Integrated motor driver/controller with sensorless or sensored commutation

Patent metadata

Field	Value
Publication number	US-9748882-B1
Application number	US-201615082534-A
Country	US
Kind code	B1
Filing date	Mar 28, 2016
Priority date	Mar 28, 2016
Publication date	Aug 29, 2017
Grant date	Aug 29, 2017

Abstract

A motor controller configured to control different types of electronically commutated motors (ECMs) includes a range of different rotor orientation signal inputs to accommodate differences between ECM motor types. The motor controller includes a control unit that receives motor operation commands and controls operation of the ECM in accordance with the motor operation commands. The control unit receives and stores data designating ECM type and estimates rotor position based on the designated ECM type.

First claim

What is claimed is:

1. A motor controller configured to control any designated one of at least three different types of electronically commutated motors (ECMs), the motor controller comprising:
a controller area network (CAN) connection;
a switching assembly configured to control current flow through a phase A stator coil of an ECM, a phase B stator coil of the ECM, and a phase C stator coil of the ECM;
a phase B current sensor configured to measure current flowing through the phase B stator coil;
a phase C current sensor configured to measure current flowing through the phase C stator coil;
rotor orientation signal inputs including:
one or more Hall sensor inputs configured to receive output generated by Hall sensors responsive to the ECM including the one or more Hall sensors configured to sense orientation of a rotor of the ECM; and
one or more encoder inputs configured to receive output generated by one or more encoders responsive to the ECM including the one or more encoders configured to sense orientation of the rotor; and

a control unit operatively coupled with the CAN connection, the rotor orientation signal inputs, the phase B current sensor, the phase C current sensor, and the switching assembly, the control unit being configured to:
receive D and Q axis current commands via the CAN connection;
receive data designating one of at least three different types of ECMs via the CAN connection and store the designated ECM type in memory, the at least three different types of ECMs including a) an ECM that includes one or more Hall sensors configured to sense rotor orientation, b) an ECM that includes one or more encoders configured to sense rotor orientation, and c) an ECM that does not include any sensors configured to sense rotor orientation; and
control the switching assembly to operate the ECM in accordance with the D and Q axis current commands using rotor orientation estimated based on at least one of a) the output generated by the one or more Hall sensors, b) the output generated by the one or more encoders, or c) outputs from the phase B current sensor and the phase C current sensor.

2. The motor controller of claim 1 , further comprising at least one of:
a brake input operatively connected to the control unit and independent of the CAN connection, the control unit being configured to control the switching assembly to operate the ECM in a braking mode that resists rotation of the rotor in response to a brake signal received via the brake input;
a sleep input operatively connected to the control unit and independent of the CAN connection, the control unit being configured to enter a sleep mode in which the motor controller has an input current of less than 5 milliamps in response to a sleep signal received via the sleep input;
a coast input operatively connected to the control unit and independent of the CAN connection, the control unit being configured to control the switching assembly to operate the ECM in a coasting mode that enables free rotation of the rotor in response to a coast signal received via the coast input; or
a safe boot input operatively connected to the control unit and independent of the CAN connection, the control unit being configured to control the switching assembly to not operate the ECM in response to a safe boot signal received via the safe boot input.

3. The motor controller of claim 1 , wherein the control unit is configured to receive commands via the CAN connection and output responses via the CAN connection that are invariant of the designated ECM type.

4. The motor controller of claim 1 , wherein the control unit is configured to control the switching assembly to employ field weakening for limited motor drive when line to line back electromotive force (EMF) exceeds a battery voltage used to drive the ECM.

5. A motor controller configured to control any designated one of a plurality of different types of electronically commutated motors (ECMs), the motor controller comprising:
an operational command connection;
a switching assembly configured to control current flow through a phase A stator coil of an ECM, a phase B stator coil of the ECM, and a phase C stator coil of the ECM;
rotor orientation signal inputs; and
a control unit operatively coupled with the operational command connection, the rotor orientation signal inputs, and the switching assembly, the control unit being configured to:
receive motor operation commands via the operational command connection;
receive data designating one of a plurality of different types of ECMs, the plurality of different types of ECMs including at least two of a) an ECM that includes one or more Hall sensors configured to generate output indicative of rotor orientation, b) an ECM that includes one or more encoders configured to generate output indicative of rotor orientation, and c) an ECM that does not include any sensors configured to generate output indicative of rotor orientation; and
control the switching assembly to operate the ECM in accordance with the motor operation commands using rotor orientation estimated based on at least two of a) the output generated by the one or more Hall sensors responsive to the designated ECM type including the one or more Hall sensors, b) the output generated by one or more encoders responsive to the designated ECM type including the one or more encoders, or c) outputs from a phase B current sensor and a phase C current sensor responsive to the designated ECM type not including any sensors.

6. The motor controller of claim 5 , wherein the control unit is configured to estimate initial rotor orientation by measuring inductance of the ECM and selecting an initial rotor orientation based on the measured ECM inductance.

7. The motor controller of claim 5 , wherein:
the operational command connection comprises a controller area network (CAN) connection; and
the control unit is configured to receive commands via the CAN connection and output responses via the CAN connection that are invariant of the designated ECM type.

8. The motor controller of claim 5 , wherein the control unit is configured to control the switching assembly to operate the ECM in a braking mode that resists rotation of the rotor in response to a brake signal received via a brake signal input.

9. The motor controller of claim 5 , wherein the control unit is configured to enter a sleep mode in which the motor controller has an input current of less than 5 milliamps in response to a sleep signal received via a sleep input.

10. The motor controller of claim 5 , wherein the control unit is configured to control the switching assembly to operate the ECM in a coasting mode that enables free rotation of the rotor in response to a coast signal received via a coast signal input.

11. The motor controller of claim 5 , wherein the control unit is configured to load a recovery-mode firm-ware image from memory in response to a safe boot signal received via a safe boot input.

12. The motor controller of claim 5 , wherein the control unit is configured to control the switching assembly to employ field weakening for limited motor drive when line to line back electromotive force (EMF) exceeds a battery voltage used to drive the ECM.

13. The motor controller of claim 5 , further comprising the phase B current sensor configured to measure current flowing through the phase B stator coil and the phase C current sensor configured to measure current flowing through the phase C stator coil, and wherein the control unit is configured to estimate rotor orientation based on the outputs from the phase B current sensor and the phase C current sensor responsive to the designated ECM type

Assignees

• Amazon Tech Inc

Inventors

• Breheny Sean Hugh
• Hayward Shaun Steven
• Trenholme Kevin John
• Garcen Sean
• Sullivan William Joseph

Classifications

• H02P6/185

  using inductance sensing, e.g. pulse excitation · CPC title

• H02P21/06 Primary

  Rotor flux based control involving the use of rotor position or rotor speed sensors · CPC title

• H02P6/14

  Electronic commutators · CPC title

• H02P3/06

  for stopping or slowing an individual dynamo-electric motor or dynamo-electric converter · CPC title

• H02P27/06

  using DC to AC converters or inverters (H02P27/05 takes precedence) · CPC title