System and method of electric motor fault detection

• US 9,618,582 B2
• Filed: 10/30/2014
• Issued: 04/11/2017
• Est. Priority Date: 10/30/2014
• Status: Active Grant

• Current Assignee: Delphi Technologies Ip Limited (BorgWarner Incorporated)
• Original Assignee: Delphi Technologies, Inc. (Aptiv PLC)
• Inventors: Walters, James E.
• Primary Examiner(s): Nguyen, Tung X
• Application Number:
  US14/528,074
• Publication Number:
  US 20160124049A1
• Time in Patent Office: 894 Days
• CPC Class Codes: G01R 31/34 Testing dynamo-electric machines
• CPC Class Codes: G01R 31/343 in operation
• CPC Class Codes: G01R 31/50 Testing of electric apparatus, lines, cables or components for short-circuits, continuity, leakage current or incorrect line connections testing of sparking plugs H01T13/58
• CPC Class Codes: H02P 6/007 wherein the position is detected using the ripple of the current caused by the commutation

Abstract

A system for detecting faults in a motor includes a drive circuit, a detection circuit, and a controller. The drive circuit is configured to apply a drive signal to a motor. The detection circuit is configured to detect a response signal generated when the drive signal is applied to the motor. The controller is configured to determine a motor fault based on a comparison of the response signal to an expected signal for the drive signal applied to the motor. The drive signal is selected to generate a rotating magnetic field in the motor with a rotation-frequency greater than a maximum mechanical-response-frequency of the motor.

Claims

1. A system for detecting faults in a motor, said system comprising:

a drive circuit configured to apply a drive signal to a motor;

a detection circuit configured to detect a response signal generated when the drive signal is applied to the motor; and

a controller configured to determine a motor fault based on a comparison of the response signal to an expected signal for the drive signal applied to the motor, wherein

the drive signal is selected to generate a rotating magnetic field in the motor with a rotation-frequency greater than a maximum mechanical-response-frequency of the motor.

2. The system in accordance with claim 1, wherein the drive signal includes a ramp-up portion after the drive signal starts, a ramp-down portion before the drive signal ends, and a test portion between the ramp-up portion and the ramp-down portion.

3. The system in accordance with claim 2, wherein the ramp-up portion and the ramp-down portion are configured to reduce current transients.

4. The system in accordance with claim 1, wherein the detection circuit is configured to measure current flowing in one or more phases of the motor, and the response signal is based on current flowing in one or more phases of the motor during a test portion of the drive signal.

5. The system in accordance with claim 4, wherein the response signal is characterized as an average magnitude of current flowing in a phase of the motor.

6. The system in accordance with claim 5, wherein the controller is configured to indicate a motor fault if the average magnitude is less than an open-circuit threshold.

7. The system in accordance with claim 5, wherein the controller is configured to indicate a motor fault if the average magnitude is greater than a short-circuit threshold.

8. The system in accordance with claim 4, wherein the response signal is characterized as a characteristic current derived from currents flowing in each phase of the motor.

9. The system in accordance with claim 8, wherein the controller is configured to indicate a motor fault if the characteristic current differs from the expected value by more than a difference threshold.

10. The system in accordance with claim 9, wherein the characteristic current is based on a transformation of the currents into a rotor reference frame.

11. The system in accordance with claim 1, wherein the controller is configured to determine a present inductance value of a phase of the motor based on the response signal during a test portion of the drive signal.

12. The system in accordance with claim 11, wherein the present inductance value is determined based on a minimum value and a maximum value of current flowing in the phase of the motor during the test portion of the drive signal.

13. The system in accordance with claim 11, wherein the controller is configured to compare the present inductance value to a baseline inductance value, and indicate a motor fault if the present inductance differs from the baseline inductance value by more than an inductance change threshold.

14. A method of detecting faults in a motor, said method comprising:

applying a drive signal to a motor;

detecting a response signal that arises when the drive signal is applied to the motor; and

determining a motor fault based on a comparison of the response signal to an expected signal for the drive signal applied to the motor, wherein

the drive signal is selected to generate a rotating magnetic field in the motor with a rotation-frequency greater than a maximum mechanical-response-frequency of the motor.

15. The method in accordance with claim 14, wherein the response signal defines an average magnitude of current flowing in a phase of the motor, and the method includes

indicating a motor fault if the average magnitude is less than the open-circuit threshold.

16. The method in accordance with claim 14, wherein the response signal defines an average magnitude of current flowing in a phase of the motor, and the method includes

indicating a motor fault if the average magnitude is greater than the short-circuit threshold.

17. The method in accordance with claim 14, wherein the response signal defines a characteristic current derived from currents flowing in each phase of the motor, and the method includes

indicating a motor fault if the characteristic current differs from the expected value by more than a difference threshold.

18. The method in accordance with claim 17, wherein the characteristic current is based on a transformation of the currents into a rotor reference frame.

19. The method in accordance with claim 14, wherein the method includes determining a present inductance value of a phase of the motor based on the response signal;

and

indicating a motor fault if the present inductance differs from a baseline inductance value by more than an inductance change threshold.