DETERMINATION OF STATOR WINDING RESISTANCE IN AN ELECTRIC MACHINE
20170126166 ยท 2017-05-04
Assignee
Inventors
- Dwarakanath V. Simili (Novi, MI, US)
- Jihoon Jang (Sunnyvale, CA, US)
- Sinisa Jurkovic (Sterling Heights, MI, US)
Cpc classification
H02P23/14
ELECTRICITY
H02P29/64
ELECTRICITY
H02P21/14
ELECTRICITY
International classification
H02P29/00
ELECTRICITY
Abstract
An electric machine assembly includes an electric machine having a stator and a rotor. The stator has stator windings at a stator winding temperature (t.sub.S) and the rotor is configured to rotate at a rotor speed (). A controller is operatively connected to the electric machine and has a processor and tangible, non-transitory memory on which is recorded instructions for executing a method for determining stator winding resistance. The controller is configured to determine a high-speed resistance factor (r.sub.H) which is based at least partially on the torque command (T*), the stator winding temperature (t.sub.S), the rotor speed (), a characterized torque error and the number of pole pairs (P). The controller may determine a total resistance value (R) based on a weighting factor (k), the high-speed resistance factor (r.sub.H) and the low-speed resistance factor (r.sub.L).
Claims
1. An electric machine assembly comprising: an electric machine including a stator and a rotor, the stator having stator windings at a stator winding temperature (t.sub.S) and the rotor being configured to rotate at a rotor speed (); wherein the electric machine defines a number of pole pairs (P); a controller operatively connected to the electric machine and configured to receive a torque command (T*); wherein, the controller has a processor and tangible, non-transitory memory on which is recorded instructions for executing a method for determining stator winding resistance; and wherein execution of the instructions by the processor causes the controller to determine a high-speed resistance factor (r.sub.H) for the stator windings, the high-speed resistance factor (r.sub.H) being based at least partially on the torque command (T*), the stator winding temperature (t.sub.S), the rotor speed () and the number of pole pairs (P); wherein the controller is configured to determine a low-speed resistance factor (r.sub.L) for the stator windings based at least partially on a predefined wire coefficient (), a measured stator resistance (r.sub.0) at a predefined measuring temperature (t.sub.0), and a temperature difference between the stator winding temperature (t.sub.S) and a predefined measuring temperature (t.sub.0) such that: r.sub.L=[r.sub.0(1+*(t.sub.S-t.sub.0)]; and wherein the controller is further configured to determine a total resistance (R) for the stator windings based at least partially on a weighting factor (k), the high-speed resistance factor (r.sub.H) and the low-speed resistance factor (r.sub.L) such that: R=[k*r.sub.H+(1-k)*r.sub.L] and 0<k<1.
2. The assembly of claim 1, further comprising: a first temperature sensor operatively connected to the controller and configured to measure the stator winding temperature (t.sub.S); a second temperature sensor operatively connected to the controller and configured to measure a rotor temperature; and a magnetic flux sensor operatively connected to the controller and configured to measure a magnetic flux of the electric machine.
3-4. (canceled)
5. The assembly of claim 1, wherein: the weighting factor (k) is one when the rotor speed () is above a predefined high speed threshold; and the weighting factor (k) is zero when the rotor speed () is below a predefined low speed threshold.
6. The assembly of claim 1, wherein determining the high-speed resistance factor (r.sub.H) includes: obtaining a first function (F.sub.1), via the controller, as a product of a look-up factor and the torque command (T*), wherein the look-up factor is based at least partially on the rotor speed (), the stator winding temperature (t.sub.S) and a characterized torque error; and wherein the characterized torque error is defined as a difference between two independent estimates of torque produced by the machine.
7. The assembly of claim 6, wherein determining the high-speed resistance factor (r.sub.H) includes: obtaining a second function (F2), via the controller, as a sum of the first function (F1), a torque achieved (T.sub.a) at a rotor temperature and a predefined first constant (Y) such that: F.sub.2=(F.sub.1+T.sub.a+Y).
8. The assembly of claim 7, wherein determining the high-speed resistance factor (r.sub.H) includes: obtaining a third function (F3), via the controller, as a product of a stator winding resistance (r.sub.C) at a baseline temperature and a torque achieved (T.sub.C) at the baseline temperature such that: F.sub.3=(T.sub.C*r.sub.C).
9. The assembly of claim 8, wherein determining the high-speed resistance factor (r.sub.H) includes: obtaining a fourth function (F4), via the controller, as a difference between the magnetic flux (.sub.tr) at the rotor temperature and the magnetic flux (.sub.C) at the baseline temperature such that: F.sub.4=(.sub.tr-.sub.C).
10. The assembly of claim 9, wherein determining the high-speed resistance factor (r.sub.H) includes: obtaining a fifth function (F.sub.5), via the controller, as a product of the pole pair (P), the rotor speed (), a commanded current (i.sub.d) and an inductance factor (L.sub.d0) such that: F.sub.5=[P**i*hd d*L.sub.d0].
11. The assembly of claim 10, wherein determining the high-speed resistance factor (r.sub.H) includes obtaining the high-speed resistance factor (r.sub.H) based at least partially on the second function (F.sub.2), the third function (F.sub.3), the fourth function (F.sub.4) and the fifth function (F.sub.5) such that: r.sub.H=[1/(2* F.sub.2)][2*F.sub.3(3*F.sub.4*F.sub.5)].
12. A method for determining stator winding resistance in an electric machine assembly, the electric machine assembly including an electric machine with a stator having stator windings, a rotor configured to rotate at a rotor speed () and a controller operatively connected to the electric machine, the controller having a processor and tangible, non-transitory memory, the method comprising: determining a high-speed resistance factor (r.sub.H) for the stator windings based at least partially on the torque command (T*), the stator winding temperature (t.sub.S), the rotor speed () and the number of pole pairs (P); determining a low-speed resistance factor (r.sub.L) for the stator windings based at least partially on a predefined wire coefficient (), a measured stator resistance (r.sub.0) at a predefined measuring temperature (t.sub.0), a temperature difference between the stator winding temperature (t.sub.S) and a predefined measuring temperature (t.sub.0) such that: r.sub.L=[r.sub.0 (1+*(t.sub.S-t.sub.0)]; determining a total resistance (R) for the stator windings based at least partially on a weighting factor (k), the high-speed resistance factor (r.sub.H) and the low-speed resistance factor (r.sub.L) such that: R=[k* r.sub.H+(1-k)*r.sub.L] and 0<k<1; and controlling the electric machine based upon the total resistance (R) for efficiency.
13-14. (canceled)
15. The method of claim 12, wherein determining the high-speed resistance factor (r.sub.H) includes: obtaining a first function (F.sub.1) as a product of a look-up factor and the torque command (T*), wherein the look-up factor is based at least partially on the rotor speed (), the stator winding temperature (t.sub.S) and a characterized torque error.
16. The method of claim 15, wherein determining the high-speed resistance factor (r.sub.H) includes: obtaining a second function (F.sub.2) as a sum of the first function (F.sub.1), a torque achieved at the rotor temperature (T.sub.tr) and a predefined first constant (Y) such that: F.sub.2=(F.sub.1+T.sub.tr +Y); and obtaining a third function (F.sub.3) as a product of a stator winding resistance (r.sub.C) at a baseline temperature and a torque achieved (T.sub.C) at the baseline temperature such that: F.sub.3=(T.sub.C* r.sub.C).
17. The method of claim 16, wherein determining the high-speed resistance factor (r.sub.H) includes: obtaining a fourth function (F.sub.4) as a difference between a magnetic flux (.sub.tr) at a rotor temperature and a magnetic flux (.sub.C) at a baseline temperature such that: F.sub.4=(.sub.tr-.sub.C).
18. The method of claim 17, wherein determining the high-speed resistance factor (r.sub.H) includes: obtaining a fifth function (F.sub.5) as a product of the pole pair (P), the rotor speed (), a commanded current (i*.sub.d) and an inductance factor (L.sub.d0) such that:
F.sub.5=[P**i*.sub.d*L.sub.d0].
19. The method of claim 18, wherein determining the high-speed resistance factor (r.sub.H) includes: obtaining the high-speed resistance factor (r.sub.H) based at least partially on the second function (F.sub.2), the third function (F.sub.3), the fourth function (F.sub.4) and the fifth function (F.sub.5) such that: r.sub.H=[1/(2*F.sub.2)][2*F.sub.3(3*F.sub.4*F.sub.5)].
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0011]
[0012]
[0013]
[0014]
DETAILED DESCRIPTION
[0015] Referring to the drawings, wherein like reference numbers refer to like components,
[0016] Referring to
[0017] The stator 14 includes a stator core 24 which may be cylindrically shaped with a hollow interior. The stator core 24 may include a plurality of inwardly-protruding stator teeth 26A-F, separated by gaps or slots 28. In the embodiment shown in
[0018] Electric current flowing in the stator windings 30 causes a rotating magnetic field in the stator 14. Referring to
[0019] Referring to
[0020] The controller 40 of
[0021] Referring to
[0022] Referring now to
[0023] In step 102A of
[0024] To obtain the look-up factor, characterization data is taken at various rotor speeds () at a baseline temperature (C). The baseline temperature (C) may be varied based on the particular application. In one example, the baseline temperature (C) is 90 Celsius. The look-up factor is based at least partially on the rotor speed (), the stator winding temperature (t.sub.S) and a characterized torque error. The characterized torque error (T) is defined as the difference between a first torque estimate T1 (i.e., torque estimated using a first method) and a second torque estimate T2 (i.e., torque estimated using a second method), such that (T=T1-T2). The first method of estimating torque may be a current-based flux map method at the baseline temperature (C), as known to those skilled in the art. The second method of estimating torque may be an active power-based method at the baseline temperature (C), as known to those skilled in the art. Any two different methods of estimating torque known to those skilled in the art may be employed.
[0025] Referring to
[0026] As shown in
[0027] In step 102B of
[0028]
[0029] Here, P.sub.mech is defined as the mechanical output power of the machine, P.sub.dc is defined as the DC power into the machine 12 and may be obtained as the product of the DC link voltage (V.sub.dc) (e.g., voltage from a battery pack 56 operatively connected to the machine 12) and the DC current (i.sub.dc). Additionally, P.sub.inv.sub._.sub.loss is defined as the inverter loss (converting DC to AC). It may be a nonlinear polynomial, based on the inverter models known to those skilled in the art. P.sub.Stat-loss is defined as the loss or heat dissipated in the stator windings 30. The value of heat dissipated may be characterized or obtained with sensors or FEA models while the machine 12 is not in use.
[0030] In step 102C of
[0031] In step 102D of
[0032] In step 102E of
[0033] In step 102F of
r.sub.H=[1/(2*F.sub.2)][2*F.sub.3(3*F.sub.4*F.sub.5)].
[0034] In step 104 of
[0035] In step 106 of
R=[k*r.sub.H+(1-k)* r.sub.L] and 0k1.
The weighting factor (k) may be one when the rotor speed () is at or above a predefined high speed threshold (e.g., 5000 rpm). The weighting factor (k) may be zero when the rotor speed () is at or below a predefined low speed threshold (e.g. 3000 rpm).
[0036] In summary, execution of the method 100 by the controller 40 determines stator winding resistance at high motor speeds corresponding to the torque command (T*), which includes the effect of AC resistance that is known to change with stator winding temperature. The method 100 utilizes magnetic flux (from a magnetic flux sensor 50 or FEA model) and the difference between two independent torque estimations, such as for example, using current-based (flux map) and active power-based estimates of torque. Stator resistance variation at high speed is non-linear and varies with operating temperature and current. Real time accurate estimation of stator winding resistance allows for improved utilization of the available DC link (such as provided by battery pack 56), thereby increasing peak torque and motor efficiency.
[0037] The controller 40 (and execution of the method 100) improves the functioning of the assembly 10 by determining the stator winding resistance of a complex system with minimal calibration required. The controller 40 of
[0038] The controller 40 of
[0039] Look-up tables, databases, data repositories or other data stores described herein may include various kinds of mechanisms for storing, accessing, and retrieving various kinds of data, including a hierarchical database, a set of files in a file system, an application database in a proprietary format, a relational database management system (RDBMS), etc. Each such data store may be included within a computing device employing a computer operating system such as one of those mentioned above, and may be accessed via a network in any one or more of a variety of manners. A file system may be accessible from a computer operating system, and may include files stored in various formats. An RDBMS may employ the Structured Query Language (SQL) in addition to a language for creating, storing, editing, and executing stored procedures, such as the PL/SQL language mentioned above.
[0040] The detailed description and the drawings or figures are supportive and descriptive of the disclosure, but the scope of the disclosure is defined solely by the claims. While some of the best modes and other embodiments for carrying out the claimed disclosure have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims. Furthermore, the embodiments shown in the drawings or the characteristics of various embodiments mentioned in the present description are not necessarily to be understood as embodiments independent of each other. Rather, it is possible that each of the characteristics described in one of the examples of an embodiment can be combined with one or a plurality of other desired characteristics from other embodiments, resulting in other embodiments not described in words or by reference to the drawings. Accordingly, such other embodiments fall within the framework of the scope of the appended claims.