ELECTRIC MOTOR CONTROL

Abstract

Methods of operating electric motor systems that comprise electric motors comprising a rotor having a magnet mounted thereto. The electric motor is initially operated in an open loop mode in which the rotor angle is estimated based on the input voltage frequency. Once the motor is running at sufficient speed, a transition to closed loop mode operation is performed, wherein the rotor angle is determined using an observed back EMF. To provide a smoother open loop to closed loop transition, the rotor angle is determined during a transition period as a function of both the open loop rotor angle and the closed loop rotor angle.

Claims

1. A method of operating an electric motor system to provide a motor load, the electric motor system comprising: a motor the motor comprising: a stator; a rotor having a magnet mounted thereto; and an electric circuit that comprises one or more phases or windings for driving rotation of the rotor when the phases or windings receive an input voltage from an electrical power supply, the input voltage having a variable frequency; and a controller that is operable to determine a back EMF induced in the motor stator; the method comprising: during a start-up cycle in which the input voltage frequency is progressively increased: initially operating the motor in an open loop mode in which an open loop rotor angle is estimated based on the input voltage frequency; and when the input voltage frequency reaches a first frequency threshold value, transitioning to a closed loop mode in which a closed loop rotor angle is determined based on the back EMF determined by the controller such that when the input voltage frequency reaches a second frequency threshold value, the motor is operated in the closed loop mode, the first and second frequency threshold values thereby defining a transition period, wherein during the transition period the rotor angle is determined as a function of both the open loop rotor angle and the closed loop rotor angle.

2. The method of claim 1, wherein during the transition period the rotor angle is determined as a weighted average of the open loop rotor angle and the closed loop rotor angle.

3. The method of claim 1, wherein during the transition period the rotor angle is determined as a function of the input voltage frequency such that the determined rotor angle changes in a smooth and continuous manner from a first rotor angle value at the first frequency threshold value to a second rotor angle value at the second frequency threshold value.

4. The method of claim 3, wherein during the transition period the rotor angle, A, at a frequency, f, is determined according to the function: $A=\frac{A_1\left(f_2-f\right)}{\left(f_2-f_1\right)}+\frac{A_2\left(f-f_1\right)}{\left(f_2-f_1\right)}$ where f.sub.1 is the first frequency threshold value, f.sub.2 is the second frequency threshold value, A.sub.1 is the rotor angle at the first frequency threshold value, A.sub.2 is the rotor angle at the second frequency threshold value, and f is a frequency during the transition period such that f.sub.1<f<f.sub.2.

5. The method of claim 1, wherein during the transition period the rotor angle determination is performed in one or more discrete steps, with each discrete step using a different function of the open loop rotor angle and the closed loop rotor angle such that there is a gradual transition from the open loop rotor angle when the input voltage frequency is at the first threshold value to the closed loop rotor angle when the input voltage frequency is at the second threshold value.

6. The method of claim 5, wherein during the transition period the rotor angle is determined as a weighted average of the open loop rotor angle and the closed loop rotor angle, and wherein at each discrete step a different weighted average of the open loop rotor angle and the closed loop rotor angle.

7. An electric motor system comprising: a motor that comprises: a stator; a rotor having a magnet mounted thereto; and an electric circuit that comprises one or more phases or windings for driving rotation of the rotor when the phases or windings receive an input voltage from an electrical power supply, the input voltage having a variable frequency; and a controller that is operable to determine a back EMF induced in the motor stator, the controller further comprising a motor control circuit that is configured to: during a start-up cycle in which the input voltage frequency is progressively increased: initially operate the motor in an open loop mode in which an open loop rotor angle is estimated based on the input voltage frequency; and when the input voltage frequency reaches a first frequency threshold value, to cause the motor to start to transition to a closed loop mode in which a closed loop rotor angle is determined based on the back EMF determined by the controller such that when the input voltage frequency reaches a second frequency threshold value, the motor is operated in the closed loop mode, the first and second frequency threshold values thereby defining a transition period, wherein during the transition period the rotor angle is determined as a function of both the open loop rotor angle and the closed loop rotor angle.

8. The system of claim 7, wherein during the transition period the motor control circuit is configured to determine the rotor angle as a weighted average of the open loop rotor angle and the closed loop rotor angle.

9. The system of claim 7, wherein during the transition period the motor control circuit is configured to determine values for the rotor angle as a function of the input voltage frequency such that the determined rotor angle changes in a smooth and continuous manner from a first rotor angle value at the first frequency threshold value to a second rotor angle value at the second frequency threshold value.

10. The system of claim 9, wherein during the transition period the rotor angle, A, at a frequency, f, is determined according to the function: $A=\frac{A_1\left(f_2-f\right)}{\left(f_2-f_1\right)}+\frac{A_2\left(f-f_1\right)}{\left(f_2-f_1\right)}$ where f.sub.1 is the first frequency threshold value, f.sub.2 is the second frequency threshold value, A.sub.1 is the rotor angle at the first frequency threshold value, A.sub.2 is the rotor angle at the second frequency threshold value, and f is a frequency during the transition period such that f.sub.1<f<f.sub.2.

11. The system of claim 7, wherein during the transition period the motor control circuit is configured to determine values for the rotor angle in one or more discrete steps, with each discrete step using a different function of the open loop rotor angle and the closed loop rotor angle such that there is a gradual transition from the open loop rotor angle when the input voltage frequency is at the first threshold value to the closed loop rotor angle when the input voltage frequency is at the second threshold value.

12. The motor of claim 11, wherein during the transition period the motor control circuit is configured to determine the rotor angle as a weighted average of the open loop rotor angle and the closed loop rotor angle, and wherein at each discrete step a different weighted average of the open loop rotor angle and the closed loop rotor angle.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0031] FIG. 1 shows a schematic of a part of a motor according to an embodiment.

[0032] FIG. 2 shows a schematic of a part of a motor drive system for use with the motor of FIG. 1.

[0033] FIGS. 3a and b show schematically a hybrid control scheme where the motor is initially operated according to an open-loop mode to bring the motor up to speed, at which point a transition to closed-loop mode is made.

[0034] FIG. 4 shows the initial open-loop rotor alignment for a single pole pair permanent magnet synchronous motor.

[0035] FIG. 5 shows the rotor positions for open-loop acceleration for a single pole pair permanent magnet synchronous motor.

[0036] FIG. 6 shows the open loop variability of the rotor position compared to the stator field.

[0037] FIG. 7 shows a control circuit (block) for determining the rotor position during the transition period according to an embodiment.

[0038] Like reference numerals are used for like components where appropriate in the Figures.

DETAILED DESCRIPTION

[0039] FIG. 1 shows a schematic of a part of a motor 1 according to an embodiment of the technology described herein. The motor is a three-phase motor comprising a stator 2, a rotor 4, a permanent magnet 6 mounted on the rotor 4, and three phases or windings 7, 8, 9 (hereinafter referred to as windings) for driving rotation of a rotor. However, embodiments are contemplated in which the motor is a multi-phase motor other than a three-phase motor, and/or which comprise a number of windings other than three.

[0040] FIG. 2 shows a schematic of a part of a motor drive system for use with the motor of FIG. 1. In this embodiment, the motor drive system includes a DC power supply 10 having a positive terminal and a relatively negative terminal (e.g. a ground terminal), three motor phases or windings 7, 8, 9 for driving rotation of the rotor 4 (shown in FIG. 1), and a motor drive unit 12 comprising an inverter for selectively electrically connecting the motor phases or windings 7-9 to the positive and negative terminals of the power supply 10. In the depicted embodiment the three phases or windings 7-9 are electrically connected to each other by a first end of each of the windings being connected at a common point. The second end of each of the windings is connected to the motor drive unit 12. However, other configurations are contemplated herein. For example, the motor 1 may comprise only two phases or windings or more than three phases or windings. Alternatively, or additionally, the phases or windings 7-9 may not be connected at a common point. It is also contemplated that an AC power supply may be provided that is converted to provide said DC power supply 10.

[0041] The inverter in the motor drive unit 12 comprises a plurality of switches 14-16 that are closed and opened so as to connect and disconnect the second end of each phase or winding 7-9 to and from the positive and negative terminals of the power supply 10. More specifically, the second end of each phase or winding 7, 8, 9 is electrically connected to the positive terminal of the power supply 10 via its own switch 14a, 15a, 16a, such that when the switch is closed the second end of that phase or winding is connected to the positive terminal and when the switch is opened the second end of that phase or winding is disconnected from the positive terminal. The second end of each phase or winding is also electrically connected to the negative terminal of the power supply 10 via its own switch 14b, 15b, 16b, such that when the switch is closed the second end of that phase or winding is connected to the negative terminal and when the switch is opened the second end of the phase or winding is disconnected from the negative terminal.

[0042] In FIG. 2, there is also illustrated a controller 11 for the motor. This controller 11 may for example, and typically is, included in the same box as the inverter in the motor drive unit 12. For instance, the controller 11 is in embodiments configured to control the switching patterns of the switches 14-16 for the inverter to control the motor operation. The controller 11 is further configured to implement a back EMF observer algorithm that is operable to monitor a back EMF induced in the stator during motor operation. For example, the controller 11 may comprise a microprocessor that executes embedded software in order to control the motor operation and, as part of this overall control operation, executes a program for monitoring the back EMF, and determining the motor position and speed accordingly. Thus, the algorithm may calculate the motor position and speed based on measured currents and the motor phase voltages. The motor phase voltages may be inferred from the switching activity of the power transistors 14a, 14b, 15a, 15b, 16a, 16b. This can be used to operate the electric motor according to a ‘closed loop’ scheme, and in a “sensorless” manner, as will be explained further below.

[0043] Sensorless motor control has been an area of active research in the past decades. Sensorless methods have been developed aiming to avoid the reliance on position encoders and resolvers that are typically embedded within certain types of motors. Resolvers and position encoder devices are used to inform the motor controller of the rotor's angle. This angle is significant for certain motors, including permanent magnet synchronous motors, where the phase voltages, currents and the stator's magnetic field need to be oriented and synchronized to the rotor's magnetic field in order to produce torque.

[0044] Sensorless methods can be broadly classified to model-based, saliency based and open loop methods. Model based methods such as back EMF observers can only function at medium to high motor speed. For example, back EMF observers rely on electrical characteristics which are observable only when the motor when it is spinning. In particular, the back EMF voltage components e.sub.alpha and e.sub.beta are a function of speed and angle as per equations 1 and 2 below.

e.sub.alpha=.sup.−k.sub.e*ω*sin(ϑ)  Equation 1

e.sub.beta=k.sub.e*ω*cos(ϑ)  Equation 2

[0045] As a consequence, the back EMF observer cannot function at standstill and does not function very accurately at low speeds.

[0046] One way to accelerate a motor at high enough speed for the back EMF observer to function is to initially accelerate the motor using an ‘open loop’ control method. In such hybrid schemes the motor is accelerated in open loop and there is a transition point where the model-based method takes over to closed loop (see FIG. 3a). As shown in FIG. 3a, the motor is accelerated in an open loop mode operation and when the back EMF is high enough, the transition to closed loop operation takes place.

[0047] Note that an additional initial step prior to open loop acceleration is performed, namely the open loop alignment where the stator's magnetic field is oriented at a constant angle so as to allow the rotor's magnetic poles to align the opposite stator's magnetic poles as shown in FIG. 4. Thus, as shown in FIG. 4, the rotor 21 is initially aligned, at 0 deg, with the stator 22.

[0048] After the rotor initial position is ensured, the stators magnetic field angle increments gradually generating torque and rotation to the rotor. The angular speed of the stator's magnetic field is equal to with the average speed of the rotor as the N-S pole pairs of stator rotor are attracted to the equivalent opposite poles of the stator, as shown in FIG. 5.

[0049] The open loop to closed loop transition depicted in FIG. 3a is used extensively in industry. However, the present Applicants have recognised that this transition point can be mechanically harsh as there is a sudden transition between the rotor angle as determined in open loop mode and the rotor angle as determined in closed loop mode when the observer is enabled. The present Applicants therefore propose an improved method to enable a smoother transition between this open loop to closed loop sensorless operation, as shown in FIG. 3b. FIG. 3b thus shows a similar process to FIG. 3a, with an additional transitional regime between the open loop and closed loop operations according to an embodiment.

[0050] For instance, the gradual acceleration performed in the open-loop mode uses an internally calculated reference angle as a substitute to the position angle from the back EMF observer. This angle controls the motor stator currents in open loop operation. The physical angle between rotor position and stator current varies between 0 deg and 90 deg during open loop acceleration. The maximum motor efficiency situation where the stator's field is at 90 degrees in relation to the rotor will rarely be true in open loop operation. For instance, friction, inertia, load torque and selected acceleration will create substantial variability of open loop angle versus actual rotor angle as best shown in FIG. 6. In closed loop operation, where there is better (more accurate) knowledge of the rotor angle, the control can however better ensure the optimal motor operation at an angle of 90 deg. Thus, a mechanical shock can be caused if the open loop angle was to suddenly change to the optimal closed loop angle at the transition between the two operation modes.

[0051] To minimize the mechanical shock at the transition point between open loop and closed loop sensorless control, the present embodiment proposes to use transitional angles calculated as the weighted average between the internally calculated angle during open loop operation and the angle produced by the sensorless observer in closed loop operation. As shown in FIG. 7, this involves a control circuit (processing block) 30 having as inputs: [0052] calculated open loop angle 31 [0053] model based observer (closed loop) angle 32

[0054] The block calculates its output 33 as a weighted average where initially 100% is taken from the open loop angle 31, and as time progresses the model based observer angle 32 reaches 100% of the weighted average. This output 33 is then provided to the motor controller 11 for use in controlling the motor.

[0055] For example, a transitional angle A at a frequency f may be calculated according to the following formula:

[00002]$\begin{array}{cc}A=\frac{A_1\left(f_2-f\right)}{\left(f_2-f_1\right)}+\frac{A_2\left(f-f_1\right)}{\left(f_2-f_1\right)}& \mathrm{Equation}3\end{array}$

[0056] Where A.sub.1 is the open loop angle and A.sub.2 is the closed loop angle, and frequencies f.sub.1 and f.sub.2 are the limits of the transitional regime, with f.sub.1<f<f.sub.2. In this way, during the transition period as illustrated in FIG. 3b, the rotor angle is progressively varied from the open loop angle A.sub.1 to the closed loop angle A.sub.2 as the frequency is increased. This then ensures a smooth transition from open loop to closed loop operation. It will be appreciated that this is just one example and any suitable formula may be used to calculate appropriate transitional angles to provide a smoother transition. For example, in some cases, rather than using a smooth, continuous transition, as may be achieved using Equation 3, the rotor angle may be increased in a discrete or stepped manner.

[0057] The above methods ensure that the angle entering the control loops does not suffer sudden changes. This in turn ensures smooth motor control at all speeds. The technology described herein can therefore ensure smoother sensorless transition from open loop to closed loop control without an impact on control quality. This benefits the system stability and lowers mechanical stress leading to lower failure rates and lower noise levels.

[0058] Variations on the examples described above fall within the scope of the claims.