The present invention relates to control of electrical motors and in particular, to the design and control of reluctance motors capable of micro-stepping position control.
Hybrid stepping motors are well known for their ability to operate in an open loop positioning mode, the rotor following a sequence of stator excitation pulses. The hybrid stepping motor is usually operated without any shaft position feedback in simple open loop position control systems. One common hybrid stepping motor has 50 rotor teeth and two phase windings. If positive current in one phase winding is switched off and is followed by positive current in the second phase winding, the rotor will move by 1.8° (one full step). A further full step in the same direction would occur if the second phase winding were de-energised and negative current applied to the first phase winding. There will be 200 discrete, full steps or holding torque positions of the rotor per revolution. The number of holding positions can be doubled by energising the second phase winding before the first is de-energised. This “two phase on—one phase on—two phase on” pattern is known as half stepping, producing 400 steps per revolution. By increasing the current in the second phase winding in small incremental steps while decreasing the current in the first phase winding in similar decrements it is possible to achieve very high open loop position control without the need for any position sensors. This mode is known as micro-stepping and stepper motors offering resolution of 50,000 steps per revolution have been developed. Hybrid stepping motors are therefore excellent for achieving smooth position control.
The high number of rotor teeth means that for each revolution of the motor there are 50 electrical cycles in the phase windings. For a stepping motor to spin at 3000 r/min would need electrical excitation in each winding of 2500 Hz. This leads to very high losses in the magnetic circuits and creates significant challenges for electronic controllers to generate the high frequency currents. The hybrid stepping motor is therefore an excellent machine for low speed accurate positioning but is usually limited to speeds less than 2000 r/min.
Switched reluctance motors, originally known as single stack variable reluctance stepping motors, have salient pole stator and rotor designs, and can be used as a large angle stepping motor with the capability to operate at higher rotational speeds without excessive losses in the magnetic circuits. The salient pole structure does however create discrete positions where the rotor and stator teeth are in complete alignment. As the current excitation is altered between one phase winding and the next phase winding the rotor of a switched reluctance or variable reluctance stepping motor will tend to move suddenly from one aligned position to the next. It is not possible to use an open loop control method to hold the rotor at intermediate positions between aligned positions of adjacent stator phase windings. It is not therefore possible to use micro-stepping techniques with a single stack variable reluctance stepping motor according to the prior art.
Similar difficulties occur in brushless permanent magnet synchronous motors. The brushless permanent magnet synchronous motor has magnetic poles on the rotor and a stator carrying the phase windings. The major difficulty with employing a brushless permanent magnet synchronous motor as a micro-stepping motor is caused by the cogging torque. This is a reluctance torque created by the interaction of the permanent magnet rotor and the teeth on the laminated stator structure. Even with zero stator currents there is a torque which will tend to hold the rotor in preferred positions. This cogging torque interacts with the electromagnetic torque produced by the stator phase currents, with the result that operation of such a motor in microstepping modes produces uneven positioning of the rotor. The current has to be increased to overcome the cogging torque and then the rotor jerks to the next cogging position.
Multi-stack variable reluctance motors do not have permanent magnets and therefore do not have any cogging torque. They also overcome the limitations of the single stack variable reluctance stepping motor. The motor is divided along its axial length into magnetically isolated sections “stacks”, and each of these sections can be excited by a separate winding. The teeth on the different stator stacks are misaligned relative to the other stators. The teeth on the rotor are usually all arranged with the same alignment. The holding position of the rotor therefore moves as the excitation is applied to each of the stator stacks in turn. Since the stacks of the motor are magnetically isolated the torque produced by each can be applied to the shaft in a cumulative manner and the rotor can be held in positions part-way between aligned positions of each stack. This motor does allow large angle steps, thus providing a motor suitable for high speed and positioning applications. However the complex construction of placing three magnetically isolated stators within the same machine makes the motor larger than competing machines for a given torque output.
It is the object of the present invention to provide a single stack variable reluctance machine which is simple to construct with field magnet sections on the stator and two or more armature phase windings also on the stator with a suitable power electronic inverter to give micro-stepping capability such that small changes in the magnitudes of one or more armature phase winding currents cause small changes in the angular position of the rotor to create a micro-stepping reluctance machine.
According to the invention there is provided microstepping reluctance motor comprising a single stack variable reluctance machine with salient stator teeth and salient rotor teeth, the stator further comprising field magnet sections created by either permanent magnets or field windings or a combination of permanent magnets and field windings, the field magnet sections located in the spaces between every alternate stator tooth and further comprising armature windings each spanning two stator teeth connected to form at least two armature phase windings, the armature phase windings connected to a power electronic inverter for the supply of positive and negative current to the armature phase windings, the power electronic inverter also capable of modulating the magnitude of the current in each armature phase winding, and capable of supplying variable current simultaneously to at least two armature phase windings such that the rotor rotates in small incremental steps in response to small changes in the current in one or more of the energised armature phase windings during any part of the machine operation.
The invention will now be described by reference to the following figures in which:
Further rotation is achieved by energising the four stator teeth of one of the other two phases causing the second set of four rotor teeth to be attracted to the energised stator teeth. The switched reluctance motor therefore can act as a large angle stepping motor and as such is known in the prior art as a single stack variable reluctance stepping motor. The magnitude of each full step is dependent on the number of teeth on the stator and rotor and on the number of phase windings. Some common examples from the prior art are given in Table 1.
Recently the switched reluctance machine has been successfully employed in many applications as a variable speed motor since the rotor is of very simple construction. At low speeds however the movement of the rotor is very uneven with the torque to angle characteristic being very non-linear with current and position. This makes the switched reluctance motor (single stack variable reluctance motor) very unsuitable for positioning applications, particularly where angular movement of less than one full step is required.
To illustrate the problems of controlling the rotor of a switched reluctance motor from one holding torque position to the next holding torque position reference can be made to
The stable or holding torque position with no load applied to the rotor for 100% Phase 2 (Line 0:100 in
When the torque versus angle curve at a particular excitation crosses the X-axis with a negative gradient, this corresponds to a stable or holding torque position for that excitation. The gradient of the torque versus angle as it passes through the holding torque position determines the stiffness of the holding position and the peak holding torque or pull out torque is shown as the peak positive or negative torque as the rotor is moved either side of the holding position.
When the current in phase 2 is decreased to 70% and current in phase 1 has increased to 30% the stable position has only moved by about 0.5° to 8°. Therefore a large change in the relative proportions of the currents in phase winding 1 and phase winding 2 does not result in a progressive change in the stable (parking or holding) position. Furthermore the peak holding torque is now approximately 50% of the original value with one phase excited.
When the currents in phase 1 and phase 2 are both 50% the torque vs angle plot is very flat with no distinct holding position.
When the current in Phase 1 becomes greater than phase 2 the rotor will move to be near the stable position where the rotor teeth are aligned with the stator teeth of Phase winding 1. This position is at 22.5° which is one full step of 15° away from the stable position of Phase winding 2.
This data confirms that a conventional switched reluctance machine cannot be used in half-stepping or micro-stepping modes since the holding position cannot be moved progressively, in small incremental steps, from a first holding position to a second holding position. The present invention overcomes this limitation of prior art switched reluctance motors when used in positioning applications.
A micro-stepping reluctance motor comprising a single stack variable reluctance electrical machine according to this invention which overcomes the disadvantage of the switched reluctance machine for open loop positioning applications will now be described. One example of the single stack variable reluctance electrical machine according to the invention is shown in
The example micro-stepping reluctance motor shown in
The unusual stator to rotor tooth geometry of the three phase single stack variable reluctance motor means that it can be used in a micro-stepping mode with a progressive change in holding position as the current in the armature phases windings are altered by small increments using a suitable power electronic controller. As a result the three phase single stack variable reluctance motor according to the invention can be used very successfully as an open loop micro-stepping motor. The plots shown in
The results of the torque versus angle at each set of stator currents is shown in
Other three phase single stack micro-stepping reluctance motors according to the invention with smaller full step angles and more electrical cycles per revolution are summarised in Table 2.
12°
A micro-stepping reluctance motor with a single stack variable reluctance motor with a stator 40 with eight stator slots can be configured as a two phase motor as shown in
The micro-stepping reluctance motor with a two phase motor with 3 teeth offers 12 full steps per rev and with 5 rotor teeth offers 20 full steps per rev. Both motors can be used in a micro-stepping mode because of the smooth change in flux linkage in each phase winding with position.
Examples of five phase micro-stepping reluctancemotors according to the invention can have, by means of example, the numbers of stator and rotor teeth shown in Table 3. An example of a 5 phase single stack variable reluctance motor according to the invention is shown in
Micro-stepping reluctance motors can be constructed according to this invention with a field excitation means and two or more armature windings. The stator of the machines will always have an even number of teeth, Ns. In the spaces between every alternate stator tooth there will be a field excitation means such that the field excitation means occupies Ns/2 spaces between the stator teeth. The field excitation means will comprise either an electrical winding carrying dc current or a permanent magnet magnetised to create an mmf acting tangentially or may contain a combination of an electrical winding and a permanent magnet acting together to create the tangential mmf. Alternate field excitation sections of the stator will be configured with opposing magnetic polarity.
In a machine according to the invention there will also be armature coils occupying the spaces or slots between alternate armature teeth and in the slots not already occupied by the field excitation means and spanning a pitch of two stator teeth. The armature coils of each phase will be connected usually in series to create q armature phase windings where q is an integer number greater than one.
The number of stator teeth, Ns, is given by the following equation:
N
s=4q*n
Where n is a positive integer, 1, 2, 3, 4, . . . representing the repetitions within the machine.
The number of rotor teeth, Nr, in a machine according to the invention is given by:
N
r=(2q±1)*n
Constructing a micro-stepping reluctance motor from a single stack variable reluctance machine with Ns stator teeth and Nr rotor teeth as described by the above equations, the stator further comprising Ns/2 field magnet sections, and armature windings connected to form at least two armature phase windings, the armature phase windings connected to a power electronic inverter for the supply of positive and negative current to the armature phase windings, the power electronic inverter also capable of modulating the magnitude of the current in each armature phase winding, and capable of supplying current simultaneously to at least two armature phase windings such that the rotor can move in small incremental steps in response to small changes in the current in one or more of the energised phase windings.
A power electronic inverter suitable for use with a two phase micro-stepping reluctance motor according to the invention is shown in
i
RED
+i
YELLOW
+i
BLUE=0
In order to implement precise position control of a three phase micro-stepping reluctance motor according to the invention, all three armature windings would carry current simultaneously. If iRED>0 and iYELLOW<0, then iBLUE can be used to control the relative size of iRED and iYELLOW and move the rotor in small incremental steps. It will be common to force the three armature phase currents to have a value according to three sinusoidal equations, each with a phase displacement of 120° (2π/3 radians or in general 2π/q) such that
where θ is the mechanical angular position of the armature excitation vector at any point in time and Imax is the current required to deliver the torque on the shaft to avoid pull out.
If it is required to move the rotor position by 1° then the position of the effective stator current vector should be moved by 1°. As an example in a three phase motor with five rotor poles the stator excitation is initially located at 40° (mechanical). To achieve this the electrical excitation angle will be 200° (i.e. Nrθ). To move the rotor by 1° to 41° the electrical excitation needs to change by 5° to 205°. The values of the three phase currents before and after the move are shown in Table 4.
By controlling the three armature currents in the micro-stepping reluctance motor in this way the position of the rotor can be changed in small angular increments without requiring a high resolution position sensor to feedback the position of the rotor. Micro-stepping reluctance motors designed according to this invention can be simple and robust positioning devices without the requirement for position feedback. As the rotor does not carry a permanent magnet they do not suffer from any cogging torque problems which tend to cause unpredictable rotor movements in low speed positioning applications. The micro-stepping reluctance motors according to this invention are simpler to construct than the multi-stack variable reluctance motor or the hybrid stepping motor and yet can deliver open loop positioning without the use of a position sensor. This cannot be achieved with prior art designs of switched reluctance motors.
In a micro-stepping reluctance machine according to the invention with q phases, the rotor can be moved in small incremental steps by controlling the current in each armature phase winding to approximately follow a sinusoidal function of a given amplitude, while ensuring that the sinusoidal function for each consecutive armature phase winding has a phase difference relative to the previous armature phase winding of 2π/q electrical radians. At any point the excitation of the armature phase windings can be frozen at the magnitudes corresponding to the instantaneous values of the sinusoidal functions for each phase. At this point the torque angle curves for the motor will be a unique curve such as one of the curves shown in
It will be appreciated that the currents in the armature phase windings do not need to be varied exactly according to the sinusoidal profiles in Table 4 and many other combinations of individual phase currents can be used to create small incremental changes in the position of the rotor.
The positioning scheme described can be used as a small part of an overall motor control strategy. For example the micro-stepping scheme according to the invention may be used to move a motor slowly and then when the speed increases an alternative control strategy using speed feedback may be used. This is a very common method of starting a motor before using a sensorless scheme which relies on some movement of the rotor to produce an armature emf which can be detected and used for control purposes. The invention therefore can be used as the main control of a micro-stepping reluctance motor as an open loop positioning device or the invention can be used for one operating region of a complete control system.
A further aspect of a micro-stepping reluctance motor according to this invention is that the position of the rotor can be tracked continuously irrespective of the method of control. If the control of a motor is transferred to a speed feedback scheme or sensorless control scheme after an initial excitation in micro-stepping mode a controller is still able to count the number of electrical cycles applied to the armature phase windings, thus maintaining an incremental position count, then as a motor slows down control could be returned to the micro-stepping control scheme according to this invention to bring the rotor to rest at a precise position.
Number | Date | Country | Kind |
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0814389.3 | Aug 2008 | GB | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/GB2009/001921 | 8/6/2009 | WO | 00 | 4/5/2011 |