

said motor control means includes:

loss increase setting means for setting a motor loss command indicating a power loss to be increased in said AC motor corresponding to the determined surplus power,

current command producing means for producing a current command for a motor current passing through said AC motor according to said torque command value of said AC motor and said motor loss command determined based on said loss increase setting means, and current control means for controlling the operation of said motor drive circuit to generate said motor current in accordance with said current command produced by said current command producing means; and

said current command producing means produces said current command such that the output torque of said AC motor matches with said torque command value and drive efficiency of said AC motor relatively lowers according to increase in said power loss caused by said motor loss command.

8. The motor drive system according to claim 7, wherein said motor control means further includes:

rectangular wave voltage control means for controlling the operation of said motor drive circuit to apply a rectangular wave voltage of a phase depending on said torque command value to said AC motor,

control mode selecting means for selecting one of said current control means and said rectangular wave voltage control means according to the operation state of said AC motor, and

control mode correcting means for cancelling the selection by said control mode select means and selecting said current control means according to said motor loss command determined by said loss increase setting means when said control mode select means selects said rectangular wave voltage control means; and

when said control mode correcting means selects said current control means, said current command producing means produces said current command in a region of drive efficiency of said AC motor lower than that achieved by the motor drive using said rectangular wave voltage control means.

9. The motor drive system according to claim 1, wherein

said motor drive system drives a plurality of said AC motors,

said motor drive circuit and said motor control means are arranged corresponding to each of said AC motors, and each of said motor drive circuits is capable of bidirectionally supplying and receiving the power to and from a rechargeable common power supply,

said motor drive system further comprises distributing means for setting consumption surplus powers in said plurality of AC motors, respectively, such that a whole of said plurality of AC motors consumes said surplus power, and

each of said motor control means controls corresponding one of said AC motors to perform the consuming operation of consuming corresponding one of said consumption surplus powers determined by said distributing means.

10. The motor drive system according to claim 9, wherein

said distributing means includes:

upper limit setting means for calculating the consumable surplus powers of said plurality of AC motors, respectively, based on a present operation state in the corresponding AC motor, and,

distribution determining means for setting the consumption surplus powers in respective said plurality of AC motors such that each of said consumption surplus powers is within a range of the corresponding consumable surplus power calculated by said upper limit setting means.

11. The motor drive system according to claim 9, wherein

said distributing means includes distribution determining means for setting the consumption surplus powers in said plurality of AC motors, respectively, in view of temperatures of said plurality of AC motors.

12. The motor drive system according to claim 9, wherein

said distributing means includes:

upper limit setting means for calculating, for respective said AC motors, the surplus powers each being consumable within a predetermined time based on a present operation state of the corresponding AC motor and

distribution determining means for setting the consumption surplus powers in respective said AC motors such that each of said consumption surplus powers is within a range of the corresponding surplus power being consumable within the predetermined time calculated by said upper limit setting means.

13. The motor drive system according to any one of the preceding claims 9 to 12, wherein

said plurality of AC motors include:

a drive motor generating a wheel drive force of a vehicle, and

a non-drive motor not directly generating said wheel drive power; and

said distributing means sets consumption surplus powers in said respective AC motors such that said non-drive motor consumes the surplus power on a priority basis.