POWER CONVERTER FOR AN ELECTRICAL MACHINE AND METHOD OF OPERATING THE MACHINE

This application claims the benefit of priority provided by U.S. provisional application 61/705,566, which was filed on Sep. 25, 2012.

The invention relates to a power converter for an electrical machine and a method of operating the machine.

Low-cost motor drives in vehicle applications, such as electric bikes (E-Bikes) operated with battery-stored energy, are sought because of their positive impact on the environment, the existing mass market of electric bikes, and the limited financial resources of the user community in China, India, and other developing nations. One of the significant cost elements of a motor drive is a power converter circuit, particularly its number of power devices, such as transistors and power diodes. Economy in the use of power devices translates into a reduced number of control circuit components, such as gate drives, logic power supplies, and device protection circuits; such economy also leads to reduced printed circuit board area, heat-sink volume, and weight. The use of fewer power devices also leads to lower cost of the power electronic system for the motor drive.

The use of fewer power devices restricts the freedom of operation of individual machine phases. Further, the control of a power converter requires signals, such as current and voltage signals, for feedback control or for the motor drive system control.

Inexpensive means of measuring and estimating currents and voltages in a converter circuit that is driving a switched reluctance or a permanent magnet brushless direct current (dc) motor and use of the measured current and voltage signals in the control of the motor drive system are aspects of this disclosure. The converter and machine described herein have two phases, and the converter is supplied energy from an electrical battery supply. An embodiment of the invention for a motor drive system with more than two phases is described and generalized for any number of phases.

A control system, employing feedback current and voltage signals, is also disclosed for operating the converter circuit, such that energy in a storage capacitor of the converter circuit is kept within specified levels. The system is described in detail with application to a two-phase switched reluctance machine (SRM), which then is generalized for SRMs with more than two phases.

Methods to estimate and predict phase-winding currents and voltages, voltages across a storage capacitor and battery pack, and currents in the storage capacitor and battery are also described. The measurements of the voltages and currents may be obtained continuously or discontinuously.

One or more objects of the disclosed subject matter may be achieved by a power converter having: (1) a capacitive storage element; (2) first and second switches that each conducts current in a conductive state and does not conduct current in a non-conductive state; and (3) first and second unidirectional current devices that each conducts current unidirectionally. The capacitive storage element, first and second switches, and first and second unidirectional current elements are interconnected such that when interconnected with a dc voltage supply and a first phase winding of an electrical machine: (a) a first operational state exists in which energy is transferred from the dc voltage supply to the first phase winding when the first switch is in the conductive state, (b) a second operational state exists in which energy stored by the first phase winding during the first operational state is transferred to the capacitive storage element when the first switch is in the non-conductive state, (c) a third operational state exists in which energy stored by the capacitive storage element is transferred to the first phase winding when the second switch is in the conductive state, and (d) a fourth operational state exists in which energy stored by the first phase winding during the third operational state is transferred to dc voltage supply when the second switch is in the non-conductive state.

One or more objects of the disclosed subject matter may also be achieved by a method of operating a power converter, the method including: (1) transferring energy from a dc voltage supply to a first phase winding of an electrical machine during a first operational state, (2) transferring energy stored by the first phase winding during the first operational state to a capacitive storage element during a second operational state, (3) transferring energy stored by the capacitive storage element to the first phase winding during a third operational state, and (4) transferring energy stored by the first phase winding during the third operational state to the dc voltage supply during a fourth operational state.

One or more objects of the disclosed subject matter may also be achieved by a power converter including: (1) a first electrical circuit comprising a dc voltage source, a first phase winding of an electrical machine, and a first switch operating in a conductive state; (2) a second electrical circuit comprising the first phase winding, a first unidirectional current device, and a capacitive storage element; (3) a third electrical circuit comprising the capacitive storage element, a second switch operating in a conductive state, and the first phase winding; and (4) a fourth electrical circuit comprising the first phase winding, the dc voltage source, and a second unidirectional current device.

One or more objects of the disclosed subject matter may also be achieved by a power converter including: (1) a dc voltage supply having a first terminal electrically connected directly to a first node and a second terminal electrically connected to a second node, either directly or through a first current sensor; and (2) a first phase module. The first phase module includes: (a) a first phase winding of an electrical machine having a first terminal electrically connected directly to the first node and a second terminal electrically connected directly to a third node, (b) a capacitive storage element having a first terminal electrically connected directly to the first node and a second terminal electrically connected directly to a fourth node, (c) a first switch having a first terminal electrically connected to the second node, either directly or through a second current sensor, and a second terminal electrically connected directly to the third node, (d) a first unidirectional current device having a first terminal electrically connected to the second node, either directly or through the second current sensor, (e) and a second terminal electrically connected directly to the third node, (f) a second switch having a first terminal electrically connected directly to the third node and a second terminal electrically connected directly to the fourth node, and (g) a second unidirectional current device having a first terminal electrically connected directly to the third node and a second terminal electrically connected directly to the fourth node.

One or more objects of the disclosed subject matter may also be achieved by a method of controlling an electrical machine, the method including: (1) generating a first signal indicating whether a value representative of a voltage of a first voltage source is less than the difference between a value representative of a voltage of a second voltage source and a reference voltage value; (2) generating a second signal indicating whether the value representative of the voltage of the first voltage source equals or exceeds the sum of the value representative of the voltage of the second voltage source and the reference voltage value; (3) transferring energy from the second energy source to a phase winding of the electrical machine during a period that the first signal indicates an affirmative condition; and (4) transferring energy from the first energy source to the phase winding during a period that the second signal indicates an affirmative condition.

One or more objects of the disclosed subject matter may also be achieved by a non-volatile storage medium storing instructions that, when executed by a processor, cause the processor to implement a method comprising: (1) transferring energy from a dc voltage supply to a first phase winding of an electrical machine during a first operational state, (2) transferring energy stored by the first phase winding during the first operational state to a capacitive storage element during a second operational state, (3) transferring energy stored by the capacitive storage element to the first phase winding during a third operational state, and (4) transferring energy stored by the first phase winding during the third operational state to the dc voltage supply during a fourth operational state.

One or more objects of the disclosed subject matter may also be achieved by a non-volatile storage medium storing instructions that, when executed by a processor, cause the processor to implement a method comprising: (1) generating a first signal indicating whether a value representative of a voltage of a first voltage source is less than the difference between a value representative of a voltage of a second voltage source and a reference voltage value; (2) generating a second signal indicating whether the value representative of the voltage of the first voltage source equals or exceeds the sum of the value representative of the voltage of the second voltage source and the reference voltage value; (3) transferring energy from the second energy source to a phase winding of an electrical machine during a period that the first signal indicates an affirmative condition; and (4) transferring energy from the first energy source to the phase winding during a period that the second signal indicates an affirmative condition.

FIG. 1 illustrates an embodiment of a power converter. A power converter 1, at its input terminals, has a battery pack 2 with voltage V_b. A two-phase switched reluctance or a permanent magnet brushless direct current (dc) machine (PMBDCM) may be used in this embodiment. The description hereafter is only with reference to switched reluctance machine (SRM), but is equally applicable to the PMBDCM.

Phase windings A and B are two, machine phase windings of an SRM. Battery 2 has a positive terminal connected to a first terminal of phase winding A, a first terminal of phase winding B, and a first terminal of a storage capacitor C. A negative terminal of battery 2 is connected to the anode of a diode D_a1, the emitter of a bipolar-junction transistor (BJT) T_a1, and the emitter of a BJT T_b1. A second terminal of phase winding A is connected to the cathode of diode D_a1, the collector of transistor T_a1, the anode of a diode D_a2, and the emitter of a BJT T_a2. A second terminal of phase winding B is connected to the collector of transistor T_b1and the anode of a diode D_b2. A second terminal of capacitor C is connected to the cathodes of diodes D_a2and D_b2and the collector of a BJT T_a2.

Diode D_a1and transistor T_a1are available in one package, such as in a metal-oxide semiconductor field-effect transistor (MOSFET) device or an insulated-gate bipolar transistor (IGBT) device. Similarly, diode D_a2and transistor T_a2are also available in one package, such as in a MOSFET device or an IGBT device. Such packaging of the circuit elements leads to space savings in circuit realization and cost savings in manufacture.

For simplicity of description, the devices described herein are assumed to be ideal. For example, the diodes, transistors, and interconnecting wires are considered to have a zero conduction voltage drop across them. In a practical embodiment, the conduction voltage drops may be considered. Neglecting these voltage drops and their associated losses does not change the essence of the description or the inferences drawn therefrom.

Energization of phase winding A is achieved in two ways. One way is to energize phase winding A with battery 2, and the other is to energize phase winding A with energy stored in capacitor C. Energization of phase winding A from battery 2 is designated Mode A1. Turning on transistor T_a1will apply battery voltage V_bacross phase winding A, which will establish a current in phase winding A so as to generate a torque in the machine, say, in the clockwise (CW) direction and, hence, move a rotor of the machine in the CW direction. If phase winding A current exceeds a set limit, transistor T_a1may be turned off, which will cut off battery voltage V_bto phase winding A. As the current is nonzero at the turn-off time of transistor T_a1, there is energy storage in the inductance of phase winding A. The energy stored in the inductance of phase winding A must be transferred to a source or result in a high rise of voltage across transistor T_a1. The only way in which the energy in phase winding A can be transferred is through the flow of current through diode D_a2and capacitor C, resulting in an increase of voltage across capacitor C. The voltage of capacitor C is also applied across phase winding A and has a polarity that is conducive for current decay, not for build-up, as the current is charging capacitor C and flowing against a capacitor voltage V_c. When the current falls below the set limit, so as to maintain current at a desired level, transistor T_a1is turned on again so that battery voltage V_bis applied across phase winding A, which is conducive for current build up. The net energy transferred to phase winding A is equal to the difference between the energy received from battery 2 and the energy delivered to capacitor C. For a machine to continue to generate torque in the CW direction, the energy transferred to the machine winding has to be positive.

Energization of phase winding A from energy stored in capacitor C is designated Mode A2. Turing on transistor T_a2allows capacitor voltage V_cto be applied across phase winding A, resulting in a current through phase winding A. To control the current when it exceeds a set limit, transistor T_a2is turned off. The current in phase winding A is forced through a current path provided by battery 2 and diode D_a1. The voltage across phase winding A transitions from +V_cto −V_b, thus forcing the current to decay in phase winding A. Phase winding A current charges battery 2, such that the energy stored in the inductance of phase winding A is transferred to battery 2. When the current in phase winding A falls below an established limit, transistor T_a2is turned on so as to reverse bias diode D_a1and transfer phase winding A current to capacitor C, rather than battery 2. The voltage across phase winding A again is +V_c, which increases the current in phase winding A. The net energy transferred to phase winding A is the difference between the energy transferred from capacitor C and the energy transferred to battery 2. So long as this net energy is positive, the energy transfer to the machine is positive and some energy is transferred to battery 2 from the energy stored in capacitor C.

Using Modes A1 and A2, phase winding A can be energized in a controlled manner and receive energy from either battery 2 or capacitor C. When energy is transferred from battery 2 to the machine, a part of the energy is also transferred to capacitor C via phase winding A; and when the energy is transferred from capacitor C to phase winding A, a part of the energy stored by capacitor C is transferred to battery 2 via phase winding A. In a battery-operated motor drive for an electric-vehicle (EV) application, where the energy supply has to come from a battery pack, as it is the only source of energy, it is important to realize that Mode A1 is the most dominant mode, but Mode A2 is a secondary mode that serves to send energy recovered during Mode A1 to a machine winding and the battery pack itself.

Some distinct features of the above-described circuit controlling phase winding A are:

• • (i) Currents of alternating polarity in phase winding A.
  • (ii) Energy transfer from battery 2 to phase winding A and then from phase winding A to storage capacitor C.
  • (iii) Energy transfer from storage capacitor C to phase winding A and then from phase winding A to battery 2.
  • (iv) Only one transistor or a diode is conducting at any given time, in this part of the circuit, resulting in high-efficiency operation of the converter subsystem, which contributes to the high overall system efficiency of the motor drive system.
  • (v) Transistor T_a1and diode D_a1can be in one package and transistor T_a2and diode D_a2can be in one package, so as to achieve some compactness in the converter using packaging that is readily available commercially.
  • (vi) Transistor T_a1, diode D_a1, transistor T_a2, and diode D_a2can be realized in the form of a single phase leg of an inverter, within an integral package, for greater compactness.

Energization of phase winding B by battery 2 is designated Mode B1. Turing on transistor T_b1will apply battery voltage V_bacross phase winding B, which will establish a current in phase winding B that generates torque in the machine, say, in the CW direction and, hence, moves the rotor in the CW direction. If phase winding B current exceeds a set limit, transistor T_b1may be turned off, which will cut off battery voltage V_bto phase winding B. As the current is nonzero at the turn-off time of T_b1, there is energy storage in the inductance of phase winding B. The energy stored in the inductance of phase winding B must be transferred to a source or result in a high rise of voltage across transistor T_b1. The only manner in which the energy in phase winding B can be transferred is through the flow of current through diode D_b2and capacitor C, resulting in an increase of voltage across capacitor C. The voltage of capacitor C is also applied across phase winding B and has a polarity that is conducive for current decay, not for build-up, as the current is charging capacitor C and flowing against capacitor voltage V_c. When the current falls below the set limit, so as to maintain current at a desired level, transistor T_b1is turned on again so that battery voltage V_bis applied across phase winding B, which is conducive for current build up. The net energy transferred to phase winding B is equal to the difference between the energy received from battery 2 and the energy delivered to capacitor C. For a machine to continue to generate torque in the CW direction, the energy transferred to the machine winding has to be positive.

The energy stored in capacitor C cannot be used to energize phase winding B. In battery operated motor drives, most of the energy to power the motor drive has to come from the battery and the energy stored in the capacitor, due to commutation of the phase windings, may not be enough to feed two phases. Therefore, there may be no need to have the converter arrangement as employed with phase winding A. Transistor T_b1and diode D_b2may be sufficient to handle phase winding B, resulting in a saving of devices, control circuits, and associated logic power supply requirements.

Distinct features of the phase winding B circuit are:

• • (i) Phase winding B conducts only unidirectional current, not bidirectional current as in the case of phase winding A.
  • (ii) Phase winding B draws energy from battery 2, and part of the energy stored in phase winding B is transferred to storage capacitor C.
  • (iii) Phase winding B cannot receive energy from storage capacitor C.
  • (iv) The circuit for phase winding B operation requires only one transistor and one diode.
  • (v) The transistor and diode can be packaged in one piece as a readily available chopper module. Such use of a chopper module leads to less assembly error in the electronics subsystem of the drive system, resulting in higher reliability of the electronics, compact packaging of the converter, and possible overall cost reduction in the electronics subsystem.

The principles of the two-phase SRM can be applied to a multiphase SRM having greater than two phases. A generalized embodiment of a multiphase SRM is presented.

FIG. 2 illustrates a modular unit M within the power converter of FIG. 1. Unit M comprises the above-described phase winding A and its related electronics of transistors T_a1and T_a2and diodes D_a1and D. Unit M is a three terminal device. A terminal 21 is connected to one end of phase winding A, a terminal 22 is connected to the emitter of transistor T_a1and anode of diode D_a1, and a terminal 23 is connected the collector of transistor T_a2and cathode of diode D_a2. The other end of phase winding A is connected to the collector of transistor T_a1, cathode of diode D_a1, emitter of transistor T_a2, and anode of diode D_a2. Thus, unit M has three external terminals 21, 22, and 23. To realize its operation, unit M's terminal 21 is connected to the positive terminal of battery 2 and capacitor C's terminal identified by symbol “−.” Terminal 22 is connected to the negative terminal of battery 2, and terminal 23 is connected to the capacitor C's terminal identified by symbol “+.”

FIG. 3 illustrates a modular unit N within the power converter of FIG. 1. Unit N comprises the above-described phase winding B and its related electronics of transistor T_b1and diode D_b2. Unit N is a three terminal device. A terminal 31 is connected to one end of phase winding B, a terminal 32 is connected to the emitter of T_b1, and a terminal 33 is connected to the cathode of diode D_b2. The other end of phase winding B is connected to the collector of transistor T_b1and anode of diode D_b2. Thus, unit N has three external terminals 31, 32, and 33. To realize its operation, unit N's terminal 31 is connected to the positive terminal of battery 2 and the terminal of capacitor C identified by symbol “−.” Terminal 32 is connected to the negative terminal of battery 2, and terminal 33 is connected to the terminal of capacitor C identified by symbol “+.”

FIG. 4 illustrates an embodiment of a power converter having any number of machine phases. Consider a machine having an integer number, h, of phases. Of these, j phases need to have energy supplied from battery 2 for some time and from a storage capacitor C for some time. Let j be less than h and k=h−j. In such a case, k phases have energy supplied only by battery 2. Thus, j unit Ms and k unit Ns are integrated with battery 2 and storage capacitor C in a power converter 40. The selection of integer values j and k is one of design based on application and cost requirements.

FIG. 5 illustrates an embodiment of the power converter illustrated by FIG. 1 having voltage and current sensors. FIG. 5 differs from FIG. 1 in the addition of such sensors. The addition of the sensors enables current and voltage measurements to be made for use in feedback control of a power converter 50 and, therefore, in the feedback control of the SRM. Battery pack 2 is connected to phase winding A through transistor T_a1and two current sensing resistors R_a1and R_a2. To sense the voltage of battery 2, a potential divider comprising two resistors R_b1and R_b2is connected across battery 2's positive terminal and terminal 22. Likewise, to measure the potential between terminal 22 and a terminal 66, a potential divider comprising resistors R_c1and R_c2is connected across terminals 66 and 22.

The current flowing through transistor T_a1or diode D_a1is measured by the voltage drop across resistor R_a1at the tap for a voltage signal V_ia1. This voltage, which is equal to the current flowing through resistor R_a1multiplied by the resistance of resistor R_a1, is with reference to terminal 22. Similarly, the current flowing through battery 2, which current is the same as that flowing through diode D_a1or transistor T_a1, is also measured by the voltage drop across resistor R_a2at the tap for a voltage signal V_ia2. The voltage of battery 2 is measured by tapping a voltage signal V_bc, which is available at the junction of resistors R_b1and R_b2. The accuracy of the battery voltage measurement is not compromised by the voltage drop across current sensing resistor R_a2, because this voltage drop is negligible compared to the battery voltage. Similarly, the voltage across terminals 66 and 22 is given by tapping a voltage signal V_tc1.

Similar insertion of a current resistor and resistors for voltage sensing is done for phase winding B. The current flowing through phase winding B and transistor T_b1is determined from the voltage drop across a resistor R_b, which is inserted between the emitter of transistor T_b1and terminal 22. A voltage signal V_ibindicates the current in transistor T_b1, according to the relation of voltage signal V_1bequals the current flowing through phase winding B multiplied by the resistance of resistor R_b. A voltage signal V_tc2across terminals 32 and 67 is measured using a potential divider comprising resistors R_c1and R_c2, and voltage signal V_tc2is with respect to terminal 22.

Three modes of operation for phase winding A are described.

Mode 1: Phase winding A current flows from terminal 21 to terminal 66, which is considered a positive current hereafter. The current in phase winding A, when transistor T_a1is turned on, is positive and represented by voltage signal V_ia1. Voltage signal V_ia1is positive for this condition with respect to terminal 22. While transistor T_a1is on, voltage signal V_tc1indicates transistor T_a1's conduction voltage, which may not be of interest in a control system during this mode of operation. Phase winding A's current signal is derived as follows:

V_ia1−i_aR_a1,  (1)

where i_ais the phase winding A current. From equation 1, the current in phase winding A is derived as:

ia=Via1Ra1.(2)

FIG. 6 illustrates, for the power converter of FIG. 5, the relation of current i_ain phase winding A and a voltage V_Aacross phase winding A. When transistor T_a1is on, during a time period 71, the voltage across phase winding A is V_b. In period 71, current i_aincreases with time, because battery voltage V_bis continuously applied to phase winding A. During a period 72 that transistor T_a1is turned off at the end of period 71, diode D_a2conveys current so as to discharge energy stored in phase winding A into capacitor C. During period 72, current i_adecreases, as energy from phase winding A is supplying capacitor C and voltage V_Aequals −V_c, where V_cis positive with respect to terminal 21 of phase winding A.

FIG. 7 illustrates, for the power converter of FIG. 5, phase winding A current i_a, voltage signal V_ia1, and a sampling of voltage signal V_ia1, identified by V_ia1(t_s), with respect to time for Mode 1 operation. Phase winding A current i_ais shown for one phase conduction period, and the current follows a rectangular current reference, as is common in SRM drives. During a period 81, transistor T_a1is turned on and current i_aand voltage signal V_ia1increase. During a period 82, transistor T_a1is turned off and current i_adecreases and voltage signal V_ia1is zero. Current i_aand voltage signal V_ia1have similar waveforms during period 81, though each is scaled by the resistance value of R_a1with respect to the other. Voltage signal V_ia1has a value of zero in period 82, because no current flows through resistor R_a1during the non-conduction period of transistor T_a1.

The waveform of current i_a, illustrated in FIG. 7, occurs in one pulse width modulation (PWM) cycle. For feedback control purposes, an average value is desired for each PWM cycle. The average value can be obtained in many ways, such as by taking an average value of the beginning and the ending values of the conduction period only. Samples of voltage signal V_ia1may be taken at the turn-on and turn-off instances 85, 86 of transistor T_a1and averaged to provide a fairly accurate value of the average phase current for phase winding A. The algorithm can be more refined depending on the accuracy required for an application.

Mode 2: When transistor T_a1is turned off, with current in phase winding A, the flow of current will transfer from transistor T_a1to diode D_a2and capacitor C, so as to charge capacitor C through a closed circuit with phase winding A. Ignoring the voltage drop across diode D_a2, the voltage across phase winding A is equal to the capacitor voltage V_c, with its positive terminal being terminal 66 with respect to terminal 21. Therefore, the voltage across terminals 22 and 66 is equal to the sum of battery voltage V_band capacitor voltage V_cand is obtained by ignoring the resistance of resistor R_a1relative to the values of resistors R_c1and R_c2. Voltage signal V_tc1is determined from a current i_sv1that flows in resistors R_c1and R_c2. Current i_sv1is expressed by:

isv1=Vb+VcRc1+Rc2.(3)

Therefore, voltage signal V_tc1is derived as:

Vtc1=isv1Rc1=Rc1Rc1+Rc2(Vb+Vc).(4)

A voltage signal V_bc, which indicates the voltage of battery 2, is determined by similar reasoning. A current i_sv2in resistors R_b1and R_b2is derived as:

isv2=VbRb1+Rb2,(5)

from which voltage signal V_bcis derived as:

Vbc=isv2Rb1=Rb1Rb1+Rb2Vb.(6)

From equation 6, battery voltage V_bis derived in terms of voltage signal V_bcas:

Vb=Rb1+Rb2Rb1Vbc.(7)

Similarly, from equation 2, the sum of the voltages of battery 2 and capacitor C is derived as:

Vb+Vc=Rc1+Rc2Rc1Vtc1.(8)

From equations 7 and 8, capacitor voltage V_cis found as:

Vc=Rc1+Rc2Rc1Vtc1-Vb=Rc1+Rc2Rc1Vtc1-Rb1+Rb2Rb1Vbc.(9)

Equation 9 shows that capacitor voltage V_cis a function of voltage signal V_bcand voltage signal V_tc1. Capacitor voltage V_cis measured when phase winding A is charging capacitor C. Battery voltage signal V_bcis available all the time, whether phase winding A is being charged by battery 2 or capacitor C.

FIG. 8 illustrates, for the power converter of FIG. 5, voltage signal V_tc1relative to voltage V_Aacross phase winding A and current i_aflowing through phase winding A for Mode 2 operation. A PWM cycle comprises periods 111 and 112. During period 111, transistor T_a1is turned on so that battery voltage V_bis applied across phase winding A and current i_aincreases. During period 112, transistor T_a1is turned off so that capacitor voltage V_cis applied across phase winding A and current i_adecreases. When transistor T_a1is turned on, the voltage across terminals 22 and 66 is almost equal to the conduction voltage drop of transistor T_a1, which conduction voltage drop is small compared to either battery voltage V_bor capacitor voltage V_cand, therefore, is treated as equal to zero in FIG. 8. When transistor T_a1is turned off, the voltage applied across phase A is equal to capacitor voltage V_c. Therefore, the voltage across terminals 22 and 66 is approximately equal to the sum of battery voltage V_band phase winding A voltage V_A, which is equal to V_c. Voltage signal V_tc1provides a scaled representation of the voltage across terminals 22 and 66.

Mode 3: The scenario of energy recovery from storage capacitor C, via the energization of phase winding A with transistor T_a2, is considered. When transistor T_a2is turned on, storage capacitor voltage V_cis applied to phase winding A, with terminal 66 being positive with respect to terminal 21. Current i_aflows from terminal 66 to terminal 21 in phase winding A and through capacitor C and transistor T_a2. By this adopted convention, current i_ain phase winding A is negative.

Current i_ais derived as follows. Phase winding A current i_ais measured for an instant, by turning off transistor T_a2for a short interval of time or during its turn-off time in a PWM switching cycle, during which time current i_awill transfer from transistor T_a2to diode D_a1via phase winding A, battery pack 2, resistor R_a2, and resistor R_a1.

FIG. 9 illustrates, for the power converter of FIG. 5, voltage signal V_ia2relative to voltage V_Aacross phase winding A and current i_aflowing through phase winding A for Mode 3 operation. A PWM cycle comprises periods 91 and 92. During period 91, transistor T_a2is turned on, the magnitude of voltage V_Aacross phase winding A is the same as capacitor voltage V_c, phase winding A current i_adecreases, and voltage signal V_ia1is zero. Neither transistor T_a1nor diode D_a1conducts current during period 91.

During period 92, transistor T_a2is turned off so that current i_afrom phase winding A goes through battery 2, resistors R_a2and R_a1, and diode D_a1. The voltage drop, represented by voltage signal V_ia2, across resistor R_a2with respect to terminal 22 is positive. Voltage V_Aapplied across phase winding A during period 92 is equal to battery voltage V_b, ignoring the resistive voltage drop across resistors R_a1and R_a2, phase winding current i_ais increasing, and voltage signal V_ia1is positive with a decreasing value over time. Voltage signal V_ia1provides a scaled representation of battery voltage V_b.

Voltage signal V_ia1can be negative for Mode 3 operation, when transistor T_a2is turned off. It is preferable for sensor signals to provide positive values; therefore, voltage signal V_ia2is used during Mode 3. Voltage signal V_ia2is positive with respect to terminal 22 and is equal to phase winding A current i_amultiplied by the resistance of resistor R. Voltage signal V_ia2is given by:

V_ia2=i_aR_a2,  (10)

where current i_ais the current flowing through phase winding A. Current i_ais derived from the measured voltage signal V_ia1as:

ia=Via2Ra2.(11)

After measuring voltage signal V_ia2for an instant, phase winding A can again be energized from storage capacitor C, by turning on transistor T_a2.

FIG. 10 illustrates signal voltage V_ia2within FIG. 9 in greater detail. The instantaneous value of current i_ain phase winding A at a moment t₁, when transistor T_a2is turned off, is indicated by i₁. Between moments t₁and t₂, voltage signal V_ia1has a decreasing value and the instantaneous value of current i_aat time t₂is indicated by i₂. At moment t₂, transistor T_a2is turned on again and maintained in the on condition until moment t_n, where the instantaneous value of current i_ais indicated by i₃and transistor t_a2is turned off again.

Between moments t₂and t_n, voltage signal V_ia2is zero and current i_ais not sensed. Instead, for Mode 3, current is sensed only when transistor T_a2is turned off and diode D_a1conducts current. This does not a create a problem in control, as most of the time an average signal is all that is required for feedback control. An average can be obtained for the period between moments t₁and t₂by taking an average of the currents i_aat those moments. Similarly, an average current between moments t_nand t_n+1can be obtained. If the current average is desired for the interval during transistor T_a2's conduction, such as between moments t₂and t_n, then it is obtained as the average of the currents i_aat the instances of t₂and t_n, which is the average of currents i₂and i₃.

FIG. 11 illustrates, for the power converter of FIG. 5, voltage V_Aacross phase winding A, phase winding A current i_a, and voltage signal V_tc1with respect to time for Mode 3 operation. A PWM cycle includes periods 121 and 122. During transistor T_a2's period of non-conduction, voltage V_Aapplied across phase winding A, assuming there has been a current previously from capacitor C via transistor T_a2into phase winding A, amounts to battery voltage V_b. Voltage V_Ais considered positive, meaning terminal 21 is positive relative to terminal 66. During time period 121, the corresponding phase winding A current i_aincreases and voltage signal V_tc1is zero. More specifically, the rate at which phase winding A current i_aincreases declines as the energy stored in phase winding A charges battery 2. Signal voltage V_tc1is zero because diode D_a1is conducting and its voltage drop is negligible. The voltage drop across diode D_a1is reflected across resistors R_c1and R_c2.

When transistor T_a2is on, voltage V_Aacross phase winding A is −V_c, that is from terminal 21 to terminal 66. Ignoring resistor R_a2, the voltage across resistors R_c1and R_c2is equal to the sum of battery voltage V_band capacitor voltage V_c. Accordingly, voltage signal V_tc1is a scaled version of the sum of voltages V_band V_c, as expressed by Equation 4.

Phase B operation of the SRM drive has only two modes, which are similar to Mode 1 and Mode 2 of phase winding A.

Mode 1: A current i_bin phase winding B, when transistor T_b1is turned on, is obtained from voltage signal V_ib. Voltage signal V_ibis positive for this condition, with respect to terminal 22. Voltage signal V_tc2indicates transistor T_b1's conduction voltage. Phase winding B current signal i_bis derived as follows:

V_ib1=i_bR_b.  (12)

From equation 12, current i_bin phase winding B is derived as:

ib=VibRb.(13)

Mode 2: When transistor T_b1is turned off with current in phase winding B, current i_bwill transfer from transistor T_b1to diode D_b2, resulting in the charging of capacitor C and the closing of a circuit via phase winding B. Ignoring the voltage drop across diode D_b2, the voltage across phase winding B is equal to capacitor voltage V_c, from the perspective of terminal 67 relative to a terminal 34. Therefore, the voltage across terminals 32 and 67 is equal to the sum of battery voltage V_band capacitor voltage V_cand is obtained by ignoring the resistance of resistor R_a2, relative to the values of resistors R_c1and R_c2. Voltage signal V_tc2is found from a current i_sv2that flows in resistors R_c1and R_c2, and current i_sv2is expressed as:

isv2=Vb+VcRc1+Rc2.(14)

Therefore, voltage signal V_tc2is derived as:

Vtc2=isv2Rc1=Rc1Rc1+Rc2(Vb+Vc).(15)

The state of battery voltage V_bis indicated by voltage signal V_bcand obtained by similar reasoning. A current i_sv2in resistors R_b1and R_b2is:

isv2=VbRb1+Rb2,(16)

from which battery voltage signal V_bcis derived as:

Vbc=isv2Rb1=Rb1Rb1+Rb2Vb.(17)

From equation 17, V_bis derived in terms of V_bcas

Vb=Rb1+Rb2Rb1Vbc.(18)

Similarly, from equation 13, the sum of battery voltage V_band capacitor voltage V_cis derived as

Vb+Vc=Rc1+Rc2Rc1Vtc2.(19)

From equations 18 and 19, capacitor voltage V_cis found as:

Vc=Rc1+Rc2Rc1Vtc2-Vb=Rc1+Rc2Rc1Vtc2-Rb1+Rb2Rb1Vbc.(20)

Equation 20 shows that capacitor voltage V_cis expressed as a function of voltage signal V_bcand voltage signal V_tc2. Capacitor voltage V_cis measured only when phase winding B is charging capacitor C. Having determined capacitor voltage V_cand battery voltage V_b, voltage V_Aapplied across phase winding A, which is either battery voltage V_bor capacitor voltage V_c, may be determined.

The current in battery 2 is determined from measurements made using the current sensors, one of which gives the incoming and the other gives the outgoing current in battery 2. Machine phase currents i_aand i_band storage capacitor currents can be derived from current sensor measurements. Wherever measurements cannot be continuously made due to the nature of the circuit, the average currents in a PWM switching cycle may be determined. Such average values over a PWM switching cycle are sufficient for control purposes.

FIG. 12 illustrates the modularization of the phase A circuitry illustrated by FIG. 5. Any number of phase modules MC may exist, with self-contained current sensing and voltage sensing circuits providing out-current signals, such as is provided by voltage signal V_ia1, and voltage signals, such as is provided by voltage signal V_tc1.

FIG. 13 illustrates the modularization of the phase B circuitry illustrated by FIG. 5. Any number of phase modules NC may exist, with self-contained current sensing and voltage sensing circuits providing out-current signals, such as is provided by voltage signal V_ib, and voltage signals, such as is provided by voltage signal V_tc2.

Current sensing that occurs while storage capacitor C is charging a phase can be obtained from voltage signal V_ia2across resistor R_a2, and this could be common for the generalized circuit. Similarly, the generalized circuit may also have the potential divider, comprising resistors R_b1and R_b2, to measure battery voltage V_bvia voltage signal V_bc.

Consider phase winding A, transistor T_a1, diode D_a1, resistors R_a1, R_c1and R_c2, transistor T_a2, and diode D_a2enclosed in dotted lines and identified as a unit MC. Unit MC has terminals, 21, 22, and 23. Similarly, a unit NC comprising transistor T_b1, current sensing resistor R_b, voltage sensing resistors R_c1and R_c2, phase winding B, and diode Db2 is a three terminal unit having terminals 32, 33, and 34.

FIG. 14 illustrates an SRM having multiples ones of the phase units illustrated in FIGS. 12 and 13. A power converter 150 includes: (1) battery 2, (2) capacitor C, (3) sensing resistor R_a2, to measure current when energy from capacitor C is transferred to phase winding A, (4) a common potential divider comprising resistors R_b1and R_b2to measure battery voltage V_bvia voltage signal V_bc, (5) j units MC connected between terminals 151, 152, and 153, where j is a desired number of phase windings A, and (6) k units NC connected between terminals 151, 152, and 153, where k is a desired number of phase windings B. Unit MC's terminals 151, 152, and 153 correspond to, for example, terminals 22, 21, and 23 in FIG. 12. Likewise, unit NC's terminals 151, 152, and 153 correspond to terminals 32, 34, and 33 in FIG. 12. Parameters j and k are any positive integer values. It is possible to have an equal number of units MC and units NC or zero units NC.

FIG. 15 illustrates a control system for controlling the power converter illustrated by FIG. 14. Phase winding A draws energy from battery 2 or storage capacitor C. For one phase conduction period, only one of battery 2 and storage capacitor C provides energy to phase winding A. The selection of the source determines which of transistors T_a1and T_a2conducts. For Mode 1 of phase A operation, current i_aflowing through resistor R_a1produces voltage signal V_ia1. A current command i_a*, corresponding to current i_a, is translated to a voltage V_ia,* corresponding to V_ia1, by flowing through a resistor R_a1whose resistance is the same as that of resistor R_a1. Since feedback current i_aand reference current i_a* are represented in the form of voltages, the difference between the reference and feedback current signals can be obtained by subtraction of their representative voltages using a summer 164, whose output is fed to a current controller 165 of control system 160. Current controller 165 may be a proportional-plus-integral controller or similar device. The output of current controller 165 provides a duty cycle signal d for transistor T_a1or T_a2. Duty cycle d is limited by current controller 165 to a maximum magnitude of one and a minimum magnitude of zero.

A transistor selection block 167 selects which of transistors T_a1and T_a2to turn on, so as to determine which of energy sources, battery 2 and capacitor C, will energize phase winding A for a particular phase cycle. Transistor selection block 167 receives duty cycle signal d, voltage signals V_tc1and V_bc, and a voltage signal ΔV indicating the allowable voltage change across storage capacitor C. The output of transistor selection block 167 provides control signals to the gates of bipolar junction transistors T_a1and T_a2. The selection of which transistor conducts during the phase cycle is based on whether voltage signal ΔV exceeds an allowable limit over battery voltage V_b, which is represented by voltage signal V_bc. Control system 160 may be implemented by a computer processor or programmable logic device.

FIG. 16 illustrates the operation of the transistor selection block illustrated in FIG. 15. A summer 190 subtracts voltage signal V_bc, representing battery voltage V_b, from voltage signal V_tc1, which represents the sum of battery voltage V_band capacitor voltage V_c, to obtain a signal 183 representing capacitor voltage Y. Logic function blocks 191 and 192 receive signal 183 representing capacitor voltage V_c, voltage signal ΔV, and a phase initiation signal 189, which is derived from the starting edge of a phase dwell signal 187. Phase dwell signal 187 is indicative of an angular duration of conduction for a phase winding, which is generated in a control system for a motor drive and determined by the rotational speed and absolute position of the rotor poles in an SRM. Phase dwell signal 187 may be a rectangular pulse that is processed through a sample and hold circuit 188, so that only the leading edge of the pulse is output as phase initiation signal 189.

A logic function block 191 determines whether signal 183 representing capacitor voltage V_cis greater than or equal to the sum of battery voltage V_band voltage signal ΔV. Logic function block 191 outputs a binary signal 185 indicating the determination. The value of signal 185 is held for one phase dwell period in accordance with phase initiation signal 189. Similarly, logic function block 192 determines whether signal 183, representing capacitor voltage V_c, is less than the difference between battery voltage V_band voltage ΔV. Logic function block 192 outputs a binary signal 186 indicating the determination. The value of signal 186 is held from the beginning to the end of the phase dwell duration in accordance with phase initiation signal 189. Signal 185 is combined by an AND logic function block 193 with duty cycle signal d to generate a gate signal 170 for transistor T.

When gate signal 170 is positive, capacitor C has enough energy to supply phase winding A. Therefore, when the phase dwell signal comes on, transistor T_a2is turned on to conduct current. Similarly, signal 186 is combined by an AND function block 194 with duty cycle signal d to generate a gate signal 169 for transistor T_a2. When gate signal 169 is positive, storage capacitor C will not be able to supply sufficient energy to phase winding A. Therefore, energy is supplied by battery 2, by turning on transistor T_a1, via gate signal 169, so as to conduct current.

Control system 160 may similarly control phase B operation using current i_bindicated by voltage signal V_iband control phase A and phase B operation using current i_aindicated by voltage sensor V_ia2.

The machine phases discussed herein are those pertaining to switched reluctance machines, but are equally applicable to PMBDC machines. The voltage measurements and estimations described herein are also applicable for control purposes other than the ones described. Such an application is the use of machine-phase voltages and currents for estimating rotor position, via a computation of the phase-flux linkages and estimated phase currents.

The disclosed method(s) may be implemented by instructions stored on a storage medium and executed by a computer processor or programmable logic device.

The foregoing description illustrates and describes one or more preferred embodiments of the invention, but the invention may be used in various other combinations, modifications, and environments. The invention is capable of change or modification, within the scope of the inventive concept, as expressed herein, that is commensurate with the above teachings and the skill or knowledge of one skilled in the relevant art. Accordingly, the description is not intended to limit the invention to the embodiments disclosed herein.