The present disclosure generally relates to methods and apparatus to drive coils or windings of multiphase electric machines (e.g., electric motor, an induction motor, generator), and in particular to methods and apparatus employing coil driver modulation techniques.
Voltage source inverters (VSI) utilize an energy storage element on a DC link to provide a fixed, low AC impedance, DC voltage to the switching elements. The storage element is generally a capacitor, but can also be other types of storage elements, for example voltage sources, for instance a primary or secondary chemical battery (e.g., a lithium ion battery), or the like. The DC voltage is then applied to a load via switches to generate the desired output voltage via variable ON time, fixed frequency, i.e., duty cycle, or less typically a combination of variable ON time and variable frequency. The switches are generally semiconductor switches (e.g., Metal Oxide Field Effect Transistors (MOSFETs), Insulated Gate Bipolar Transistors (IGBTs)).
Although analog control is possible, most inverters employ a Pulse Width Modulation (PWM) pattern using a microcontroller with specifically designed timer/counter blocks. The main principle of PWM technique is that through ON/OFF control on the switches (e.g., semiconductor switches), a series of pulses with the same amplitude and different width are generated on an output port to replace the sinusoidal wave or other waveforms typically used. The duty cycle of the output waveform needs to be modulated by a certain rule and as a result both the output voltage and output frequency of the inverter can be regulated.
The most common approach is called “center aligned PWM”, where all the pulses for the various phases (e.g., three phases) use the same “timer top”. Another approach is called “edge aligned PWM” where all of the phases (e.g., three phases) share the leading edge, but turn OFF at different times to generate the desired average voltage per phase.
Due to an interaction between the three generated line voltages in a conventional three phase inverter there is not a lot of flexibility in varying the way the duty cycles are applied to the output in order to generate the desired voltages.
The energy storage element on the DC link supplies the current, and the switches are operated at the PWM frequency to generate the desired output voltage/current. Generating the desired output voltage/current puts a large ripple current stress on the storage element. A general rule of thumb is that a DC link storage element worst case Root Mean Square (RMS) ripple current exposure is approximately 0.6× the RMS phase current. As an example, a 100 A RMS per phase inverter would generate about 60 A RMS ripple current in the DC link storage element.
The large RMS current requirement on a DC link storage element drives both cost and size/weight. Therefore reducing the RMS current results in a cost and size/weight reduction for motor drives.
The PWM drive scheme described herein in conjunction with an inverter topology comprising a pair of half bridges (H bridges) and a series switch can advantageously provide a large reduction in RMS ripple current stress on the DC storage element. The described motor drive topology, where there is essentially no PWM or voltage interaction between phases, makes it possible to change the PWM pattern(s) to reduce the ripple current stress on the storage element.
It should be noted that modulator angle refers to an angle of a saw tooth carrier generating the PWM for each H bridge. This saw tooth carrier can be an analog voltage used to compare against the demand by a comparator, or a waveform generated by count up/down timers and counter compare.
Compared to conventional three phase inverters, the disclosed coil driver utilizing the disclosed modulation method has much lower ripple current, peak-to-peak current, and raises the order of the harmonic content. This greatly simplifies capacitor and EMI filter design and reduces their size/weight.
According to one aspect, an apparatus may be summarized as a coil driver for each phase of a multi-phase electric machine that comprises:
According to one aspect, in the first mode an angle of a modulator carrier varies to drive each phase of a pulse width modulated pattern.
According to one aspect, in the first mode the angle of the modulator carrier varies for each phase by one of +/−120 degrees and +/−60 degrees.
According to one aspect, in the second mode two H bridges drive identical current.
According to one aspect, in the second mode two identical currents are interleaved.
According to one aspect, in the second mode a modulator carrier varies to drive each phase with a carrier angle offset between at least 60° and 120°.
In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not necessarily intended to convey any information regarding the actual shape of the particular elements, and may have been solely selected for ease of recognition in the drawings.
In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc.
Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is, as “including, but not limited to.”
Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
The headings and Abstract of the Disclosure provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.
The electric machine 100 can take the form a multiphase electric machine, for instance a three phase electric motor (e.g., three phase permanent magnet (PM) motor), induction motor, or the like. The electric machine 100 can, for example, include a rotor with a plurality of permanent magnets arrayed thereabout, and a stator with a plurality of coils or windings arrayed thereabout. The rotor is mounted to rotate with respect to the stator, for instance in response to selective excitation of magnetic fields in the coils or windings.
The control system 120 is coupled to control the electric machine by one or more control lines 130, for example via operation of various switches to control the selective excitation of magnetic fields in the coils or windings, as described in detail herein. The control system 120 can include one or more processors (e.g., microprocessors, microcontrollers, digital signal processors (DSPs), graphics processing units (GPUs), field programmable gate arrays (FPGAs), programmable logic units (PLUs), motor controllers, or other control circuits. The control system can include one or more nontransitory storage media, for example memory (e.g., read only memory (ROM), random access memory (RAM), FLASH memory) or other media (e.g., magnetic disk drive, optical disk drive), which stores processor-executable instructions, which when executed by one or more processors cause the one or more processors to execute logic to control operation of the electric machine, for instance as described herein. The control system can include one or more sensors 140 or receive information from one or more sensors 140, for example one or more current sensors, voltage sensors, position or rotary encoders, Hall effect sensors, or Reed switches, which allow the operation of the electric machine and control circuitry to be monitored.
In
The coil driver depicted in
The coil driver for each phase of a multiphase electric machine shown in
There are two distinct operating modes that provide different opportunity for ripple current reduction. In a series mode coil pairs from each phase are switched in series and driven by one H bridge per phase. In a parallel mode the coil pairs are individually driven by their own H bridge, resulting in 2 H bridges per phase.
Each of the two operating modes are distinct and offer different opportunities for ripple current reduction.
To compare the effect of the presented modulation scheme the following simulations were adjusted such that the operating point for the inverter and coil driver is kept consistent. Since it is well known in the field that modulation depth, current angle, and the like have a large influence on DC link ripple current, the load and operating voltage is adjusted to maintain these the same. It should be noted that this is only done for academic reasons, because in reality series and parallel modes allow a machine to operate over a wider range of speeds and torques resulting in widely varying operating conditions. Specifically, the operating point in series and in parallel, by definition, cannot be the same.
Ia+Ib+Ic=0 (eq. 1).
One aspect of the proposed modulation method utilizes the property of the three phase quantities to adjust the PWM such that a maximum current cancelation occurs.
One aspect of the invention is to reduce capacitor size. One factor that affects capacitor sizing is frequency. Accordingly, the modulation method would drive the current harmonics up in frequency, which has the effect of reducing capacitance requirements and simplifying EMI filter requirements.
In one example, each coil has a peak current of 100 A. In other words, two coils in parallel means that the delta leg current is 200 A peak. Delta Leg to phase current has a √{square root over (3)} relation, specifically,
i*√{square root over (3)}=ipeak (eq. 2)
In the given example, 200*√{square root over (3)}=346 Apk, which corresponds to 244 A RMS, which matches a calculated result.
At this operating point a 3 phase drive generates an RMS ripple stress of approximately 160 Arms. This value matches the rule of thumb for 3 phase inverter which is
RMS ripple≈0.6*Iphase RMS (eq. 3)
Thus, the DC link RMS ripple is calculated as 245*0.6=147 Arms.
Further, a peak current stress on the DC link is +130 A to −270 A, or about 400 A peak-to-peak. The peak-to-peak quantity is important because it represents a larger di/dt, which tends to generate larger overvoltages due to system inductance.
The frequency relationship in unipolar modulation (H bridge) or common 3 phase bridge PWM methods has the following relationship linking switching frequency of the half bridge legs to the frequency applied to the load.
F_load=2*F_PWM (eq. 4)
Since the DC link storage element has to supply the combined currents from all the bridge legs, this storage element is exposed to this same frequency of 2*F_PWM.
Series Mode Modulation Configuration
One aspect of the invention provides a series mode modulation configuration. For H bridges a unipolar modulation is utilized that drives the switches at a drive modulation frequency. Unipolar modulation utilizes a zero vector and produces a voltage across the load with a frequency factor of 2×. In other words, in the series mode, the AC voltages across the coils have a frequency factor that is twice the drive modulation frequency. This is a modulation method for 3 phase bridges. In operation, a 10 kHz half bridge frequency applies 20 kHz to the load.
In series mode for a 3-phase application, the coil driver operates as three independent H bridges. This configuration allows each phase to place the PWM signals in a manner such that ripple is reduced.
The series mode coil driver will run twice the current density into a series connected coil, representing twice the torque production in the machine. From a performance stand point, the coil driver is delivering twice the torque of the 3-phase drive, at the expense of a reduction in base speed due to the higher number of effective turns in the machine. Further, when in series mode, the overall load characteristic changes, compared to the same coils parallel connected, the resistance and inductance increases four times, and the induced voltage two times.
In a 3-phase system, because each phase is independent, each H bridge gets its own modulator. Each modulator can then be adjusted so the angle of the modulator carrier moves the PWM signals relative to each other as shown in
As the angle of the carrier is swept from 0° to 180° the impact on RMS ripple current is shown in in
The ripple current spectrum of the series mode modulation shown in
Parallel Mode Modulation Configuration
One aspect of the invention is a parallel mode modulation configuration. The parallel mode builds on the series mode modulation. In the parallel mode modulation configuration there are two H bridges driving two coils with identical current. These currents can be interleaved to further reduce the ripple current stress.
Each H bridge uses unipolar modulation. One way to generate this modulation is to use the same reference for each half bridge and provide a carrier with a 180° phase shift. In other words, one carrier is at 0° and the other carrier is at 180° for one H bridge. When the second H bridge is added, the carriers for the two half bridges are then −90° and 90° offset from the first H bridge. Subsequently, for each phase a rotation of +/−120° is applied equally to all four modulators of that phase.
When the two H bridges are combined, 90° is not the best value. As seen in
Combining the disclosed modulation methods reduces the DC link ripple current from 160 A RMS for a conventional inverter delivering the same current, to a little under 40 A RMS for the coil driver. The harmonic content is also quadrupled (20 kHz to 80 kHz) in frequency. The dominant harmonic current is 80 kHz in contrast to 20 kHz of the previous modulation method, given a bridge leg switching frequency of 10 kHz. More generally the harmonic content is increased from 2*F_PWM to 8*F_PWM. The harmonic current at 80 kHz along with the dramatically reduced ripple current greatly simplifies capacitor design.
In the above description, certain specific details are set forth in order to provide a thorough understanding of various disclosed implementations. However, one skilled in the relevant art will recognize that implementations may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures associated with computer systems, server computers, and/or communications networks have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the implementations.
The foregoing detailed description has set forth various embodiments of the devices and/or processes via the use of block diagrams, schematics, and examples. Insofar as such block diagrams, schematics, and examples contain one or more functions and/or operations, it will be understood by those skilled in the art that each function and/or operation within such block diagrams, flowcharts, or examples can be implemented, individually and/or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof. In one embodiment, the present subject matter may be implemented via Application Specific Integrated Circuits (ASICs). However, those skilled in the art will recognize that the embodiments disclosed herein, in whole or in part, can be equivalently implemented in standard integrated circuits, as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more controllers (e.g., microcontrollers) as one or more programs running on one or more processors (e.g., microprocessors), as firmware, or as virtually any combination thereof, and that designing the circuitry and/or writing the code for the software and or firmware would be well within the skill of one of ordinary skill in the art in light of this disclosure.
In addition, those skilled in the art will appreciate that the mechanisms taught herein are capable of being distributed as a program product in a variety of forms, and that an illustrative embodiment applies equally regardless of the particular type of physical signal bearing media used to actually carry out the distribution. Examples of signal bearing media include, but are not limited to, the following: recordable type media such as floppy disks, hard disk drives, CD ROMs, digital tape, and computer memory.
The various embodiments described above can be combined to provide further embodiments. Aspects of the embodiments can be modified, if necessary, to employ systems, circuits and concepts of the various patents, applications and publications identified herein to provide yet further embodiments.
Unless the context requires otherwise, throughout the specification and claims that follow, the word “comprising” is synonymous with “including,” and is inclusive or open-ended (i.e., does not exclude additional, unrecited elements or method acts).
Reference throughout this specification to “one implementation”, “one aspect”, or “an implementation” means that a particular feature, structure or characteristic described in connection with the implementation is included in at least one implementation. Thus, the appearances of the phrases “in one implementation”, “in an implementation”, or “in one aspect” in various places throughout this specification are not necessarily all referring to the same implementation. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more implementations.
The headings and abstract provided herein are for convenience only and do not interpret the scope or meaning of the implementations.
Thus, while there have shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method acts that perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method acts shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.
The present application for patent claims the benefit of U.S. Provisional Patent Application No. 63/188,151 filed May 13, 2021, and expressly incorporated by reference herein.
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