Motor drive control system and method for controlling the same

• US 8,040,083 B2
• Filed: 03/16/2007
• Issued: 10/18/2011
• Est. Priority Date: 03/24/2006
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Okamura, Masaki, Yaguchi, Hideaki
• Primary Examiner(s): Ro; Bentsu
• Assistant Examiner(s): GLASS, ERICK DAVID
• Application Number:
  US12/224,848
• Publication Number:
  US 20090021198A1
• Time in Patent Office: 1,677 Days
• Field of Search: 318/139, 318/812, 318/434, 180/65.1, 180/65.21, 180/65.225, 180/65.25
• US Class Current: 318/139
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 6/365 with the gears having orbital motion
• CPC Class Codes: B60K 6/445 Differential gearing distribution type
• CPC Class Codes: B60L 2240/525 Temperature of converter or components thereof
• CPC Class Codes: B60L 2270/14 of noise
• CPC Class Codes: B60L 2270/142 acoustic
• CPC Class Codes: B60L 3/00 Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption methods or circuit arrangements for monitoring or controlling batteries or fuel cells B60L58/00
• 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: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 58/14 Preventing excessive discharging
• CPC Class Codes: B60L 58/15 Preventing overcharging
• CPC Class Codes: B60L 58/27 by heating
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• 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 2510/08 Electric propulsion units
• CPC Class Codes: F02N 2011/0888 DC/DC converters
• 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 27/06 using dc to ac converters or inverters H02P27/05 takes precedence
• CPC Class Codes: H02P 29/032 Preventing damage to the motor, e.g. setting individual current limits for different drive conditions
• 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

In a motor drive control system configured to include a converter capable of stepping up the voltage, when the locked state of MG2 operating as an electric motor does not occur (NO in S130), a voltage command value VHref for the converter output voltage is set according to respective required voltages of MG1 operating as an electric generator and MG2 (S140). In contrast, when the locked state of MG2 occurs (YES in S130), the voltage command value VHref is set to a limit voltage Vlmt or less for limiting the voltage step-up by the converter (S150, S180). When the locked state occurs, the converter output voltage is decreased and accordingly the DC voltage switched by the inverter is lowered, so that a switching loss at the switching device forming a part of the inverter is reduced and the temperature increase due to the heat generation can be suppressed.

Claims

1. A motor drive control system comprising:

a DC power supply;

a converter configured to be able to step up an output voltage of said DC power supply and configured to variably control the output voltage of said DC power supply according to a voltage command value to output the output voltage to a DC power supply line;

an electric motor;

a first inverter performing electric power conversion, by means of a plurality of switching devices, between a DC power on said DC power supply line and an AC power for driving said electric motor such that said electric motor operates according to an operational command;

an electric generator configured such that the electric generator can be rotationally driven by an external force;

a second inverter performing electric power conversion, by means of a plurality of switching devices, between a DC power on said DC power supply line and an AC power for driving said electric generator such that said electric generator operates according to an operational command;

voltage setting means for setting said voltage command value for said converter according to respective operational states of said electric motor and said electric generator;

lock detecting means for detecting a locked state of said electric motor;

voltage limiting means for setting said voltage command value to lower one of said voltage command value set by said voltage setting means and a predetermined limit voltage when said lock detecting means detects said locked state; and

power generation ensuring means for supplying electric power from said electric generator to said DC power supply line when said lock detecting means detects the locked state of said electric motor.

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

said voltage setting means includes:

first setting means for calculating said voltage command value that is to be set according to the operational state of said electric motor;

second setting means for calculating said voltage command value that is to be set according to the operational state of said electric generator; and

third setting means for setting said voltage command value for said converter to larger one of respective voltage command values calculated by said first setting means and said second setting means.

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

said power generation ensuring means sets said limit voltage such that electric power can be supplied from said electric generator to said DC power supply line when the locked state of said electric motor is detected.

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

said second inverter includes a rectifying device connected in parallel with said plurality of switching devices each such that electric power generated by said electric generator can be directed to said DC power supply line, and

when said lock detecting means detects said locked state, said power generation ensuring means turns off said switching devices each in said second inverter and increases rotational speed of said electric generator such that an amplitude of an AC voltage induced in said electric generator is larger than a voltage on said DC power supply line.

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

said motor drive control system is mounted on a vehicle including an engine operated by combustion of fuel,

said electric motor is configured to generate a driving force for said vehicle, and

said electric generator is configured to generate electric power by being rotationally driven by at least a part of an output of said engine, when said engine is operating.

6. The motor drive control system according to claim 5, further comprising:

stall detecting means for detecting a stall state in which both of an accelerator pedal and a brake pedal of said vehicle are operated; and

operational region limiting means generating, when said lock detecting means detects said locked state and said stall detecting means detects said stall state, an operational command value for said electric motor for limiting operational regions of said electric motor and said electric generator within a predetermined low-rotational-speed region and low-output-torque region.

7. A motor drive control system mounted on a vehicle, comprising:

a DC power supply;

a converter configured to be able to step up an output voltage of said DC power supply and configured to variably control the output voltage of said DC power supply according to a voltage command value to output the output voltage to a DC power supply line;

an electric motor configured to generate a driving force for said vehicle;

a first inverter performing electric power conversion, by means of a plurality of switching devices, between a DC power on said DC power supply line and an AC power for driving said electric motor such that said electric motor operates according to an operational command; and

lock detecting means for detecting a locked state of said electric motor, wherein

an engine operated by combustion of fuel and a starting electric motor supplied, from said DC power supply line, with a voltage higher than the output voltage of said DC power supply, for starting said engine are further mounted on said vehicle, and

said motor drive control system further comprises start limiting means for limiting start of said engine when said lock detecting means detects the locked state of said electric motor.

8. The motor drive control system according to claim 7, wherein

said starting electric motor is formed of a motor generator configured to be able to generate electric power by being rotationally driven by at least a part of an output of said engine, when said engine is operating, and to be able to start said engine by generating a torque for rotationally driving said engine, when said engine is stopping.

9. A motor drive control system mounted on a vehicle, comprising:

a DC power supply;

a converter configured to be able to step up an output voltage of said DC power supply and configured to variably control the output voltage of said DC power supply according to a voltage command value to output the output voltage to a DC power supply line;

an electric motor configured to generate a driving force for said vehicle;

a first inverter performing electric power conversion, by means of a plurality of switching devices, between a DC power on said DC power supply line and an AC power for driving said electric motor such that said electric motor operates according to an operational command; and

lock detecting means for detecting a locked state of said electric motor, wherein

an engine operated by combustion of fuel and a starting electric motor supplied, from said DC power supply line, with a voltage higher than the output voltage of said DC power supply for starting said engine are further mounted on said vehicle, and

said motor drive control system further comprises start ensuring means for temporarily increasing said voltage command value for said converter to a required voltage of said starting electric motor only within a predetermined period of time required for starting said engine, when said lock detecting means detects said locked state and said engine is instructed to start.

10. A method for controlling a motor drive control system,

said motor drive control system including:

a DC power supply;

a converter configured to be able to step up an output voltage of said DC power supply and configured to variably control the output voltage of said DC power supply according to a voltage command value to output the output voltage to a DC power supply line;

an electric motor;

a first inverter performing electric power conversion, by means of a plurality of switching devices, between a DC power on said DC power supply line and an AC power for driving said electric motor such that said electric motor operates according to an operational command;

an electric generator configured such that the electric generator can be rotationally driven by an external force; and

a second inverter performing electric power conversion, by means of a plurality of switching devices, between a DC power on said DC power supply line and an AC power for driving said electric generator such that said electric generator operates according to an operational command, and

said method comprising the steps of;

setting said voltage command value for said converter according to respective operational states of said electric motor and said electric generator;

detecting a locked state of said electric motor;

limiting said voltage command value to lower one of said voltage command value that is set according to the operational state of said electric motor and a predetermined limit voltage when said locked state is detected; and

ensuring power generation by said electric generator such that electric power is supplied from said electric generator to said DC power supply line when the locked state of said electric motor is detected.

11. The method for controlling the motor drive control system according to claim 10, wherein

said step of setting said voltage command value includes:

a first sub step of calculating said voltage command value that is to be set according to the operational state of said electric motor;

a second sub step of calculating said voltage command value that is to be set according to the operational state of said electric generator; and

a third sub step of setting said voltage command value for said converter to larger one of respective voltage command values calculated by said first sub step and said second sub step.

12. The method for controlling the motor drive control system according to claim 10, wherein

said step of ensuring power generation sets said limit voltage such that electric power can be supplied from said electric generator to said DC power supply line when the locked state of said electric motor is detected.

13. The method for controlling the motor drive control system according to claim 10, wherein

said second inverter includes a rectifying device connected in parallel with said plurality of switching devices each such that electric power generated by said electric generator can be directed to said DC power supply line, and

when the locked state of said electric motor is detected, said step of ensuring power generation turns off said switching devices each in said second inverter and increases rotational speed of said electric generator such that an amplitude of an AC voltage induced in said electric generator is larger than a voltage on said DC power supply line.

14. The method for controlling the motor drive control system according to claim 10, wherein

said motor drive control system is mounted on a vehicle including an engine operated by combustion of fuel, and said electric motor is configured to generate a driving force for said vehicle, and

said electric generator is configured to generate electric power by being rotationally driven by at least a part of an output of said engine, when said engine is operating.

15. The method for controlling the motor drive control system according to claim 14, further comprising the steps of:

detecting a stall state in which both of an accelerator pedal and a brake pedal of said vehicle are operated; and

generating, when said locked state of said electric motor is detected and said stall state is detected, an operational command value for said electric motor for limiting operational regions of said electric motor and said electric generator within a predetermined low-rotational-speed region and low-output-torque region.

16. A method for controlling a motor drive control system mounted on a vehicle,

said motor drive control system including:

a DC power supply;

a converter configured to be able to step up an output voltage of said DC power supply and configured to variably control the output voltage of said DC power supply according to a voltage command value to output the output voltage to a DC power supply line;

an electric motor configured to generate a driving force for said vehicle; and

a first inverter performing electric power conversion, by means of a plurality of switching devices, between a DC power on said DC power supply line and an AC power for driving said electric motor such that said electric motor operates according to an operational command,

an engine operated by combustion of fuel and a starting electric motor supplied, from said DC power supply line, with a voltage higher than the output voltage of said DC power supply, for starting said engine being further mounted on said vehicle, and

said method comprising the steps of;

detecting a locked state of said electric motor; and

limiting start of said engine when the locked state of said electric motor is detected.

17. The method for controlling the motor drive control system according to claim 16, wherein

said starting electric motor is formed of a motor generator configured to be able to generate electric power by being rotationally driven by at least a part of an output of said engine, when said engine is operating, and to be able to start said engine by generating a torque for rotationally driving said engine, when said engine is stopping.

18. A method for controlling a motor drive control system mounted on a vehicle,

said motor drive control system including

a DC power supply;

a converter configured to be able to step up an output voltage of said DC power supply and configured to variably control the output voltage of said DC power supply according to a voltage command value to output the output voltage to a DC power supply line;

an electric motor configured to generate a driving force for said vehicle; and

a first inverter performing electric power conversion, by means of a plurality of switching devices, between a DC power on said DC power supply line and an AC power for driving said electric motor such that said electric motor operates according to an operational command,

an engine operated by combustion of fuel and a starting electric motor supplied, from said DC power supply line, with a voltage higher than the output voltage of said DC power supply, for starting said engine being further mounted on said vehicle, and

said method comprising the steps of;

detecting a locked state of said electric motor; and

temporarily increasing said voltage command value for said converter to a required voltage of said starting electric motor only within a predetermined period of time required for starting said engine, when the locked state of said electric motor is detected and said engine is instructed to start.