Controller and method for transitioning between control angles

• US 9,912,263 B2
• Filed: 07/10/2017
• Issued: 03/06/2018
• Est. Priority Date: 08/10/2009
• Status: Active Grant

• Current Assignee: Copeland Corporation LLC (Emerson Electric Company)
• Original Assignee: Emerson Climate Technologies Incorporated (Emerson Electric Company)
• Inventors: Green, Charles E., Marcinkiewicz, Joseph G.
• Primary Examiner(s): Ismail, Shawki S
• Assistant Examiner(s): IMTIAZ, ZOHEB S
• Application Number:
  US15/645,983
• Publication Number:
  US 20170310251A1
• Time in Patent Office: 239 Days
• CPC Class Codes: H02M 1/0025 Arrangements for modifying reference values, feedback values or error values in the control loop of a converter
• CPC Class Codes: H02M 1/0085 Partially controlled bridges
• CPC Class Codes: H02M 1/4225 using a non-isolated boost converter
• CPC Class Codes: H02M 3/1584 with a plurality of power processing stages connected in parallel
• CPC Class Codes: H02P 6/06 Arrangements for speed regulation of a single motor wherein the motor speed is measured and compared with a given physical value so as to adjust the motor speed
• CPC Class Codes: H02P 6/20 Arrangements for starting H02P6/08 takes precedence
• CPC Class Codes: H02P 6/34 Modelling or simulation for control purposes
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

A control system for a refrigeration system motor includes an angle determination module that generates an output rotor angle indicating a desired angle of a rotor of the motor. A control module controls the motor based on the output rotor angle. An estimator module determines an estimated rotor angle. A transition module generates a transition signal in response to convergence of the estimator module. Upon startup, the angle determination module generates the output rotor angle based on a first rotor angle. Upon generation of the transition signal, the angle determination module generates the output rotor angle based on the first rotor angle and the estimated rotor angle. After generation of the transition signal, the angle determination module reduces a contribution of the first rotor angle to the output rotor angle over time until the output rotor angle is based on the estimated rotor angle independent of the first rotor angle.

Claims

1. A control system for a motor in a refrigeration system, the control system comprising:

an angle determination module configured to generate an output rotor angle indicative of a desired angle of a rotor of the motor;

a control module configured to control current supplied to the motor based on the output rotor angle;

an estimator module configured to determine an estimated rotor angle of the motor; and

a transition module configured to generate a transition signal in response to convergence of the estimator module,

wherein the angle determination module is configured to;

upon startup of the motor, generate the output rotor angle based on a first rotor angle,

upon generation of the transition signal, generate the output rotor angle based on both (i) the first rotor angle and (ii) the estimated rotor angle, and

subsequent to generation of the transition signal, reduce a contribution of the first rotor angle to the output rotor angle over time until the output rotor angle is based on the estimated rotor angle independent of the first rotor angle.

2. The control system of claim 1 further comprising an angle generation module configured to generate the first rotor angle in response to a commanded speed of the motor.

3. The control system of claim 2 further comprising:

a rate limiting module configured to generate the commanded speed by applying an upper limit to a rate of change of a requested speed,

wherein the angle generation module is configured to generate the first rotor angle by integrating the commanded speed.

4. The control system of claim 1, wherein the transition module is further configured to generate the transition signal in response to at least one of:

an estimated speed of the motor exceeding a predetermined speed;

a commanded speed of the motor exceeding a predetermined threshold; and

a time period since startup of the motor exceeding a predetermined period.

5. The control system of claim 1, wherein the angle determination module is configured to, upon startup of the motor, generate the output rotor angle based on the first rotor angle independent of the estimated rotor angle.

6. The control system of claim 1, wherein:

the angle determination module is configured to, upon generation of the transition signal, generate the output rotor angle based on (i) the estimated rotor angle and (ii) an offset value, and

the offset value is based on a difference between (i) the first rotor angle at a time when the transition signal is generated and (ii) the estimated rotor angle at the time when the transition signal is generated.

7. The control system of claim 6, wherein the angle determination module is configured to, upon generation of the transition signal, generate the output rotor angle based on a sum of (i) the estimated rotor angle and (ii) the offset value.

8. The control system of claim 7, wherein the angle determination module is configured to, subsequent to generation of the transition signal, decrease the offset value to zero over time.

9. The control system of claim 1, wherein the angle determination module is configured to, subsequent to generation of the transition signal, adjust the output rotor angle to reduce a difference between the output rotor angle and the estimated rotor angle over time.

10. The control system of claim 1 further comprising a pulse-width modulation (PWM) module configured to control switching of an inverter that powers the motor,

wherein the PWM module drives the inverter with a PWM waveform based on the output rotor angle.

11. A system comprising:

the control system of claim 1;

the motor; and

at least one of (i) a compressor driven by the motor, (ii) a condenser fan driven by the motor, and (iii) an evaporator fan driven by the motor.

12. A control method for a motor in a refrigeration system, the method comprising:

generating an output rotor angle indicative of a desired angle of a rotor of the motor;

controlling current supplied to the motor based on the output rotor angle;

determining an estimated rotor angle of the motor; and

generating a transition signal in response to convergence of the estimated rotor angle,

wherein the generating the output rotor angle includes;

upon startup of the motor, generating the output rotor angle based on a first rotor angle,

upon generation of the transition signal, generate the output rotor angle based on both (i) the first rotor angle and (ii) the estimated rotor angle, and

subsequent to generation of the transition signal, reduce a contribution of the first rotor angle to the output rotor angle over time until the output rotor angle is based on the estimated rotor angle independent of the first rotor angle.

13. The method of claim 12 further comprising generating the first rotor angle in response to a commanded speed of the motor.

14. The method of claim 13 further comprising:

generating the commanded speed by applying an upper limit to a rate of change of a requested speed,

wherein the first rotor angle is generated by integrating the commanded speed.

15. The method of claim 12, further comprising at least one of:

generating the transition signal in response to an estimated speed of the motor exceeding a predetermined speed;

generating the transition signal in response to a commanded speed of the motor exceeding a predetermined threshold; and

generating the transition signal in response to a time period since startup of the motor exceeding a predetermined period.

16. The method of claim 12, wherein the generating the output rotor angle includes, upon startup of the motor, generating the output rotor angle based on the first rotor angle independent of the estimated rotor angle.

17. The method of claim 12, wherein:

the generating the output rotor angle includes, upon generation of the transition signal, generating the output rotor angle based on (i) the estimated rotor angle and (ii) an offset value, and

the offset value is based on a difference between (i) the first rotor angle at a time when the transition signal is generated and (ii) the estimated rotor angle at the time when the transition signal is generated.

18. The method of claim 17, wherein the generating the output rotor angle includes, upon generation of the transition signal:

generating the output rotor angle based on a sum of (i) the estimated rotor angle and (ii) the offset value; and

decreasing the offset value to zero over time.

19. The method of claim 12, wherein the generating the output rotor angle includes, subsequent to generation of the transition signal, adjusting the output rotor angle to reduce a difference between the output rotor angle and the estimated rotor angle over time.

20. The method of claim 12 further comprising driving an inverter that powers the motor with a pulse-width modulation (PWM) waveform based on the output rotor angle.