System and method for permanent magnet motor control

• US 9,991,834 B2
• Filed: 04/24/2017
• Issued: 06/05/2018
• Est. Priority Date: 04/26/2012
• Status: Active Grant

• Current Assignee: Copeland Corporation LLC (Emerson Electric Company)
• Original Assignee: Emerson Climate Technologies Incorporated (Emerson Electric Company)
• Inventors: Marcinkiewicz, Joseph G., Green, Charles E., Henderson, Michael I.
• Primary Examiner(s): Santana, Eduardo Colon
• Assistant Examiner(s): Bouziane, Said
• Application Number:
  US15/494,591
• Publication Number:
  US 20170229989A1
• Time in Patent Office: 407 Days
• Field of Search: None
• CPC Class Codes: B60H 1/00428 electric
• CPC Class Codes: F25B 2500/26 characterised by the startup of the refrigeration cycle
• CPC Class Codes: F25B 2600/021 Inverters therefor
• CPC Class Codes: F25B 2700/171 of the compressor
• CPC Class Codes: F25B 49/025 Motor control arrangements
• CPC Class Codes: H02P 21/141 Flux estimation
• CPC Class Codes: H02P 21/18 Estimation of position or speed
• CPC Class Codes: H02P 21/22 Current control, e.g. using a current control loop
• CPC Class Codes: H02P 29/0241 the fault being an overvoltage
• CPC Class Codes: H02P 6/12 Monitoring commutation; Providing indication of commutation failure
• CPC Class Codes: H02P 6/21 Open loop start
• CPC Class Codes: Y02T 10/88 Optimized components or subsystems, e.g. lighting, actively controlled glasses

Abstract

A method of operating an electric motor is disclosed. The method includes: determining a d-axis resistance of an electric motor and a Q-axis resistance of the electric motor as a function of a bulk current; determining a d-axis inductance of the electric motor and a Q-axis inductance of the electric motor as a function of the bulk current; generating an estimated flux of the electric motor based on the d-axis resistance of the electric motor, the Q-axis resistance of the electric motor, the d-axis inductance of the electric motor, and the Q-axis inductance of the electric motor; generating an estimated angle of the electric motor based on the estimated flux of the electric motor; and, based on the estimated angle of the electric motor, controlling switching of an inverter that powers the electric motor.

Claims

1. A system comprising:

a bulk current determination module that determines a bulk current based on a Q-axis current of an electric motor and a d-axis current of the electric motor determined based on measured currents of the electric motor;

a resistance determination module that determines a d-axis resistance of the electric motor and a Q-axis resistance of the electric motor as a function of the bulk current;

an inductance determination module that determines a d-axis inductance of the electric motor and a Q-axis inductance of the electric motor as a function of the bulk current;

a flux estimation module that generates an estimated flux of the electric motor based on the d-axis resistance of the electric motor, the Q-axis resistance of the electric motor, the d-axis inductance of the electric motor, and the Q-axis inductance of the electric motor;

an angle estimation module that generates an estimated angle of the electric motor based on the estimated flux of the electric motor; and

a pulse-width modulation (PWM) module that, based on the estimated angle of the electric motor, controls switching of an inverter that powers the electric motor.

2. The system of claim 1 wherein the bulk current determination module determines a second bulk current based on the Q-axis current of the electric motor and the d-axis current of the electric motor and that determines the bulk current based on the second bulk current and a maximum allowable value of the bulk current.

3. The system of claim 2 wherein the bulk current determination module sets the bulk current equal to the second bulk current divided by the maximum allowable value of the bulk current.

4. The system of claim 1 further comprising a gain setting module that sets a gain,

wherein at least one of:

the resistance determination module determines the d-axis resistance further based on the gain;

the resistance determination module determines the Q-axis resistance further based on the gain;

the inductance determination module determines the d-axis inductance further based on the gain;

the inductance determination module determines the Q-axis inductance further based on the gain; and

the flux estimation module generates the estimated flux of the electric motor further based on the gain.

5. The system of claim 4 wherein the gain setting module sets the gain based on at least one of the d-axis resistance, the Q-axis resistance, the d-axis inductance, and the Q-axis inductance.

6. The system of claim 4 wherein the gain setting module sets the gain based on a first average of the d-axis resistance and the Q-axis resistance and a second average of the d-axis inductance and the Q-axis inductance.

7. The system of claim 4 wherein the gain setting module sets the gain based on a speed of the electric motor.

8. The system of claim 7 further comprising a speed estimation module that generates an estimated speed of the electric motor based on the estimated angle of the electric motor,

wherein the gain setting module sets the gain based on the estimated speed of the electric motor.

9. The system of claim 8 wherein the gain setting module sets the gain based on the bulk current.

10. The system of claim 4 wherein:

the flux estimation module that updates the estimated flux of the electric motor at a first rate; and

the gain setting module updates the gain at a second rate that is equal to or slower than the first rate.

11. A system comprising:

a compressor including an electric motor;

an inverter power module that includes a plurality of switches, that receives direct current (DC) power, and that powers the electric motor;

a bulk current determination module that determines a bulk current based on a Q-axis current of the electric motor and a d-axis current of the electric motor determined based on measured currents of the electric motor;

a resistance determination module that determines a d-axis resistance of the electric motor and a Q-axis resistance of the electric motor as a function of the bulk current;

an inductance determination module that determines a d-axis inductance of the electric motor and a Q-axis inductance of the electric motor as a function of the bulk current;

a flux estimation module that generates an estimated flux of the electric motor based on the d-axis resistance of the electric motor, the Q-axis resistance of the electric motor, the d-axis inductance of the electric motor, and the Q-axis inductance of the electric motor;

an angle estimation module that generates an estimated angle of the electric motor based on the estimated flux of the electric motor; and

a pulse-width modulation (PWM) module that controls switching of the switches of the inverter power module based on the estimated angle of the electric motor.

12. A method comprising:

determining a bulk current based on a Q-axis current of an electric motor and a d-axis current of the electric motor determined based on measured currents of the electric motor;

determining a d-axis resistance of the electric motor and a Q-axis resistance of the electric motor as a function of the bulk current;

determining a d-axis inductance of the electric motor and a Q-axis inductance of the electric motor as a function of the bulk current;

generating an estimated flux of the electric motor based on the d-axis resistance of the electric motor, the Q-axis resistance of the electric motor, the d-axis inductance of the electric motor, and the Q-axis inductance of the electric motor;

generating an estimated angle of the electric motor based on the estimated flux of the electric motor; and

,

based on the estimated angle of the electric motor, controlling switching of an inverter that powers the electric motor.

13. The method of claim 12 further comprising:

determining a second bulk current based on the Q-axis current of the electric motor and the d-axis current of the electric motor; and

determining the bulk current based on the second bulk current and a maximum allowable value of the bulk current.

14. The method of claim 13 further comprising setting the bulk current equal to the second bulk current divided by the maximum allowable value of the bulk current.

15. The method of claim 12 further comprising:

setting a gain; and

at least one of;

determining the d-axis resistance further based on the gain;

determining the Q-axis resistance further based on the gain;

determining the d-axis inductance further based on the gain;

determining the Q-axis inductance further based on the gain; and

generating the estimated flux of the electric motor further based on the gain.

16. The method of claim 15 further comprising setting the gain based on at least one of the d-axis resistance, the Q-axis resistance, the d-axis inductance, and the Q-axis inductance.

17. The method of claim 15 further comprising setting the gain based on a first average of the d-axis resistance and the Q-axis resistance and a second average of the d-axis inductance and the Q-axis inductance.

18. The method of claim 15 further comprising setting the gain based on a speed of the electric motor.

19. The method of claim 18 further comprising:

generating an estimated speed of the electric motor based on the estimated angle of the electric motor; and

setting the gain based on the estimated speed of the electric motor.

20. The method of claim 19 further comprising:

setting the gain based on the bulk current.

21. The method of claim 15 further comprising:

updating the estimated flux of the electric motor at a first rate; and

updating the gain at a second rate that is equal to or slower than the first rate.