Multiple inverter system with single controller and related operating method

• US 7,277,304 B2
• Filed: 09/23/2005
• Issued: 10/02/2007
• Est. Priority Date: 09/23/2005
• Status: Expired due to Fees

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations Incorporated (Motors Liquidation Co. GUC Trust)
• Inventors: Stancu, Constantin C., Selogie, Mark L
• Primary Examiner(s): BERHANE, ADOLF D
• Application Number:
  US11/233,840
• Publication Number:
  US 20070070667A1
• Time in Patent Office: 739 Days
• Field of Search: 363/65, 363/71, 363/95, 363/131
• US Class Current: 363/71
• CPC Class Codes: B60L 2210/46 with more than three phases
• CPC Class Codes: B60L 2220/58 with more than three phases
• CPC Class Codes: B60L 2240/526 Operating parameters
• CPC Class Codes: B60L 3/003 relating to inverters
• CPC Class Codes: B60L 3/0092 with use of redundant elements for safety purposes
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 3/12 Recording operating variables ; Monitoring of operating variables
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: H02M 1/32 Means for protecting converters other than automatic disconnection
• CPC Class Codes: H02M 1/325 with means for allowing continuous operation despite a fault, i.e. fault tolerant converters
• CPC Class Codes: H02M 7/493 the static converters being arranged for operation in parallel
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

A multiple DC-to-AC inverter system, which is suitable for an electric or hybrid vehicle application, includes a plurality of inverters controlled by a single controller. One example embodiment includes four three-phase inverters driving one six-phase motor, where the output of the first inverter is coupled to the output of the fourth inverter and the output of the second inverter is coupled to the output of the third inverter. In response to the failure of an inverter, the drive signals to the inverter that is coupled to the faulty inverter are updated such that the partner inverter can remain active without being driven into an over-current condition.

Claims

1. A multiple DC-to-AC inverter system, the inverter system comprising:

a plurality of inverters, each having a DC input and an AC output, and each being configured to generate, at its AC output, a respective AC output signal in response to a DC input signal applied to said DC input;

a plurality of gate drives, each having a gate drive input and a gate drive output coupled to a respective one of said inverters, and each being configured to produce, at its gate drive output, an inverter drive signal set in response to a gate drive signal set; and

a controller having a plurality of gate drive signal outputs, each being coupled to a respective one of said gate drives, said controller being configured to;

generate, at said gate drive signal outputs, a plurality of gate drive signal sets for said gate drives;

detect a fault status for a faulty inverter among said plurality of inverters;

disable said faulty inverter in response to detection of said fault status;

determine new operating parameters for a non-faulty inverter among said plurality of inverters; and

generate an updated gate drive signal set for said non-faulty inverter, said updated gate drive signal set being influenced by said new operating parameters.

2. A system according to claim 1, said updated gate drive signal set being generated to prevent an over-current condition in said non-faulty inverter.

3. A system according to claim 1, said fault status being provided by said gate drive for said faulty inverter.

4. A system according to claim 1, said DC input signal being common to all of said inverters.

5. A system according to claim 1, wherein:

said plurality of inverters comprises a first inverter, a second inverter, a third inverter, and a fourth inverter;

said AC output of said first inverter is coupled to said AC output of said fourth inverter to provide a first combined AC output signal; and

said AC output of said second inverter is coupled to said AC output of said third inverter to provide a second combined AC output signal.

6. A system according to claim 5, wherein:

during normal operation, said gate drive signal set for said first inverter corresponds to said gate drive signal set for said fourth inverter; and

during normal operation, said gate drive signal set for said second inverter corresponds to said gate drive signal set for said third inverter.

7. A system according to claim 1, further comprising a plurality of AC system outputs, each being configured to provide a combined AC output signal from a respective subset of said inverters.

8. A multiple DC-to-AC inverter system, said inverter system comprising:

a plurality of inverters, each having a DC input and an AC output, and each being configured to generate, at its AC output, a respective AC output signal in response to a DC input signal applied to said DC input, wherein;

said plurality of inverters comprises a first inverter, a second inverter, a third inverter, and a fourth inverter;

said AC output of said first inverter is coupled to said AC output of said fourth inverter to provide a first combined AC output signal; and

said AC output of said second inverter is coupled to said AC output of said third inverter to provide a second combined AC output signal;

a plurality of gate drives, each having a gate drive input and a gate drive output coupled to a respective one of said inverters, and each being configured to produce, at its gate drive output, an inverter drive signal set in response to a gate drive signal set; and

a controller having a plurality of gate drive signal outputs, each being coupled to a respective one of said gate drives, said controller being configured to;

generate, at said gate drive signal outputs, a plurality of gate drive signal sets for said gate drives;

detect a fault status for a faulty inverter among said plurality of inverters;

if said faulty inverter is said first inverter, determine new operating parameters for said fourth inverter and generate, in response thereto, an updated gate drive signal set for said fourth inverter;

if said faulty inverter is said second inverter, determine new operating parameters for said third inverter and generate, in response thereto, an updated gate drive signal set for said third inverter;

if said faulty inverter is said third inverter, determine new operating parameters for said second inverter and generate, in response thereto, an updated gate drive signal set for said second inverter; and

if said faulty inverter is said fourth inverter, determine new operating parameters for said first inverter and generate, in response thereto, an updated gate drive signal set for said first inverter.

9. A multiple DC-to-AC inverter controller comprising:

a plurality of gate drive input/output groups for control signal outputs and gate drive status inputs corresponding to a plurality of inverters controlled by the inverter controller;

a signal generator coupled to said gate drive input/output groups, said signal generator being configured to generate a plurality of gate drive signal sets for driving a plurality of gate drives corresponding to the inverters; and

a processor coupled to said signal generator, said processor being configured to;

detect a fault status for a faulty inverter among the inverters;

produce, in response to detection of said fault status, a disabling gate drive signal set for said faulty inverter;

determine new operating parameters for a non-faulty inverter among the inverters; and

produce an updated gate drive signal set for said non-faulty inverter, said updated gate drive signal set being influenced by said new operating parameters.

10. A controller according to claim 9, said processor being configured to determine said new operating parameters to prevent an over-current condition in said non-faulty inverter.

11. A controller according to claim 9, wherein said updated gate drive signal set comprises a disabling gate drive signal set for said non-faulty inverter.

12. A controller according to claim 9, said processor being configured to calculate updated load current requirements that account for disabling of said faulty inverter, and to determine said new operating parameters in response to said updated load current requirements.