Method and apparatus for detecting phase current imbalance in a power generator

• US 9,063,202 B2
• Filed: 09/15/2008
• Issued: 06/23/2015
• Est. Priority Date: 09/15/2008
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Hendrickson, Matthew, Gottemoller, Benjamin P.
• Primary Examiner(s): Desta, Elias
• Application Number:
  US12/210,853
• Publication Number:
  US 20100066294A1
• Time in Patent Office: 2,472 Days
• Field of Search: 702/58, 702/64, 702/60, 702/117, 324/765, 324/772, 323/229, 123/655, 123/656
• US Class Current: 1/1
• CPC Class Codes: B60L 2200/36 Vehicles designed to transport cargo, e.g. trucks
• 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 3/0069 relating to the isolation, e.g. ground fault or leak current
• 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: G01R 29/16 Measuring asymmetry of polyphase networks
• CPC Class Codes: G01R 31/42 AC power supplies
• 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 controller (500) in an electric drive system is used to determine whether a phase current imbalance in the output winding of a power generator (204) exists. During operation, the controller (500) receives a set of power generator diagnostic values corresponding to the phase currents output by the power generator (204). Next, the controller (500) determines a set of expected operating phase current values. The controller (500) then compares the obtained diagnostic values to one or more corresponding expected operating values. If the difference is greater than a threshold, the controller (500) provides an appropriate fault indication indicative of a phase current imbalance.

Claims

1. A method for determining a malfunction condition of a diode within a rectifier circuit in an electric drive system, the electric drive system including a prime mover disposed to provide an output and a power generator with a rotating portion coupled with the output of the prime mover, and an output winding disposed to provide a generator output to the rectifier circuit, the method comprising:

receiving a set of diagnostic values associated with the output winding of the power generator, the set of diagnostic values including a first phase current value, a second phase current value, and a third phase current value;

comparing the first phase current value, the second phase current value, and the third phase current value; and

setting a diagnostic flag indicating that at least one of the diodes of the rectifier circuit has failed when the ratio of first phase current value to the second phase current value or ratio of the first phase current value to the third phase current value exceeds a threshold.

2. The method of claim 1, wherein the power generator is a multi-phase AC synchronous generator.

3. The method of claim 2, wherein the first phase current value, the second phase current value, and third phase current value are root mean square (rms) values.

4. The method of claim 3, wherein the threshold corresponds to a ratio of about 1.2.

5. The method of claim 4, wherein the rectifier circuit comprises a first leg with at least a first diode, a second leg with at least a second diode, and a third leg with at least a third diode and wherein the first phase current value corresponds to the phase current supplied to the first leg, the second phase current value corresponds to the current supplied to the second leg, and the third phase current value corresponds to the current supplied to the third leg.

6. The method of claim 5, further comprising:

setting a diagnostic flag indicating that the first diode of the rectifier circuit has failed when the ratio of the first phase current value to the second phase current value or ratio of the first phase current value to the third phase current value exceeds a threshold.

7. The method of claim 6, further comprising:

setting an additional diagnostic flag indicating that the first diode specifically has failed when the first phase current value has an opposite direction of current flow than the second phase current value and the third phase current value.

8. A controller disposed to monitor the imbalance of phase current supplied at the output of a power generator in an electric drive system including an engine, the power generator, and a rectifier circuit, the power generator including a rotating portion coupled with the output of the engine, and an output winding coupled to the rectifier circuit and disposed to provide a first phase current, a second phase current and a third phase current, the controller comprising:

an input receiving portion configured to receive a first value corresponding to the first phase current, a second value corresponding to the second phase current and a third value corresponding to the third phase current;

a logic portion configured to compare the first value, the second value and the third value; and

an indicator portion configured to set a diagnostic flag when the ratio of first value to the second value or ratio of the first value to the third value exceeds a threshold.

9. The controller of claim 8, wherein the first value, the second value, and third value are root mean square (rms) values.

10. The controller of claim 9, wherein the threshold corresponds to a ratio of about 1.2.

11. The controller of claim 10, wherein the rectifier circuit comprises a first leg with at least a first diode, a second leg with at least a second diode, and a third leg with at least a third diode and wherein the first value corresponds to the phase current supplied to the first leg, the second value corresponds to the current supplied to the second leg, and the third value corresponds to the current supplied to the third leg.

12. The controller of claim 11 wherein the indicator portion is further disposed to set a diagnostic flag indicating that the first diode of the rectifier circuit has failed when the ratio of the first value to the second value or ratio of the first value to the third value exceeds a threshold.

13. The controller of claim 12 wherein the indicator portion is further disposed to set a diagnostic flag indicating that the at least first diode has failed when the first value corresponds to a current supplied to the first leg that has a direction of flow being opposite than a direction of flow of current supplied to the second leg and to the third leg.

14. A power circuit configured to perform diagnostic monitoring of phase current supplied at the output of a power generator in an electric drive system including an engine, the power generator including a rotating portion coupled with the output of the engine, and an output winding disposed to provide a first phase current, a second phase current and a third phase current:

a rectifier circuit coupled to the output of the generator; and

a controller configured to receive a first value corresponding to the first phase current, a second value corresponding to the second phase current, and a third value corresponding to the third phase current, the controller being further configured to compare the first value, the second value and the third value, and to set a diagnostic flag indicating a phase current imbalance condition based upon the comparison.

15. The power circuit of claim 14, the first value, the second value, and third value correspond to root mean square (rms) current values.

16. The power circuit of claim 15, wherein the controller sets the diagnostic flag when the ratio of the first value compared to the second value exceeds about 1.2.

17. The power circuit of claim 14, wherein the rectifier circuit comprises a first leg with at least a first diode, a second leg with at least a second diode, and a third leg with at least a third diode and wherein the first value corresponds to the phase current supplied to the first leg, the second value corresponds to the current supplied to the second leg, and the third value corresponds to the current supplied to the third leg.

18. The power circuit of claim 17 wherein the controller sets a diagnostic flag indicating that the first diode of the rectifier circuit has failed when the ratio of the first value to the second value or the ratio of the first value to the third value exceeds a threshold.

19. The power circuit of claim 18 wherein the controller is further disposed to set a diagnostic flag indicating that the first diode, specifically, has failed when the phase current supplied to the first leg is in an opposite current flow direction than the current supplied to the second leg and the current supplied to the third leg of the rectifier.

20. The power circuit of claim 19 further comprising:

a DC link coupled to the rectifier circuit;

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.