Method for detecting a motor phase fault of a motor arrangement and drive circuit for driving an electronically commutated motor
11509254 · 2022-11-22
Assignee
Inventors
Cpc classification
H02H11/005
ELECTRICITY
H02P2201/15
ELECTRICITY
International classification
G05F1/70
PHYSICS
H02P23/00
ELECTRICITY
H02P29/024
ELECTRICITY
Abstract
In a method for detecting a motor phase fault of a motor arrangement, the motor phases of which are connected to a drive circuit having a DC voltage intermediate circuit and an inverter. A motor phase voltage at at least one of the motor phases with respect to a reference potential is captured while the inverter is switched off; and a voltage profile of the captured motor phase voltage is used to determine whether there is a motor phase fault on one of the motor phases of the motor arrangement.
Claims
1. A method for detecting a motor phase fault of a motor configuration, motor phases of the motor configuration being connected to a drive circuit having a DC voltage intermediate circuit and an inverter, wherein a first motor phase of the motor phases is connected to a first reference potential via at least one first resistor, and each other one of the motor phases is connected to a second reference potential via at least one further resistor, the method which comprises: while the inverter is switched off, capturing a divided motor phase voltage of the first motor phase by a voltage divider; using a voltage profile of the voltage measurement captured to determine whether there is the motor phase fault on one of the motor phases of the motor configuration; and quantitatively calculating a fault current value of an insulation fault during a fault check and/or a resistance value of the insulation fault and/or a maximum possible fault current value of the insulation fault during operation with the inverter switched on based on the motor phase voltage captured.
2. The method according to claim 1, which further comprises calculating the fault current value of the insulation fault during a fault check and/or the resistance value of the insulation fault solely on a basis of resistance values of the at least one first resistor and the at least one further resistor, a measurement voltage of the divided motor phase voltage, as captured by the voltage divider, a network voltage of a supply network and an intermediate circuit voltage across the DC voltage intermediate circuit.
3. The method according to claim 1, which further comprises calculating a maximum possible fault current value of the insulation fault during operation with the inverter switched on solely on a basis of resistance values of the at least one first resistor and the at least one further resistor, a measurement voltage of the divided motor phase voltage, as captured by means of the voltage divider, a network voltage of a supply network and an intermediate circuit voltage across the DC voltage intermediate circuit.
4. A method for operating a drive circuit having a DC voltage intermediate circuit, a power factor correction filter and an inverter for driving an electronically commutated motor, which further comprises: providing a motor configuration including motor phases connected to the inverter of the drive circuit, wherein the motor configuration includes the electronically commutated motor; checking for a presence of a motor phase fault in the motor configuration by: capturing a motor phase voltage from at least one of the motor phases with respect to a reference potential while the inverter is switched off; and using a voltage profile of the motor phase voltage captured to determine whether there is the motor phase fault on one of the motor phases of the motor configuration; and switching off the power factor correction filter when driving the electronically commutated motor after capturing the motor phase voltage if a maximum possible fault current value for an insulation fault on a motor phase below a predefined limit value has been determined.
5. A drive circuit for driving an electronically commutated motor, the drive circuit comprising: a power correction filter; a DC voltage intermediate circuit; an inverter connected to said DC voltage intermediate circuit, wherein the inverter is connectable to motor phases of a motor configuration including the electronically commutated motor, and wherein at least one of the motor phases of the electronically commutated motor is connected via resistors to a first reference potential and a second reference potential; a detection circuit for capturing a motor phase voltage from at least one of the motor phases with respect to a reference potential; and a controller configured to operate said detection circuit for capturing the motor phase voltage while said inverter is switched off and to determine, on a basis of a voltage profile of the motor phase voltage captured, whether there is a motor phase fault on one of the motor phases of the motor configuration; 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 motor phase fault has been determined.
6. The drive circuit according to claim 5, wherein said detection circuit has at least one first resistor, via which at least one motor phase is connected to the first reference potential, and at least one further resistor, via which the at least one motor phase is connected to the second reference potential.
7. The drive circuit according to claim 5, wherein said detection circuit has at least one first resistor, via which a first motor phase of the motor phases is connected to the first reference potential, and at least one further resistor, via which another motor phase of the motor phases is respectively connected to the second reference potential.
8. The drive circuit according to claim 5, wherein said detection circuit has a voltage divider for capturing the motor phase voltage.
9. The drive circuit according to claim 5, wherein said detection circuit is configured to capture the motor phase voltage when the at least one of the motor phases is connected to the first reference potential and the at least one of the motor phases or at least one other one of the motor phases is connected to a second reference potential.
10. A method for detecting a motor phase fault of a motor configuration, motor phases of the motor configuration being connected to a drive circuit having a DC voltage intermediate circuit and an inverter, which comprises the steps of: connecting at least one motor phase to a plus pole of a DC-bus via at least one first resistor; connecting the at least one motor phase to a minus pole of the DC-bus via at least one further resistor; capturing a divided motor phase voltage from at least one of the motor phases with respect to a reference potential while the inverter is switched off; and using a voltage profile of the motor phase voltage captured to determine whether there is the motor phase fault on one of the motor phases of the motor configuration.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
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DETAILED DESCRIPTION OF THE INVENTION
(14) Referring now to the figures of the drawings in detail and first, particularly to
(15) The drive circuit 10 is used to drive an electronically commutated motor 12. In the exemplary embodiment from
(16) 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 is connected to a supply network 26 via the AC connection 24. In the exemplary embodiment from
(17) Optionally, a power factor correction filter (PFC filter) 30 can also be connected between the rectifier 22 and the DC voltage intermediate circuit 14. The PFC filter 30 may be configured in a boost converter topology in this example and contains, in particular, an inductance L8, a switch M8 and a rectifier diode D5. The PFC filter 30 may optionally also be present in the other exemplary embodiments, even though it is not depicted in
(18) The drive circuit 10 also has a non-illustrated control device, for example in the form of a microcontroller, which controls the power semiconductor switches M1 to M6 of the inverter 16.
(19) In the case of such a drive circuit 10, there are various types of motor phase faults which can occur on the side of the connected motor 12. Insulation faults of the motor phases 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
(20) The drive circuit 10 has a detection circuit 28 for the purpose of detecting all of these insulation faults R7a, R7b, R7c, R7d.
(21) In addition, interruptions in the motor phases U, V, W can arise on account of a severed motor cable 18 or a burnt-out motor winding of the motor 12.
(22) The detection circuit 28 from
(23) The inverter 16 is switched off by switching off/opening all power semiconductor switches M1 . . . M6 of the inverter 16, with the result that the motor 12 connected to the motor phase connection 20 is not actively energized by the drive circuit 10. The fault check is preferably carried out by the detection circuit 28 not only when the inverter 16 is switched off, but also when the motor is at a standstill, with the result that no voltages can be induced by a rotor of the motor 12 which is still rotating.
(24) In the exemplary embodiment from
(25) It is now described, on the basis of
(26) The graphs from
(27) Since the insulation fault resistance is infinite in the fault-free case, the motor phase voltage Uu (for the case of R1+R2=R8+R9) assumes half the intermediate circuit voltage U.sub.+HV/2. As a comparison of the graphs in
(28) The fault current I.sub.R7 flows only when the diode D7 of the rectifier 22 is conductive in the positive half-wave of the network voltage U.sub.Netz and the diode D9 of the rectifier 22 is conductive in the negative have-wave of the network voltage U.sub.Netz. When the inverter 16 is switched off, this state occurs only when the network voltage U.sub.Netz exceeds half the value of the intermediate circuit voltage U.sub.+HV/2. As illustrated in
(29) The motor phase voltage Uu can be expressed as a function of the measured divided voltage Um by means of a simple voltage divider formula:
(30)
(31) In the positive half-wave of the network voltage U.sub.Netz, the insulation fault resistance R7 can be calculated by means of the following expression:
(32)
(33) and in the negative half-wave of the network voltage U.sub.Netz, the insulation fault resistance R7 can be calculated by means of the following expression:
(34)
(35) In the positive half-wave of the network voltage U.sub.Netz, the fault current I.sub.R7 during the fault check can be calculated by means of the following expression:
(36)
(37) and in the negative half-wave of the network voltage U.sub.Netz, the fault current I.sub.R7 during the fault check can be calculated by means of the following expression:
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(39) The maximum possible fault current I.sub.R7,max during operation with the inverter 16 switched on can be determined, on the basis of the quotient of the intermediate circuit voltage and the determined resistance value R7 of the insulation fault, during the positive half-wave of the network voltage U.sub.Netz by means of the following expression:
(40)
(41) and in the negative half-wave of the network voltage U.sub.Netz, the maximum possible fault current I.sub.R7,max can be calculated by means of the following expression:
(42)
(43) That is to say, the insulation fault resistances R7, the fault current values I.sub.R7 of the insulation fault and the maximum possible fault current values I.sub.R7,max during operation with the inverter 16 switched on can be calculated solely on the basis of the resistance values of the first and further resistors R1, R2, R8, R9 of the detection circuit 28, the measurement voltage Um of the divided motor phase voltage Uu, as captured by the voltage divider R1, R2 of the detection circuit 28, the intermediate circuit voltage U.sub.+HV across the DC voltage intermediate circuit 14 and the network voltage U.sub.Netz.
(44) In addition to the qualitative detection of an insulation fault, a quantitative detection of an insulation fault can also be carried out with the aid of the last two expressions. The maximum possible fault current values I.sub.R7,max calculated in this manner can be compared with predefined limit values, for example. An insulation fault is detected, for example, if a fault current value I.sub.R7 exceeds 6 mA. If, in contrast, only a small maximum possible fault current value I.sub.R7,max below a predefined limit value of 6 mA or 10 mA, for example, is determined, the motor 12 can then be operated at possibly low power with the PFC filter 30 switched off and a fault signal can also be transmitted to the user or customer service.
(45) The drive circuit 10 having the detection circuit 28 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.
(46) Referring to
(47) In the exemplary embodiment from
(48) The graphs from
(49) Since the insulation fault resistance is infinite in the fault-free case, the motor phase voltage Uu (for the case of R1+R2=R8+R9) assumes half the intermediate circuit voltage U.sub.+HV/2. As a comparison of the graphs in
(50) In the case of the three-phase power supply system, a fault current I.sub.R7 continuously flows in the event of a fault because at least one diode D7 . . . 12 of the bridge rectifier 22 is conductive at any time.
(51) The resistance values and fault currents of the insulation fault are calculated in the case of the three-phase power supply system using the same formulas as for the single-phase power supply system in the first exemplary embodiment.
(52) Referring to
(53) In the exemplary embodiment from
(54) The graphs from
(55) The resistance values and fault currents of the insulation fault are calculated in the case of the single-phase three-wire network using the same formulas as for the single-phase power supply system in the first exemplary embodiment.
(56) In the fault-free case, the motor phase voltage Uu assumes the following value:
(57)
(58) In the case of the single-phase three-wire network, a fault current I.sub.R7 flows only when the network voltage between the two outer conductors L1, L2 exceeds the following voltage value:
(59)
(60) Referring to
(61) In the exemplary embodiment from
(62) The graphs from
(63) In the fault-free case, the motor phase voltage Uu assumes the following value:
(64)
(65) In the case of the single-phase three-wire network, a fault current I.sub.R7 flows only when the network voltage between the two outer conductors L1, L2 exceeds the following voltage value:
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(67) In the positive half-wave of the network voltage U.sub.Netz, the insulation fault resistance R7 can be calculated by means of the following expression:
(68)
(69) and in the negative half-wave of the network voltage U.sub.Netz, the insulation fault resistance R7 can be calculated by means of the following expression:
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(71) In the positive half-wave of the network voltage U.sub.Netz, the fault current I.sub.R7 during the fault check can be calculated by means of the following expression:
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(73) and in the negative half-wave of the network voltage U.sub.Netz, the fault current I.sub.R7 during the fault check can be calculated by means of the following expression:
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(75) Accordingly, the maximum possible fault current I.sub.R7,max during operation with the inverter 16 switched on during the positive half-wave of the network voltage U.sub.Netz can be determined by means of the following expression:
(76)
and in the negative half-wave of the network voltage U.sub.Netz, the maximum possible fault current I.sub.R7,max can be calculated by means of the following expression:
(77)
(78) Referring to
(79) In a similar manner to the above embodiment variant of the detection circuit 28, the detection circuit 28′ has a voltage divider comprising two first resistors R1 and R2, via which a first motor phase (here: W) is connected, in a high-impedance manner, to earth as the first reference potential P1 in order to capture and evaluate the corresponding motor phase voltage Uw as the measurement voltage Um of the voltage divider R1, R2. In contrast to the above embodiment variant of the detection circuit 28, however, this first motor phase W is also not connected to the positive pole of the DC voltage intermediate circuit 14. Instead, the other motor phases U and V are each connected, in a high-impedance manner, to the positive pole of the DC voltage intermediate circuit 14 as the second reference potential P2 via two further resistors R3, R4 and R5, R6, respectively. A divided motor phase voltage Uw is therefore captured as the measurement voltage Um via the voltage divider R1, R2.
(80) If the drive circuit 10 is connected to single-phase or multi-phase power supply systems 26 and in the case of a total of three motor phases U, V, W, the sums of the resistance values R3+R4 and R5+R6 of the further resistors (for example approximately 2 megohms) are preferably twice as large as the sum of the resistance values R1+R2 of the first resistors (for example approximately 1 megohm), with the result that the measured motor phase voltage Um in the fault-free case again assumes half the intermediate circuit voltage, like in the preceding exemplary embodiments from
(81) The detection of an insulation fault R7a . . . c on a motor phase U, V, W and the calculations of the insulation fault resistance R7, the fault current I.sub.R7 during the fault check and the maximum possible fault current I.sub.R7,max during operation with the inverter 16 switched on are carried out in a similar manner to the fault checks described on the basis of
(82) 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, 28′ Detection circuit 30 Power factor correction filter (PFC filter) C1, C2 Intermediate circuit capacitor of 14 D1, D2 Rectifier diodes of 22 D5 Rectifier diode of 30 D7-D12 Rectifier diodes of 22 L1, L2, L3 Phase conductor of 26 L8 Inductance of 30 M1-M6 power semiconductor switches of 16 M8 Switch of 30 N Neutral conductor of 26 PE Protective earthing P1 First reference potential P2 Second reference potential R1, R2 First resistors of 28, 28′ R3, R4 Further resistors of 28′ R5, R6 Further resistors of 28′ R7 Insulation fault resistance R7a . . . d Insulation fault resistances R8, R9 Further resistors of 28 SP Neutral point of 12 U, V, W Motor phases of 12, 16, 18 X Interruption in a motor phase ΔI Capacitor current I.sub.R7 Fault current U.sub.+HV Intermediate circuit voltage U.sub.Lx Voltage captured by 28, 28′ U.sub.Netz Network voltage Uu,Uv,Uw Motor phase voltages