System and method for controlling a motor

Patent metadata

Field	Value
Publication number	US-9825560-B2
Application number	US-201414489078-A
Country	US
Kind code	B2
Filing date	Sep 17, 2014
Priority date	Sep 17, 2014
Publication date	Nov 21, 2017
Grant date	Nov 21, 2017

Abstract

An interleaved bridgeless power factor correction (PFC) converter-based motor drive system is provided. The system includes a first inductor coupled to a second inductor. The coupled first and second inductors are coupled to a first input configured to be coupled to a first line of an alternating current (AC) power supply. The system also includes a third inductor coupled to a fourth inductor. The coupled third and fourth inductors are coupled to a second input configured to be coupled to a second line of the AC power supply. The system further includes a digital active power factor correction (PFC) controller configured to cause current in at least one of the coupled first and second inductors and the coupled third and fourth inductors to be interleaved.

First claim

What is claimed is:

1. A motor drive system comprising: a first inductor coupled to a second inductor by a first common toroid core having two windings to boost inductance, said coupled first and second inductors comprising a first side commonly coupled to a first input configured to be coupled to a positive line input of an alternating current (AC) power supply;
a third inductor coupled to a fourth inductor by a second common toroid core having two windings to boost inductance, said coupled third and fourth inductors comprising a first side commonly coupled to a second input configured to be coupled to a negative line input of the AC power supply,
a digital active power factor correction (PFC) controller coupled to at least one switch having a first terminal coupled to an output of one of said first, second, third, and fourth inductors and a second terminal coupled to one of a first and a second shunt resistor, said digital active PFC controller is configured to:
receive a measured value of the at least one operating parameter of said interleaved bridgeless PFC converter-based motor drive system;
determine a duty cycle using the measured value of the at least one operating parameter:
output a pulse width modulation (PWM) signal for controlling said at least one switch in accordance with the determined duty cycle; and
configured to cause current in at least one of said coupled first and second inductors and said coupled third and fourth inductors to be interleaved.

2. The motor drive system of claim 1 , further comprising an integrated choke coupled between said first input and said coupled first and second inductors, and said second input and said coupled third and fourth inductors.

3. The motor drive system of claim 2 , wherein said integrated choke comprises a toroid core, a first winding, and a second winding, said integrated choke is configured to increase common mode inductance for suppressing common mode electromagnetic interference (EMI).

4. The motor drive system of claim 3 , wherein said integrated choke has a common mode inductance between about 10 mH and about 20 mH.

5. The motor drive system of claim 1 , wherein said integrated choke comprises a toroid core and a plurality of ferrite blocks within said toroid core, said integrated choke is configured to increase differential mode inductance for suppressing differential mode EMI.

6. The motor drive system of claim 5 , wherein said integrated choke has a differential mode inductance between about 200 μH and about 300 μH.

7. The motor drive system of claim 1 , further comprising a first shunt resistor and a second shunt resistor, each of said first and second shunt resistors having a first terminal coupled to two semiconductor switches and a second terminal coupled to a negative rail of a DC-link capacitor.

8. The motor drive system of claim 1 , wherein the at least one operating parameter includes at least one of an input voltage, a DC link voltage, and a total return current from said at least one switch.

9. The motor drive system of claim 1 , wherein said digital active PFC controller is further configured to:
subtract a measured DC link voltage from a reference voltage to determine a voltage error signal;
multiply the voltage error signal and a measured input voltage; and
filter the multiplied voltage error signal and measured input voltage to determine a current reference signal and to reduce zero-crossing distortion of inductor current from said first, second, third, and fourth inductors.

10. The motor drive system of claim 9 , wherein said digital active PFC controller is further configured to:
receive a measured total return current from a current sensing circuit;
calculate a difference between the current reference signal and the measured total return current;
filter the calculated difference to obtain the duty cycle; and
output the pulse width modulation (PWM) signal for controlling said at least one switch in accordance with the determined duty cycle.

11. The motor drive system of claim 10 , wherein said digital active PFC controller is further configured to:
compare the duty cycle to a triangle signal induced by a timer that ranges from 0 to 1 to obtain a first PWM signal; and
subtract the duty cycle from a unity value of 1 and compare the subtracted duty cycle value to the triangle signal to obtain a second PWM signal.

12. The motor drive system of claim 1 , wherein said digital active PFC controller is further configured to provide active current-sharing control to balance current between said coupled first and second inductors and said coupled third and fourth inductors.

13. The motor drive system of claim 12 , wherein to provide active current-sharing control, said digital active PFC controller is further configured to:
calculate current information of said first shunt when said at least one switch is ON to determine an average current of the corresponding inductor current in a first boost converter;
calculate half of the total return current in said second shunt;
process an error signal between the average current of the corresponding inductor current and the calculated half of the total return current; and
add the processed error signal to the PWM signal to adjust e duty cycle.

14. A method of controlling an interleaved bridgeless power factor correction (PFC) converter-based motor drive system, said method comprising:
coupling a first inductor to a second inductor using a first common toroid core having two windings to boost inductance, the coupled first and second inductors having a first side commonly coupled to a first input configured to be coupled to a positive line input of an alternating current (AC) power supply;
coupling a third inductor to a fourth inductor using a second common toroid core having two windings to boost inductance, the coupled third and fourth inductors comprising a first side commonly coupled to a second input configured to be coupled to a negative line input of the AC power supply;
receiving, by a digital active PFC controller, a measured value of at least one operating parameter of the interleaved bridgeless PFC converter-based motor drive system;
determining, by the digital active PFC controller, a duty cycle using the measured value of the at least one operating parameter; and
outputting, by the digital active PFC controller, a pulse width modulation (PWM) signal to cause current in at least one of the coupled first and second inductors on the positive line input and the coupled third and fourth inductors on the negative line input to be interleaved.

15. The method of claim 14 , further comprising:
subtracting a measured DC link voltage from a reference voltage to determine a voltage error signal;
multiplying the voltage error al and a measured input voltage; and
filtering the multiplied voltage error signal and measured input voltage to determine a current reference signal and to reduce zero-crossing distortion of inductor current from the first, second, third, and fourth inductors.

16. The method of claim 15 , further comprising:
receiving a measured total return current from a current sensing circuit;
calculating a difference between the current reference signal and the measured total return current;
filtering the calculated difference to obtain the duty cycle; and
outputting the PWM signal for controlling at least one switch in accordance with the determined duty cycle.

17. The method of claim 16 , further comprising:
comparing the duty cycle to a triangle signal induced by a timer that ranges from 0 to 1 to obtain a first

Assignees

• Regal Beloit America Inc

Inventors

• Li Ming
• Yi Peizhong
• Becerra Roger Carlos
• Chretien Ludovic Andre

Classifications

• H02P2201/09

  Boost converter, i.e. DC-DC step up converter increasing the voltage between the supply and the inverter driving the motor · CPC title

• H02P2201/15

  Power factor correction [PFC] circuit generating the DC link voltage for motor driving inverter · CPC title

• H01F17/04

  with magnetic core · CPC title

• H02M3/1584

  with a plurality of power processing stages connected in parallel · CPC title

• H02M2001/123

  Electricity · mapped topic