The present invention relates to a method for detecting a fault in a motor arrangement with an electrical machine, particularly a synchronous motor, and to a motor controller for controlling an electrical machine, particularly a synchronous motor, with a fault detection unit for detecting a fault in the motor arrangement. Furthermore, the invention relates to a motor arrangement with an electrical machine, particularly a synchronous motor, and a motor controller.
In modern motor vehicles, electrical machines, such as synchronous motors, are increasingly used as drive motors. In order to regulate the electrical machine, rotation angle sensors are frequently arranged on the electrical machine in electric or hybrid vehicles, said rotation angle sensors sensing the speed and the rotation angle of the rotor and of the electrical machine. Such a rotation angle sensor is known from DE 102 10 372 A1, for example.
By way of example, a rotation angle sensor may have a sensor element and a sensor disk, the sensor disk having a signal trace with a known shape. If the signal trace is sinusoidal, for example, then the rotation angle sensor delivers a sinusoidal signal. Usually, a rotation angle sensor with a sinusoidal signal trace has a further sensor element that is fitted at an interval of 90° with respect to the first sensor element and therefore delivers a cosine-shaped signal. For these two signals, i.e. the sine signal and the cosine signal, it is possible to calculate the rotation angle using the arctangent. The rotation angle of the rotor of the electrical machine may be needed particularly for field-oriented regulation of the electrical machine.
For safety reasons, the correct operation of the electrical machine needs to be monitored constantly. By way of example, EP 1 479 157 B1 discloses a method for fault detection for electric motors in the motor vehicle domain.
One embodiment provides a method for detecting a fault in a motor arrangement with an electrical machine, particularly a synchronous motor, having the steps of: ascertainment of rotation angle data that, in the absence of the fault, are dependent on a rotation angle of a rotor of the electrical machine, ascertainment of additional data that allow the fault to be inferred, and detection of the fault when the rotation angle data meet a first criterion and the additional data meet a second criterion.
In a further embodiment, the first criterion is met when the rotation angle data essentially correspond to a predetermined rotation angle.
In a further embodiment, the method further includes the steps of checking whether the rotation angle data meet the first criterion, and, if the rotation angle data meet the first criterion, checking whether the rotation angle data are constant.
In a further embodiment, the step of ascertainment of additional data comprises the step of sensing of a torque requirement as additional data when the rotation angle data meet the first criterion.
In a further embodiment, the step of sensing a torque requirement is executed at least twice and the method additionally comprises the steps of determination of a maximum and a minimum torque requirement on the basis of the sensed torque requirements, calculation of a difference between the maximum and the minimum torque requirement, and checking whether the calculated difference meets the second criterion, particularly whether the calculated difference exceeds a predetermined difference threshold value.
In a further embodiment, the method includes the step of checking whether the rotation angle data meet the first criterion when the calculated difference meets the second criterion.
In a further embodiment, the step of ascertainment of additional data comprises the step of ascertainment of a speed of the electrical machine on the basis of the ascertained rotation angle data.
In a further embodiment, the step of ascertainment of a speed of the electrical machine comprises the steps of ascertainment of first rotation angle data, waiting for a predetermined first period of time, ascertainment of second rotation angle data, and ascertainment of the speed of the electrical machine on the basis of the first and second rotation angle data and also the predetermined first period of time.
In a further embodiment, the step of ascertainment of a speed is executed twice, as a result of which the step of ascertainment of additional data comprises the steps of ascertainment of a first speed, waiting for a predetermined second period of time, ascertainment of a second speed, ascertainment of a rate of change of the ascertained speeds as addition data on the basis of the first and second speeds and also the predetermined second period of time, and checking whether the ascertained rate of change meets the second criterion, particularly whether the ascertained rate of change exceeds a predetermined rate of change threshold value.
In a further embodiment, the fault detected is loss of a connection between a rotation angle sensor for ascertaining rotation angle data and a ground.
Another embodiment provides a motor controller for controlling an electrical machine, particularly a synchronous motor, in a motor arrangement, having: at least one input for receiving sensor signals for ascertaining rotation angle data that, in the absence of the fault, are dependent on a rotation angle of a rotor of the electrical machine, means for ascertaining additional data that allow a fault in the motor arrangement to be inferred, and a fault detection unit for detecting the fault when the rotation angle data meet a first criterion and the additional data meet a second criterion.
In a further embodiment, the motor controller includes a processing unit and a data memory, which contains a program that can be executed by a processing unit and that comprises instructions for executing the steps of the method as disclosed above.
Another embodiment provides a motor arrangement having an electrical machine, particularly a synchronous motor, that has a rotation angle sensor that is connected to a ground via a line, and a motor controller as disclosed above that is set up to detect loss of the connection between the rotation angle sensor and the ground.
Example embodiments are explained below with reference to the figures, in which:
Embodiments of the present invention provide a method and an associated motor controller for detecting a fault in a motor arrangement with an electrical machine that are able to detect at least one fault inexpensively and reliably. A further object is to provide an associated motor arrangement.
Accordingly, one embodiment provides a method for detecting a fault in a motor arrangement with an electrical machine, particularly a synchronous motor, having the steps of ascertainment of rotation angle data that, in the absence of the fault, are dependent on a rotation angle of a rotor of the electrical machine, ascertainment of additional data that allow the fault to be inferred, and detection of the fault when the rotation angle data meet a first criterion and the additional data meet a second criterion.
In this case, the rotation angle data can meet the first criterion particularly when they essentially correspond to a predetermined rotation angle. If the sine and cosine paths of the rotation angle sensor and of the associated evaluation electronics on the motor controller are of identical design, the predetermined rotation angle may be 45°, for example.
If a rotation angle sensor of the electrical machine loses its connection to the ground, the rotation angle sensor still delivers sensor signals, which, although constant and independent of the rotation angle of the rotor, are nevertheless interpreted by a processing unit of the motor controller. The processing unit thus ascertains an angle that does not correspond to the rotation angle of the rotor but could nevertheless arise during normal operation of the electrical machine. When a characteristic angle appears that indicates possible loss of the connection between rotation angle sensor and ground, the ascertainment of additional data allows a check to be performed to determine whether the corresponding fault actually exists. Thus, the fault is established only when the rotation angle data meet a first criterion and the additional data meet a second criterion.
As already mentioned, electrical machines usually have a rotation angle sensor that provides sensor signals from which it is possible to derive a rotation angle of a rotor of the electrical machine. Accordingly, the step of ascertainment of rotation angle data may comprise the steps of measurement of a value of a sensor signal, the value of the sensor signal being indicative of the rotation angle, and calculation of the rotation angle on the basis of the measured value of the sensor signal in order to ascertain the rotation angle data.
As already described, the predetermined rotation angle also arises during normal operation without a fault. Accordingly, the disclosed method may have the steps of checking whether the rotation angle data meet the first criterion, and, if the rotation angle data meet the first criterion, checking whether the rotation angle data are constant. By way of example, when the predetermined rotation angle is detected, rotation angle data can be determined once again after a certain stipulated period of time in order to check whether they continue to correspond to the predetermined rotation angle.
In one embodiment, the step of ascertainment of additional data comprises the step of sensing of a torque requirement as additional data when the rotation angle data meet the first criterion. If the rotation angle data correspond to the predetermined rotation angle, for example, a check is thus performed to determine whether a torque requirement exists for the electrical machine. By way of example, such a torque requirement exists when the driver of the vehicle steps on the gas pedal.
In one embodiment, the step of sensing of a torque requirement is executed at least twice and the disclosed method additionally comprises the steps of determination of a maximum and a minimum torque requirement on the basis of the sensed torque requirements, calculation of a difference between the maximum and the minimum torque requirement, and checking whether the calculated difference meets the second criterion. In particular, it is possible to check whether the calculated difference exceeds a predetermined threshold value.
Preferably, when the calculated difference meets the second criterion, another check is performed to determine whether the rotation angle data still meet the first criterion. If the rotation angle data essentially correspond to the predetermined rotation angle, it is thus ascertained whether the driver of the motor vehicle is operating the gas pedal and whether this alters the rotation angle of the rotor of the electrical machine. If a torque requirement exists without the rotation angle of the rotor changing, the fault can be inferred. This is because such a case cannot arise with a working rotation angle sensor because the rotor would rotate sufficiently even in a firmly braked vehicle owing to the soft motor suspension in the vehicle.
In one embodiment, the step of ascertainment of additional data comprises the step of ascertainment of a speed of the electrical machine on the basis of the ascertained rotation angle data.
The step of ascertainment of a speed of the electrical machine may comprise particularly the steps of ascertainment of first rotation angle data, waiting for a predetermined first period of time, ascertainment of second rotation angle data and ascertainment of the speed of the electrical machine on the basis of the first and second rotation angle data and also the predetermined first period of time.
In this way, the rotation angle sensor can also be reused for ascertaining a speed of the electrical machine.
In one embodiment, the step of ascertainment of a speed is executed twice, so that the step of ascertainment of additional data comprises the steps of ascertainment of a first speed, waiting for a predetermined second period of time, ascertainment of a second speed and ascertainment of a rate of change of the ascertained speeds as additional data on the basis of the first and second speeds and also the predetermined second period of time. A check is then performed to determine whether the ascertained rate of change meets the second criterion. In particular, it is possible to check whether the ascertained rate of change exceeds a predetermined rate of change threshold value.
If the fault occurs while traveling, the measured speed would change suddenly. If the rotation angle data then change such that they meet the first criterion, it is possible to infer the existence of the fault. Preferably, following a sudden change in the speed, the method thus undergoes the step of checking whether the rotation angle data meet the first criterion, and, if the rotation angle data meet the first criterion, checking whether the rotation angle data are constant. If the rotation angle data meet the first criterion and the additional data meet the second criterion, the fault is detected.
Using the disclosed method, the fault detected may be loss of a connection between a rotation angle sensor for ascertaining rotation angle data and a ground.
Another embodiment provides a motor controller for controlling an electrical machine, particularly a synchronous motor, in a motor arrangement. Said motor controller has at least one input for receiving sensor signals for ascertaining rotation angle data that, in the absence of the fault, are dependent on a rotation angle of a rotor of the electrical machine. In addition, the motor controller comprises means for ascertaining additional data that allow a fault in the motor arrangement to be inferred, and a fault detection unit for detecting the fault when the rotation angle data meet a first criterion and the additional data meet a second criterion.
The motor controller can have a processing unit and a data memory, which contains a program that can be executed by the processing unit and that comprises instructions for executing the disclosed method.
Another embodiment provides a motor arrangement having an electrical machine, particularly a synchronous motor, that has a rotation angle sensor that is connected to a ground via a line, and also having a controller configured to detect loss of the connection between the rotation angle sensor and the ground.
The electrical machine 2 has a rotation angle sensor 7 that is connected to the shaft 3 and that transmits its sensor signals to a motor controller 10 via two lines 8a, 8b. In this case, the line 8a is used to transmit the sine signal and the line 8b is used to transmit the cosine signal.
The line 11 is used to supply the motor controller 10 with a supply voltage 12. The ground line 13 connects the electrical machine 2 and the motor controller 10 to the ground 14. The line 9a is used to supply the rotation angle sensor 7 with a voltage from the motor controller 10, and the line 9b is used for the rotation angle sensor 7 as a ground connection.
If the line 9b in this motor arrangement 1 based on the prior art fractures and the rotation angle sensor 7 no longer has a connection to the ground, this line interruption is not detected. If the circuits for evaluating the sine signal and the cosine signal are each of identical design, the motor controller 10 assumes that the rotation angle of the rotor of the electrical machine 2 is 45°, since the voltages that are transmitted on the lines 8a and 8b are each of the same magnitude. As
A state in which the voltage values of the sine signal 15 and the cosine signal 16 are of the same magnitude is therefore regularly encountered when the rotor is rotating. Even when the vehicle is stationary, e.g. on a hill, such a state can arise over a relatively long time, which means that it is not a simple matter to detect loss of a connection to the ground.
For reasons of simple illustration,
In step S4, at least two torque requirements are sensed as additional data. Within the sensed torque requirements, a maximum and a minimum torque requirement are determined in step S5. In step S6, a difference between the maximum and minimum torque requirements is calculated. Next, in step S7, a check is performed to determine whether the calculated difference meets the second criterion. In the present example, the second criterion is met when the calculated difference exceeds a predetermined difference threshold value. If the second criterion is met by the calculated difference, the process continues with step S8. Otherwise, it returns to step S1.
In step S8, a check is performed to determine whether the rotation angle data still meet the first criterion. For this, it is naturally necessary for the rotation angle data to be ascertained once again. If the rotation angle data still meet the first criterion, the process branches to step S9, in which the fault is detected. Otherwise, it returns to step S1.
In step S14, the process then waits for a predetermined second period of time. Third rotation angle data are then determined in step S15. In step S16, the process then again waits for a predetermined first period of time before fourth rotation angle data are ascertained in step S17. On the basis of the third and fourth rotation angle data and the predetermined first period of time, a second speed is then determined in step S18. In step S19, the first and second speeds and the predetermined second period of time are then taken as a basis for ascertaining a rate of change of the ascertained speeds as additional data.
In step S20, a check is performed to determine whether the ascertained rate of change meets the second criterion. In the present example, a check is performed to determine whether the ascertained rate of change exceeds a predetermined rate of change threshold value. If this is the case, the process branches to step S21. Otherwise, it returns to step S10. In step S21, rotation angle data are again ascertained. In step S22, a check is performed to determine whether the rotation angle data ascertained in step S21 meet the first criterion. In the example shown, a check is performed to determine whether the rotation angle data essentially correspond to a predetermined rotation angle, e.g. 45°. Should this be the case, the process branches to step S23. Otherwise, it returns to step S10. In step S23, a check is then performed to determine whether the rotation angle data are constant. By way of example, this can be accomplished by waiting for a predetermined period of time, then determining the rotation angle data once again and subsequently deciding whether said rotation angle data still meet the first criterion. Should the rotation angle data be constant, the process branches to step S24, in which the fault is detected. Otherwise, it returns to step S10.
While the first embodiment 29 is suitable particularly for a stationary vehicle, the second embodiment 30 can be used for a traveling vehicle, in particular. The present invention allows rapid detection of the loss of a connection between the rotation angle sensor and the ground. This requires no additional hardware that monitors the sensor supply current. Instead, the method can be implemented as a pure software extension.
The explanations provided with reference to the figures are intended to be understood as purely illustrative and nonlimiting. Many amendments can be made to the embodiments described without departing from the scope of protection of the invention as set out in the appended claims. The features of the embodiments can be combined with one another so as to provide further embodiments optimized for the instance of application.
Number | Date | Country | Kind |
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10 2012 213 709.2 | Aug 2012 | DE | national |
This application is a U.S. National Stage Application of International Application No. PCT/EP2013/065464 filed Jul. 23, 2013, which designates the United States of America, and claims priority to DE Application No. 10 2012 213 709.2 filed Aug. 2, 2012, the contents of which are hereby incorporated by reference in their entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2013/065464 | 7/23/2013 | WO | 00 |