Systems and methods for the control and operation of a parallel motor controller architecture

• US 9,209,721 B2
• Filed: 04/29/2014
• Issued: 12/08/2015
• Est. Priority Date: 04/29/2014
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Solodovnik, Eugene V., Karimi, Kamiar J., Liu, Shengyi
• Primary Examiner(s): Ismail, Shawki S
• Assistant Examiner(s): BROWN, BRADLEY R
• Application Number:
  US14/264,423
• Publication Number:
  US 20150311832A1
• Time in Patent Office: 588 Days
• Field of Search: 318/51, 318/99, 318/719, 318/801, 318/807
• US Class Current: 1/1
• CPC Class Codes: B23C 3/16 Working surfaces curved in two directions
• CPC Class Codes: B64C 13/24 Transmitting means
• CPC Class Codes: G05B 19/042 using digital processors G05B19/05 takes precedence
• CPC Class Codes: H02J 1/14 Balancing the load in a network
• CPC Class Codes: H02J 2310/44 for aircrafts
• CPC Class Codes: H02J 3/14 by switching loads on to, or off from, network, e.g. progressively balanced loading
• CPC Class Codes: H02J 4/00 Circuit arrangements for mains or distribution networks not specified as ac or dc
• CPC Class Codes: H02P 5/68 controlling two or more dc dynamo-electric motors H02P5/46, H02P5/60 take precedence
• CPC Class Codes: H04L 12/423 with centralised control, e.g. polling
• CPC Class Codes: H04L 12/433 with asynchronous transmission, e.g. token ring, register insertion
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility

Abstract

A method for real time power control over a plurality of motor controllers by at least one processor on a computer system may include determining a power load demand from a first set of motors, selecting a combination of motor controllers to match the power load demand, assigning a first set of system-wide priorities, configuring a power switching network to connect the first set of motors to the motor controllers, receiving from a control unit a power request for a motor, determining a priority designation for that motor, assigning a second set of system-wide priorities, determining a second power load demand from a second set of motors, wherein the second plurality of active motors comprises the first plurality of active motors and the first motor, selecting a second combination of motor controllers necessary to match the second power load demand, and configuring the power switching network in accordance with the second set of system-wide priorities.

Claims

1. A method for real time power control over a plurality of motor controllers by at least one processor on a computer system, the method comprising:

determining a first power load demand from a first plurality of active motors, wherein the first plurality of active motors is a subset of a plurality of motors;

selecting a first combination of motor controllers of the plurality of motor controllers necessary to provide sufficient power to meet the first power load demand based at least in part on a maximum power output of the plurality of motor controllers;

assigning a first set of system-wide priorities based at least in part on the maximum power output and the first power load demand;

configuring a power switching network such that the first plurality of active motors are electrically connected to the first combination of motor controllers in accordance with the first set of system-wide priorities;

receiving from a first control unit a power request for a first motor, wherein the power request is associated with a first priority level;

determining a first priority designation for the first priority level in relation to the first set of system-wide priorities;

assigning a second set of system-wide priorities based at least in part on the first priority designation and the first set of system-wide priorities;

determining a second power load demand from a second plurality of active motors, wherein the second plurality of active motors comprises the first plurality of active motors and the first motor;

selecting a second combination of motor controllers of the plurality of motor controllers necessary to provide sufficient power to meet the second power load demand; and

configuring the power switching network such that the second plurality of active motors are electrically connected to the second combination of motor controllers in accordance with the second set of system-wide priorities.

2. The method of claim 1, further comprising:

receiving a first signal from a second control unit, wherein the first signal is associated with the power request; and

adjusting the first priority designation based on the first signal and thereby adjusting the second set of system-wide priorities.

3. The method of claim 2, further comprising:

determining that the second power load demand is greater than the maximum power output of the plurality of motor controllers; and

disconnecting a subset of lower priority active motors.

4. The method of claim 2, further comprising:

determining that the second power load demand is greater than the maximum power output of the plurality of motor controllers; and

configuring the power switching network such that the second combination of motor controllers deliver an amount of power to a subset of lower priority active motors that is reduced below an optimal operating amount of power for the subset of lower priority active motors in accordance with the second set of system-wide priorities.

5. The method of claim 4, further comprising:

identifying that the power request is no longer valid;

re-assigning the first set of system-wide priorities; and

configuring the power switching network such that the amount of power delivered to a subset of lower priority active motors is increased back to the optimal operating amount of power for the subset of lower priority active motors in accordance with the first set of system-wide priorities.

6. The method of claim 2, further comprising:

determining that the maximum power output of the plurality of motor controllers has been reduced to a lower maximum power output; and

disconnecting a subset of lower priority active motors.

7. The method of claim 2, further comprising:

determining that the maximum power output of the plurality of motor controllers has been reduced to a lower maximum power output; and

configuring the power switching network such that an amount of power delivered to a subset of lower priority active motors is reduced below an optimal operating level for the subset of lower priority active motors in accordance with the second set of system-wide priorities.

8. The method of claim 1, wherein said first control unit is a bus power control unit.

9. The method of claim 1, wherein said each one of said plurality of motors may be selected from the group comprising a main engine electric start, a starter, a generator, an electronic engine controller, an auxiliary power unit controller, an auxiliary engine electric start, an auxiliary starter generator, a battery auxiliary engine electric start control unit, an electric taxi motor, a cabin air compressor, a hydraulic pump, a nitrogen generation motor, an environmental control system fan, and a cargo chilling motor.

10. The method of claim 2, wherein said second control unit is selected from the group comprising a generator control unit, an electronic engine controller, an auxiliary power unit controller, an auxiliary generator control unit, a battery voltage boost unit controller, an electric taxi controller, an electric brake controller, an air conditioning pack control unit, a hydraulic pump controller, a nitrogen generation system controller, an environmental control system fan controller, and a cargo chilling system controller.

11. A motor control system, comprising:

a plurality of motors;

a plurality of motor controllers configured for parallel electrical connection;

a power switching network electrically connecting the plurality of motors to the plurality of motor controllers; and

a parallel modular converter for dynamically controlling the power switching network, comprising a computer with at least one processor and a non-transitory storage medium having computer executable instructions stored thereon which, when executed on the computer, cause the computer to;

determine a first power load demand from a first plurality of active motors, wherein the first plurality of active motors is a subset of the plurality of motors;

select a first combination of motor controllers of the plurality of motor controllers necessary to provide sufficient power to meet the first power load demand based at least in part on a maximum power output of the plurality of motor controllers;

assign a first set of system-wide priorities based at least in part on the maximum power output and the first power load demand;

configure the power switching network such that the first plurality of active motors are electrically connected to the first combination of motor controllers in accordance with the first set of system-wide priorities;

receive from a first control unit a power request for a first motor, wherein the power request is associated with a first priority level;

determine a first priority designation for the first priority level in relation to the first set of system-wide priorities;

assign a second set of system-wide priorities based at least in part on the first priority designation and the first set of system-wide priorities;

determine a second power load demand from a second plurality of active motors, wherein the second plurality of active motors comprises the first plurality of active motors and the first motor;

select a second combination of motor controllers of the plurality of motor controllers necessary to provide sufficient power to meet the second power load demand; and

configure the power switching network such that the second plurality of active motors are electrically connected to the second combination of motor controllers in accordance with the second set of system-wide priorities.

12. The system of claim 11, wherein said computer executable instructions stored thereon further cause the computer to:

receive a first signal from a second control unit, wherein the first signal is associated with the power request; and

adjust the first priority designation based on the first signal and thereby adjusting the second set of system-wide priorities.

13. The system of claim 12, wherein said computer executable instructions stored thereon further cause the computer to:

determine that the second power load demand is greater than the maximum power output of the plurality of motor controllers; and

disconnect a subset of lower priority active motors.

14. The system of claim 12, wherein said computer executable instructions stored thereon further cause the computer to:

determine that the second power load demand is greater than the maximum power output of the plurality of motor controllers; and

configure the power switching network such that the second combination of motor controllers deliver an amount of power to a subset of lower priority active motors that is reduced below an optimal operating amount of power for the subset of lower priority active motors in accordance with the second set of system-wide priorities.

15. The system of claim 14, wherein said computer executable instructions stored thereon further cause the computer to:

identify that the power request is no longer valid;

re-assign the first set of system-wide priorities; and

configure the power switching network such that the amount of power delivered to a subset of lower priority active motors is increased back to the optimal operating amount of power for the subset of lower priority active motors in accordance with the first set of system-wide priorities.

16. The system of claim 12, wherein said computer executable instructions stored thereon further cause the computer to:

determine that the maximum power output of the plurality of motor controllers has been reduced to a lower maximum power output; and

disconnect a subset of lower priority active motors.

17. The system of claim 12, wherein said computer executable instructions stored thereon further cause the computer to:

determine that the maximum power output of the plurality of motor controllers has been reduced to a lower maximum power output; and

configure the power switching network such that an amount of power delivered to a subset of lower priority active motors is reduced below an optimal operating level for the subset of lower priority active motors in accordance with the second set of system-wide priorities.

18. The system of claim 11, wherein said each one of said plurality of motors may be selected from the group comprising a main engine electric start, a starter, a generator, an electronic engine controller, an auxiliary power unit controller, an auxiliary engine electric start, an auxiliary starter generator, a battery auxiliary engine electric start control unit, an electric taxi motor, a cabin air compressor, a hydraulic pump, a nitrogen generation motor, an environmental control system fan, and a cargo chilling motor.

19. The system of claim 12, wherein said second control unit is selected from the group comprising a generator control unit, an electronic engine controller, an auxiliary power unit controller, an auxiliary generator control unit, a battery voltage boost unit controller, an electric taxi controller, an electric brake controller, an air conditioning pack control unit, a hydraulic pump controller, a nitrogen generation system controller, an environmental control system fan controller, and a cargo chilling system controller.

20. An aircraft having a motor control system, the motor control system comprising:

a plurality of motors;

a plurality of motor controllers configured for parallel electrical connection;

a power switching network electrically connecting the plurality of motors to the plurality of motor controllers; and

a parallel modular converter for dynamically controlling the power switching network, comprising a computer with at least one processor and a non-transitory storage medium having computer executable instructions stored thereon which, when executed on the computer, cause the computer to;

receive a communication including a requested mode and a requested mode power amount;

calculate a maximum power capacity based at least in part on a total number of motor controllers and a power amount associated with each motor controller;

calculate a current power usage based at least in part on what modes are currently running and what power is getting consumed as a result of those running modes;

determine a current power capacity that is currently available for use by taking the difference between the maximum power capacity and the current power usage;

run the requested mode and reduce the current power capacity to account for the running of the requested mode, only if the current power capacity is not less than the requested mode power amount, but if the current power capacity is less than the requested mode power amount, then

determine a requested mode priority designation relative to all other running modes;

run the requested mode at only the current power capacity and then reduce the current power capacity to account for the running of the requested mode, only if the priority of the requested mode is less than or equal to the priority of all other running modes, but if the priority of the requested mode is not less than or equal to the priority of all other currently running modes, then

determine if there exist any lower priority modes having a priority designation only lower than the requested mode priority designation, and if there exist any lower priority modes, then;

determine if the only lower priority modes that exist are first least priority modes having a priority designation only a single level lower than the requested mode priority designation, and if there exist any first least priority modes, then;

determine a first least priority modes total power that is currently used by those first least priority modes, then

partially reduce the first least priority modes total power, direct that partially reduced power to the requested mode, and set the current power capacity to zero, only if it is possible to make a partial reduction of the first least priority modes total power, if it is not possible to make a partial reduction of the first least priority modes total power, then;

completely reduce the first least priority modes total power, direct that completely reduced power to the requested mode, and set the current power capacity to zero;

determine if there exist second least priority modes having a priority designation between the first least priority modes designation level and the requested mode priority designation level, and if there exist any second least priority modes, then

partially reduce the first least priority modes total power, direct that partially reduced power to the requested mode, only if it is possible to make a partial reduction of the first least priority modes total power, if it is not possible to make a partial reduction of the first least priority modes total power, then

completely reduce the first least priority modes total power;

determine a second least priority modes total power that is currently used by those second least priority modes;

partially reduce the second least priority modes total power, direct that partially reduced power to the requested mode, only if it is possible to make a partial reduction of the second least priority modes total power, if it is not possible to make a partial reduction of the second least priority modes total power, then;

completely reduce the first least priority modes total power and the second least priority modes total power, direct that combined completely reduced power to the requested mode, and set the current power capacity to zero.