Method and control system for controlling mobility vehicles

• US 9,257,926 B2
• Filed: 09/15/2011
• Issued: 02/09/2016
• Est. Priority Date: 09/28/2010
• Status: Active Grant

• Current Assignee: Dynamic Contols
• Original Assignee: Dynamic Controls
• Inventors: Pettigrew, Warren Gordon, Palmer, Ian
• Primary Examiner(s): Olszewski, John R
• Assistant Examiner(s): MELTON, TODD M
• Application Number:
  US13/574,406
• Publication Number:
  US 20130035816A1
• Time in Patent Office: 1,608 Days
• Field of Search: 701/22
• US Class Current: 1/1
• CPC Class Codes: B60L 2200/20 Vehicles specially adapted for children, e.g. toy vehicles
• CPC Class Codes: B60L 2200/22 Microcars, e.g. golf cars
• CPC Class Codes: B60L 2200/34 Wheel chairs
• CPC Class Codes: B60L 2220/20 DC electrical machines
• CPC Class Codes: B60L 3/0061 relating to electrical machines
• CPC Class Codes: G01R 31/343 in operation
• CPC Class Codes: H02P 7/29 using pulse modulation
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

A method of controlling at least one motor in a motorized mobility vehicle, wherein the motor is part of a drive circuit for mobilizing the mobility vehicle, the method comprising the steps of: utilizing a stored profile of a motor performance parameter to develop a compensation term for controlling the motor, wherein the stored profile is of a resistance based variable associated with the motor as a function of a further variable and dynamically updating the compensation term when the mobility vehicle is in use.

Claims

1. A method of regulating the speed of at least one motor in a motorised mobility vehicle, wherein the motor is part of a drive circuit for mobilising the mobility vehicle, the method comprising:

developing a resistance versus load current based profile of the motor based on at least one motor performance parameter,

storing the developed profile,

utilising the stored profile to develop a compensation term for controlling the motor power, and

controlling the motor power to regulate the speed of the motor in the motorised mobility vehicle by dynamically updating the compensation term based on the stored profile, wherein dynamically updating the compensation term includes deriving a resistance of the motor from the stored profile based on a load current measured while the motorised mobility vehicle is being driven.

2. The method of claim 1, wherein the motor is one of:

a permanent magnet motor;

a shunt wound motor;

a brushless DC motor;

a DC brush motor.

3. The method of claim 1, wherein the compensation term is updated continuously.

4. The method of claim 1, further comprising dynamically updating the compensation term within a millisecond time frame.

5. The method of claim 1, further comprising constantly sensing the load current and dynamically updating the compensation term based on the sensed load current.

6. The method of claim 1, further comprising developing the load current in real time to generate a real time compensation term to be applied to a motor control circuit for the motor.

7. The method of claim 1, wherein the compensation term compensates for the resistance of the motor circuit.

8. The method of claim 7, wherein 100% of the compensation term is applied to the motor during all levels of motor loading.

9. The method of claim 7, wherein a portion of 100% of the compensation term is applied to the motor as the levels of motor loading vary.

10. The method of claim 9, wherein a reduced compensation term is applied as the motor loading increases.

11. The method of claim 7, wherein the stored profile is further shaped by speed.

12. The method of claim 7, wherein the compensation term is shaped by the stored profile.

13. The method of claim 7, wherein the compensation term is used to adjust the power applied to the motor.

14. The method of claim 1, further comprising applying the compensation term as a proportional control term.

15. The method of claim 1, further comprising applying the compensation term as an integral control term.

16. The method of claim 1, wherein the mobility vehicle is one of a power wheelchair and mobility scooter.

17. The method of claim 1, wherein the method controls two or more motors forming part of a differential steering mechanism of the mobility vehicle and each motor has a separate compensation term applied to it.

18. The method of claim 1, further comprising repeatedly updating the profile of the motor while the motor is in motion.

19. The method of claim 18, further comprising updating the profile of the motor based on a back EMF method.

20. The method of claim 19, wherein the back EMF method comprises developing the compensation term based on the developed load current.

21. The method of claim 19, wherein the back EMF sampling method comprises:

developing the terminal voltage across the motor, the load current and the back EMF, and

developing the compensation term based on the developed terminal voltage, load current and back EMF.

22. The method of claim 21, wherein the back EMF is developed after the motor is turned off for a period of time.

23. The method of claim 22, wherein the period of time is pre-determined or based on a stored algorithm.

24. The method of claim 18, further comprising determining whether the motor is being operated under a high load, and upon a positive determination, not updating the profile.

25. The method of claim 18, further comprising updating the profile of the motor during servicing or repair of the mobility vehicle.

26. The method of claim 18, further comprising updating the profile of the motor during normal use of the mobility vehicle.

27. The method of claim 26, further comprising updating the profile of the motor during normal use of the mobility vehicle without affecting the operation of the motor during the update.

28. The method of claim 1, further comprising:

monitoring the resistance versus load current based profile,

predicting an operation scenario based on the monitoring step, and

providing an output based on the predicted operation scenario.

29. The method of claim 28, further comprising:

detecting a predefined increase in a performance parameter of the motor based on the monitoring of the profile.

30. The method of claim 28, further comprising:

detecting a trend in a performance parameter of the motor based on the monitoring of the profile.

31. The method of claim 28, further comprising:

detecting a performance parameter of the motor has exceeded a predefined threshold value based on the monitoring of the profile.

32. The method of claim 28, further comprising the output limiting power to the motor.

33. The method of claim 32, wherein the power to the motor is limited by adjusting a limiting term applied to a control system for controlling the operation of the motor.

34. The method of claim 28, further comprising the output creating an audible or visible signal.

35. The method of claim 28, further comprising the output indicating when a service for the mobility vehicle is due.

36. The method of claim 28, further comprising the output providing a warning signal.

37. The method of claim 28, further comprising the output providing a fault indication.

38. The method of claim 28, wherein the mobility vehicle is one of a power wheelchair and mobility scooter.

39. The method of claim 28, wherein the motor is one of:

a permanent magnet motor;

a shunt wound motor;

a brushless DC motor;

a brush DC motor.

40. A control system in a motorised mobility vehicle, the control system arranged to regulate the speed of at least one motor wherein the motor is part of a drive circuit for mobilising the mobility vehicle, the control system comprising:

a profile development module arranged to develop a resistance versus load current based profile of the motor based on at least one motor performance parameter,

a storage module arranged to store the developed profile,

a compensation term development module arranged to;

utilise a stored profile to develop a compensation term for controlling the motor power, and

dynamically update the compensation term, wherein dynamically updating the compensation term includes deriving a resistance of the motor from the stored profile based on a load current measured while the motorised mobility vehicle is being driven, and

a control module arranged to control the motor power to regulate the speed of the motor in the motorised mobility vehicle based on the dynamically updated compensation term while the motorised mobility vehicle is being driven.

41. The system of claim 40, further comprising:

a profile monitoring module arranged to monitor the resistance versus load current based profile,

a scenario prediction module arranged to predict an operation scenario based on the monitoring, and

an output module arranged to provide an output based on the predicted operation scenario.

42. A method of regulating the speed of at least one motor in a motorised mobility vehicle, wherein the motor is part of a drive circuit for mobilising the mobility vehicle, the method comprising:

developing at least one motor performance parameter of the motor,

developing a resistance versus load current based profile of the motor based on the developed motor performance parameter,

storing the developed profile, and

controlling the motor power to regulate the speed of the motor in the motorised mobility vehicle by dynamically updating a compensation term based on the stored profile and applying the compensation term to control the motor power, wherein dynamically updating the compensation term includes deriving a resistance of the motor from the stored profile based on a load current measured while the motorised mobility vehicle is being driven.

43. The method of claim 42, further comprising repeatedly updating the profile.

44. The method of claim 43, further comprising updating the profile after determining that the motor temperature has changed or after a pre-determined operating period.

45. The method of claim 43, further comprising updating the profile after a pre-determined operating period.

46. The method of claim 42, further comprising developing an initial profile during assembly or commissioning of the vehicle.

47. The method of claim 42, further comprising developing the motor performance parameter to create an instantaneous profile of the motor.

48. The method of claim 42, further comprising storing the profile as a look up table or a set of polynomial values.

49. The method of claim 42, wherein the motor performance parameter is an electrical resistance of the motor, and the profile provides a resistance value for the measured load current.

50. The method of claim 49, wherein the profile is developed for load currents based on forward and reverse driving current values.

51. The method of claim 49, wherein the profile is developed for load currents based on forward driving current values only, and load currents for reverse driving current values are developed by mirroring the load currents based on the forward driving current values.

52. The method of claim 49, wherein the profile is developed for a range of operating load currents.

53. The method of claim 42, wherein the profile is developed for each of four control quadrants of the motor.

54. The method of claim 42, wherein the profile is developed in a first control quadrant of the motor, and subsequently used to control the motor in all four control quadrants of the motor.

55. The method of claim 42, wherein the motor performance parameter is developed based on motor current, driven terminal voltage and back EMF.

56. The method of claim 55, wherein the motor current and driven terminal voltage are developed prior to developing the back EMF of the motor.

57. The method of claim 55, wherein, when the driven terminal voltage is a PWM signal, the PWM signal is filtered to develop the motor characteristic.

58. The method of claim 55, wherein, when a signal representing the driven terminal voltage is a PWM signal, the motor characteristic is developed by calculating the mean driven terminal voltage based on the mean peak voltage and PWM ratio of the signal.

59. The method of claim 55, wherein the motor performance parameter further comprises a resistance calculation of the motor based on the motor current, driven terminal voltage and back EMF.

60. The method of claim 55, wherein the development of the motor performance parameter is repeated at various motor current values to develop a full profile.

61. The method of claim 60, wherein the values developed in claim 50 are interpolated to complete the profile of the full current range of the motor.

62. The method of claim 60, wherein the values developed in claim 50 are applied to a best fit equation to complete the profile.

63. The method of claim 42, wherein the motor performance parameter is further developed as a function of motor speed and/or motor age.

64. The method of claim 42, wherein the motor performance parameter is further developed as a function of motor age.

65. The method of claim 42, further comprising determining whether the profile is outside the limits of a predetermined threshold, and, upon a positive determination, developing a warning signal.

66. The method of claim 65, wherein the developed warning signal is provided to a user of the mobility vehicle during use.

67. The method of claim 65, wherein the developed warning signal is provided to a service entity during service of the mobility vehicle.

68. The method of claim 65, wherein the developed warning signal is used to limit the power being applied to the motor.

69. The method of claim 42, further comprising storing the profile in a memory.

70. The method of claim 69, wherein trends in the profile are provided to a service entity during service of the mobility vehicle.

71. A control system in a motorised mobility vehicle, the control system arranged to control regulate the speed of at least one motor, wherein the motor is part of a drive circuit for mobilising the mobility vehicle, the control system comprising;

a motor performance parameter development module arranged to develop at least one motor performance parameter of the motor,

a profile development module arranged to develop a resistance versus load current based profile of the motor based on the developed motor performance parameter,

a storage module arranged to store the developed profile, and

a control module arranged to control the motor power to regulate the speed of the motor in the motorised mobility vehicle by dynamically updating a compensation term based on the stored profile and applying the compensation term to control the motor power, wherein dynamically updating the compensation term includes deriving a resistance of the motor from the stored profile based on a load current measured while the motorised mobility vehicle is being driven.