Method for implementing bootstrap-supply charging in a motor controller at energized motor and motor controller using such a method

• US 8,860,344 B2
• Filed: 02/18/2011
• Issued: 10/14/2014
• Est. Priority Date: 02/18/2010
• Status: Active Grant

• Current Assignee: Danfoss Drives A/S (Danfoss A/S)
• Original Assignee: Danfoss Drives A/S (Danfoss A/S)
• Inventors: Andersen, Henrik Rosendal
• Primary Examiner(s): Masih, Karen
• Application Number:
  US13/577,718
• Publication Number:
  US 20130038259A1
• Time in Patent Office: 1,334 Days
• Field of Search: 318/400.28, 318/400.26, 318/563, 318/400.05, 318/801, 318/400.35, 318/400.32, 318/400.21, 318/400.3, 318/400.02, 318/400.01
• US Class Current: 318/400.28
• CPC Class Codes: H02P 1/029 Restarting, e.g. after power failure
• CPC Class Codes: H02P 27/08 with pulse width modulation
• CPC Class Codes: H02P 6/18 without separate position detecting elements
• CPC Class Codes: H02P 6/20 Arrangements for starting H02P6/08 takes precedence
• CPC Class Codes: H03K 17/567 Circuits characterised by the use of more than one type of semiconductor device, e.g. BIMOS, composite devices such as IGBT
• CPC Class Codes: H03K 2217/0081 Power supply means, e.g. to the switch driver

Abstract

The present invention relates to a motor controller employing bootstrap-capacitor supplies and in particular to the situation where the bootstrap supplies have to be charged, while the motor controller is connected to a spinning and energized motor. The present invention introduces a method of recharging based on choosing a recharging sequence from a set of recharging sequences, where the choice depends on the state of the connected motor and in particular on the back-EMF voltages of the motor.

Claims

1. A method of recharging a controller with inoperative switching elements comprising a bootstrap capacitor and having at least two output phases, the controller being connected to a load generating back-EMFs at the output terminals of the controller, wherein the load is a motor and the controller is a motor controller, the method comprising a recharge sequence for the bootstrap capacitor of each output phase, and selecting each recharge sequence from a set of at least two recharge sequences in relation to or as a function of the back-EMFs of the load, where the choice is based on the spinning of the load in relation to a base frequency, or alternatively the amplitude of the back-EMFs in relation to a base amplitude of the back-EMFs.

2. The method according to claim 1, wherein the recharging sequences are bootstrap-charging processes.

3. The method according to claim 1, wherein the back-EMF is caused by a spinning motor.

4. The method according to claim 1, wherein the motor is a three-phase motor, the motor controller thus being a three-phase motor controller.

5. The method according to claim 1, wherein the set of recharging sequences comprises a high-frequency zone, defined as when the motor spins above an upper threshold level.

6. The method according to claim 5, wherein the set of recharging sequences comprises a low-frequency zone, defined as when the motor spins below a lower threshold level, the lower threshold level possibly being the same as the upper threshold level.

7. The method according to claim 6, wherein the set of recharging sequences further comprises a medium-frequency zone, defined as being below the upper threshold level and/or above the lower threshold level.

8. The method according to claim 1, wherein a first sequence of the set of sequences is to initiate the recharging process of all three phases essentially at the same time.

9. The method according to claim 1, wherein a second sequence in the set of sequences is to initiate the recharging process of two phases essentially at the same time, when they both are negative, optionally at the zero crossing point of one of the two phases, or when they are both lower than a recharge-threshold level, or when they cross having similar negative back-EMF values, the recharging process of third phase then being initiated at its zero-crossing region or when under a recharge-threshold level.

10. The method according to claim 1, wherein a third sequence in the set of sequences is initiation of the charging process of all three phases in succession, when they have negative back-EMF values respectively, optionally at their zero-crossing point or below a recharge threshold level.

11. The method according to claim 10, wherein the first sequence corresponds to the low-frequency zone, the second sequence corresponds to the medium-frequency zone and the third sequence corresponds to the high-frequency zone, and where the set of sequences comprises at least two of the first, second and third sequences.

12. A motor controller including the method according to claim 1.

13. A device including the method according to claim 1.

14. A method to re-start an electric motor, where the motor is re-started subsequently to the bootstrap capacitors of the controller having been recharged according to the recharging process of claim 1.