Method for detecting an insulation fault in a motor arrangement, method for detecting a motor phase interruption in a motor arrangement, and drive circuit for driving an electronically commutated motor

Abstract

A drive circuit for driving an electronically commutated motor contains a DC voltage intermediate circuit, and an inverter which is connected to the latter and has a bridge circuit containing a plurality of transistors, to which the motor phases of a motor configuration containing the motor can be connected. For detecting an insulation fault in the motor configuration, a positive or negative transistor of the inverter is switched on, while all other transistors of the inverter are switched off before all transistors of the inverter are switched off. A motor phase voltage of a selected motor phase of the motor phases with respect to a reference potential is then captured, while all transistors of the inverter remain switched off in order to determine whether there is an insulation fault on the motor phase on a basis of a voltage profile of the motor phase voltage.

Claims

1. A method for detecting an insulation fault in a motor configuration, motor phases of the motor configuration are connected to a drive circuit, the drive circuit including a DC voltage intermediate circuit and an inverter having a bridge circuit with transistors including at least one positive transistor and at least one negative transistor, which comprises the steps of: switching on the at least one positive or the at least one negative transistor of the inverter, while all other ones of the transistors of the inverter are switched off; switching off all the transistors of the inverter; capturing a motor phase voltage of at least one selected motor phase of the motor phases with respect to a reference potential, while all the transistors of the inverter remain switched off; and determining whether there is the insulation fault on one of the motor phases of the motor configuration on a basis of a voltage profile of the motor phase voltage captured.

2. The method according to claim 1, which further comprises: connecting the selected motor phase to the reference potential via a high-value measuring impedance; and capturing a divided motor phase voltage of the selected motor phase.

3. The method according to claim 2, which further comprises capturing the motor phase voltage or the divided motor phase voltage by means of a voltage divider.

4. The method according to claim 1, wherein the DC voltage intermediate circuit of the drive circuit is connected to an AC connection on an input side via a rectifier, and the drive circuit further has a power factor correction filter with a switch between the rectifier and the DC voltage intermediate circuit, which further comprises: switching off the switch of the power factor correction filter before switching on the at least one positive transistor or the at least one negative transistor of the inverter.

5. A method for detecting a motor phase interruption in a motor configuration, motor phases of motor configuration are connected to a drive circuit, the drive circuit containing a DC voltage intermediate circuit and an inverter having a bridge circuit with transistors including at least one positive transistor and at least one negative transistor, which comprises the steps of: switching on the at least one positive transistor or the at least one negative transistor of the inverter, while all other ones of the transistors of the inverter are switched off; capturing a motor phase voltage of at least one selected motor phase of the motor phases with respect to a reference potential; and determining whether there is a motor phase interruption in one of the motor phases of the motor configuration on a basis of a voltage profile of the motor phase voltage captured.

6. The method according to claim 5, which further comprises: connecting the selected motor phase to the reference potential via a high-value measuring impedance; and capturing a divided motor phase voltage of the selected motor phase.

7. The method according to claim 6, which further comprises capturing the motor phase voltage or the divided motor phase voltage by means of a voltage divider.

8. The method according to claim 5, wherein the DC voltage intermediate circuit of the drive circuit is connected to an AC connection on an input side via a rectifier, and the drive circuit further has a power factor correction filter with a switch between the rectifier and the DC voltage intermediate circuit, which further comprises: switching off the switch of the power factor correction filter before switching on the at least one positive transistor or the at least one negative transistor of the inverter.

9. A drive circuit for driving an electronically commutated motor, the drive circuit comprising: a DC voltage intermediate circuit; an inverter connected to said DC voltage intermediate circuit and having a bridge circuit with transistors including at least one positive transistor and at least one negative transistor, and to said transistors motor phases of a motor configuration containing the electronically commutated motor can be connected; a detection circuit for capturing a motor phase voltage of at least one selected motor phase of the motor phases with respect to a reference potential; a controller configured to individually switch said transistors of said inverter on and off and to operate said detection circuit for capturing the motor phase voltage; and said controller configured to determine, on a basis of a voltage profile of the motor phase voltage captured, whether there is an insulation fault on one of the motor phases of the motor configuration and/or is configured to determine, on a basis of the voltage profile of the motor phase voltage, whether there is a motor phase interruption in one of the motor phases of the motor configuration.

10. The drive circuit according to claim 9, wherein said detection circuit has a high impedance measuring via which the selected motor phase is connected to the reference potential.

11. The drive circuit according to claim 9, wherein said detection circuit has a voltage divider for capturing the motor phase voltage.

12. The drive circuit according to claim 9, wherein said drive circuit further has at least one additional capacitor which is connected to earth from one of the motor phases.

13. The drive circuit according to claim 9, further comprising an AC connection; further comprising a rectifier; wherein said DC voltage intermediate circuit has an input side, said DC voltage intermediate circuit is connected to said AC connection on said input side via said rectifier; further comprising a power factor correction filter having a switch connected between said rectifier and said DC voltage intermediate circuit; and wherein said controller is configured to switch off said switch of said power factor correction filter before switching on said at least one positive transistor or said at least one negative transistor of said inverter.

14. The drive circuit according to claim 13, wherein said controller is configured to prevent switching-on of said inverter and/or of said power factor correction filter after capturing the motor phase voltage if the insulation fault or the motor phase interruption has been determined.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

(1) FIG. 1 is a circuit diagram of a drive circuit with a connected motor and various possible insulation faults on the motor phases;

(2) FIG. 2 is a circuit diagram of the drive circuit with the connected motor according to one exemplary embodiment of the invention;

(3) FIG. 3 is an illustration of graphs showing control signals of an inverter, a motor phase voltage and a captured divided motor phase voltage of an insulation fault detection for the drive circuit from FIG. 2 during a positive half-wave of a network voltage in a fault-free case without insulation faults;

(4) FIG. 4 is an illustration of graphs showing the control signals of the inverter, the motor phase voltage and the captured divided motor phase voltage of the insulation fault detection for the drive circuit from FIG. 2 during the positive half-wave of the network voltage in the event of an insulation fault on one of the motor phases;

(5) FIG. 5 is an illustration of showing the control signals of the inverter, the motor phase voltage and the captured divided motor phase voltage of the insulation fault detection for the drive circuit from FIG. 2 during a negative half-wave of the network voltage in the fault-free case without insulation faults; and

(6) FIG. 6 is an illustration of graphs showing the control signals of the inverter, the motor phase voltage and the captured divided motor phase voltage of the insulation fault detection for the drive circuit from FIG. 2 during the negative half-wave of the network voltage in the event of an insulation fault on one of the motor phases.

DETAILED DESCRIPTION OF THE INVENTION

(7) Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a drive circuit 10 is used to drive an electronically commutated motor 12. In the example from FIG. 1, the motor is a three-phase brushless motor 12 having three motor phases U, V, W which are connected to one another at a neutral point SP. The motor 12 is fed from a DC voltage intermediate circuit 14 via an inverter 16. The DC voltage intermediate circuit 14 has an intermediate circuit capacitor C1, and the inverter 16 has a three-phase inverter bridge circuit in this exemplary embodiment having a total of six transistors M2 to M7 (for example MOSFETs or IGBTs having diodes with an antiparallel connection) in its half-bridges. The three motor windings of the motor 12 are connected, via a motor cable 18, to a motor phase connection 20 which is connected to the three center taps of the half-bridges of the inverter 16. The motor 12 and the motor cable 18 each have three motor phases U, V, W and are parts of the motor arrangement.

(8) On the input side, the DC voltage intermediate circuit 14 is connected to an AC connection 24 via a rectifier 22. The drive circuit 10 can be connected to a supply network 26 via the AC connection 24. In the example from FIG. 1, the supply network 26 is a single-phase power supply system, the drive circuit 10 is connected to the phase conductor L and to the neutral conductor N of the single-phase power supply system, and the supply network 26 also has protective earthing PE. In this example, the rectifier 22 has a rectifier bridge circuit with a total of four rectifier diodes D7 to D10.

(9) Optionally, a power factor correction filter (PFC filter) 28 can also be connected between the rectifier 22 and the DC voltage intermediate circuit 14. The PFC filter 28 is configured in a boost converter topology in this example and contains, in particular, an inductance L1, a switch M1 and a rectifier diode D1.

(10) The drive circuit 10 also has a control device (not illustrated in FIG. 1), for example in the form of a microcontroller, which controls the switch M1 of the PFC filter 28, if present, and the transistors M2 to M7 of the inverter 16 using appropriate control signals S1 and S2 . . . 7.

(11) In the case of such a drive circuit 10, there are various types of insulation faults which can occur on the side of the connected motor 12. Insulation faults of the motor phases U, V, W in the motor cable 18 and insulation faults of the neutral point SP of the motor windings of the motor 12 may arise. The various types of insulation faults are illustrated in FIG. 1 as insulation faults with the resistors R7a, R7b, R7c for the motor phases U, V, W of the motor capable 12 and with the resistor R7d for the neutral point SP of the motor windings of the motor 12.

(12) Referring to FIG. 2, the structure and method of operation of a drive circuit for an electronically commutated motor according to one exemplary embodiment of the invention are now explained in more detail. In this case, identical or corresponding components are denoted using the same reference numerals as in FIG. 1.

(13) The drive circuit 10 from FIG. 2 corresponds substantially to the drive circuit from FIG. 1. In addition to the rectifier 22, optional PFC filter 28, DC voltage intermediate circuit 14 and inverter 16, the drive circuit 10 according to the invention contains a detection circuit 30 which can be used to detect all above-described insulation faults on the motor phases of the motor arrangement.

(14) The detection circuit 30 contains a high impedance measuring which is formed by a first resistor R1 and via which a selected motor phase (here: V) of the motor phases U, V, W is connected to a reference potential PR. The reference potential PR is, for example, the negative pole of the DC voltage intermediate circuit 14 or earth. The first resistor R1 has a resistance value of 10 megohms, for example.

(15) The detection circuit 30 also has a voltage divider which is formed by the first resistor R1 and a second resistor R2 which are connected in series between the motor phase V and the reference potential PR. The second resistor R2 has a resistance value of 50 kilohms, for example. This voltage divider R1, R2 can be used to capture, as the measurement voltage Um, a divided voltage of the motor phase voltage Uv which can then be evaluated by an analogue/digital converter of the control device 32.

(16) In the exemplary embodiment from FIG. 2, the detection circuit 30 captures the divided motor phase voltage Um of the motor phase V. In other embodiments of the invention, divided motor phase voltages Um of the other motor phases U, W or divided motor phase voltages Um of a plurality of motor phases U, V, W can also be captured in a similar manner.

(17) FIG. 2 also depicts the parasitic capacitances C2, C3, C4 between the motor phases U, V, W and the protective earthing PE and, for example, an insulation fault resistance R7b of the motor phase V with respect to the protective earthing PE.

(18) Insulation fault detection on the motor phases U, V, W of the motor arrangement 12, 18 is carried out as follows.

(19) During the positive half-wave of the network voltage U.sub.Netz, the control device 32 first of all uses appropriate control signals S2 . . . 7 to switch on at least one of the three positive transistors (high-side switches) M2, M3, M4 of the inverter 16, while the three negative transistors (low-side switches) M5, M6, M7 remain permanently switched off. In a similar manner, during the negative half-wave of the network voltage U.sub.Netz, the control device 32 uses appropriate control signals S2 . . . 7 to switch on at least one of the negative transistors (low-side switches) M5, M6, M7, while the three positive transistors (high-side switches) M2, M3, M4 remain permanently switched off. As a result, the parasitic capacitances C2, C3, C4 are first of all charged to the intermediate circuit voltage U.sub.+HV (positive half-wave of the network voltage) or discharged (negative half-wave of the network voltage).

(20) If the fault current detection is used in a drive circuit 10 with an active PFC filter 28, this active PFC filter 28 is preferably switched off by the control device 32 using an appropriate control signal S1 during the charging operation in order to prevent possible DC faults since these DC faults could impair the function of a type A RCD.

(21) FIG. 3 shows the curve profiles of the control signals S2 . . . 4 of the inverter 16, the motor phase voltage Uv and the captured divided motor phase voltage Um during the insulation fault detection for the fault-free case during the positive half-wave of the network voltage U.sub.Netz.

(22) After the charging operation, all transistors M2 to M7 are switched off by the control device 32. In the fault-free case, the parasitic capacitances C2, C3, C4 are then discharged via the high-impedance voltage divider R1, R2 of the detection circuit 30. As a result of the high RC time constant on account of the high impedance discharge resistor, the voltage on the motor phase V falls only slowly during the time in which the transistors M2, M3, M4 are also switched off.

(23) FIG. 4 shows the curve profiles of the control signals S2 . . . 4 of the inverter 16, the motor phase voltage Uv and the captured divided motor phase voltage Um during the insulation fault detection for the case of an existing insulation fault, for example on the motor phase V of the motor arrangement 12, 18, during the positive half-wave of the network voltage U.sub.Netz.

(24) If there is an insulation fault on the motor phase V, for example, the discharge path of the parasitic capacitances C2, C3, C4 no longer leads via the high-impedance voltage divider R1, R2 of the detection circuit 30, but rather via the insulation fault resistance R7b which has a comparatively much lower resistance. For this reason, the voltage on the motor phase V now falls much more quickly during the time in which the positive transistors M2, M3, M4 are also switched off than in the fault-free case. The analogue/digital converter of the control device 32 evaluates the divided measurement signal Um of the motor phase voltage Uv and detects, on the basis of the voltage profile, whether there is an insulation fault on one of the motor phases U, V, W or at the neutral point SP.

(25) FIG. 5 shows the curve profiles of the control signals S5 . . . 7 of the inverter 16, the motor phase voltage Uv and the captured divided motor phase voltage Um during the insulation fault detection for the fault-free case during the negative half-wave of the network voltage U.sub.Netz.

(26) After the discharging operation, all transistors M2 to M7 are switched off by the control device 32. In the fault-free case, the parasitic capacitances C2, C3, C4 are then charged via the high-impedance voltage divider R1, R2 of the detection circuit 30. As a result of the high RC time constant on account of the high impedance discharge resistor, the voltage on the motor phase V changes only very slowly during the time in which the transistors M2, M3, M4 are also switched off.

(27) FIG. 6 shows the curve profiles of the control signals S5 . . . 7 of the inverter 16, the motor phase voltage Uv and the captured divided motor phase voltage Um during the insulation fault detection for the case of an existing insulation fault, for example on the motor phase V of the motor arrangement 12, 18, during the negative half-wave of the network voltage U.sub.Netz.

(28) If there is an insulation fault on the motor phase V, for example, the charge path of the parasitic capacitances C2, C3, C4 no longer leads via the high-impedance voltage divider R1, R2 of the detection circuit 30, but rather via the insulation fault resistance R7b which has a comparatively much lower resistance. For this reason, the voltage on the motor phase V now rises much more quickly during the time in which the positive transistors M2, M3, M4 are also switched off than in the fault-free case. The analogue/digital converter of the control device 32 evaluates the divided measurement signal Um of the motor phase voltage Uv and can detect, on the basis of the voltage profile, whether there is an insulation fault on one of the motor phases U, V, W or at the neutral point SP.

(29) Since the magnitude of the parasitic capacitances C2, C3, C4 is greatly dependent on the application, the parasitic capacitances can be increased, in motor structures of particularly low capacitance (for example short motor cable 18, low-capacitance motor 12), by means of additional capacitors in the drive circuit 10 which are each connected to earth from a motor phase U, V, W. The described principle of fault current detection on the motor side can therefore also be used in applications with low-capacitance motor arrangements.

(30) In the positive half-wave of the network voltage U.sub.Netz, the insulation fault resistance R7b can be calculated by means of the following expression:

(31) $R7b=-\frac{t}{C_{2,3,4}*\ln \left(\frac{\frac{R1+R2}{R2}*\mathrm{Um}\left(t\right)}{U_{+\mathrm{HV}}}\right)}$
where t is the time, C.sub.2,3,4 is the total capacitance of the three parasitic capacitances C2, C3, C4, and U.sub.+HV is the intermediate circuit voltage across the DC voltage intermediate circuit 14.

(32) The maximum insulation fault current which flows at the voltage maximum of the positive half-wave of the network voltage can be calculated as follows from the insulation fault resistance R7b determined in this manner:

(33) $I_{R7,\max }=\frac{U_{+\mathrm{HV}}}{R7b}=\frac{U_{+\mathrm{HV}}*C_{2,3,4}*\ln \left(\frac{\frac{R1+R2}{R2}*\mathrm{Um}\left(t\right)}{U_{+\mathrm{HV}}}\right)}{t}$

(34) The maximum fault current is the greatest possible fault current which flows during normal motor operation with the inverter switched on if there is an insulation fault with respect to protective earth on a motor phase or an insulation fault from the motor neutral point to protective earth and the zero vector (all motor phases simultaneously switched to high) is switched (the neutral point assumes the intermediate circuit voltage only in this case).

(35) In the negative half-wave of the network voltage U.sub.Netz, the insulation fault resistance R7b can be calculated by means of the following expression:

(36) $R7b=-\frac{t}{C_{2,3,4}*\ln \left(\frac{U_{N\mathrm{etz}}\left(t\right)-\frac{R1+R2}{R2}*\mathrm{Um}\left(t\right)}{U_{N\mathrm{etz}}}\right)}$

(37) where t is the time, C.sub.2,3,4 is the total capacitance of the three parasitic capacitances C2, C3, C4, and U.sub.Netz is the network voltage.

(38) The maximum insulation fault current which flows at the voltage maximum of the negative half-wave of the network voltage can be calculated as follows from the insulation fault resistance R7b determined in this manner:

(39) $I_{R7,\max }=\frac{U_{+\mathrm{HV}}}{R7b}=\frac{U_{+\mathrm{HV}}*C_{2,3,4}*\ln \left(\frac{U_{N\mathrm{etz}}\left(t\right)-\frac{R1+R2}{R2}*\mathrm{Um}\left(t\right)}{U_{N\mathrm{etz}}}\right)}{t}$

(40) The drive circuit 10 having the detection circuit 30 according to the invention for detecting an insulation fault on the side of the motor arrangement 12, 18 can also be used in combination with other supply networks 26 and accordingly adapted rectifiers 22.

(41) The concept described on the basis of FIGS. 1 to 6 can additionally also be used to detect motor phase interruptions which can occur, for example, as a result of a severed motor cable, a defective motor cable, an incorrectly connected motor cable or a burnt-out motor winding of the motor.

(42) In order to detect a motor phase interruption, the control device 32 uses appropriate control signals S2 . . . 7 to switch on one of the three positive transistors M2, M3, M4 of the inverter 16 during the positive half-wave of the network voltage U.sub.Netz, while the three negative transistors M5, M6, M7 remain permanently switched off, or the control device 32 uses appropriate control signals S2 . . . 7 to switch on one of the negative transistors M5, M6, M7 during the negative half-wave of the network voltage U.sub.Netz, while the three positive transistors M2, M3, M4 remain permanently switched off. If the motor phase interruption detection is used in a drive circuit 10 with an active PFC filter 28, this active PFC filter 28 is preferably switched off by the control device 32 using an appropriate control signal S1.

(43) In the fault-free state without a motor phase interruption, the motor phase voltage Uv behaves as described above. In contrast, if there is an interruption in the motor phase U, V or W, to which the switched-on circuit breaker M2 . . . 7 of the inverter 16 is assigned, the motor phase voltage Uv of the selected motor phase does not assume the intermediate circuit voltage U.sub.+HV (positive half-wave of the network voltage) or does not assume 0 volts (negative half-wave or the network voltage).

(44) All positive or negative transistors M2 to M7 of the inverter 16 are preferably individually switched on in succession and the voltage profile of the selected motor phase voltage Uv is then evaluated in order to examine all existing motor phases U, V, W for a possible interruption.

(45) The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention: 10 Drive circuit 12 Motor 14 DC voltage intermediate circuit 16 Inverter 18 Motor cable 20 Motor phase connection 22 Rectifier 24 AC connection 26 Supply network 28 Power factor correction filter (PFC filter) 30 Detection circuit 32 Control device C1 Intermediate circuit capacitor of 14 C2-C4 Parasitic capacitances on motor and motor cable D1 Rectifier diode of 28 D7-D10 Rectifier diodes of 22 L Phase conductor of 26 L1 Inductance of 28 M1 Switch transistor of 28 M2-M7 transistors of 16 N Neutral conductor of 26 PE Protective earthing PR Reference potential R1, R2 Resistors of 30 R7 Insulation fault resistance R7a-R7d Insulation fault resistances SP Neutral point of 12 U, V, W Phases of 12, 16, 18 I.sub.R7 Fault current S1 Control signal for M1 S2-S7 Control signals for M2-M7 U.sub.+HV Intermediate circuit voltage Um Voltage captured by 30 U.sub.Netz Network voltage Uu, Uv, Uw Motor phase voltage