Method and device for operating a brushless motor

• US 9,312,796 B2
• Filed: 05/23/2012
• Issued: 04/12/2016
• Est. Priority Date: 05/24/2011
• Status: Active Grant

• Current Assignee: Continental Automotive GmbH (Continental AG)
• Original Assignee: Continental Automotive GmbH (Continental AG)
• Inventors: Donner, Andreas, Gurzawski, Timo, Gyri, Csaba, Sofronescu, Bogdan
• Primary Examiner(s): Ismail, Shawki S
• Assistant Examiner(s): Carrasquillo, Jorge L
• Application Number:
  US14/119,518
• Publication Number:
  US 20140077736A1
• Time in Patent Office: 1,420 Days
• Field of Search: 318/400.21, 318/400.22, 318/563, 318/782, 318/400.26, 318/799, 318/809, 701/39, 701/43, 701/62, 701/76, 701/92, 701/97, 701/107, 701/31.9
• US Class Current: 1/1
• CPC Class Codes: B62D 5/0484 for reaction to failures, e.g. limp home
• CPC Class Codes: B62D 5/0487 detecting motor faults B62D5/0496 takes precedence
• CPC Class Codes: H02H 7/1225 responsive to internal faults, e.g. shoot-through avoiding shoot-through H02M1/38
• 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: H02P 6/085 in a bridge configuration
• CPC Class Codes: H02P 6/12 Monitoring commutation; Providing indication of commutation failure

Abstract

The invention relates to a method for operating a brushless electric motor, the windings of which are controlled by an inverter using six switches, wherein the inverter comprises three outputs, which are associated with the windings of the electric motor, and wherein a respective power semiconductor switch is arranged between the output of the inverter and the windings, and wherein a detection unit for detecting defective switches, a unit for measuring the voltage at the outputs of the inverter, and a microcontroller for controlling switches are provided. The invention further relates to a device operating a brushless electric motor. In order not to damage the power semiconductor switches, according to the invention of the inverter is switched off by the microcontroller after a defective switch has been detected, such that no additional power is introduced in the windings (U, V, W) of the electric motor and the power semiconductor switches are opened in a predetermined motor angle position (φU, φv, φw). For said purpose, the motor angle positions (φu, φv, φw) are associated with a respective winding (U, V, W) and the power semiconductor switches thereof and are selected such that the associated power semiconductor switches are not damaged during opening.

Claims

1. A method for operating a brushless electric motor with an AC converter comprising three outputs allocated to the windings (U, V, W) of the electric motor, a respective power semiconductor switch arranged between each output of the AC converter and windings (U, V, W) of the brushless electric motor, a plurality of supply voltage switches, a detection unit, a measuring unit and a microcontroller, the method comprising:

detecting, by the detection unit, defective switches,

measuring, by the measuring unit, the voltage at the outputs of the AC converter,

monitoring, by current comparators, a voltage drop across the power semiconductor switches,

determining, by the microcontroller, motor position angles (φ

U, φ

V, φ

W) based on the voltage drop across the power semiconductor switches, and

controlling, by the microcontroller, the plurality of supply voltage switches and the power semiconductor switches, such that after detecting a defective switch, the plurality of supply voltage switches are switched off such that power is no longer introduced into the windings (U, V, W) of the electric motor, and such that the power semiconductor switches are switched off in succession at previously defined motor position angles (φ

U, φ

V, φ

W) respectively.

2. The method as claimed in claim 1, wherein the motor position angles (φ

U, φ

V, φ

W) are allocated in each case to a winding (U, V, W) and to the power semiconductor switch thereof and are selected in such a manner that the allocated power semiconductor switches are not damaged during the opening process.

3. The method as claimed in claim 1, wherein the motor position angles (φ

U, φ

V, φ

W) are selected in such a manner that the drain current (ID) prevailing at the power semiconductor switches is zero or almost zero.

4. The method as claimed in claim 1, wherein the motor position angles (φ

U, φ

V, φ

W) are selected in such a manner that the drain current (ID) prevailing at the power semiconductor switches is negative.

5. The method as claimed in claim 1, wherein the motor position angles (φ

U, φ

V, φ

W)are not dependent upon the position of the defective switch and are defined solely in dependence upon the rotation direction of the electric motor.

6. A device for operating a brushless electric motor, the device comprising:

an AC converter including three outputs allocated to the windings (U, V, W) of the electric motor;

a respective power semiconductor switch arranged between each output of the AC converter and windings (U, V, W) of the brushless electric motor;

a plurality of supply voltage switches;

a detection unit for detecting defective switches;

a measuring unit for measuring the voltage at the outputs of the AC converter;

and a microcontroller for controlling the plurality of supply voltage switches and the power semiconductor switches such that after the detection of a defective switch by the microcontroller, the plurality of supply voltage switches are switched OFF such that power is no longer introduced into the windings (U, V, W) of the electric motor, and such that the power semiconductor switches are switched OFF in succession at previously defined motor position angles (φ

U, φ

V, φ

W) respectively, wherein current comparators are provided, which current comparators monitor a voltage drop across the power semiconductor switches, and the microcontroller determines the motor position angles (φ

U, φ

V, φ

W) with the aid of this information.

7. The device as claimed in claim 6, wherein the microcontroller is designed so as to allocate the motor position angles (φ

U, φ

V, φ

W) in each case to a winding (U, V, W) and to the power semiconductor switch thereof and to select said power semiconductor switches in such a manner that the allocated power semiconductor switches are not damaged during the opening process.

8. The device as claimed in claim 6, wherein the microcontroller is designed so as to select the motor position angles (φ

U, φ

V, φ

W) in such a manner that the drain current (ID) prevailing at the power semiconductor switches is zero, almost zero or negative.

9. The device as claimed in claim 6, wherein the power semiconductor switches are embodied as power MOSFET transistors.

10. The device as claimed in claim 6, wherein the unit for detecting defective switches and the unit for measuring voltage at the outputs of the AC converter are integrated into the microcontroller.

11. The device as claimed in claim 6, wherein a motor position angle sensor is provided for determining the motor position angle (φ

).

12. A device for operating a brushless electric motor the windings (U, V, W) of which are controlled by an AC converter with the aid of six switches, wherein the AC converter comprises three outputs that are allocated to the windings (U, V, W) of the electric motor and wherein a power semiconductor switch is arranged in each case between the outputs of the AC converter and the windings (U, V, W) and wherein a detection unit for detecting defective switches, a unit for measuring the voltage at the outputs of the AC converter and a microcontroller for controlling the switches and the power semiconductor switches is provided, wherein the microcontroller is designed so as to switch off the AC converter after the detection of a defective switch by the microcontroller in such a manner that power is no longer introduced into the windings (U, V, W) of the electric motor and the microcontroller is further designed so as to open the power semiconductor switches in succession in a previously defined motor position angle (φ

U, φ

V, φ

W), wherein current comparators are provided, which current comparators monitor a voltage drop across the power semiconductor switches, and the microcontroller determines the motor position angles (φ

U, φ

V, φ

W ) with the aid of this information.