EP4695899A1 - An electric drive unit, method for operating an electric drive and corresponding vehicle - Google Patents

An electric drive unit, method for operating an electric drive and corresponding vehicle

Info

Publication number
EP4695899A1
EP4695899A1 EP24710371.6A EP24710371A EP4695899A1 EP 4695899 A1 EP4695899 A1 EP 4695899A1 EP 24710371 A EP24710371 A EP 24710371A EP 4695899 A1 EP4695899 A1 EP 4695899A1
Authority
EP
European Patent Office
Prior art keywords
rotor
electric drive
drive unit
motor
magnets
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP24710371.6A
Other languages
German (de)
French (fr)
Inventor
Jeong Kwon
Divya RAJU
Xiaodong Shi
Xiaoqing CAO
Marko Sinistaj
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mercedes Benz Group AG
Original Assignee
Mercedes Benz Group AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mercedes Benz Group AG filed Critical Mercedes Benz Group AG
Publication of EP4695899A1 publication Critical patent/EP4695899A1/en
Pending legal-status Critical Current

Links

Classifications

    • 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
    • H02P29/60—Controlling or determining the temperature of the motor or of the drive
    • H02P29/66—Controlling or determining the temperature of the rotor
    • H02P29/662—Controlling or determining the temperature of the rotor the rotor having permanent magnets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
    • H02K21/24—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
    • 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
    • H02P21/00—Arrangements or methods for the control of electric machines by vector control, e.g. by control of field orientation
    • H02P21/0003—Control strategies in general, e.g. linear type, e.g. P, PI, PID, using robust control
    • H02P21/0025—Control strategies in general, e.g. linear type, e.g. P, PI, PID, using robust control implementing a off line learning phase to determine and store useful data for on-line 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
    • H02P21/00—Arrangements or methods for the control of electric machines by vector control, e.g. by control of field orientation
    • H02P21/0085—Arrangements or methods for the control of electric machines by vector control, e.g. by control of field orientation specially adapted for high speeds, e.g. above nominal speed
    • H02P21/0089—Arrangements or methods for the control of electric machines by vector control, e.g. by control of field orientation specially adapted for high speeds, e.g. above nominal speed using field weakening
    • 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
    • H02P21/00—Arrangements or methods for the control of electric machines by vector control, e.g. by control of field orientation
    • H02P21/14—Estimation or adaptation of machine parameters, e.g. flux, current or voltage
    • H02P21/141—Flux estimation

Definitions

  • An electric drive unit method for operating an electric drive and corresponding vehicle
  • the present invention relates to the field of automobiles. More specifically, the present invention relates to an electric drive unit including an electric motor, which can be used by a vehicle, in particular a car, van, truck, or similar. Furthermore, the present invention relates to a method for operating the electric drive unit and a corresponding vehicle.
  • An electric motor of an electric drive unit may consist of a rotor with permanent magnets and a stator.
  • An electric motor with permanent magnets may have different magnetic field strengths due to temperature changes in the magnets belonging to the rotor. When the magnetic field strength decreases, the output torque and the operating efficiency of the electric motor may decrease. Therefore, there is a need to determine the temperature of the magnets particularly in order to be able to operate the electric motor particularly advantageously.
  • a first aspect of the present invention relates to an electric drive unit (EDU).
  • the electric drive unit includes an electric motor, which may be configured as an axial flux motor and includes a rotor with rotor magnets and a stator with stator magnets corresponding thereto, and a motor control unit, which is configured to estimate the temperature of the rotor magnets out of an input power measured by a sensor of the electric drive unit and is configured to control the electric motor in dependence on a temperature of the rotor magnets.
  • the EDU may include, for example, a high voltage DC input current sensor and/or a high voltage sensor.
  • the EDU may determine or estimate an EDU Input Power and an EDU Output Power with the current and/or voltage sensor.
  • an EDU operation condition may be provided or used.
  • the electric drive unit may estimate rotor flux difference and/or magnet temperature difference with the EDU Input Power and for example the EDU operating condition.
  • the rotor flux difference and/or magnet temperature difference may be used to determine or estimate the temperature of the rotor magnets.
  • the motor control unit may then generate a control command for controlling the electric motor.
  • the electric motor is in particular a motor for an electric drivetrain of a vehicle, which itself is in particular a car, a van, or a truck.
  • the motor controller may be an electronic control unit or computing device of the vehicle.
  • An axial flux motor is an electric motor, whose rotor has in particular the shape of a disc. Its coils and/or windings, for example, have the shape of a disc and are in particular coreless, which in this context means without an iron core.
  • the axial flux motor may be characterized by the fact that the magnetic field is in parallel to the axis of rotation.
  • the diameter of the electric motor may be in particular greater than its length.
  • the EDU may estimate for example a motor torque difference (i.e. error), a rotor flux difference, a rotor magnet temperature difference, and/or an estimated rotor magnet temperature based on the rotor magnet temperature difference.
  • the EDU may calculate these values using DC Power and DC current sensor such as a high voltage DC current sensor or AC current sensor.
  • DC Power and DC current sensor such as a high voltage DC current sensor or AC current sensor.
  • the EDU may use Input Power with a current sensor to measure the DC input power to determine motor torque difference (i.e. error), rotor flux difference, and rotor magnet temperature difference.
  • the EDU may also use the AC current sensor and a pulse wave modulation (PWM) command for each phase to determine the motor torque difference (i.e. error), rotor flux difference, and rotor magnet temperature difference.
  • PWM pulse wave modulation
  • the EDU may also collect information regarding the input power with a high voltage sensor, the torque command, the motor speed, and efficiency-related data from a
  • the present invention is based on the fact that rotor flux (A f ) may vary by ⁇ 10 % with magnet temperature of the rotor. Therefore, magnet temperature information of the rotor may be important to achieve accuracy torque control and high efficiency operation. For example, if the magnetic field strength decreases, the output torque and/or the efficiency of the electric motor may decrease.
  • the operation of the axial flux motor may be sensitive to changes in the temperature of the rotor magnet. Furthermore overheated magnets of the rotor may cause damage to the structure of the rotor of axial flux motors. With magnet temperature information of the rotor, the motor controller may protect the electric motor, in particular the magnets against overheating.
  • one advantage of the present invention is that the electric motor can be operated in a particularly precise and/or fail-safe manner.
  • the senor is a high voltage DC input current sensor and/or a high voltage sensor.
  • a high voltage DC input current sensor may be used.
  • a high voltage sensor which may be configured to measure AC and/or DC input power may be used.
  • the rotor magnets may be configured as permanent magnets and/or the stator magnets may be configured as electromagnets.
  • Rotating rotor permanent magnets may be used which may reduce complexity of the electric motor because a motor design could, for example, be brushless or without connectors for rotating electromagnets.
  • electromagnets may be placed on the stator, thus making connections to a power supply effortless.
  • An advantage thereof is that the complexity and/or volume of the electric motor may be particularly low.
  • a second aspect of the present invention relates to a method for operating an electric drive unit which includes an electric motor which is designed as an axial flux motor and has a rotor with rotor magnets and a stator with stator magnets corresponding thereto, a motor control unit controlling the electric motor in dependence on a temperature of the rotor magnets, an input power being measured by a sensor and the temperature of the rotor magnets being determined on the basis of the measured input power.
  • At least one electric drive unit operating state value may be determined in addition to the input power that may be used for determining the rotor magnet temperature.
  • the temperature may be estimated by the input power and a value characterizing the operating state of the electric drive unit, in particular the electric motor.
  • the at least one operating state value may be determined by the sensor and/or a further sensor and/or by derivation.
  • the value describing the operating state of the electric drive unit may be determined by the sensor and/or the further sensor, which for example may also be a high voltage sensor.
  • the value may be derived for example from other known values or measurements of operating parameters such as the torque of the electric machine, which is capable of forming the base for the derivation.
  • the electric motor may be operated in a particularly precise manner due to the possibility that the temperature can be calculated, determined, or estimated in an improved manner.
  • an output power may be determined.
  • the output power of the electric motor and/or the electric drive unit may be used.
  • a rotor flux may be determined and in particular the temperature may be determined via the rotor flux.
  • the rotor flux may be used to calculate or determine the temperature of the rotor. This means that a dependency existing between the rotor flux and the temperature may be used to determine the values for improved electric motor control.
  • a control command may be generated by the motor control unit for controlling the electric motor.
  • torque command may be generated and the control command of the torque command may be determined in dependence on the determined temperature and therefore the EDU may be operated in a particularly precise and/or fail-safe manner.
  • a third aspect of the present invention relates to a vehicle.
  • the vehicle includes an electric drive unit according to the first aspect of the present invention and/or may be configured to perform a method according to the second aspect of the present invention.
  • FIG. 1 a schematic diagram of a method of operating an electronic drive unit;
  • Fig. 2 another schematic diagram of another embodiment of the method;
  • FIG. 3 a schematic diagram of a vector control for the method according to Fig. 1 and/or Fig. 2;
  • FIG. 4 another schematic diagram of another embodiment of the vector control according to Fig. 3.
  • Figs. 1 to 4 are used to describe an electric drive unit 10 that may include a motor control unit 14 and vector control unit 26, which may be a component of the motor control unit 14, a method for operating an electric drive unit 10, and a corresponding vehicle, which includes the electric drive unit 10 and/or is configured to perform the method described herein.
  • the electric drive unit 10 includes an electric motor 12, which is configured as an axial flux motor and includes a rotor with rotor magnets and a stator with stator magnets corresponding thereto.
  • the electric drive unit 10 further includes a motor control unit 14, which is configured to control the electric motor 12 in dependence on a temperature of the rotor magnets and is configured to determine the temperature of the rotor magnets based on an input power measured by a sensor of the electric drive unit 10.
  • the motor control unit 14 may include a vector control unit 26.
  • the method described here is for operating an electric drive unit 10, which includes a three-phase inverter 16, an electric motor 12, which is designed as an axial flux motor and has a rotor with rotor magnets and a stator with stator magnets corresponding thereto, a motor control unit 14 controlling the electric motor 12 in dependence on a temperature of the rotor magnets, an input power being measured by a sensor, and the temperature of the rotor magnets being determined on the basis of the measured input power.
  • a motor control unit 14 controlling the electric motor 12 in dependence on a temperature of the rotor magnets, an input power being measured by a sensor, and the temperature of the rotor magnets being determined on the basis of the measured input power.
  • the system may use a high voltage DC input current sensor and/or a high voltage sensor.
  • Other sensors or at least one other sensor may be used, which may be configured as a high voltage DC input current sensor and/or a high voltage sensor.
  • the sensor or the at least one other sensor may therefore be used to measure or determine the operating state value and/or the input power which may be used to estimate or determine or calculate the temperature of the rotor magnets or at least the temperature difference.
  • the rotor magnets may be configured as permanent magnets. Additionally or alternatively, the stator magnets may be configured as electromagnets and therefore include coils and/or windings, which are connected via a three-phase inverter 16 with a power supply unit 18, which may be a battery of the vehicle.
  • the electric drive unit 10 is in particular a part of an electric drivetrain of the vehicle.
  • Using an axial flux motor as the shown electric motor 12 for the electric drivetrain of the vehicle may be advantageous because axial flux motors may be operated with high power density and/or high efficiency at an operating range of the vehicle.
  • the axial flux motor output torque may be represented with the following equation:
  • the motor output torque equation may simplify at most of vehicle operating range:
  • the rotor flux may vary while operating the electric motor 12 within ⁇ 10 % due to the temperature of the rotor magnets. Therefore magnet temperature information may be important to achieve high accuracy torque control and high efficiency operation.
  • Magnetic Flux Difference ( error ) Power Error EDU /(Torque Command x a> m )
  • the electric drive unit 10 may determine the motor torque difference, the rotor flux difference, the rotor magnet temperature difference, and the rotor magnet temperature based on the rotor magnet temperature difference.
  • the electric drive unit 10 may determine these values using information regarding DC power and DC current, for example, measurement from a high voltage DC current sensor. Additionally or alternatively, the sensor or another sensor may provide further measurements.
  • the electric drive unit 10 may use input power with the sensor to measure the DC input power to determine the motor torque difference, the rotor flux difference, and the rotor magnet temperature difference.
  • the electric drive unit 10 or EDU 10 may also use an AC current sensor and a pulse width modulation (PWM) command for each phase to determine the motor torque difference, the rotor flux difference, and the rotor magnet temperature difference.
  • the EDU 10 may also collect information regarding DC voltage via a high voltage sensor or another sensor. Further information collected by the EDU 10 may include a torque command, a motor speed, and efficiency-related data, which may be provided by a look-up table 20.
  • Fig. 1 shows part of the method for operating the electric drive unit 10.
  • Fig. 1 shows steps for determining a magnet temperature difference and rotor flux difference with DC power input.
  • the input parameters or input values are IP1 to IP4.
  • mathematical operations are shown or are highlighted by the operator boxes 22.
  • the mathematical operation, which is executed, is shown within each operator box 22.
  • the inputs IP1 to IP4 are as follows: the DC voltage IP1 , the DC current IP2, a torque command IP3, and a motor speed IP4.
  • the input power in particular the DC input power
  • the efficiency may be determined, which may be multiplied with the efficiency, which determined gained by the left-most look-up table 20 in Fig. 1. This multiplication provides that measured output power.
  • IP3, IP4 may be used as inputs in the look-up table 20. Multiplying the torque command IP3 with the motor speed IP4 may provide a command output power.
  • a low pass filter 24 may be used, so that a result of a torque error may be determined as a first result R1 , which represents output torque minus command torque.
  • the magnetic flux difference (A error) may be determined as result R2.
  • the magnet temperature error can be determined as result R3.
  • torque command IP3 may be used the input.
  • Fig. 2 shows the determination of the magnetic flux difference, rotor flux difference, and magnet temperature difference using DC output power instead of DC input power as shown in Fig. 1 output.
  • the inputs include DC voltage IP1 , a torque command IP3, a motor speed IP4, and DC current IP5.
  • the difference to the determination unit Fig. 1 is that DC output current is provided as the input parameter IP5. Which leads with the multiplication performed by the leftmost operator box 22 with DC voltage to the DC output power.
  • the determination unit otherwise operates in the same way as shown in Fig. 1 .
  • the output power in particular the DC output power, may be determined, which may be multiplied with the efficiency, which determined gained by the left-most look-up table 20 in Fig. 2.
  • This multiplication provides that measured output power.
  • IP3, IP4 may be used as inputs in the look-up table 20. Multiplying the torque command IP3 with the motor speed IP4 may provide a command output power.
  • a low pass filter 24 may be used, so that a result of a torque error may be determined as a first result R1 , which represents output torque minus command torque.
  • the magnetic flux difference (A error) may be determined as result R2.
  • the magnet temperature error can be determined as result R3.
  • torque command IP3 may be used the input.
  • FIG. 3 and 4 show a vector control which may also be referred to as a field-orientated control (FOC), which is a variable frequency drive control method for a three-phase AC electric motor 12.
  • FOC field-orientated control
  • the vector control may in particular be performed in a vector control unit 26.
  • vector control alternating variables, such as alternating voltages and/or alternating currents, are not controlled directly in their temporal instantaneous value, but in an instantaneous value adjusted for the phase angle within the period.
  • the required AC quantities may each be transferred to a coordinate system rotating with the frequency of the AC quantities.
  • the alternating variables result in constant variables to which all the usual methods of control engineering may be applied.
  • a power supply unit 18 is shown, which is in particular the battery of the vehicle, which is in particular an electric vehicle or at least a hybrid vehicle.
  • the power supply unit 18 is connected to a three-phase inverter 16, which may be controlled by the vector control unit 26 and may provide the current for the electric motor 12 based on the determined rotor magnet temperature.
  • the torque is zero.
  • the rotor-related d/q system may be determined or calculated on the basis of a stator-related three-phase system with the aid of the Clarke transformation and subsequent d/q transformation (Park transformation).
  • the d and q vectors are perpendicular to each other, the q value maps the torque and the d value maps the magnetic flux density, and may be modeled similarly to a DC machine with PI controller.
  • the torque of the machine may be influenced by an externally specified q reference value.
  • the d reference value may be zero in the base speed range, provided that the d and q inductances are equal, i.e. there is no reluctance contribution to the torque.
  • the electric drive unit 10 may update the magnet temperature determination unit 34 based on a default magnetic flux and rotor magnetic flux determination, which is shown in Fig. 3, and/or the rotor magnet temperature determination unit, which is shown in Fig. 4, in order to provide data for the current command converter 34 based on torque command and operating conditions, this current command converter 34 may generate a current command with magnetic flux and the torque command IP3 for the electric motor 12.
  • Fig. 3 the box with the dashed lines shows a magnet temperature determination unit, which uses the magnetic flux error R2, wherein the default magnetic flux is given as an input parameter IP6.
  • the PI estimator 28 of the magnet temperature determination unit the error of the flux R2 is summed up to the default magnetic flux IP6 and then operated in the current command convertor 34 with the torque command IP3.
  • a flux weaken control 30 is used as another input parameter.
  • Fig. 4 shows instead of the magnet temperature determination unit 32, which has the magnet temperature error R3 as the input.
  • the magnet temperature determination unit 32 uses the magnet temperature error R3 as an input in conjunction with the default temperature as input parameter IP7.
  • the magnet temperature error R3 may be operated in the PI estimator 28 before the magnet temperature error R3 is summed up to the default temperature IP7 and a magnet temperature may be determined as a fourth result R4.
  • the determined magnet temperature R4 may be used as an input in the look-up table 20 in Fig. 4.
  • output of the look-up table 20 may be operated in the current command convertor 34 with the torque command IP3.
  • a flux weaken control 30 is used as another input parameter.
  • Figs. 3 and 4 show the vector control unit 26 providing control signals for controlling the three-phase inverter 16 for the electric motor 12.
  • the methods in the present disclosure for operating the electric drive unit 10, and the corresponding vehicle may provide improved accuracy of torque control and may prevent overheating of the magnets.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Databases & Information Systems (AREA)
  • Control Of Ac Motors In General (AREA)

Abstract

The present invention relates to an electric drive unit (10) including an electric motor (12), which is configured as an axial flux motor and comprises a rotor with rotor magnets and a stator with stator magnets corresponding thereto, and a motor control unit (14), which is configured to estimate a temperature of the rotor magnets based on an input power measured by a sensor of the electric drive unit (10) and configured to control the electric motor (12) based on the temperature of the rotor magnets. Furthermore, the present invention relates to a corresponding method for operating an electric drive unit (10) and a corresponding vehicle.

Description

An electric drive unit, method for operating an electric drive and corresponding vehicle
FIELD OF THE INVENTION
[0001] The present invention relates to the field of automobiles. More specifically, the present invention relates to an electric drive unit including an electric motor, which can be used by a vehicle, in particular a car, van, truck, or similar. Furthermore, the present invention relates to a method for operating the electric drive unit and a corresponding vehicle.
BACKGROUND INFORMATION
[0002] An electric motor of an electric drive unit may consist of a rotor with permanent magnets and a stator. An electric motor with permanent magnets may have different magnetic field strengths due to temperature changes in the magnets belonging to the rotor. When the magnetic field strength decreases, the output torque and the operating efficiency of the electric motor may decrease. Therefore, there is a need to determine the temperature of the magnets particularly in order to be able to operate the electric motor particularly advantageously.
SUMMARY OF THE INVENTION
[0003] Therefore, it is an object of the present invention to provide an electric drive unit, a method for operating the electric motor, and a vehicle, by which a temperature of at least one magnet of the electric motor can be determined particularly precisely.
[0004] This object is solved by an electric drive unit, a method, and a vehicle according to the present invention. Advantageous embodiments are presented in the dependent claims, the description and the drawings. [0005] A first aspect of the present invention relates to an electric drive unit (EDU). The electric drive unit includes an electric motor, which may be configured as an axial flux motor and includes a rotor with rotor magnets and a stator with stator magnets corresponding thereto, and a motor control unit, which is configured to estimate the temperature of the rotor magnets out of an input power measured by a sensor of the electric drive unit and is configured to control the electric motor in dependence on a temperature of the rotor magnets.
[0006] In other words, the EDU may include, for example, a high voltage DC input current sensor and/or a high voltage sensor. The EDU may determine or estimate an EDU Input Power and an EDU Output Power with the current and/or voltage sensor. Additionally, an EDU operation condition may be provided or used. The electric drive unit may estimate rotor flux difference and/or magnet temperature difference with the EDU Input Power and for example the EDU operating condition. The rotor flux difference and/or magnet temperature difference may be used to determine or estimate the temperature of the rotor magnets. The motor control unit may then generate a control command for controlling the electric motor.
[0007] The electric motor is in particular a motor for an electric drivetrain of a vehicle, which itself is in particular a car, a van, or a truck. The motor controller may be an electronic control unit or computing device of the vehicle. An axial flux motor is an electric motor, whose rotor has in particular the shape of a disc. Its coils and/or windings, for example, have the shape of a disc and are in particular coreless, which in this context means without an iron core. The axial flux motor may be characterized by the fact that the magnetic field is in parallel to the axis of rotation. The diameter of the electric motor may be in particular greater than its length.
[0008] The EDU may estimate for example a motor torque difference (i.e. error), a rotor flux difference, a rotor magnet temperature difference, and/or an estimated rotor magnet temperature based on the rotor magnet temperature difference. The EDU may calculate these values using DC Power and DC current sensor such as a high voltage DC current sensor or AC current sensor. For example, the EDU may use Input Power with a current sensor to measure the DC input power to determine motor torque difference (i.e. error), rotor flux difference, and rotor magnet temperature difference. The EDU may also use the AC current sensor and a pulse wave modulation (PWM) command for each phase to determine the motor torque difference (i.e. error), rotor flux difference, and rotor magnet temperature difference. The EDU may also collect information regarding the input power with a high voltage sensor, the torque command, the motor speed, and efficiency-related data from a look-up table.
[0009] The present invention is based on the fact that rotor flux (Af) may vary by ± 10 % with magnet temperature of the rotor. Therefore, magnet temperature information of the rotor may be important to achieve accuracy torque control and high efficiency operation. For example, if the magnetic field strength decreases, the output torque and/or the efficiency of the electric motor may decrease. The operation of the axial flux motor may be sensitive to changes in the temperature of the rotor magnet. Furthermore overheated magnets of the rotor may cause damage to the structure of the rotor of axial flux motors. With magnet temperature information of the rotor, the motor controller may protect the electric motor, in particular the magnets against overheating.
[0010] Thus, one advantage of the present invention is that the electric motor can be operated in a particularly precise and/or fail-safe manner.
[0011] According to an embodiment of the present invention, the sensor is a high voltage DC input current sensor and/or a high voltage sensor. In other words, in particular for determining or measuring the input power, a high voltage DC input current sensor may be used. Additionally or alternatively, a high voltage sensor, which may be configured to measure AC and/or DC input power may be used. An advantage thereof is that for example the input power can be determined in an improved manner.
[0012] According to another embodiment of the present invention, the rotor magnets may be configured as permanent magnets and/or the stator magnets may be configured as electromagnets. Rotating rotor permanent magnets may be used which may reduce complexity of the electric motor because a motor design could, for example, be brushless or without connectors for rotating electromagnets. Additionally or alternatively, electromagnets may be placed on the stator, thus making connections to a power supply effortless. An advantage thereof is that the complexity and/or volume of the electric motor may be particularly low.
[0013] A second aspect of the present invention relates to a method for operating an electric drive unit which includes an electric motor which is designed as an axial flux motor and has a rotor with rotor magnets and a stator with stator magnets corresponding thereto, a motor control unit controlling the electric motor in dependence on a temperature of the rotor magnets, an input power being measured by a sensor and the temperature of the rotor magnets being determined on the basis of the measured input power.
[0014] Advantageous embodiments of the first aspect of the present invention are to be regarded as advantageous embodiments of the second aspect of the present invention and vice versa.
[0015] According to an embodiment of the present invention, additionally at least one electric drive unit operating state value may be determined in addition to the input power that may be used for determining the rotor magnet temperature. In other words, the temperature may be estimated by the input power and a value characterizing the operating state of the electric drive unit, in particular the electric motor. An advantage thereof is that the electric motor may be operated in a particularly precise manner.
[0016] According to yet another embodiment of the present invention, the at least one operating state value may be determined by the sensor and/or a further sensor and/or by derivation. In other words, the value describing the operating state of the electric drive unit may be determined by the sensor and/or the further sensor, which for example may also be a high voltage sensor. Additionally or alternatively, the value may be derived for example from other known values or measurements of operating parameters such as the torque of the electric machine, which is capable of forming the base for the derivation. Here the advantage is also that the electric motor may be operated in a particularly precise manner due to the possibility that the temperature can be calculated, determined, or estimated in an improved manner.
[0017] In yet another embodiment of the present invention, as the at least one operating state value an output power may be determined. In other words, for determining the rotor magnet temperature, the output power of the electric motor and/or the electric drive unit may be used. An advantage of this method is that the temperature can be determined in an improved manner.
[0018] According to another embodiment, a rotor flux may be determined and in particular the temperature may be determined via the rotor flux. In other words, the rotor flux may be used to calculate or determine the temperature of the rotor. This means that a dependency existing between the rotor flux and the temperature may be used to determine the values for improved electric motor control. [0019] In still another embodiment of the present invention, a control command may be generated by the motor control unit for controlling the electric motor. In other words, to operate the electric motor a, for example, torque command may be generated and the control command of the torque command may be determined in dependence on the determined temperature and therefore the EDU may be operated in a particularly precise and/or fail-safe manner.
[0020] A third aspect of the present invention relates to a vehicle. The vehicle includes an electric drive unit according to the first aspect of the present invention and/or may be configured to perform a method according to the second aspect of the present invention.
[0021] Advantageous embodiments of the first and second aspect of the present invention are to be regarded as advantageous embodiments of the third aspect of the present invention and vice versa.
[0022] Further advantages, features, and details of the present invention derive from the following description of preferred embodiments as well as from the drawings. The features and feature combinations previously mentioned in the description as well as the features and feature combinations mentioned in the following description of the figures and/or shown in the figures alone can be employed not only in the respectively indicated combination but also in any other combination or taken alone without leaving the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The novel features and characteristic of the present disclosure are set forth in the appended claims. The accompanying drawings, which are incorporated in and constitute a part of this present disclosure, illustrate exemplary embodiments and together with the description, serve to explain the disclosed principles. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described below, by way of example only, and with reference to the accompanying figures.
[0024] The drawings show in:
[0025] Fig. 1 a schematic diagram of a method of operating an electronic drive unit; [0026] Fig. 2 another schematic diagram of another embodiment of the method;
[0027] Fig. 3 a schematic diagram of a vector control for the method according to Fig. 1 and/or Fig. 2; and
[0028] Fig. 4 another schematic diagram of another embodiment of the vector control according to Fig. 3.
[0029] In the figures the same elements or elements having the same function are indicated by the same reference signs.
DETAILED DESCRIPTION
[0030] In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration". Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
[0031] While the present disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the present disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure.
[0032] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion so that a setup, device or method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in a system or apparatus preceded by “comprises” or “comprise” does not or do not, without more constraints, preclude the existence of other elements or additional elements in the system or method.
[0033] In the following detailed description of the embodiments of the present disclosure, reference is made to the accompanying drawings that form part hereof, and in which is shown by way of illustration a specific embodiment in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the present disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
[0034] Figs. 1 to 4 are used to describe an electric drive unit 10 that may include a motor control unit 14 and vector control unit 26, which may be a component of the motor control unit 14, a method for operating an electric drive unit 10, and a corresponding vehicle, which includes the electric drive unit 10 and/or is configured to perform the method described herein.
[0035] The electric drive unit 10 includes an electric motor 12, which is configured as an axial flux motor and includes a rotor with rotor magnets and a stator with stator magnets corresponding thereto.
[0036] The electric drive unit 10 further includes a motor control unit 14, which is configured to control the electric motor 12 in dependence on a temperature of the rotor magnets and is configured to determine the temperature of the rotor magnets based on an input power measured by a sensor of the electric drive unit 10. The motor control unit 14 may include a vector control unit 26.
[0037] The method described here is for operating an electric drive unit 10, which includes a three-phase inverter 16, an electric motor 12, which is designed as an axial flux motor and has a rotor with rotor magnets and a stator with stator magnets corresponding thereto, a motor control unit 14 controlling the electric motor 12 in dependence on a temperature of the rotor magnets, an input power being measured by a sensor, and the temperature of the rotor magnets being determined on the basis of the measured input power.
[0038] To measure the input power and/or a value, which may be a value which describes the electric drive unit operation state and may be therefore an electric drive unit operation state value, the system may use a high voltage DC input current sensor and/or a high voltage sensor. Other sensors or at least one other sensor may be used, which may be configured as a high voltage DC input current sensor and/or a high voltage sensor.
[0039] The sensor or the at least one other sensor may therefore be used to measure or determine the operating state value and/or the input power which may be used to estimate or determine or calculate the temperature of the rotor magnets or at least the temperature difference.
[0040] The rotor magnets may be configured as permanent magnets. Additionally or alternatively, the stator magnets may be configured as electromagnets and therefore include coils and/or windings, which are connected via a three-phase inverter 16 with a power supply unit 18, which may be a battery of the vehicle. The electric drive unit 10 is in particular a part of an electric drivetrain of the vehicle.
[0041] Using an axial flux motor as the shown electric motor 12 for the electric drivetrain of the vehicle may be advantageous because axial flux motors may be operated with high power density and/or high efficiency at an operating range of the vehicle.
[0042] The axial flux motor output torque may be represented with the following equation:
[0043] Because of the magnetic circuit of the axial flux motor, the motor output torque equation may simplify at most of vehicle operating range:
[0044] The rotor flux may vary while operating the electric motor 12 within ± 10 % due to the temperature of the rotor magnets. Therefore magnet temperature information may be important to achieve high accuracy torque control and high efficiency operation.
[0045] The following formulas show the output power of the electric drive unit 10, a command power of the electric drive unit 10, an error of the power of the electric drive unit 10, and the relation of the magnetic flux difference.
~ p y. Vdc x idc Command Pow er EDU = TorqueCommand x a)m
Power ErrorEDU = Output Pow erEDU— Command Pow er EDU
Magnetic Flux Difference ( error)= Power ErrorEDU/(TorqueCommand x a>m)
[0046] This leads to the shown relation of the magnet temperature difference:
Magnet Temperature Difference = Magnet Temper atuterReai
- Magnet TernperatureCommand
« f (Magnet Flux Difference, Torquecommand)
[0047] In the shown embodiments, the electric drive unit 10 may determine the motor torque difference, the rotor flux difference, the rotor magnet temperature difference, and the rotor magnet temperature based on the rotor magnet temperature difference. The electric drive unit 10 may determine these values using information regarding DC power and DC current, for example, measurement from a high voltage DC current sensor. Additionally or alternatively, the sensor or another sensor may provide further measurements. For example, the electric drive unit 10 may use input power with the sensor to measure the DC input power to determine the motor torque difference, the rotor flux difference, and the rotor magnet temperature difference. The electric drive unit 10 or EDU 10 may also use an AC current sensor and a pulse width modulation (PWM) command for each phase to determine the motor torque difference, the rotor flux difference, and the rotor magnet temperature difference. The EDU 10 may also collect information regarding DC voltage via a high voltage sensor or another sensor. Further information collected by the EDU 10 may include a torque command, a motor speed, and efficiency-related data, which may be provided by a look-up table 20.
[0048] Fig. 1 shows part of the method for operating the electric drive unit 10. In particular, Fig. 1 shows steps for determining a magnet temperature difference and rotor flux difference with DC power input. The input parameters or input values are IP1 to IP4. Therein, mathematical operations are shown or are highlighted by the operator boxes 22. The mathematical operation, which is executed, is shown within each operator box 22. The inputs IP1 to IP4 are as follows: the DC voltage IP1 , the DC current IP2, a torque command IP3, and a motor speed IP4.
[0049] With IP1 and IP2, the input power, in particular the DC input power, may be determined, which may be multiplied with the efficiency, which determined gained by the left-most look-up table 20 in Fig. 1. This multiplication provides that measured output power. For determining the efficiency IP1 , IP3, IP4 may be used as inputs in the look-up table 20. Multiplying the torque command IP3 with the motor speed IP4 may provide a command output power. After further calculations as the operator boxes 22 indicate, a low pass filter 24 may be used, so that a result of a torque error may be determined as a first result R1 , which represents output torque minus command torque.
[0050] Using another low-pass filter 24 after operations with the torque command IP3 and motor speed IP4, the magnetic flux difference (A error) may be determined as result R2. With the right-most look-up table 20 in Fig. 1 , the magnet temperature error can be determined as result R3. For determining the look-up table 20 value, torque command IP3 may be used the input.
[0051] Fig. 2 shows the determination of the magnetic flux difference, rotor flux difference, and magnet temperature difference using DC output power instead of DC input power as shown in Fig. 1 output. With DC output current ldc_output » CurrentJJ * PWM DutyJJ + Current_V * PWM_Duty_V + Current_W * PWM_Duty_W. In Fig. 2, the inputs include DC voltage IP1 , a torque command IP3, a motor speed IP4, and DC current IP5.
[0052] The difference to the determination unit Fig. 1 is that DC output current is provided as the input parameter IP5. Which leads with the multiplication performed by the leftmost operator box 22 with DC voltage to the DC output power. The determination unit otherwise operates in the same way as shown in Fig. 1 . With IP1 and IP5, the output power, in particular the DC output power, may be determined, which may be multiplied with the efficiency, which determined gained by the left-most look-up table 20 in Fig. 2. This multiplication provides that measured output power. For determining the efficiency IP1 , IP3, IP4 may be used as inputs in the look-up table 20. Multiplying the torque command IP3 with the motor speed IP4 may provide a command output power. After further calculations as the operator boxes 22 indicate, a low pass filter 24 may be used, so that a result of a torque error may be determined as a first result R1 , which represents output torque minus command torque.
[0053] Using another low-pass filter 24 after operations with the torque command IP3 and motor speed IP4, the magnetic flux difference (A error) may be determined as result R2. With the right-most look-up table 20 in Fig. 2, the magnet temperature error can be determined as result R3. For determining the look-up table 20 value, torque command IP3 may be used the input.
[0054] The diagrams in Fig. 3 and 4 show a vector control which may also be referred to as a field-orientated control (FOC), which is a variable frequency drive control method for a three-phase AC electric motor 12. The vector control may in particular be performed in a vector control unit 26. With the shown vector control alternating variables, such as alternating voltages and/or alternating currents, are not controlled directly in their temporal instantaneous value, but in an instantaneous value adjusted for the phase angle within the period.
[0055] For this purpose, the required AC quantities may each be transferred to a coordinate system rotating with the frequency of the AC quantities. With the rotating coordinate system the alternating variables then result in constant variables to which all the usual methods of control engineering may be applied.
[0056] On the right side of the vector control unit 26 a power supply unit 18 is shown, which is in particular the battery of the vehicle, which is in particular an electric vehicle or at least a hybrid vehicle. The power supply unit 18 is connected to a three-phase inverter 16, which may be controlled by the vector control unit 26 and may provide the current for the electric motor 12 based on the determined rotor magnet temperature.
[0057] If a stator flux and a stator current in the rotating d/q field are parallel in a synchronous motor, such as the electric motor 12, the torque is zero. The rotor-related d/q system may be determined or calculated on the basis of a stator-related three-phase system with the aid of the Clarke transformation and subsequent d/q transformation (Park transformation). The d and q vectors are perpendicular to each other, the q value maps the torque and the d value maps the magnetic flux density, and may be modeled similarly to a DC machine with PI controller. The torque of the machine may be influenced by an externally specified q reference value. In the case of synchronous motors permanently excited in the rotor, the d reference value may be zero in the base speed range, provided that the d and q inductances are equal, i.e. there is no reluctance contribution to the torque.
[0058] With, for example, a tracking algorithm, such as a PI estimator 28, the electric drive unit 10 may update the magnet temperature determination unit 34 based on a default magnetic flux and rotor magnetic flux determination, which is shown in Fig. 3, and/or the rotor magnet temperature determination unit, which is shown in Fig. 4, in order to provide data for the current command converter 34 based on torque command and operating conditions, this current command converter 34 may generate a current command with magnetic flux and the torque command IP3 for the electric motor 12.
[0059] In Fig. 3 the box with the dashed lines shows a magnet temperature determination unit, which uses the magnetic flux error R2, wherein the default magnetic flux is given as an input parameter IP6. With the PI estimator 28 of the magnet temperature determination unit the error of the flux R2 is summed up to the default magnetic flux IP6 and then operated in the current command convertor 34 with the torque command IP3. For the vector control unit 26, a flux weaken control 30 is used as another input parameter.
[0060] In contrast to Fig. 3, Fig. 4 shows instead of the magnet temperature determination unit 32, which has the magnet temperature error R3 as the input. The magnet temperature determination unit 32 uses the magnet temperature error R3 as an input in conjunction with the default temperature as input parameter IP7.
[0061] The magnet temperature error R3 may be operated in the PI estimator 28 before the magnet temperature error R3 is summed up to the default temperature IP7 and a magnet temperature may be determined as a fourth result R4. The determined magnet temperature R4 may be used as an input in the look-up table 20 in Fig. 4. [0062] Then output of the look-up table 20 may be operated in the current command convertor 34 with the torque command IP3. For the vector control unit 26, a flux weaken control 30 is used as another input parameter.
[0063] Figs. 3 and 4 show the vector control unit 26 providing control signals for controlling the three-phase inverter 16 for the electric motor 12. With the shown electric drive unit 10 and motor control unit 14, the methods in the present disclosure for operating the electric drive unit 10, and the corresponding vehicle, may provide improved accuracy of torque control and may prevent overheating of the magnets.
Reference Signs
10 electric drive unit
12 electric motor
14 motor control unit
16 three-phase inverter
18 power supply unit
20 look-up table
22 operator box
24 low pass filter
26 vector control unit
28 PI estimator
30 flux weaken control
32 magnet temperature determination unit
34 current command converter
IP1 first input parameter
IP2 second input parameter
IP3 third input parameter
IP4 fourth input parameter
IP5 fifth input parameter
IP6 sixth input parameter
IP7 seventh input parameter
R1 first result
R2 second result
R3 third result
R4 fourth result

Claims

1 . An electric drive unit (10) comprising an electric motor (12), which is configured as an axial flux motor and comprises a rotor with rotor magnets and a stator with stator magnets corresponding thereto, and a motor control unit (14), which is configured to estimate a temperature of the rotor magnets based on an input power measured by a sensor of the electric drive unit (10) and configured to control the electric motor (12) based on the temperature of the rotor magnets.
2. The electric drive unit (10) according to claim 1 , characterized in that the sensor is a high voltage DC input current sensor and/or a high voltage sensor.
3. The electric drive unit (10) according to claim 1 or 2, characterized in that the rotor magnets are configured as permanent magnets and/or the stator magnets are configured as electromagnets.
4. A method for operating an electric drive unit (10) which comprises an electric motor (12) which is designed as an axial flux motor and has a rotor with rotor magnets and a stator with stator magnets corresponding thereto, a motor control unit (14) controlling the electric motor (12) based on a temperature of the rotor magnets and an input power, wherein the input power is measured by a sensor and the temperature of the rotor magnets is based on the input power.
5. The method according to claim 4, characterized in that additionally at least one electric drive unit operating state value is determined, which is used for determining the rotor magnet temperature.
6. The method according to claim 4 or 5, characterized in that the at least one operating state value is determined by the sensor and/or a further sensor and/or by derivation.
7. The method according to any one of claims 4 or 6, characterized in that as the at least one operating state value an output power is determined.
8. The method according to any one of claims 4 or 7, characterized in that a rotor flux is determined, wherein the temperature of the rotor magnets is based on the rotor flux.
9. The method according to any one of claims 4 or 8, characterized in that a control command is generated by the motor control unit (14) for controlling the electric motor (12).
10. A vehicle comprising an electric drive unit (10) according to any one of claims 1 to 3 and/or configured to perform a method according to any one of claims 4 to 9.
EP24710371.6A 2023-04-11 2024-03-07 An electric drive unit, method for operating an electric drive and corresponding vehicle Pending EP4695899A1 (en)

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GB2305268.1A GB2628979A (en) 2023-04-11 2023-04-11 An electric drive unit, method for operating an electric drive and corresponding vehicle
PCT/EP2024/055931 WO2024213316A1 (en) 2023-04-11 2024-03-07 An electric drive unit, method for operating an electric drive and corresponding vehicle

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US11936256B2 (en) 2020-04-24 2024-03-19 Jacobi Motors, Llc Flux-mnemonic permanent magnet synchronous machine and magnetizing a flux-mnemonic permanent magnet synchronous machine
US12558980B2 (en) 2023-11-09 2026-02-24 Jacobi Motors, Llc Integrated variable flux memory motor charger
US12614998B2 (en) 2024-03-04 2026-04-28 Jacobi Motors, Llc System for multi-variable flux memory motor configuration

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JP2002034283A (en) * 2000-07-18 2002-01-31 Unisia Jecs Corp Electric motor temperature estimation device
US7262536B2 (en) * 2003-08-11 2007-08-28 General Motors Corporation Gearless wheel motor drive system
FR2991119B1 (en) * 2012-05-23 2016-01-08 Renault Sas METHOD FOR CONTROLLING AN ELECTRIC MACHINE FOR DETERMINING THE ROTOR TEMPERATURE
US20150022126A1 (en) * 2013-07-18 2015-01-22 GM Global Technology Operations LLC Method and apparatus for monitoring a permanent magnet electric machine
WO2015118678A1 (en) * 2014-02-10 2015-08-13 株式会社日立産機システム Motor power conversion device
US10148215B2 (en) * 2016-10-17 2018-12-04 Hyundai Motor Company System of calculating temperature using thermal equivalent circuit
KR20210081056A (en) * 2019-12-23 2021-07-01 엘지전자 주식회사 Motor driving device, and vehicle including the same
CN114244245B (en) * 2021-12-07 2024-05-28 广州小鹏汽车科技有限公司 Motor rotor temperature estimation method, estimation device, vehicle and storage medium

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