Method and apparatus for detecting a short circuit in a DC link

• US 7,996,163 B2
• Filed: 09/15/2008
• Issued: 08/09/2011
• Est. Priority Date: 09/15/2008
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Hendrickson, Matthew, Beach, Frederick, Bailey, Bradley
• Primary Examiner(s): Nghiem; Michael P
• Assistant Examiner(s): Desta; Elias
• Application Number:
  US12/210,888
• Publication Number:
  US 20100066316A1
• Time in Patent Office: 1,058 Days
• Field of Search: 702/58, 702/60, 702/64, 702/117, 363/15, 340/648, 327/104, 324/548, 318/107, 318/400.26, 318/400.3, 307/2, 307/22, 307/26, 290/5, 290/7, 731/145.9, 731/146.1
• US Class Current: 702/58
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/441 Speed
• CPC Class Codes: B60L 3/003 relating to inverters
• CPC Class Codes: B60L 50/13 using AC generators and AC motors
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 7/06 for vehicles propelled by ac motors
• CPC Class Codes: B60W 2510/0638 Engine speed
• CPC Class Codes: B60W 2510/081 Speed
• CPC Class Codes: B60Y 2200/142 Heavy duty trucks
• CPC Class Codes: B60Y 2200/412 Excavators
• CPC Class Codes: G01R 31/007 using microprocessors or computers
• CPC Class Codes: G01R 31/40 Testing power supplies testing photovoltaic devices H02S50/10
• CPC Class Codes: G01R 31/52 Testing for short-circuits, leakage current or ground faults
• CPC Class Codes: H02P 9/006 Means for protecting the generator by using control H02H7/06 takes precedence; control effected upon generator excitation circuit to reduce harmful effects of overloads or transients H02P9/10
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors

Abstract

A system for detecting a short circuit in a direct current (DC) link (312), wherein the DC link (312) is coupled with a rectifier (206) which includes a set of rectifier diode pairs (310). During operation, a controller (500) receives a set of outputs of a power generator 204, a set of machine parameters, and a set of diagnostic values. Next, the controller (500) determines a set of expected operating values corresponding to the set of diagnostic values. The controller (500) then compares diagnostic values to corresponding expected operating values. If the difference between the diagnostic values and the expected operating values exceeds a threshold, the controller (500) provides a flag to indicate that a short circuit condition exists.

Claims

1. A method for detecting a short in a direct current (DC) link for a power circuit in an electric drive coupled with a prime mover, the power circuit including a rectifier circuit having at least a diode pair coupled with a power generator and disposed to provide a DC output voltage to the DC link, the method comprising:

receiving at least one power generator output at a controller;

receiving at least one machine parameter associated with the prime mover at the controller;

receiving a set of diagnostic values associated with the DC link and the at least one power generator output at the controller;

determining a set of expected operating values based on the at least one power generator output and the at least one machine parameter by the controller, the set of expected operating values corresponding to the received set of diagnostic values;

comparing each diagnostic value from the set of diagnostic values to a corresponding expected operating value from the set of expected operating values by the controller to determine a difference for each diagnostic value; and

setting an indicator flag by the controller that a short circuit condition with respect to the DC link exists if the difference between one or more diagnostic values and a corresponding one or more expected values exceeds a threshold.

2. The method of claim 1, wherein the power generator is a multi-phase alternating current (AC) synchronous generator having a rotating input coupled with a prime mover output, an input winding disposed to receive an excitation signal as the at least one power generator output, an output winding magnetically coupled with the input winding and disposed to provide a set of alternator phase currents to the rectifier circuit, wherein each phase current comprises one of the diagnostic values associated with the DC link.

3. The method of claim 2, wherein the at least one machine parameter includes a prime mover output speed.

4. The method of claim 3, wherein the diagnostic values of the set associated with the DC link includes a DC link voltage developed across the DC link and a DC link current provided at the rectifier output.

5. The method of claim 4, wherein the power circuit includes a plurality of diode pairs, and wherein the method further includes identifying a malfunctioning pair from the plurality of diode pairs.

6. The method of claim 5 further including the step of providing an alert in response to setting the indicator flag that specifies the short circuit condition.

7. The method of claim 1, further comprising setting an indicator flag if a difference between a first diagnostic value and a first theoretical diagnostic value does not correlate to a difference between a second diagnostic value and a second theoretical value.

8. The method of claim 6 wherein the step of providing the alert includes activating a visual indicator.

9. A controller disposed to monitor whether a short circuit condition exists in a direct current (DC) link within a power circuit of an electric drive system in a machine that includes a prime mover disposed to provide an output to a power generator, the controller comprising:

an input receiving portion configured to receive;

a set of power generator outputs,

a set of engine parameters associated with the prime mover,

a set of diagnostic values associated with the power generator outputs, and

set of diagnostic values associated with the DC link;

a determination portion configured to determine, based on the set of power generator outputs and the set of engine parameters, a set of expected operating values corresponding to the sets of diagnostic values;

a comparison portion configured to compare each of the diagnostic values for the sets of diagnostic values to a corresponding expected operating value from the set of expected operating values to determine a set of differences;

a logic portion configured to determine whether a short circuit condition in the DC link has occurred based on the set of differences; and

an indicator portion configured to set a flag when the short circuit condition in the DC link has been determined.

10. The controller of claim 9, wherein the power generator is a multi-phase alternating current (AC) synchronous generator having a rotating input coupled with a prime mover output, an input winding disposed to receive an excitation signal, an output winding magnetically coupled with the input winding and disposed to provide a set of alternator phase currents to the rectifier circuit, wherein each phase current from the set of alternator phase currents is associated with a different phase value.

11. The controller apparatus of claim 10, wherein the set engine parameters associated with the engine includes a prime mover output speed.

12. The controller apparatus of claim 11, wherein the set of diagnostic values associated with the power generator outputs includes an excitation value developed at the power generator input winding.

13. The controller apparatus of claim 12, wherein the set of diagnostic values associated with the DC link includes a DC link voltage developed across the DC link and a DC link current developed at the rectifier output.

14. The controller of claim 13, further comprising an identification portion configured to identify a malfunctioning leg of the rectifier circuit based on the phase values of the alternator phase currents developed at the power generator output winding.

15. The controller of claim 9, wherein the logic portion is further configured to determine whether a short circuit condition in the DC link has occurred if a difference between a first diagnostic value and a first expected operating value does not correlate to a difference between a second diagnostic value and a second expected operating value.

16. The controller of claim 9, further including an alert portion responsive to the indicator portion and being configured to activate a visual indicator associated with the controller when the short circuit condition in the DC link has been determined.

17. A system including a power generator associated with an electric drive system in a machine including a prime mover disposed to provide an output coupled with the power generator, the system comprising:

a rectifier circuit coupled to an output of the power generator;

a DC link coupled to the rectifier circuit having a DC link voltage defined between a first DC rail and a second DC rail; and

a controller configured to receive;

a set of generator outputs,

a set of machine parameters associated with the machine, and

a set of diagnostic values associated with the DC link,

the controller being further configured to determine a set of expected operating values of the DC link, to compare the set of diagnostic values with the set of expected values, and to set a flag indicating a short circuit condition between the first DC rail and the second DC rail when the comparison exceeds a threshold.

18. The system of claim 17, wherein the power generator is a multi-phase alternating current (AC) synchronous generator having a input coupled with the output of the prime mover, an input winding disposed to provide at least one of the set of diagnostic values associated with the generator, an output winding magnetically coupled with the input winding and disposed to provide a set of alternator phase currents to the rectifier circuit, wherein the set of diagnostic values associated with the generator includes the set of alternator phase currents.

19. The system of claim 18, wherein the set of machine parameters includes a prime mover output speed.

20. The system of claim 17 further comprising:

an inverter circuit coupled with the DC link;

an output drive coupled with the inverter circuit; and

a retard circuit coupled with the DC link, the inverter circuit, and the output drive and disposed to dissipate retard energy supplied by the output drive through the inverter circuit during a retard mode of operation.