Converter for an electrical machine, controller and method for operating a converter

• US 9,242,564 B2
• Filed: 07/11/2012
• Issued: 01/26/2016
• Est. Priority Date: 07/11/2011
• Status: Active Grant

• Current Assignee: Magna Steyr Battery Systems GmbH & Co. oG (Samsung SDI Company Limited)
• Original Assignee: Magna Powertrain AG & Company KG (Magna International Incorporated)
• Inventors: Feichtinger, Thomas, Paul, Wolfgang, Spindelberger, Christian, Tannheimer, Jrgen
• Primary Examiner(s): Ismail, Shawki S
• Assistant Examiner(s): Carrasquillo, Jorge L
• Application Number:
  US13/546,031
• Publication Number:
  US 20130015796A1
• Time in Patent Office: 1,294 Days
• Field of Search: 318/400.14, 318/400.17, 318/400.2, 318/400.26, 318/400.35, 318/400.09, 318/434, 318/400.22, 318/801, 318/803, 318/563, 318/400.21, 318/515, 318/599, 318/782, 318/590, 363/41, 363/56.03, 363/17, 363/56.02, 363/58, 363/98, 363/132, 363/136, 363/37, 363/38, 363/55, 363/56.01, 363/109, 363/131, 363/120
• US Class Current: 1/1
• CPC Class Codes: B60L 7/14 for vehicles propelled by ac motors
• CPC Class Codes: H02P 27/06 using dc to ac converters or inverters H02P27/05 takes precedence
• CPC Class Codes: H02P 29/024 Detecting a fault condition, e.g. short circuit, locked rotor, open circuit or loss of load
• CPC Class Codes: H02P 29/0241 the fault being an overvoltage
• CPC Class Codes: H02P 3/22 by short-circuit or resistive braking
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility

Abstract

A converter for an electrical machine having a plurality of phase lines for connecting the electrical machine. For each phase line the converter has a half-bridge with a first semiconductor switch is configured to electrically connect at least one of the phase lines intermittently to a first supply line of the converter, and a second semiconductor switch configured to electrically connect the phase line intermittently to a second supply line of the converter. The converter is configured for operation in a first energy recovery limiting mode in which at least two of the first semiconductor switches are at least intermittently on simultaneously.

Claims

1. A converter for an electrical machine, the converter comprising:

a plurality of phase lines for connecting the electrical machine and the converter;

and

a controller having first and second control elements to respectively determine a malfunction in the converter and thereby initiate a first energy recovery limiting mode or a second energy recovery limiting mode when the malfunction is determined, the first control element having a first plausibility checker which is configured to check outputs from the second control element and determine a presence of a malfunction in the converter and to initiate one of the first energy recovery limiting mode and the second energy recovery limiting mode when a malfunction is detected, and the second control element has a second plausibility checker which is configured to check outputs from the first control element and determine a presence of a malfunction in the converter and to initiate one of the first energy recovery limiting mode and the second energy recovery limiting mode when a malfunction is detected;

wherein;

each phase line for the converter has a half-bridge with a plurality of first semiconductor switches and a plurality of second semiconductor switches;

the first semiconductor switches are to electrically connect at least one of the phase lines intermittently to a first supply line of the converter;

the second semiconductor switches are to electrically connect the phase line intermittently to a second supply line of the converter;

the converter is configured for operation intermittently in the first energy recovery limiting mode in which at least two of the first semiconductor switches are at least intermittently on simultaneously; and

the converter is configured for operation at least intermittently in the second energy recovery limiting mode in which at least two of the second semiconductor switches are at least intermittently on simultaneously.

2. The converter of claim 1, wherein the converter is configured for operation at least intermittently in the first energy recovery limiting mode when the second semiconductor switches are off.

3. The converter of claim 1, wherein the converter is configured for operation at least intermittently in the second energy recovery limiting mode when the first semiconductor switches are off.

4. The converter of claim 1, wherein the converter is configured to adopt one of the first energy recovery limiting mode and the second energy recovery limiting mode when at least one of the control elements is inactive.

5. The converter of claim 1, wherein the converter is configured to adopt one of the first energy recovery limiting mode and the second energy recovery limiting mode when the control elements are inactive.

6. A controller for a converter for an electrical machine, the converter having a plurality of phase lines for connecting the electrical machine and the converter and which is configured for operation intermittently in a first energy recovery limiting mode and a second energy recovery limiting mode, the controller comprising:

at least one control element including a first control element and a second control element, and which is configured to determine a malfunction in the converter and thereby initiate one of the first energy recovery limiting mode and the second energy recovery limiting mode in the event of a malfunction in the converter, the first control element having a first plausibility checker which is configured to check outputs from the second control element and determine a presence of a malfunction in the converter and to initiate one of the first energy recovery limiting mode and the second energy recovery limiting mode when a malfunction is detected, and the second control element has a second plausibility checker which is configured to check outputs from the first control element and determine a presence of a malfunction in the converter and to initiate one of the first energy recovery limiting mode and the second energy recovery limiting mode when a malfunction is detected,

wherein;

each phase line for the converter has a half-bridge with a first semiconductor switch and a second semiconductor switch;

the first semiconductor switch is configured to electrically connect at least one of the phase lines intermittently to a first supply line of the converter;

the second semiconductor switch is configured to electrically connect the phase line intermittently to a second supply line of the converter.

7. The controller of claim 6, wherein:

in the first energy recovery limiting mode, at least two of the first semiconductor switches are at least intermittently on simultaneously; and

in the second energy recovery limiting mode, at least two of the second semiconductor switches are at least intermittently on simultaneously.

8. The controller of claim 7, wherein the controller is configured to initiate at least one of:

the first energy recovery limiting mode when one of the first semiconductor switches can no longer be switched off; and

the second energy recovery limiting mode when one of the second semiconductor switches can no longer be switched off.

9. The controller of claim 7, wherein the controller is configured to initiate at least one of:

the first energy recovery limiting mode when one of the second semiconductor switches can no longer be switched on; and

the second energy recovery limiting mode when one of the first semiconductor switches can no longer be switched on.

10. The controller of claim 7, wherein the controller is configured to activate the first energy recovery limiting mode on the basis of at least one of:

a sensed temperature from an area of at least one of the semiconductor switches;

a sensed frequency sensor from at least one of the phase lines;

a sensed temperature from an area of at least one winding of the electric motor of the electric machine; and

a sensed speed from the electric motor.

11. The controller of claim 7, wherein the controller is configured to activate the second energy recovery limiting mode on the basis of at least one of:

a sensed temperature from an area of at least one of the semiconductor switches;

a sensed frequency sensor from at least one of the phase lines;

a sensed temperature from an area of at least one winding of the electric motor of the electric machine; and

a sensed speed from the electric motor.

12. The controller of claim 7, wherein the controller is configured to activate the first energy recovery limiting mode and the second energy recovery limiting mode on the basis of at least one of:

a sensed temperature from an area of at least one of the semiconductor switches;

a sensed frequency sensor from at least one of the phase lines;

a sensed temperature from an area of at least one winding of the electric motor of the electric machine; and

a sensed speed from the electric motor.

13. The controller of claim 7, wherein the controller is configured to activate at least one of the first energy recovery limiting mode and the second energy recovery limiting mode on the basis of at least one of:

sensed information produced in the converter; and

sensed information supplied to the converter.

14. The controller of claim 13, wherein the controller is configured to adjust a time ratio for a time component of the activation of the first energy recovery limiting mode to a time component of the activation of the second energy recovery limiting mode.

15. The controller of claim 14, wherein the controller is configured to adjust a time ratio for a time component on the basis of at least one of a temperature distribution between the semiconductor switches and a power distribution between the semiconductor switches.

16. A method for operating a converter of an electrical machine, the method comprising:

providing a converter comprising a plurality of phase lines for connecting the electrical machine and the converter, wherein for each phase line the converter has a half-bridge with a plurality of first semiconductor switches and a plurality of second semiconductor switches, the first semiconductor switches being configured to electrically connect the phase lines intermittently to a first supply line of the converter, and the second semiconductor switches being configured to electrically connect the phase lines intermittently to a second supply line of the converter;

monitoring the converter in order to recognize a malfunction in the converter, wherein the monitoring includes which is configured to checking, by a first plausibility checker, outputs from a second control element and determining a presence of a malfunction in the converter, and checking, by a second plausibility checker, outputs from a first control element and determining a presence of a malfunction in the converter; and

then

operating the converter, when a malfunction in the converter has been recognized, in one of a first energy recovery limiting mode or a second energy recovery limiting mode in which at least two of the first semiconductor switches are at least intermittently on simultaneously.