Method and apparatus for speed reversal control of motor drive

• US 9,716,460 B2
• Filed: 01/28/2015
• Issued: 07/25/2017
• Est. Priority Date: 01/28/2015
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Al-nabi, Ehsan, Nondahl, Thomas, Liu, Jingbo, Royak, Semyon, Schmidt, Peter B., Dai, Jingya
• Primary Examiner(s): Santana, Eduardo Colon
• Assistant Examiner(s): Bouziane, Said
• Application Number:
  US14/607,505
• Publication Number:
  US 20160218657A1
• Time in Patent Office: 909 Days
• Field of Search: 318254
• CPC Class Codes: H02M 7/00 Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
• CPC Class Codes: H02M 7/48 using discharge tubes with control electrode or semiconductor devices with control electrode
• CPC Class Codes: H02P 27/08 with pulse width modulation
• CPC Class Codes: H02P 6/08 Arrangements for controlling the speed or torque of a single motor H02P6/10, H02P6/28 take precedence
• CPC Class Codes: H02P 6/21 Open loop start
• CPC Class Codes: H02P 6/30 Arrangements for controlling the direction of rotation H02P6/22 takes precedence

Abstract

Motor drive control apparatus and methods are presented for speed reversal control for drives used with output filters and transformers using a high or maximal drive current command to facilitate dissipation of regenerative energy seen in this system during speed reversal with open loop control to reverse the spin direction of a driven motor while quickly transitioning through zero speed.

Claims

1. A method for speed reversal control in a motor drive with an inverter driving a motor through an output filter and a transformer to reverse rotation of the motor from a first direction to an opposite second direction, the method comprising:

generating pulse width modulation control signals to operate the inverter to drive the motor according to a high or maximal drive current command using closed loop control while the motor is rotating in the first direction at a motor frequency having an absolute value greater than a predetermined threshold frequency; and

generating pulse width modulation control signals to operate the inverter to drive the motor using open loop control according to the high or maximal drive current command while the motor is rotating in the first direction at a motor frequency having an absolute value less than or equal to the predetermined threshold frequency to transition the motor speed through zero to reverse rotation of the motor from the first direction to the second direction.

2. The method of claim 1, comprising:

while the motor is rotating in the first direction at a backspin frequency, generating pulse width modulation control signals for operation of the inverter at least partially according to the high or maximal drive current command;

transitioning a motor frequency reversal command at a first ramp rate from the backspin frequency towards zero while generating the pulse width modulation control signals at least partially according to the high or maximal drive current command and at least partially according to the motor frequency reversal command until a motor frequency reaches a first predetermined frequency while the motor continues to rotate in the first direction;

in response to the motor frequency reaching the first predetermined frequency, quickly transitioning the motor frequency reversal command at a second ramp rate from the first predetermined frequency in the first direction to a second predetermined frequency in the opposite second direction while generating the pulse width modulation control signals using open loop control at least partially according to the high or maximal drive current command and at least partially according to the motor frequency reversal command, the second ramp rate being faster than the first ramp rate; and

in response to the motor frequency reaching the second predetermined frequency, resuming normal control to drive the motor in the second direction by generating the pulse width modulation control signals for operation of the inverter at least partially according to a target drive current command and a target motor frequency command.

3. The method of claim 2, comprising determining an operating motor frequency while the motor is rotating in the first direction at least partially according to measured or calculated voltages.

4. The method of claim 3, comprising determining the operating motor frequency while the motor is rotating in the first direction at least partially according to measured voltages at an output of the inverter or measured voltages at an output of the output filter.

5. The method of claim 3, comprising determining the operating motor frequency while the motor is rotating in the first direction at least partially according to command voltages calculated for generating the pulse width modulation control signals.

6. The method of claim 1, comprising determining an operating motor frequency while the motor is rotating in the first direction at least partially according to measured or calculated voltages.

7. The method of claim 6, comprising determining the operating motor frequency while the motor is rotating in the first direction at least partially according to measured voltages at an output of the inverter or measured voltages at an output of the output filter.

8. The method of claim 6, comprising determining the operating motor frequency while the motor is rotating in the first direction at least partially according to command voltages calculated for generating the pulse width modulation control signals.

9. The method of claim 1, comprising:

operating the inverter to drive the motor using closed loop current control according to the high or maximal drive current command and closed loop velocity control while the motor is rotating in the first direction to facilitate dissipation of regenerative energy in the motor drive; and

operating the inverter to drive the motor using closed loop current control according to the high or maximal drive current command and open loop velocity control while transitioning the motor speed through zero to reverse rotation of the motor from the first direction to the second direction.

10. A non-transitory computer readable medium with computer executable instructions for:

generating pulse width modulation control signals to operate an inverter circuit to drive a motor according to a high or maximal drive current command using closed loop control while the motor is rotating in a first direction at a motor frequency having an absolute value greater than a predetermined threshold frequency; and

generating pulse width modulation control signals to operate the inverter circuit to drive the motor using open loop control according to the high or maximal drive current command while the motor is rotating in the first direction at a motor frequency having an absolute value less than or equal to the predetermined threshold frequency to transition the motor speed through zero to reverse rotation of the motor from the first direction to an opposite second direction.

11. The non-transitory computer readable medium of claim 10, comprising computer executable instructions for:

determining an operating motor frequency while the motor is rotating in the first direction at least partially according to measured or calculated voltages.

12. The non-transitory computer readable medium of claim 11, comprising computer executable instructions for:

determining the operating motor frequency while the motor is rotating in the first direction at least partially according to measured voltages at an output of the inverter or measured voltages at an output of the output filter.

13. The non-transitory computer readable medium of claim 11, comprising computer executable instructions for:

determining the operating motor frequency while the motor is rotating in the first direction at least partially according to command voltages calculated for generating the pulse width modulation control signals.

14. A power conversion system, comprising:

an inverter comprising a plurality of switching devices operative according to pulse width modulated inverter switching control signals to convert DC power to drive an AC motor load through an output filter and a transformer; and

a controller (20) including at least one processor operatively coupled with an electronic memory, the at least one processor programmed to reverse rotation of the motor from a first direction to an opposite second direction by;

generating the pulse width modulated inverter switching control signals to drive the motor at least partially according to a high or maximal drive current command using closed loop control while the motor is rotating in the first direction at a motor frequency having an absolute value greater than a predetermined threshold frequency; and

generating the pulse width modulated inverter switching control signals to drive the motor using open loop control according to the high or maximal drive current command while the motor is rotating in the first direction at a motor frequency having an absolute value less than or equal to the predetermined threshold frequency to transition the motor speed through zero to reverse rotation of the motor from the first direction to the second direction.

15. The power conversion system of claim 14, wherein the at least one processor is programmed to:

generate pulse width modulation control signals for operation of the inverter at least partially according to a high or maximal drive current command while the motor is rotating in the first direction at a backspin frequency;

transition a motor frequency reversal command at a first ramp rate from the backspin frequency towards zero while generating the pulse width modulation control signals at least partially according to the high or maximal drive current command and at least partially according to the motor frequency reversal command until a motor frequency reaches a first predetermined frequency while the motor continues to rotate in the first direction;

in response to the motor frequency reaching the first predetermined frequency, quickly transition the motor frequency reversal command at a second ramp rate from the first predetermined frequency in the first direction to a second predetermined frequency in the opposite second direction while generating the pulse width modulation control signals using open loop control at least partially according to the high or maximal drive current command and at least partially according to the motor frequency reversal command, the second ramp rate being faster than the first ramp rate; and

in response to the motor frequency reaching the second predetermined frequency, resume normal control to drive the motor in the second direction by generating the pulse width modulation control signals for operation of the inverter at least partially according to a target drive current command and a target motor frequency command.

16. The power conversion system of claim 14, wherein the at least one processor is programmed to:

determine an operating motor frequency while the motor is rotating in the first direction at least partially according to measured or calculated voltages.

17. The power conversion system of claim 16, wherein the at least one processor is programmed to:

determine the operating motor frequency while the motor is rotating in the first direction at least partially according to measured voltages at an output of the inverter or measured voltages at an output of the output filter.

18. The power conversion system of claim 16, wherein the at least one processor is programmed to:

determine the operating motor frequency while the motor is rotating in the first direction at least partially according to command voltages calculated for generating the pulse width modulation control signals.