CN101855813B - 用于使节能最大化的电机控制器系统和方法 - Google Patents

用于使节能最大化的电机控制器系统和方法 Download PDF

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CN101855813B
CN101855813B CN200880115946.5A CN200880115946A CN101855813B CN 101855813 B CN101855813 B CN 101855813B CN 200880115946 A CN200880115946 A CN 200880115946A CN 101855813 B CN101855813 B CN 101855813B
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induction machine
voltage
control line
electric
running parameter
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CN101855813A (zh
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保罗·H·凯利
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Powerwise Group Inc
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P23/00—Arrangements or methods for the control of AC motors characterised by a control method other than vector control
    • H02P23/02—Arrangements or methods for the control of AC motors characterised by a control method other than vector control specially adapted for optimising the efficiency at low load
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P23/00—Arrangements or methods for the control of AC motors characterised by a control method other than vector control
    • H02P23/0004—Control strategies in general, e.g. linear type, e.g. P, PI, PID, using robust control
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P23/00—Arrangements or methods for the control of AC motors characterised by a control method other than vector control
    • H02P23/0077—Characterised by the use of a particular software algorithm
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P23/00—Arrangements or methods for the control of AC motors characterised by a control method other than vector control
    • H02P23/08—Controlling based on slip frequency, e.g. adding slip frequency and speed proportional frequency
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P23/00—Arrangements or methods for the control of AC motors characterised by a control method other than vector control
    • H02P23/14—Estimation or adaptation of motor parameters, e.g. rotor time constant, flux, speed, current or voltage
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P23/00—Arrangements or methods for the control of AC motors characterised by a control method other than vector control
    • H02P23/26—Power factor control [PFC]
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P25/00—Arrangements or methods for the control of AC motors characterised by the kind of AC motor or by structural details
    • H02P25/16—Arrangements or methods for the control of AC motors characterised by the kind of AC motor or by structural details characterised by the circuit arrangement or by the kind of wiring
    • H02P25/24—Variable impedance in stator or rotor circuit
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P29/00—Arrangements for regulating or controlling electric motors, appropriate for both AC and DC motors
    • H02P29/02—Providing protection against overload without automatic interruption of supply
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/14—Electronic commutators
    • H02P6/16—Circuit arrangements for detecting position
    • H02P6/18—Circuit arrangements for detecting position without separate position detecting elements
    • H02P6/182—Circuit arrangements for detecting position without separate position detecting elements using back-emf in windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/28—Arrangements for controlling current

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Control Of Ac Motors In General (AREA)
  • Control Of Electric Motors In General (AREA)

Abstract

用于在各负载情况下使AC感应电机(3)中的节能最大化的电机控制器(4)和方法，其中，在两个或多个负载点处校准电机以建立控制线(6)，所述控制线(6)然后被编程到电机控制器的非易失性存储器(30)中。基于DSP的闭环电机控制器观测电机的电机参数诸如触发角/占空比(23)、电压(37)、电流(9)和相角，以达到沿着控制线以任意负载运转电机所需的最小电压。电机控制器执行闭环控制以保持电机在计算出的目标控制点运行，使得通过经脉冲宽度调制降低电压来实现使节能最大化。

Description

用于使节能最大化的电机控制器系统和方法
相关申请的交叉引用
本申请要求2007年9月14日提交的美国临时申请第60/933,706号、以及2008年7月21提交的美国临时申请第61/135,402号的优先权。
技术领域
本发明涉及用于在各负载情况下使AC(交流)感应电机中的节能最大化的系统和方法，更特别地，涉及使用数字信号处理器的系统和方法，其校准控制线以确定电机的最有效工作特性。
背景技术
在与使用电机的控制线的节能电机控制器有关的现有系统和方法中，使用恒相角和/或恒功率因数控制来确定控制线。这意味着，控制线是水平的并且电机控制器不能将电机控制到各个负载情况的特定校准的工作点来使节能最大化。
从而，需要如下的用于AC感应电机的方法和系统：其将电机控制到各个负载情况的特定的校准的工作点。通过所有负载而获得的工作点定义了控制线或控制曲线。此外，需要如下的用于AC感应电机的方法和系统：其能够识别何时电机开始空转以及何时要停转、并使用该信息来确定校准后的控制线以便使在各个负载情况的节能最大化。
现有技术的相关专利包括以下内容：
专利/序列号  发明人    授权/公布日期
2008/0100245 Turner    05-01-2008
7,288,911    MacKay    10-30-2007
7,279,860    MacKay    10-09-2007
7,256,564    MacKay    08-14-2007
7,211,982    Chang等人  05-01-2007
7,081,729    Chang等人  07-25-2006
6,643,149    Arnet等人  11-04-2003
6,489,742    Lumsden    12-03-2002
5,506,484    Munro等人  04-09-1996
5,350,988    Le         09-27-1994
发明内容
本发明的主要目的是提供一种可以在各个负载情况下使AC感应电机中的节能最大化的系统和方法。
本发明的另一目的是提供识别何时电机开始空转以及何时电机将要停转的系统和方法。
本发明的又一目的是提供在各个负载情况下将电机控制到特定的校准的工作点的系统和方法。
本发明的另一目的是提供能够观测AC感应电机的工作特性的电机控制器。
本发明的又一目的是提供：当AC感应电机正在运行并且在闭环控制下时，能够对RMS电机电压进行校正的电机控制器。
本发明的另一目的是提供能够实时响应AC感应电机的负载变化的电机控制器。
本发明通过如下方式来实现以上及其它的目的：提供用于在各个负载情况下使电机中的节能最大化的电机控制器系统和方法，其中，在一个或多个负载点处校准电机；建立控制线或控制曲线，该控制线或控制曲线然后被编程到电机控制器的非易失性存储器中。电机控制器的闭环结构的部分、数字信号处理器(DSP)具有观测电机参数诸如电流、相角和电机电压的能力。作为半自动校准处理的一部分，该基于DSP的电机控制器还能够在开环模式中控制触发角/占空比。在正常工作中，基于DSP的电机控制器执行闭环控制以保持电机在计算的目标控制点运行，使得实现使节能最大化。这里描述的方法等效作用于单相和三相电机。
该方法的优选实现使用DSP来通过利用模数转换器在分离的时间处对电机中的电流和电压进行采样。根据这些信号，DSP可以计算包括RMS电机电压、RMS电流和相角的关键电机参数。此外，基于DSP的电机控制器可以使用定时器和脉冲宽度调制(PWM)技术以精确地控制RMS电机电压。典型地，通过使用功率控制器件诸如TRIAC(三端双向可控硅开关元件)、SCR(可控硅整流器)、IGBT(绝缘栅双极型功率管)和MOSFET(金属氧化物半导体场效应管)来实现PWM。
对于本领域的技术人员来说，当阅读以下结合附图的详细描述时，本发明的以上及其它目的、特性和优势应该变得更加明显，其中，在附图中示出并描述了本发明的例示性实施例。
附图说明
在以下的详细描述中，将参考附图进行描述，其中：
图1是本发明的具有硬件输入和输出的数字信号处理器(DSP)的框图，示出了硬件输入和输出；
图2是本发明的基于DSP的电机控制器的框图；
图3是示出本发明的相序(phase rotation)检测方法的图；
图4是示出本发明的相序检测方法的流程图；
图5是示出针对正相序的功率控制器件输出的图形；
图6是示出针对负相序的功率控制器件输出的图形；
图7是窗比较器的框图；
图8是窗比较器的示意图；
图9是电流波形和过零信号的图形；
图10是虚中性电路的示意图；
图11是示出针对单相应用的功率控制器件输出的图形；
图12是示出本发明的三维控制线的三维图形；
图13是示出投影到一个平面上的控制线的三维图形；
图14是示出二维绘制的控制线的图形；
图15是示出在半自动校准中扫描触发角/占空比的图形；
图16是示出导引扫描的触发角/占空比的图形；
图17是示出绘制的半自动校准数据的图形；
图18是示出绘制的半自动校准数据的图形；
图19是示出绘制的半自动校准数据的图形；
图20是半自动高级校准的流程图；
图21是半自动高级校准的流程图；
图22是手动校准的流程图；
图23是固定电压钳位的流程图；
图24是示出RMS电机电压钳位的图形；
图25是示出RMS电机电压钳位的图形；
图26是停转缓解技术的流程图；以及
图27是示出停转缓解技术的图形。
具体实施方式
为了描述优选实施例，所使用的术语按照附图中的附图标记如下：
1.数字系统处理器(DSP)          2.硬件输入
3.电机                         4.电机控制器
5.观测到的相角                 6.控制线
7.通过扫描控制空间的观测到的   8.电源分压电阻
校准数据曲线
9.电流                         10.目标相角
11.相位误差信号                12.比例积分微分(PID)控制器
13.均方根(RMS)电机电压         14.功率控制器件输出
15.相位A线电压过零点           16.相位B线电压过零点
17.相位C线电压过零点           18.正相序
19.负相序                      20.上电复位(POR)
21.停转点                    22.a、b、c相位接通时间
23.触发角/占空比             24.百分比负载
25.参变控制线                26.工作点
27.低输出阻抗放大器          28.相位误差
29.控制电压                  30.点b
31.拐点                      32.校准按钮
33.功率控制器件              34.点c
35.电压最小量(Vmin)          36.相过零输入
37.相线电压                  38.相电机电压
39.测量时间                  40.时间大于或小于90°？
41.ABC旋转                   42.ACB旋转
43.点d                       44.置于加载配置
45.置于空载配置              46.运行校准
47.控制线端部被校准          48.计算控制线
49.保存控制线                50.线电压
51.将触发角/占空比设置为90° 52.测量电机参数
53.检测拐点                  54.将触发角/占空比降低2°
55.保存相角和电机电压        56.重复四次
57.计算平均值                58.增加触发角/占空比
59.测量下一步                60.固定的电压钳位
61.合并控制段                62.模数转换器
63.相位计算                  64.计算相位误差
65.计算电压误差              66.将RMS电机电压与固定电压阈值
                             比较
67.控制目标是正的？          68.运行电压环
69.运行控制线环              70.电机置于功率计上
71.将电机连接到计算机           72.增加触发角/占空比并且降低电压
73.记录校准点                   74.启动电机
75.调整触发角/占空比            76.形成控制线
77.差动到单端放大器             78.输入电阻
79.衰减器                       80.反馈电阻
81.接地参考电阻                 82.保护二极管
83.求和放大器                   84.DC阻隔电容
85.求和电阻                     86.中性点
87.用于交替的中性连接的跳线块   88.窗比较器
89.提供电机电流                 90.提供正电压
91.提供负电压                   92.电压经过两个比较器
93.电压经过运算(OR)门           94.创建过零数字信号
95.电流波形                     96.正电压半周
97.负电压半周                   98.OR函数
99.DSP监视电流的增加            100.观测到增加
101.将电机电压变成全面开通      102.将电机电压降低到控制线
103.电机上的负载                104.施加到电机上的功率
105.点a                         106.计数扫描
参考图1，其示出本发明的数字信号处理器(DSP)1和硬件输入及输出的框图。DSP1可以观测电机的工作特性并且对于正在运行且在闭环控制下的电机进行均方根(RMS)电压校正。硬件输入2获得相过零输入36、相线电压37、相电机电压38以及电流9，并通过DSP1处理，然后通过功率控制器件输出14输出到功率控制器件上。
现在参考图2，其示出本发明的基于DSP的电机控制器4的系统和方法的框图。首先，电机控制器4读取各相A、B和C的电压37和电流9以获得过零输入36。在此，使用转换器62可把电压13和电流9从模拟转换到数字。接下来，执行每相的电机相角的计算63以产生观测到的相角5。接下来，将通过预编程的控制线6推导出的目标相角10与观测到的相角5比较。目标相角10与观测到的相角5之间的差异产生作为结果的相位误差信号11，其由称为比例积分微分(PID)控制器12的数字滤波器处理，其中，比例积分微分(PID)控制器12具有比例、积分和微分部分。来自PID控制器12的输出是到电机3的新控制电压以产生RMS电机电压13的功率控制器件输出14，所述新控制电压可以通过使用诸如TRIAC、SCR、IGBT或MOSFET的功率控制器件33而获得，其中，为了使节能最大化，为RMS电机电压13每相供应线电压50。
在该闭环系统中，不断地监视电机3的每相的电压13和电流。电机控制器4将把观测到的相角5驱动到校准后的控制线6上对应于电机上的负载的点。在该点处，由于控制线6基于来自电机3的已知校准数据，所以可以将实现使节能最大化。电机控制器4可以如技术员手工设置电压13一样来控制电机3。差别在于，DSP1可以动态地实时响应负载中的变化并且逐周地进行这些调整。
现在参考图3，在三相系统中，电机控制器4用于自动确定相序。线电压上的过零检测器提供对相位A线电压过零点15与相位B线电压过零点16之间角度的准确测量。对于正相序18，角度标称为120°；而对于负相序19，角度标称为60°。
参考图4，其示出相序检测的流程图。在上电复位(POR)20之后，电机控制器4可以容易地确定正相序18和负相序19。首先，测量从相位A线电压过零点到相位B线电压过零点的时间(39)。接下来，确定时间是否大于或者小于90度(40)。如果大于90度，则是ACB旋转(42)。如果时间小于90度，则是ABC旋转(41)。本发明的电机控制器4可以利用相同的基本软件和硬件结构来控制三相或单相电机。对于三相的情况，电机控制器4可以根据相序来驱动功率控制器件输出14。
现在参见图5，图5示出针对正驱动旋转的功率控制器件输出，电机控制器在由椭圆22a表示的相位A线电压过零点15接通时间期间，一起驱动相位A功率控制器件输出14和相位B功率控制器件输出14。类似地，电机控制器在由椭圆22b表示的相位B接通时间期间驱动功率控制器件(一起驱动相位B功率控制器件输出16和相位C功率控制器件输出14)。最后，电机控制器4在由椭圆22c表示的相位C功率控制器件输出14接通时间期间，一起驱动相位C功率控制器件输出17和相位A功率控制器件输出14。注意，图5和6中示出的示例绘制了90°的触发角/占空比23。
现在参见图6，图6示出针对负相序的TRIAC驱动输出，电机控制器4在由椭圆22c表示的相位A线电压过零点15接通时间期间，一起驱动相位A功率控制器件输出14和相位C功率控制器件输出14。类似地，电机控制器4在由椭圆22a表示的相位B线电压过零点16接通时间期间，一起驱动相位B功率控制器件输出16和相位A功率控制器件输出14。最后，电机控制器在由椭圆22b表示的相位C线电压过零点17接通时间期间，一起驱动相位C功率控制器件输出14和相位B功率控制器件输出14。
现在参考图7，图7示出窗比较器的框图。本发明的基于DSP的电机控制器使用窗比较器88来检测电流波形的正半部分和负半部分的过零点。当电机控制器降低RMS电机电压时，因为两个半周的显著部分的电流是零，因此难以检测出电流波形的过零点。首先，提供电机电流89，提供正电压90作为正半周的参考并且提供负电压91作为参考。接下来，将电流、正电压和负电压呈现给两个比较器92，然后经过运算(OR)门93以创建组合过零数字信号94。
此外如图8所例示，其示出窗比较器88的示意图。提供电机电流89，提供正电压90作为正半周的参考并且提供负电压91作为参考。接下来，两个比较器92处理表示为正电压和负电压的电流，然后将它们传送到OR门93以创建组合过零数字信号94。
此外，图9示出电流波形95、正电压半周96、负电压半周97和OR函数98的图形。
现在参考图10，其示出虚中性电路的示意图。在三相功率仅在德尔塔模式中可用并且没有给出中性点用作参考的情况下，可使用虚中性电路作为参考。虚中性电路包括三个差动到单端放大器77。由于相到相电压很高，因此使用输入电阻78连同反馈电阻80和接地参考电阻81来形成合适的衰减器79。由于存在相位损失的危险，因此使用保护二极管82来保护差动到单端放大器77。差动到单端放大器77连同反馈电阻80通过DC阻隔电容84和求和电阻85耦合到求和放大器83。放大器27对求和放大器83的输出进行增强，从而提供中性电势的低阻抗输出。另外的电阻对供电干线进行划分，从而允许求和放大器83来处理交替的正和负信号。在中性点86以及交替的中性连接的跳线块87可用的情况下，交替的连接是可用的。
现在参考图11，图11示出针对单相应用的功率控制器件输出14，相位A的输出14基于从电压过零输入15推导出的功率控制器件输出14而在每个半周接通。在DSP 1中禁用相位B线电压过零点和相位C线电压过零点的功率控制器件输出14，并且可以不提供硬件。在三相的情况下，功率控制器件输出14是不成对的。
现在参考图12，图12针对受y轴上观测到的相角5约束的电机的电机工作空间例示了三维控制线。在x轴上示出了表示电压下降的受控的触发角/占空比23并且在z轴上示出电机上的百分比负载24。每个电机在其工作空间内按照参变控制线25工作。例如，当给定电机是50％负载并且将触发角/占空比23被设置为100°时，观测到相角5近似为55°。
通从左上角中的加载情况44到右下角中的空载情况45的范围内的五个参变工作点26限定了图12中示出的参变控制线25。此外，由于参变控制线25是电机可能在使用最少能量时的线，因此它具有具体意义。如果增加触发角/占空比23并且降低电机电压13，那么电机将减慢并且可能停转。如果增加电机3上的负载，那么将看到类似的结果。
如图13所例示，将参变控制线25用参数表示并且投影到一个平面上，其中，所述平面由垂直方向中的相角5以及水平方向中的触发角/占空比23描述。
此外，如图14所示，将参变控制线25显示在二维图形上。在x轴上，增加触发角/占空比23可等效于降低电机电压。这是因为小触发角/占空比产生高电压以及大触发角/占空比产生低电压。电机控制器将把观测到的相角5驱动到控制线25上与电机上当前负载对应的点上。为了实现该目标，DSP计算电压和电流之间的相角5。
返回参考图2的框图，DSP1然后基于RMS电压13的当前值、或等效的触发角/占空比的当前值而计算下一个目标相角5。观测到的相角和目标相角10之间的差异产生相角误差，其通过比例积分微分(PID)控制器12或类似器件进行处理以生成新的控制目标。该控制目标以使相角误差最小的方式改变电压。目标相角10是动态的并且根据触发角/占空比而改变。
如上所述，电机控制器4将把观测到的相角5驱动到控制线25上与电机3上当前负载对应的点上。由于控制线25是根据正受控的电机3直接校准的，因此该工作点26可提供可能的最大节能。
该用于校准的优选方法称为半自动校准。半自动校准基于对电机的控制空间进行扫描的DSP1。如图15所示，扫描控制空间意味着DSP增加触发角/占空比23并且沿途在离散点记录每相的电流9和触发角/占空比23。因此，以该方式可以看到电机的停转点21的开端。用于确定控制线6上的点的、通过扫描控制空间而获得的观测到的校准数据曲线7的明确的线性部分在较低的触发角/占空比23处具有恒定的负斜率。然后，随着触发角/占空比23不断增加，电流9开始变平；并且随着电机3开始空转并且开始停转(即称为“拐点”31)，电流9实际上开始增加。
如图16所示，随后的扫描可以被导引在电机电压的较小范围处，以在拐点上“放大”。为了得到统计上准确的数据，电机控制器4需要多次扫描。在扫描次数和校准控制线25所需时间之间存在折衷。可以由DSP1使用公知的统计处理来维持对校准质量的测量，并且如果需要，可以进行额外的扫描。由于DSP1通过第一次扫描知道了拐点31的近似位置，因此这是可以实现的。
由于装置的受控环境，因此在半自动扫描期间几乎不存在停转的危险。技术员或操作员有助于确保：在进行半自动校准的同时，不会向在测试中的电机3突然施加负载。
可以以任何固定的负载执行扫描控制空间的处理。例如，可以利用满载的电机3执行一次并且利用空载的电机3执行一次。这两个点变成限定控制线25的两个点。也不必恰好在这两个点执行校准。如果需要，DSP1将在这两个点之外延展控制线25。
存在许多可以用来寻找电流-电机电压的图23中的停转点21的数值方法。如图17所示，优选的方法是使用“最小二乘”法来计算出最好地拟合累积数据(通过最初五个电机电压23而列出)的直线。
在图18中示出该方法的继续。使用在前的数据点，可预测电流9的值。用图表表示，DSP1检查与预测出的直线的正方向偏离的一个或多个点。
如图19所示，DSP1寻找曲线中的拐点的开端。偏离预测出的控制线的第一个点可以是或不是拐点31的开端。具有正误差的第一个点仅仅是噪声数据点。验证通过扫描控制空间而获得的观测到的校准数据曲线7翻转的唯一方式是观测通过额外扫描而获得的数据。
可以在实际应用中执行半自动校准。现在参考图20，其示出了显示如何执行半自动校准的流程图。首先，将电机3置于重负载配置(44)。理想地，该配置多于满额定负载的50％。接下来，按压电机控制器4上的校准按钮(32)以告诉DSP1来执行满载测量。DSP1运行校准(46)，其需要几秒钟来探测电机3的工作空间以确定满载点。电机控制器4通过接通发光二级管(LED)表示已经完成了该步骤。
接下来，将电机3置于空载配置(45)。理想地，该配置小于额定负载的25％。然后，按压电机控制器4上的校准按钮(32)以告诉DSP1来执行空载测量。DSP1运行校准(46)以确定空载点。电机控制器4通过接通发光二级管(LED)表示已经完成了控制线25两端(47)的校准。DSP1然后使用所述两个测量确定控制线48并且当它操纵电机3时应用该控制线。将控制线25的值存储到非易失性存储器49中。
图21示出半自动校准的更详细的流程图。首先，利用设置为特定度数的电机电压(51)来运行第一次校准扫描(46)，根据是运行了第一次扫描还是运行了在前的扫描(106)，电机控制器测量电机(52)直到电机控制器检测到拐点(53)。如果检测到拐点(53)，那么将触发角/占空比降低两度(54)并且将相角和电机电压记录到存储器(55)。重复该处理以获得至少四次扫描(56)从而得到相角和触发角/占空比的计算平均值(57)。如果在校准扫描中的任意步骤期间，没有检测到拐点，那么将触发角/占空比增加至少一度(58)并且执行循环步骤(59)。
用于校准的可替选方法称为手动校准。图22示出手动校准的流程图。首先，将电机置于功率计上(70)。接下来，将电机连接到用于手动控制的计算机上(71)，所述计算机允许电机以开环模式运行并且允许将AC感应电机的触发角/占空比手动设置到任意工作点。然后，将电机置于空载配置(45)。接下来，增加触发角/占空比并且降低RMS电机电压(72)直到电机恰好将要停转。记录所述触发角/占空比和相角并且这变成记录的校准点(73)。然后全面开通驱动元件来启动电机(74)。然后将电机置于满载配置(44)。接下来，增加或降低触发角/占空比直到电机恰好将要停转时电机控制器斩断RMS电机电压(75)。记录所述触发角/占空比并且这变成被记录的另一个校准点(73)。最后，所述两个校准点用于形成控制线(76)。
当RMS线电压大于编程的固定电压时，DSP控制器将RMS电机电压钳位在该固定电压处，使得即使在满载处也可能节能。例如，在单相电机的情况下，如果主电压高于115V的电机铭牌额定电压，那么将电机电压钳位在115V处。即使当电机在单相或三相应用中满载时，该钳位电机电压的操作也允许电机控制器来节省能量。
图23示出固定电压钳位的流程图。首先，计算相位误差(64)。接下来，计算电压误差(65)。然后，确定AC感应电机的RMS电机电压并将它与固定电压阈值比较(66)。如果RMS电机电压大于固定电压阈值，那么确定控制目标是否为正(67)。如果控制目标为正，那么运行电压控制环(68)。如果AC感应电机的RMS电机电压小于固定电压阈值，那么运行控制线闭环(69)并且重复整个处理。如果确定控制目标不为正，那么运行控制线环(69)并且再重复整个处理。
在一些情况下，在校准处理期间，不可能完全满载电机3。当将电机安装在实际应用中时，大概50％是达到最大负载。相反，不可能完全空载电机，这是因为只有40％达到最轻负载。图24示出接近工作范围的中间的两个负载点的示例。在控制线25的右侧处的空载端45上，DSP1将把电压的固定电压钳位60设置为最小电压35。当电机上的负载增加时，DSP1将沿着控制线移动到左上控制段61。该实现是保守的方式并且防止电机3在未校准的空间运行。
此外如图25所示，在左侧处的满载端44，DSP1将合并具有较大负斜率的控制段61。该实现是保守的方式并且驱动电压全面开通。
现在参考图26，基于DSP的电机控制器使用具体的技术来防止电机停转。首先，DSP主动监视电流的显著增加(99)，所述电流的显著增加表示电机上的负载增加了。接下来，如果观测到显著增加(100)，那么DSP将电机电压变成全面开通(101)。接下来，DSP将试图降低电机电压以回到控制线(102)并且DSP回到主动监视电流的显著增加(99)。对于DSP试图跟踪此时未知的功率需求而言，该技术是保守并安全的替选方案。
此外如图27所示，其是停转缓减技术的图形，在x轴上表示电机上的负载并且在y轴上表示时间。下面的线表示电机上的负载(103)并且上面的线表示由DSP施加到电机上的功率(104)。在点a105之前，DSP动态地控制固定负载处的电机。在点a105和点b30之间，电机上的负载突然增加并且DSP将电机电压变成全面开通。在点c34处，DSP将电机电压减少到点d43。
尽管公开了用于使节能最大化的电机控制器方法和系统的优选实施例，但是应该理解，本发明并不限于这里描述和示出部分的具体形式或布置。本领域的技术人员显然可以认识到，在不脱离本发明范围的情况下可进行各种改变，并且本发明的范围不限于说明书和附图中示出和描述的内容。

Claims (39)

1.一种用于控制以恒定频率工作的AC感应电机以保存能量的系统，该系统包括：
用于扫描所述AC感应电机的控制空间并对所述AC感应电机的工作参数进行测量的装置；
用于根据所述测量来建立控制线的装置；
用于将所述控制线存储到电机控制器中的装置；
用于按照所述控制线执行所述AC感应电机的闭环控制的装置；
用于相对于所述控制线驱动所述AC感应电机的至少一个所测量的工作参数的装置，所述工作参数包括电流；以及
用于每个周期检测所述AC感应电机中电流波形的正半部分和负半部分的过零点的装置。
2.根据权利要求1所述的系统，
其中，用于驱动至少一个所测量的工作参数的装置驱动所述AC感应
电机的所述至少一个所测量的工作参数以对应于满载配置。
3.根据权利要求1所述的系统，
其中，用于驱动至少一个所测量的工作参数的装置驱动所述AC感应
电机的所述至少一个所测量的工作参数以对应于空载配置。
4.根据权利要求1所述的系统，还包括：
用于测量所述AC感应电机的所述电流的装置。
5.根据权利要求4所述的系统，其中：
使用数字信号处理器来实现所述AC感应电机的所述电流测量。
6.根据权利要求1所述的系统，还包括：
用于测量所述AC感应电机的相角的装置。
7.根据权利要求6所述的系统，其中：
使用数字信号处理器实现所述AC感应电机的所述相角测量。
8.根据权利要求1所述的系统，其中所测量的一个工作参数是相角，并且所述系统还包括：
用于控制所述AC感应电机的触发角／占空比的装置。
9.根据权利要求8所述的系统，其中：
通过数字信号处理器实现用于控制所述AC感应电机的所述触发角／占空比的所述装置。
10.根据权利要求1所述的系统，其中：
通过自动地改变所述AC感应电机的均方根电机电压来实现用于扫描所述AC感应电机的所述控制空间以及测量所述工作参数的所述装置。
11.根据权利要求10所述的系统，其中：
用于改变所述AC感应电机的所述均方根电机电压的所述装置是数字信号处理器。
12.根据权利要求1所述的系统，其中：
用于根据所述测量建立所述控制线的所述装置是数字信号处理器。
13.根据权利要求1所述的系统，其中：
用于在所述电机控制器中存储所述控制线的所述装置是非易失性存储器。
14.根据权利要求1所述的系统，其中：
用于执行所述AC感应电机的所述闭环控制的所述装置是数字信号处理器。
15.根据权利要求1所述的系统，其中：
用于执行所述AC感应电机的所述闭环控制的所述装置是用于执行脉冲宽度调制的装置。
16.根据权利要求15所述的系统，其中：
使用至少一个TRIAC驱动器来执行所述脉冲宽度调制。
17.根据权利要求15所述的系统，其中：
使用至少一个SCR驱动器来执行所述脉冲宽度调制。
18.根据权利要求15所述的系统，其中：
使用至少一个IGBT驱动器来执行所述脉冲宽度调制。
19.根据权利要求15所述的系统，其中：
使用至少一个MOSFET驱动器来执行所述脉冲宽度调制。
20.根据权利要求1所述的系统，还包括：
用于将所述AC感应电机的工作电机电压钳位在最大电压处的装置。
21.根据权利要求1所述的系统，还包括：当配置为扫描所述AC感应电机的控制空间的停转点时用于防止所述AC感应电机以低于最小电压的电压运行的装置。
22.根据权利要求1所述的系统，其中：
用于检测所述电流波形的正半部分和负半部分的所述过零点的所述装置是至少一个窗比较器。
23.根据权利要求22所述的系统，其中：
正电压被提供给所述至少一个窗比较器作为正半周的参考；
负电压被提供给所述至少一个窗比较器作为负半周的参考；以及
来自所述至少一个窗比较器的信号被配置为经过OR门以创建组合电流过零数字信号。
24.根据权利要求1所述的系统还包括：
用于防止所述AC感应电机停转的装置。
25.根据权利要求24所述的系统，其中用于防止停转的装置包括：
数字信号处理器，配置为：
在针对电机电流的增加而不断监视所述AC感应电机的控制空间时，主动控制所述AC感应电机；
当检测到所述电机电流的增加时，将电机电压变成完全开通；以及
在所述电机电流减小之后，降低所述电机电压以符合所述控制线。
26.一种用于控制以恒定频率工作的AC感应电机以保存能量的方法，所述方法包括如下步骤：
扫描所述AC感应电机的控制空间并测量所述AC感应电机的工作参数；
每个周期检测所述AC感应电机中电流波形的正半部分和负半部分的过零点；
根据所测量的工作参数建立所述AC感应电机的控制线；
将所述控制线存储到电机控制器中；
在建立所述控制线的步骤之后，按照所述控制线执行所述AC感应电机的闭环控制；
相对于所述控制线，驱动所述AC感应电机的至少一个所测量的工作参数。
27.根据权利要求26所述的方法，其中所述扫描的步骤包括步骤：
将所述AC感应电机的工作参数置于完全负载配置；
确定所述AC感应电机的满载点；
将所述AC感应电机的工作参数置于空载配置；以及
确定所述AC感应电机的空载点。
28.根据权利要求27所述的方法，还包括步骤：
连接所述满载点和所述空载点以建立所述AC感应电机的所述控制线。
29.根据权利要求27所述的方法，其中扫描步骤还包括步骤：
当(i)所述工作参数被置于满载配置或(ii)所述工作参数被置于空载配置时，将所述AC感应电机的触发角／占空比从八十度增加到一百五十度；以及
沿着所述控制线记录电机电流和所观测的相角，其中所测量的工作参数包括相角。
30.根据权利要求26所述的方法，还包括步骤：
沿着所述控制线自动记录电机电流和所观测的相角。
31.根据权利要求26所述的方法，还包括步骤：
使用脉冲宽度调制沿着所述控制线来控制电压，其中所述电压是所测量的工作参数之一。
32.根据权利要求31所述的方法，其中：
使用至少一个TRIAC驱动器来执行所述脉冲宽度调制。
33.根据权利要求31所述的方法，其中：
使用至少一个SCR驱动器来执行所述脉冲宽度调制。
34.根据权利要求31所述的方法，其中：
使用至少一个IGBT驱动器来执行所述脉冲宽度调制。
35.根据权利要求31所述的方法，其中：
使用至少一个MOSFET驱动器来执行所述脉冲宽度调制。
36.根据权利要求26所述的方法，其中控制步骤还包括步骤：
将所述AC感应电机的电压钳位在最小电压处以防止所述AC感应电机以低于最小电压的电压运行。
37.根据权利要求26所述的方法，其中，所述检测AC感应电机中的电流波形的正半部分和负半部分的过零点包括：
将正电压提供给至少一个窗比较器作为正半周的参考；
将负电压提供给所述至少一个窗比较器作为负半周的参考；以及
来自所述至少一个窗比较器的信号被配置为经过OR门以创建组合电流过零数字信号。
38.根据权利要求26所述的方法，在执行步骤之后还包括步骤：
防止所述AC感应电机停转。
39.根据权利要求38所述的方法，其中防止停转包括：
在针对电机电流的增加而不断监视所述AC感应电机的控制空间时，主动控制所述AC感应电机；
当检测到所述电机电流的增加时，将电机电压变成完全开通；以及
在所述电机电流减小之后，降低所述电机电压以符合所述控制线。
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CA2699428C (en) 2016-10-25

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