Control of a single coil BLDC motor
11515823 · 2022-11-29
Assignee
Inventors
Cpc classification
International classification
Abstract
A motor driver for driving a rotor of a single coil motor in a clockwise or counterclockwise rotation direction concerning a stator of the single coil motor is adapted for generating a position signal which is representative for the angular position of the rotor regarding the stator and comprises a controller which comprises a direction input to define the rotation direction of the rotor, and which is adapted for generating a driving signal for rotating the rotor in the defined rotation direction, wherein the driving signal is based on the position signal and is based on a signal indicative for an electrical lead angle wherein the signal indicative for the electrical lead angle is set such that the total lead angle is positive in both rotation directions of the rotor.
Claims
1. A motor driver for driving a rotor of a single coil motor in a clockwise or counterclockwise rotation direction with respect to a stator of the single coil motor, the motor driver being adapted for generating a position signal which is representative for an angular position of the rotor with respect to the stator wherein a lead angle of the position signal is the angle with which a zero crossing of the position signal is leading a north/south zero crossing of magnetic poles in the rotor, and comprising a controller which comprises a direction input to define the rotation direction of the rotor, and which is adapted for generating a driving signal for rotating the rotor in the defined rotation direction, wherein the driving signal is generated such that it has an electrical lead angle with respect to the position signal in function of the rotation direction of the rotor and is based on a signal which is indicative for the electrical lead angle, wherein the signal indicative for the electrical lead angle is set such that a total lead angle, which is a sum of the lead angle of the position signal and the electrical lead angle, is positive for both rotation directions of the rotor, wherein the at least one signal which is indicative for the electrical lead angle is predefined for each rotation direction.
2. The motor driver according to claim 1, wherein the signal indicative of the electrical lead angle is obtained by electrically setting the position signal in function of the rotation direction of the rotor and wherein the controller is adapted for generating the driving signal based on the position signal such that the electrical lead angle is set by the position signal.
3. The motor driver according to claim 1, the motor driver comprising an interface for retrieving the predefined signals, which are indicative for the electrical lead angles, from an external device.
4. The motor driver according to claim 1, the motor driver comprising an internal memory for retrieving the predefined signals which are indicative for the electrical lead angles.
5. The motor driver according to claim 1, wherein the one or more signals which are indicative for the electrical lead angles are determined based on one or more parameters that give an indication of the ratio of the resistance and inductance of the rotor.
6. The motor driver according to claim 1, wherein the at least one signal which is indicative for the electrical lead angle is determined based on a speed of the rotor.
7. The motor driver according to claim 1, wherein the position signal is generated by a position sensor which is a magnetic sensor.
8. The motor driver according to claim 1, wherein the controller comprises a wave form generator for generating the driving signal.
9. A motor system, comprising a single coil motor which comprises a rotor and a stator, the motor system comprising a motor driver according to claim 1, for driving the rotor of the single coil motor in a clockwise or counterclockwise direction with respect to the stator.
10. The motor driver according to claim 5, wherein a Hall sensor is positioned such that no substantial electrical lead angle adjustment is needed in one rotation direction.
11. The motor driver according to claim 6, wherein a Hall sensor is positioned at a substantially zero magnetic lead angle.
12. A method for driving a rotor of a single coil motor in a clockwise or counterclockwise rotation direction with respect to a stator, the method comprising: generating a position signal which is representative of an angular position of the rotor with respect to the stator, wherein a lead angle of the position signal is the angle with which a zero crossing of the position signal is leading a north/south zero crossing of magnetic poles in the rotor, defining a desirable rotation direction, generating a driving signal for rotating the rotor in the defined rotation direction, wherein the driving signal is generated such that it has an electrical lead angle with respect to the position signal in function of the rotation direction of the rotor and on a signal which is indicative for the electrical lead angle, wherein the signal indicative for the electrical lead angle is set such that a total lead angle, which is a sum of the lead angle of the position signal and the electrical lead angle, is positive for both rotation directions of the rotor, wherein the at least one signal which is indicative for the electrical lead angle is predefined for each rotation direction.
13. The method according to claim 12, the method comprising: electrically adjusting the position signal when changing the rotation direction of the rotor, generating the driving signal based on the adjusted position signal such that the electrical lead angle is changing due to changes in the adjusted position signal.
14. A motor driver for driving a rotor of a single coil motor in a clockwise or counterclockwise rotation direction with respect to a stator of the single coil motor, the motor driver being adapted for generating a position signal which is representative for an angular position of the rotor with respect to the stator wherein a lead angle of the position signal is the angle with which a zero crossing of the position signal is leading a north/south zero crossing of magnetic poles in the rotor, and comprising a controller which comprises a direction input to define the rotation direction of the rotor, and which is adapted for generating a driving signal for rotating the rotor in the defined rotation direction, wherein the driving signal is generated such that it has an electrical lead angle with respect to the position signal in function of the rotation direction of the rotor and is based on a signal which is indicative for the electrical lead angle, wherein the signal indicative for the electrical lead angle is set such that a total lead angle, which is a sum of the lead angle of the position signal and the electrical lead angle, is positive for both rotation directions of the rotor, wherein the at least one signal which is indicative for the electrical lead angle is predefined for each rotation direction, wherein the one or more signals which are indicative for the electrical lead angles are determined based on one or more parameters that give an indication of the ratio of the resistance and inductance of the rotor.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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(10) Any reference signs in the claims shall not be construed as limiting the scope.
(11) In the different drawings, the same reference signs refer to the same or analogous elements.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
(12) The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and the relative dimensions do not correspond to actual reductions to practice of the invention.
(13) The terms first, second and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequence, either temporally, spatially, in ranking or in any other manner. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.
(14) It is to be noticed that the term “comprising”, used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It is thus to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression “a device comprising means A and B” should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.
(15) Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.
(16) Similarly it should be appreciated that in the description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the detailed description are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separate embodiment of this invention.
(17) Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.
(18) In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.
(19) Where in embodiments of the present invention reference is made to a Hall effect sensor, reference is made to any kind of magnetic sensor, such as but not limited to a Magneto-Resistive sensor, or an Inductive sensor.
(20) Where in embodiments of the present invention reference is made to the driving signal, reference is made to the signal which generates a current through the motor coil of the single coil BLDC motor. The current may be generated by an average voltage difference over the motor coil generated by an output driver (e.g. a full bridge output driver). The driving signal may be a pulse width modulated (PWM) signal, or a linear controlled signal.
(21) The average voltage difference across the motor coil in case of an embodiment with supply VDD, may be anywhere between 0V and VDD. The current scales up accordingly.
(22) In a PWM driving method, the voltage is provided in a time interrupted way resulting in an average voltage difference over the coil. When neglecting resistive losses in the bridge driver and the motor coil of the single coil BLDC motor, the average voltage difference is 12V when driving the motor with a supply voltage VDD=12V and a DCout=100% PWM. With e.g. a DCout=50% PWM driving signal the average voltage difference is 6V over the coils. Also, when applying the PWM driving method the phase current scales up accordingly, and can be represented at any time as Icoil(t)=(VDD*DCout(t)−BEMF(t))/Z, in which Z is the impedance of the bridge driver and the motor coil, and in which BEMF is the Back Electromotive Force voltage induced into the coil by the rotating permanent magnets on the rotor.
(23) Where in embodiments of the present invention reference is made to the lead angle or lead time, reference is made to the relationship in angle or time between the starting position and the corresponding pole position. In the remaining of this patent description the term lead angle refers to lead angle or lead time.
(24) Where in embodiments of the present invention reference is made to a signal which is indicative for an electrical lead angle, reference is made to a signal which allows the controller to generate the driving signal with a specific electrical lead angle. The driving signal may be such that the total lead angle is positive for both rotation directions. The driving signal may be generated relative to the position signal such that the driving signal is leading the BEMF with the lead angle.
(25) Where in embodiments of the present invention reference is made to the zero magnetic lead angle, reference is made to the angle at which no force is applied to the rotor when applying a current through the coils. This is also referred to as the N/S zero crossing of the magnetic poles in the rotor. If the position sensor generates a position signal which is zero when the rotor is at this position, the position sensor is at the zero magnetic lead angle.
(26) Where in embodiments of the present invention reference is made to the magnetic lead angle, reference is made to the angle with which the zero crossing of the position signal is leading the N/S zero crossing of the magnetic poles in the rotor.
(27) In a first aspect embodiments of the present invention relate to a motor driver 100 for driving a rotor 211 of a single coil motor 210 in a clockwise or counterclockwise rotation direction with respect to a stator 212 of the single coil motor 210.
(28) The motor driver 100 is adapted for generating a position signal which is representative for the angular position of the rotor 211 with respect to the stator 212. It may therefore comprise a position sensor 110 or a component which implements a sensor-less method with what the rotor position can be retrieved and the position signal can be generated.
(29) The motor driver comprises a controller 120. The controller 120 comprises a direction input 150 to define the rotation direction of the rotor 211. The controller 120 is adapted for generating a driving signal for rotating the rotor in the defined rotation direction. The driving signal is generated based on the position signal and based on a signal which is indicative for an electrical lead angle wherein the signal indicative for the electrical lead angle is set in function of the rotation direction of the rotor 211.
(30) As will be illustrated later on, peaks in the resulting driving current through the coil can be reduced by generating a driving signal based on a signal which is indicative of the electrical lead angle and which is set in function of the rotation direction of the rotor, compared to a motor driver for which the electrical lead angle is not set in function of the rotation direction.
(31) In embodiments of the present invention the signal indicative of the electrical lead angle is obtained by electrically adjusting the position signal in function of the rotation direction of the rotor. The signal may thereby be delayed or advanced in function of the position signal. The change in electrical lead angle may for example range between 0 and 10 electrical degree, for high inductance motors this may increase up to 22 electrical degree, or even 35 electrical degree. The controller is thereby adapted for generating the driving signal based on the adjusted position signal such that the lead angle is changing due to the adjusted position signal.
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(34) In the example of
(35) In embodiments of the present invention at least one signal which is indicative for the electrical lead angle may be predefined for each rotation direction. This may for example be done in the component 130. The component 130 is an optional component. It is an internal memory in which predefined electrical lead angles (or signals indicative for the electrical lead angles) may be stored. These electrical lead angles (or indicative signals thereof) can be retrieved by the controller. Alternatively, or in combination therewith, the controller may be adapted for retrieving the predefined electrical lead angles (or indicative signals thereof) from an external device through the interface 140. In embodiments of the present invention the one or more signals which are indicative for the electrical lead angles are determined based on one or more parameters that give an indication of the ratio of the resistance and inductance of the rotor, the shape of the current wave form during an EHP while the rotor is rotating, the motor speed, etc. For instance, the rise time of a pulse can be such an indication. Such a test pulse may for example be applied before starting the motor.
(36) In embodiments of the present invention the signal indicative of the electrical lead angle of the driving signal may be defined as a fixed angle, or a fixed time, or a variable angle or time. The signal may be defined as a function of speed, current, or current shape. The signal indicative of the electrical lead angle may be set depending on the rotation direction of the motor, or the rotation direction in which the motor should be started. The advantage of defining the total lead angle by applying an electrical lead angle will be illustrated with the graphs of
(37) The controller itself is adapted for generating the driving signal for the motor 210. A complete motor system 200 according to a second aspect of the present invention, comprising a motor 210 and a motor driver 100 in accordance with embodiments of the present invention is also illustrated in
(38) In the example of
(39) In
(40) In
(41) In
(42) In
(43) From top to bottom, the following graphs are shown in
(44) As can be seen from these graphs, the eventual motor current shape is different depending on the hall sensor location versus the zero magnetic lead angle. The motor current shape is influenced by the voltage drive wave form, the motor inductance, the motor speed, the mechanical load, and others.
(45) In case the rotor should only rotate in one rotation direction, the optimal position of the hall sensor compared to the zero magnetic lead angle can be found by positioning the hall sensor with a small magnetic lead angle and evaluate the shape of the current. Based on the current shape it can be decided to further increase the magnetic lead angle or reduce the magnetic lead angle. Typical shapes of current are shown in
(46) The shape of the current at the optimal magnetic lead angle position offers several benefits compared to the other shapes. This current shape may offer a higher efficiency, a lower acoustic noise, lower vibrations, etc.
(47) As can be seen from
(48) The graphs in
(49) In embodiments of the present invention the driving signal is generated such that it has an electrical lead angle with respect to the position signal in function of the rotation direction of the rotor. The driving signal may be generated in phase with a signal indicative of the electrical lead angle. The signal indicative of the electrical lead angle may be obtained by delaying or advancing the position signal. As a result, the lead angle can be changed by delaying or advancing the position signal with the same lead or lag as the lead or lag adjustments of the position signal. The position signal may be an analog or a digital position signal.
(50) A preferred embodiment thereof is illustrated in
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(52) When changing the rotation direction of the rotor in this example in the CW direction this results in a big lag angle which is, according to embodiments of the present invention, compensated by applying an electrical lead angle.
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(54) The controller 120 comprises a lead angle generator 122 for controlling the electrical lead angle of the driving signal in function of the rotation direction of the rotor. This lead angle generator 122 may for example be configured for adjusting the position signal. In that case the wave form generator 121 may be adapted for generating the driving signal synchronous with the adjusted position signal.
(55) The controller 120 comprises an output for outputting an FG/RD signal.
(56) In this example the motor driver 100 comprises a position sensor 110 which is a Hall sensor. The Hall sensor analog signal is digitized before submitting it to the controller 120.
(57) The controller 120 receives optionally additional inputs from internal memory 130 (e.g. E2PROM) or through an external interface 140 (e.g. using a resistor or other discrete configurations) and defines the wave form, and either shifts the waveform over an additional time or number of electrical degrees depending on the configuration, or updates the waveform to reflect the electrical lead angle. This adjustment is done in function of the selected rotation direction and may be changing when changing the rotation direction. The direction can either be communicated through the PWM input, through some encoding, or through an external (for instance a dedicated input pin 150) or internal input (e.g. reprogramming of internal registers or E2PROM).
(58) In embodiments of the present invention the controller may be adapted for setting the electrical lead angle as function of the speed, the current or other parameters. In embodiments of the present invention the electrical lead angle may be calculated by the controller based on actual measurements, for instance of the motor coil inductance or L/R. Since the motor coil contains an inductance, any applied voltage shape will result with some delay in a current shape. Such delay may become significant when the commutation speed approaches the delay timing. Therefore, as speed increases, the applied voltage shape is shifted forward compared to the rotor position.
(59) For optimal efficiency the lead angle should increase as the mechanical commutation speed approaches the delay of the current versus the speed. Alternatively, a fixed lead time may be used, in which automatically as speed increases, the time is converted in a progressive angle.
(60) In some cases, it is desired that the lead angle increases more than proportionally and a reduction in efficiency is exchanged for some additional peak power.
(61) For starting the motor different startup methods may be applied. The controller may be adapted for applying a soft start method in one direction to minimize the inrush current (which causes audible noise and puts mechanical stress on the fan construction, thus limiting fan life time), and a more aggressive start in the opposite direction in order to jump over the zero torque position, and then fall back on the smoother start up.
(62) A controller according to embodiments of the present invention may be adapted for starting up the motor in the CW or CCW direction.
(63) In order to start up the fan in both directions, a modification may be implemented in the startup sequence of a controller in accordance with embodiments of the present invention. When the rotor of a motor with asymmetrical shoe poles is stopped close to the zero torque position, more current must be injected in order to jump over the zero torque point, compared to the other rotation direction.
(64) Such an adjustment may be implemented in the controller 120. The lead angle generator 122 may for example be adapted for increasing or decreasing the signal which is indicative for the electrical lead angle. This may for example be achieved by delaying or advancing the position signal.
(65) The motor driver may for example have two output pins OUT1 and OUT2 which can be connected with the single coil of the motor. When starting up, the controller may for be adapted for driving the motor according to the following table.
(66) TABLE-US-00001 Rotor polarisation Magnetic field at the stop position strength detected of the hall sensor by Hall sensor OUT 1 OUT2 Direction South pole B > B.sub.OP Low High CW North pole B < B.sub.RP High Low CW South pole B > B.sub.OP High Low CCW North pole B < B.sub.RP Low High CCW
(67) This table is only an example and depends on the winding connection of the motor. In this example the position sensor is a Hall sensor, and the thresholds B.sub.op and B.sub.RP are defined for determining how to start the motor. For starting up the motor, the controller may be configured such that when the Hall sensor detects a magnetic field B>B.sub.op the controller generates a driving signal such that OUT1 goes low, and OUT2 is the phase that goes high. This is illustrated by the first row in the table. For applications which include variable speed control, OUT2 can be controlled with a DCout output duty cycle. In this example the current flows in a first direction through the coil, such that the motor spins in CW direction due to electromagnetic interaction between the rotor magnet and the current through the stator coil.
(68) According to the second row in this table the controller generates a driving signal such that when B<Brp, OUT2 goes low, and OUT1 goes high, causing the current to flow in the opposite direction. Since the rotor magnet is opposite as well the rotor will spin again in the CW direction.
(69) In case the rotor should spin in the CCW direction, the reaction of the controller is adapted such that it generates a driving signal such that For B>Bop, OUT2 goes low, and OUT1 goes high. And for B<Brp, OUT1 goes low and OUT2 goes high.
(70) It is an advantage of embodiments of the present invention that an improved start and operation both in clockwise as in counterclockwise rotation direction can be achieved.
(71) In a third aspect embodiments of the present invention relate to a method for driving a rotor of a single coil motor in a clockwise or counterclockwise rotation direction with respect to the stator. The method comprises: generating a position signal which is representative for the angular position of the rotor with respect to the stator, defining a desirable rotation direction, generating a driving signal for rotating the rotor in the defined rotation direction, wherein the driving signal is based on the position signal and on a signal which is indicative for an electrical lead angle wherein the signal indicative for the electrical lead angle is set such that the total lead angle, which is the sum of the lead angle of the position signal and the electrical lead angle, is positive for both rotation directions of the rotor. In embodiments of the present invention the electrical lead angle is set in function of the rotation direction of the rotor.
(72) In embodiments of the present invention the method comprises: electrically adjusting the position signal in function of the rotation direction of the rotor, generating the driving signal based on the adjusted position signal such that the electrical lead angle is changing due to changes in the adjusted position signal.
(73) In embodiments of the present invention the signal which is indicative for the electrical lead angle is obtained by delaying or advancing the position signal.