Electric motor using multiple reference frames for flux angle

Patent metadata

Field	Value
Publication number	US-9509240-B2
Application number	US-201514609242-A
Country	US
Kind code	B2
Filing date	Jan 29, 2015
Priority date	Dec 30, 2014
Publication date	Nov 29, 2016
Grant date	Nov 29, 2016

Abstract

A drive unit includes: an electric motor; a flux estimator circuit configured to estimate at least a flux angle; a synchronous frame generator coupled to a rotor of the AC induction motor and configured to detect a rotor mechanical angle; and a switch configured to selectively provide either the flux angle or the rotor mechanical angle for controlling the motor.

First claim

What is claimed is:

1. A drive unit comprising:
an electric motor;
a flux estimator configured to estimate at least a flux angle;
a synchronous frame generator coupled to a rotor of the electric motor and configured to detect a rotor mechanical angle;
a switch configured to selectively provide either the flux angle or the rotor mechanical angle for controlling the electric motor,
a motor control that uses a torque request,
a q current regulator, wherein the switch is configured to provide, based on a torque request and a q current being below a threshold, the rotor mechanical angle for controlling the electric motor; and
a d current regulator, wherein a d current reference for the d current regulator is set based on switching to the rotor mechanical angle for controlling the electric motor.

2. The drive unit of claim 1 , wherein the torque request is zero.

3. The drive unit of claim 2 , wherein the d current reference for the d current regulator is set to zero.

4. The drive unit of claim 3 , further comprising a flux regulator linked to the d current regulator, wherein the flux regulator is delinked from the d current regulator based on switching to the rotor mechanical angle for controlling the electric motor.

5. The drive unit of claim 1 , wherein the flux estimator circuit operates based on a DC bus voltage signal.

6. The drive unit of claim 1 , wherein the electric motor is configured to enter hibernation while the switch provides the rotor mechanical angle, wherein during the hibernation all current in the electric motor is lined up with the rotor mechanical angle.

7. A drive unit comprising:
an electric motor;
means for selectively providing either a flux angle or a rotor mechanical angle for controlling the electric motor;
means for setting a rotor mechanical angle as a reference frame instead of a stator flux angle based on a first requested torque and a flux of the electric motor being above a first threshold;
means for setting the stator flux angle as the reference frame instead of the rotor mechanical angle based on a second requested torque from the electric motor and a q current of the electric motor being below a second threshold; and
means for setting a d current reference for a d current regulator of the electric motor in response to setting the rotor mechanical angle as the reference frame.

8. A method comprising:
operating an electric motor, wherein a stator flux angle is a reference frame for a controller for the electric motor;
based on a requested torque from the electric motor being below a third threshold and a q current of the electric motor being below a first threshold, setting a rotor mechanical angle as the reference frame instead of the stator flux angle;
based on the requested torque being above a fourth threshold and a flux of the electric motor being above a second threshold, setting the stator flux angle as the reference frame instead of the rotor mechanical angle; and
in response to setting the rotor mechanical angle as the reference frame instead of the stator flux angle, setting a d current reference for a d current regulator of the electric motor.

9. The method of claim 8 , further comprising hibernating the electric motor while the switch provides the rotor mechanical angle, wherein during the hibernation all current in the electric motor is lined up with the rotor mechanical angle.

10. The method of claim 9 , further comprising setting a hibernation inhibition to prevent hibernation of the electric motor, wherein the electric motor is hibernated while the switch provides the rotor mechanical angle only if the hibernation inhibition is removed.

11. The method of claim 8 , wherein the d current reference is set to zero.

12. The method of claim 11 , wherein setting the d current reference to zero further comprises delinking a flux regulator from the d current regulator.

13. The method of claim 11 , further comprising evaluating, after setting the d current reference to zero, a current threshold as a condition for turning off an inverter of the electric motor.

14. The method of claim 11 , further comprising awaiting, after setting the d current reference to zero, a timer countdown as a condition for turning off an inverter of the electric motor.

15. The method of claim 8 , wherein an inverter of the electric motor is turned off while the rotor mechanical angle is set as the reference frame, the method further comprising turning the inverter back on upon the requested torque being nonzero.

16. The method of claim 8 , further comprising also taking into account a flux threshold as a condition for setting the rotor mechanical angle as the reference.

17. The method of claim 8 , further comprising taking into account a flux threshold as a condition for setting the stator flux angle as the reference frame.

18. The method of claim 17 , wherein the stator flux angle is provided by a flux estimator circuit, the method further comprising, before the flux threshold is met, seeding the flux estimator circuit with the rotor mechanical angle.

Assignees

• Tesla Motors Inc

Inventors

• Holveck Mark

Classifications

• H02P21/141 Primary

  Flux estimation · CPC title

• H02P6/181 Primary

  using different methods depending on the speed · CPC title

• H02P21/0021

  using different modes of control depending on a parameter, e.g. the speed · CPC title