Motor drive voltage-boost control

• US 8,004,220 B2
• Filed: 07/08/2005
• Issued: 08/23/2011
• Est. Priority Date: 07/10/2004
• Status: Active Grant

• Current Assignee: TRW Limited (Zeppelin - Stiftung der Stadt Friedrichshafen)
• Original Assignee: TRW Limited (Zeppelin - Stiftung der Stadt Friedrichshafen)
• Inventors: Sparey, Malcolm Eric, Szabo, Adrian, Chen, Yangsheng, White, Graham William, Williams, Connel Brett, Coles, Jeffrey Ronald
• Primary Examiner(s): Ro; Bentsu
• Application Number:
  US11/632,111
• Publication Number:
  US 20080265808A1
• Time in Patent Office: 2,237 Days
• Field of Search: 318/700, 318/400.01, 318/400.14, 318/400.22, 318/400.24, 318/400.26, 318/400.3, 318/400.41, 318720-724, 318/479, 318/504
• US Class Current: 318/400.22
• 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 6/16 Circuit arrangements for detecting position
• CPC Class Codes: H02P 6/182 using back-emf in windings

Abstract

A drive system for a motor having a rotor and a phase winding (a, b, c) comprises; a drive circuit including switch means associated with the winding a, b, c for varying the current passing through the winding; rotor position sensing means arranged to sense the position of the rotor; control means arranged to provide drive signals to control the switch means; a power input for connection to a power supply at a nominal voltage; and boost means in electric communication with the power input and power output, and controllable to boost the nominal voltage to a higher voltage for application to the winding.

Claims

1. A drive system for a motor having a rotor and at least one phase winding, the system comprising:

a drive circuit including at least one switch associated with the winding for varying the current passing through the winding;

a rotor position sensing device arranged to sense the position of the rotor;

a power input for connection to a power supply at a nominal voltage;

a boost circuit in electric communication with the power input, and controllable to boost the nominal voltage to a higher boosted voltage for application to the winding; and

a controller arranged to provide drive signals to control the at least one switch, the controller being operable to define a current demand and a required phase advance angle of the current passing through the at least one winding relative to the magnetic field of the rotor, the controller being further operable to control the potential difference applied to the at least one winding to achieve the demanded current and the required phase advance, and to control the boosted voltage output by the boost circuit, wherein the controller is arranged to define the phase angle so that it will vary with the speed of the motor.

2. A system according to claim 1 wherein the controller is arranged to provide voltage boost for motor speeds above a predetermined boost introduction speed.

3. A system according to claim 2 wherein the controller is arranged to increase the voltage boost in a stepped manner when the motor speed reaches the boost introduction speed.

4. A system according to claim 2 wherein the controller is arranged to increase the voltage boost with increasing motor speeds over a range of motor speeds from the boost introduction speed to a higher full boost speed.

5. A system according to claim 1 wherein the controller is arranged to control the phase of the current to produce a varying phase advance of the current relative to the rotor position.

6. A system according to claim 5 wherein the controller is arranged to increase the phase advance with increasing motor speed for speeds above a phase advance introduction speed.

7. A system according to claim 6 wherein the controller is arranged to set the phase advance to zero over at least a range of zero phase advance motor speeds below the phase advance introduction speed.

8. A system according to claim 6 wherein the controller is arranged to provide a non-zero phase advance over a range of increased phase advance motor speeds below the phase advance introduction speed.

9. A system according to claim 8 wherein the controller is arranged, within the range of increased phase advance motor speeds, to provide a phase advance that increases with motor speed up to a maximum phase advance.

10. A system according to claim 9 wherein the controller is arranged within the range of increased phase advance motor speeds to provide a phase advance that decreases with motor speed from the maximum phase advance.

11. A system according to claim 8 wherein the controller is arranged to provide voltage boost for motor speeds above a predetermined boost introduction speed and further wherein the range of increased phase advance motor speeds includes a range of speeds immediately below the boost introduction speed.

12. A system according to claim 11 wherein the range of increased phase advance motor speeds includes the boost introduction speed.

13. A system according to claim 12 wherein the range of increased phase advance motor speeds includes a range of speeds immediately above the boost introduction speed.

14. A system according to claim 6 wherein the controller is arranged to provide voltage boost for motor speeds above a predetermined boost introduction speed and further wherein the phase advance introduction speed is greater than the boost introduction speed.

15. A drive system for a motor having a rotor and a phase winding, the system comprising:

a drive circuit including at least one switch associated with the winding for varying the current passing through the winding;

a power input for connection to a power supply at a nominal voltage;

a boost circuit in electric communication with the power input, the boost circuit controllable to boost the nominal voltage to a higher boosted voltage for application to the winding, wherein the at least one parameter includes the level of boost provided by the boost circuit; and

a controller arranged to provide drive signals to control the at least one switch, the controller being operable to determine a maximum current limit for the power supply and the magnitude of the current from the power supply and, the controller also being operable to control at least one control parameter of the motor thereby to limit the magnitude of the current from the power supply to the maximum current limit determined by the controller.

16. A drive system for a motor having a rotor and a phase winding, the system comprising:

a drive circuit including at least one switch associated with the winding for varying the current passing through the winding;

a power input for connection to a power supply at a nominal voltage; and

a controller arranged to provide drive signals to control the at least one switch, the controller being operable to determine a maximum current limit for the power supply and the magnitude of the current from the power supply, the controller also being operable to control at least one control parameter of the motor thereby to limit the magnitude of the current from the power supply to the maximum current limit determined by the controller with the at least one parameter including phase advance with the phase advance being the angle that motor phase current is advanced relative to a back emf produced by the motor.

17. A drive system for a motor having a rotor and a phase winding, the system comprising:

a drive circuit including at least one switch associated with the winding for varying the current passing through the winding;

a power input for connection to a power supply at a nominal voltage; and

a controller arranged to provide drive signals to control the at least one switch, the controller being operable to determine a maximum current limit for the power supply and the magnitude of the current from the power supply and, the controller also being operable to control at least one control parameter of the motor that includes at least one of a q-axis current limit and an over-modulation level thereby to limit the magnitude of the current from the power supply to the maximum current limit determined by the controller.

18. A drive system for a motor having a rotor and a plurality of phase winding, the system comprising:

an input arranged to receive a battery current from a battery;

a switching device associated with the winding for varying the current passing through each of the windings;

a dc link arranged to provide an input current to the switching device;

a current sensor arranged to produce a sensor output which is a measure of the current in the dc link;

a low pass filter arranged to average the output from the current sensor to produce an averaged output, and

a controller arranged to receive the current sensor output and the averaged output from the low pass filter to determine the battery current from the averaged output of the current sensor and to calculate the current passing through each of the windings from the sensor output.

19. A drive system according to claim 18 wherein at least one system component is provided between the input and the dc link, and the controller is arranged to determine the battery current from the output of the current sensor using a factor related to the system component.

20. A drive system according to claim 19 wherein the factor is the efficiency of the component.

21. A drive system according to claim 19 wherein the system component is a voltage booster.

22. A drive system according to claim 19 wherein the controller is arranged to determine the factor on the basis of at least one operating parameter of the system.

23. A drive system according to claim 22 wherein the parameter comprises at least one of the input voltage of the booster, the output voltage of the booster, the link current, and the temperature.

24. A drive system for a motor having a rotor and a phase winding, the system comprising:

a drive circuit including at least one switch associated with the winding for varying the current passing through the winding;

a rotor position sensing device arranged to sense the position of the rotor;

a power input for connection to a power supply at a nominal voltage; and

a boost circuit in electric communication with the power input, the boost circuit controllable to boost the nominal voltage to a higher boosted voltage for application to the winding, the boost circuit including;

a push-pull voltage boost circuit that includes a bifilar wound component having two windings on a common magnetic core, each winding having one end connected to a common first potential;

two active switches arranged to be switched on alternately to connect a respective one of the windings to a second potential thereby to produce a boosted voltage across the pair of windings; and

two further switches arranged to be switched on alternately to connect a respective one of the windings to an output thereby to apply the boosted voltage to the output; and

a controller arranged to provide drive signals to control the at least one switch;

the controller also arranged to define a current demand and a required phase advance of the current passing through the winding relative to the magnetic field of the rotor and to control the potential difference applied to the winding to achieve the demanded current and the required phase advance while also controlling the boosted voltage output with the boost circuit.

25. A drive system according to claim 24 wherein the switches of the boost circuit can all be switched to an off state such that the push-pull voltage boost circuit operates in a passive mode in which current can flow through both of the windings to the output.

26. A drive system according to claim 24 wherein the further switches in the push-pull voltage boost circuit can be switched on to reduce their resistance while the active switches are switched off, so that current can flow through both of the windings to the output through further switches with reduced losses.

27. A drive system according to claim 24 wherein the active switches in the push-pull voltage boost circuit can be turned off and the further switches turned on such that regenerative current can flow from the output through the circuit.