Motor drive apparatus

• US 7,511,447 B2
• Filed: 05/10/2005
• Issued: 03/31/2009
• Est. Priority Date: 05/26/2004
• Status: Active Grant

• Current Assignee: Aisin AW Company Limited (Aisin Corp.), DENSO Corporation
• Original Assignee: Aisin AW Company Limited (Aisin Corp.), Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Ishikawa, Tetsuhiro, Minezawa, Yukihiro
• Primary Examiner(s): IP, SHIK LUEN PAUL
• Application Number:
  US11/578,241
• Publication Number:
  US 20070216323A1
• Time in Patent Office: 1,421 Days
• Field of Search: 318800-811, 318/254, 363/132, 701/22
• US Class Current: 318/801
• CPC Class Codes: B60L 15/007 Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
• CPC Class Codes: B60L 15/20 for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
• CPC Class Codes: B60L 2210/14 Boost converters
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 3/156 with automatic control of output voltage or current, e.g. switching regulators
• CPC Class Codes: H02M 7/5387 in a bridge configuration
• CPC Class Codes: H02P 27/06 using dc to ac converters or inverters H02P27/05 takes precedence
• 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 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

When a torque command value from an external ECU is within a predetermined variation width, a control unit generates a signal and outputs the signal to a voltage command calculation unit so that electrostatic energy stored in a capacitor is kept at a predetermined threshold value or larger. Based on the signal, the voltage command calculation unit determines a target voltage of a voltage step-up converter that corresponds to a terminal-to-terminal voltage of the capacitor. In contrast, when the torque command value is out of the predetermined variation width, the control unit determines electric power to be supplied from a DC power supply to an inverter for allowing electric power to be supplied predominantly from the capacitor rather than from the DC power supply and outputs a signal. Based on this signal, the voltage command calculation unit determines the target voltage.

Claims

1. A motor drive apparatus comprising:

a drive circuit driving a motor;

a voltage converter including a switching element and using a switching operation of said switching element for converting a DC voltage between a power supply and said drive circuit;

a capacitor element provided between said voltage converter and said drive circuit for smoothing the converted DC voltage to input the smoothed DC voltage to said drive circuit; and

a control circuit controlling said switching operation based on magnitude of a required output of said motor, wherein

said drive circuit is supplied with electric power, according to the required output of said motor, from said power supply and from said capacitor element, and

said control circuit controls said switching operation so that the electric power supplied from said capacitor element to said drive circuit is larger than the electric power supplied from said power supply to said drive circuit when the magnitude of said required output is out of a predetermined variation width.

2. The motor drive apparatus according to claim 1, wherein

said control circuits makes a determination as to whether the magnitude of said required output is within a range of said predetermined variation width and determines a target voltage of said switching operation according to result of the determination.

3. The motor drive apparatus according to claim 2, wherein

said control circuit has a predetermined control width of the target voltage of said switching operation and sets, when the magnitude of said required output is out of the range of said predetermined variation width, the target voltage of said switching operation at a lower voltage level within a range of said predetermined control width.

4. The motor drive apparatus according to claim 3, wherein

said predetermined control width of the target voltage of said switching operation has its upper limit and a voltage level corresponding to the upper limit is higher than a voltage level corresponding to an upper limit of said predetermined variation width of the magnitude of said required output.

5. The motor drive apparatus according to claim 4, further comprising a voltage sensor detecting a terminal-to-terminal voltage of said capacitor element, wherein

when the terminal-to-terminal voltage of said capacitor element detected by said voltage sensor is lower than the target voltage of said switching operation, said control circuit controls said switching operation so that the terminal-to-terminal voltage of said capacitor element is equal to the target voltage of said switching operation.

6. The motor drive apparatus according to claim 2, further comprising:

a first electric-current sensor detecting a power-supply current input/output to/from said power supply;

a second electric-current sensor detecting motor drive current for driving said motor; and

a voltage sensor detecting a terminal-to-terminal voltage of said capacitor elements, wherein

when the magnitude of said required output is out of the range of said predetermined variation width, said control circuit calculates the electric power supplied from said capacitor element based on said power supply current and said motor drive current detected respectively by said first electric-current sensor and said second electric-current sensor as well as the terminal-to-terminal voltage of said capacitor element detected by said voltage sensor, determines the electric power supplied from said power supply so that the electric power supplied from said power supply is smaller than said calculated electric power supplied from said capacitor element, and determines the target voltage of said switching operation as the terminal-to-terminal voltage of said capacitor element when the determined electric power is supplied from said power supply.

7. The motor drive apparatus according to claim 6, wherein

when the magnitude of said required output is within the range of said predetermined variation width, said control circuit calculates stored electric power that is stored in said capacitor element based on the terminal-to-terminal voltage of said capacitor element that is detected by said voltage sensor and determines the target voltage of said switching operation so that said calculated stored electric power is at least a predetermined threshold value.

8. The motor drive apparatus according to claim 7, wherein

said control circuit determines, when said stored electric power is smaller than said predetermined threshold value, the target voltage of said switching operation as the terminal-to-terminal voltage of said capacitor element when said stored electric power is equal to said predetermined threshold value.

9. The motor drive apparatus according to claim 8, wherein

when the magnitude of said required output is out of said predetermined variation width, said predetermined threshold value has a level of the stored electric power that allows electric power to be supplied from said capacitor element to said drive circuit.

10. The motor drive apparatus according to claim 3, further comprising:

a first electric-current sensor detecting a power-supply current input/output to/from said power supply;

a second electric-current sensor detecting motor drive current for driving said motor; and

a voltage sensor detecting a terminal-to-terminal voltage of said capacitor element, wherein

when the magnitude of said required output is out of the range of said predetermined variation width, said control circuit calculates the electric power supplied from said capacitor element based on said power supply current and said motor drive current detected respectively by said first electric-current sensor and said second electric-current sensor as well as the terminal-to-terminal voltage of said capacitor element detected by said voltage sensor, determines the electric power supplied from said power supply so that the electric power supplied from said power supply is smaller than said calculated electric power supplied from said capacitor element, and determines the target voltage of said switching operation as the terminal-to-terminal voltage of said capacitor element when the determined electric power is supplied from said power supply.

11. The motor drive apparatus according to claim 10, wherein

when the magnitude of said required output is within the range of said predetermined variation width, said control circuit calculates stored electric power that is stored in said capacitor element based on the terminal-to-terminal voltage of said capacitor element that is detected by said voltage sensor and determines the target voltage of said switching operation so that said calculated stored electric power is at least a predetermined threshold value.

12. The motor drive apparatus according to claim 11, wherein

said control circuit determines, when said stored electric power is smaller than said predetermined threshold value, the target voltage of said switching operation as the terminal-to-terminal voltage of said capacitor element when said stored electric power is equal to said predetermined threshold value.

13. The motor drive apparatus according to claim 12, wherein

when the magnitude of said required output is out of said predetermined variation width, said predetermined threshold value has a level of the stored electric power that allows electric power to be supplied from said capacitor element to said drive circuit.