WO2019131659A1 - Electric motor device and electric brake device in which same is used - Google Patents

Abstract

Provided are an electric motor device and electric brake device with which it is possible to adequately restrict the motor maximum power consumption regardless of variations in motor properties, and to improve the output performance of an electric motor by maximizing the use of electric power within the allowable range. This electric motor device is provided with an electric motor (1) and a control device (2). The control device (2) is provided with: a power calculator (19) for estimating the voltage and current of an electric motor (1) and estimating the power consumption of the electric motor (1) from the estimated current and voltage; and a rotation motion estimator (15) for estimating the angular velocity of the electric motor (1). The control device (2) is provided with a motor output restrictor (8) for restricting, on the basis of the angular velocity, etc., the torque command value of the electric motor (1) so that the torque command value does not exceed a threshold value and outputting the result as a restricted value. The motor output restrictor (8) has a variable restrictor (20) which, if the power consumption estimated by the power calculator (19) is greater than a predetermined value, adjusts the restricted value so that the torque command value falls to a prescribed value.

Description

Electric motor device and electric brake device using the same Related application

This application claims the priority of Japanese Patent Application No. 2017-251099 filed on Dec. 27, 2017, which is incorporated by reference in its entirety.

The present invention relates to an electric motor device and an electric brake device, and relates to a technology capable of limiting maximum motor power consumption and improving motor output performance.

The following techniques have been proposed as an electric motor device and an electric actuator using the electric motor.
1. An electric brake device using an electric motor, a linear motion mechanism, and a reduction gear (Patent Document 1).
2. The electric motor apparatus which controls an electric motor based on reactive power (patent document 2).

JP 2003-247576 Unexamined-Japanese-Patent No. 2017-11937

In the electric motor devices as described in Patent Documents 1 and 2, the maximum power consumption of the electric motor must often be limited in advance to a predetermined value so as not to exceed the capacity of the power supply. For example, in the electric brake device of Patent Document 1 or the electric steering device which is another in-vehicle electrical equipment, when the power consumption of the electric motor exceeds a predetermined capacity, the electric vehicle (EV) or HEV (Hybrid Electric Vehicle) is used. A problem may occur that the power of the battery is reduced due to lack of DC / DC converter power supply from the high voltage power supply or power supply from the alternator in the engine car. In addition, when the load on the battery is increased, the battery life may be reduced than expected.

However, it is often difficult in advance to strictly limit the power consumption of the motor due to characteristic fluctuation such as fluctuation of copper loss to a predetermined current condition due to temperature change of motor coil, harness, drive circuit, etc. . Further, in the case of a permanent magnet type motor, the magnetic flux fluctuates due to the temperature change of the magnet and the like, and the power for a predetermined angular velocity and current condition fluctuates. Furthermore, it may be difficult to accurately estimate the core loss of a magnetic circuit such as a laminated steel sheet particularly at high speed rotation.

To solve the above problems, if the motor drive conditions are set so that the power supply capacity is not exceeded after assuming the worst condition, a motor with a large volume is needed to compensate for the decrease in motor output, and the mounting space increases. And other problems.

Further, for example, in the case of the electric brake device of Patent Document 1, generally, a plurality of electric motors are simultaneously driven with respect to a predetermined power supply system, so the upper limit value of power consumption changes depending on other motor driving conditions. At this time, if the drive condition of each electric motor is set unchanged so that the total sum of the maximum power consumption of all the electric motors does not exceed the power source capacity, the motor output becomes small, for example, the response of the brake It may decrease.

An object of the present invention is to provide an electric motor apparatus capable of appropriately limiting maximum motor power consumption regardless of motor characteristic fluctuation and the like, and improving output performance of the electric motor by using electric power within the allowable range to the maximum. And providing an electric brake device.

Hereinafter, the present invention will be described with reference to the reference numerals of the embodiments for the sake of convenience to facilitate understanding.

The electric motor device of the present invention is an electric motor device including an electric motor 1 and a control device 2 for controlling the electric motor 1,
The control device 2 is
A power consumption estimation function unit 19 for estimating the current and voltage of the electric motor 1 and estimating the power consumption of the electric motor 1 from the estimated current and voltage;
Angular velocity estimation means 15 for estimating the angular velocity of the electric motor 1;
A command value of at least one of a torque command value, a current command value, and a voltage command value generated from the motor operation command given to the control device 2 is determined including the angular velocity estimated by the angular velocity estimating means 15 An output restriction function unit 8 which restricts so as not to exceed a threshold based on conditions and outputs as a restricted value;
A drive circuit 6 for driving the electric motor 1 based on the restricted value given from the output restriction function unit 8;
When the power consumption estimated by the power consumption estimation function unit 19 is larger than the predetermined value, the output restriction function unit 8 adjusts the restricted value so that the command value is reduced to the predetermined value. A restriction unit 20 is provided.
The predetermined condition, the threshold value, and the respective predetermined values are conditions, threshold values, and values arbitrarily determined by design etc., for example, conditions suitable for one or both of a test and a simulation, etc. The threshold value is determined by determining the value.

According to this configuration, the power consumption estimation function unit 19 estimates the power consumption of the electric motor 1 from the current and voltage of the electric motor 1. The output limiting function unit 8 limits the command value of at least one of the torque command value, the current command value, and the voltage command value so that the threshold value is not exceeded based on the angular velocity and the like. The output restriction function unit 8 can output the command value as a restricted value. As a result, the electric motor 1 can be used to the maximum usable output, and the output performance of the electric motor 1 can be improved. Therefore, it is possible to prevent the responsiveness of the brake or the like from being undesirably reduced. However, the variable limiting unit 20 of the output limiting function unit 8 adjusts the restricted value so that the command value decreases to a defined value when the estimated power consumption is larger than the defined value. As a result, motor power consumption can be appropriately limited to a constant value regardless of motor characteristic fluctuation or the like.

When the power consumption estimated by the power consumption estimation function unit 19 is smaller than the predetermined value, the variable limitation unit 20 of the output restriction function unit 8 is limited to increase the command value to the predetermined value. The value may be adjusted. As described above, when the estimated power consumption of the electric motor 1 is small, it is possible to increase the power consumption and to use the power within the allowable range as much as possible.

The variable limiting unit 20 of the output limiting function unit 8 includes a first limiting unit 21, a second limiting unit 22 whose power consumption is relatively smaller than that of the first limiting unit 21, and the first and second limiting units. And a limit value combining unit 23 for deriving a value obtained by combining the output limit values from the second limiting units 21 and 22 according to a defined ratio as a limited value to be finally output from the output limit function unit 8; The limit value combining unit 23 may adjust the determined ratio based on the power consumption estimated by the power consumption estimation function unit 19. The predetermined ratio is an arbitrary ratio determined by design or the like, and is determined by obtaining an appropriate ratio by, for example, one or both of a test and a simulation. In this case, since estimated power consumption can be derived more accurately than using a value obtained through gain as an excess of estimated power consumption as an adjustment amount to decrease the command value, motor power consumption can be further increased. It may be appropriately limited.

The variable limiting unit 43 of the output limiting function unit 8 derives a voltage value that can be the maximum power consumption from the determined maximum power consumption and the current estimated by the power consumption estimating function unit 19, and the electric motor The voltage applied to 1 may be limited to the derived voltage value. The determined maximum power consumption is the maximum power consumption inherent to the electric motor 1, and is determined, for example, by a test and / or simulation to determine an appropriate maximum power consumption. In this case, it is advantageous in strictly managing the power consumption of the electric motor 1.

The variable limiting unit 20 of the output limiting function unit 8 sets a value based on a gain to an excess of the power consumption estimated by the power consumption estimating function unit 19 with respect to the determined maximum power consumption. The amount of adjustment to be decreased may be applied to any one of the torque command value, the current command value, and the voltage command value. The determined maximum power consumption is the maximum power consumption inherent to the electric motor 1, and is determined, for example, by a test and / or simulation to determine an appropriate maximum power consumption. In this case, a LUT (Look Up Table) or the like that limits motor output is not necessary, which is advantageous in saving resources such as memory.

An electric motor system according to the present invention is an electric motor system including a plurality of electric motor devices DM according to any one of the above,
The electric power distribution means 27 which defines the maximum power consumption of each electric motor apparatus DM is provided so that the sum total of the estimated power consumption in the plurality of electric motor apparatuses DM does not exceed a predetermined system maximum power consumption.
The predetermined system maximum power consumption is a system maximum power consumption which is arbitrarily determined by design or the like, and is determined by, for example, a test and / or a simulation to obtain an appropriate system maximum power consumption.

The power distribution unit 27 has a function of determining a power consumption degree, which is a degree of power consumption of the electric motor device DM, based on comparison between the maximum power consumption and the estimated power consumption of the electric motor device DM.
Among the plurality of electric motor devices DM, when the electric motor device DM having the power consumption degree higher than the reference value and the electric motor device DM having the power consumption degree lower than the reference value coexist, the electric power The distribution means 27 sets the maximum power consumption of the electric motor device DM having a high degree of power consumption to be larger than a predetermined value, and the maximum power consumption of the electric motor device DM having a low degree of power consumption is set to a predetermined value. May be set small.
The reference value and the determined value are reference values and values arbitrarily determined by design etc., and are determined by obtaining appropriate reference values and values by, for example, one or both of a test and a simulation. .

In this case, when there is an electric motor apparatus DM having a surplus in power consumption and an electric motor apparatus DM having high power operation and no margin for the power consumption, the electric motor apparatus DM having a surplus in power consumption is consumed By allocating to the electric motor apparatus DM which has no surplus power, the output of the electric motor apparatus DM in high output operation can be improved.

The electric brake device DB of the present invention comprises the electric motor device DM according to any one of the above, a brake rotor 32, a friction member 33 which generates a braking force by contacting the brake rotor 32, and the friction member 33 In the electric brake device, provided with friction member operating means 35 operable by the motor 1;
A power variable function unit 27a that makes the maximum power consumption of the electric brake device variable is provided, and the limited value in the output restriction function unit 8 is adjusted based on the maximum power consumption given from the power variable function unit 27a. Ru.

As described above, the maximum power consumption of the electric brake device is made variable, and the limited value in the output limiting function unit 8 is adjusted based on the maximum power consumption given from the power variable function unit 27a. It is possible to use the electric power in the range as much as possible to improve the performance of the electric brake system.

An electric brake system according to the present invention is an electric brake system including a plurality of electric brake devices DB, wherein
Power distribution means 27 for determining the maximum power consumption of each of the electric brake devices DB so that the sum of the estimated power consumption of the plurality of electric brake devices DB does not exceed the determined maximum power consumption of the electric brake system;
Wheel speed estimation means 28 for estimating a wheel speed which is a rotational speed of a plurality of wheels on which the plurality of electric brake devices DB are respectively mounted;
Slip state estimation means 29 for estimating slip states of individual wheels using information including a plurality of wheel speeds estimated by the wheel speed estimation means 28;
An anti-skid control function unit 30 performing anti-skid control for adjusting the braking force of the electric brake device DB so that the slip state is suppressed when the slip state estimated by the slip state estimation means 29 exceeds a threshold; Equipped with
When the electric brake device DB performing anti-skid control and the electric brake device DB not performing anti-skid control among the plurality of electric brake devices DB are mixed, the power distribution unit 27 performs anti-skid control. The maximum power consumption of the electric brake device DB performing the skid control is set larger than a predetermined value, and the maximum power consumption of the electric brake device DB not performing the antiskid control is set smaller than the predetermined value. .

According to this configuration, by increasing the maximum power consumption of the electric brake device DB in anti-skid control requiring high-power operation, higher-speed brake operation can be enabled and anti-skid control performance can be improved. .

Any combination of the at least two configurations disclosed in the claims and / or the description and / or the drawings is included in the invention. In particular, any combination of two or more of the claims is included in the invention.

The invention will be more clearly understood from the following description of the preferred embodiments with reference to the accompanying drawings. However, the embodiments and the drawings are for the purpose of illustration and description only and are not to be taken as limiting the scope of the present invention. The scope of the invention is defined by the appended claims. In the accompanying drawings, the same reference numerals in multiple drawings indicate the same or corresponding parts.

It is a block diagram of an electric motor device concerning an embodiment of this invention. It is a figure which shows the operation example of the same electric motor apparatus. It is a figure which shows the operation example of the same electric motor apparatus. It is a block diagram showing an example of composition of an electric brake device using the electric motor device, and an electric brake system provided with two or more this electric brake device. It is a figure which shows the operation example of the same electric brake system. These are figures which show the operation example of the electrically-driven brake system of a prior art example. It is a figure showing roughly the composition of the electric brake device. It is a block diagram of the electric motor apparatus which concerns on other embodiment of this invention. It is a block diagram of the electric motor apparatus which concerns on further another embodiment of this invention. It is a block diagram of the electric motor apparatus which concerns on further another embodiment of this invention. It is a block diagram of the electric motor apparatus which concerns on further another embodiment of this invention. Is an example in which any one of the electric motor devices is applied to an in-wheel motor drive type vehicle. These are figures which show roughly the example which applied the electric motor apparatus of either to the vehicle of 2 motor on-board type by planar view.

Embodiments of the invention will be described in conjunction with FIGS. 1-5. The electric motor device of this embodiment is applied to, for example, an electric brake device (described later) mounted on a vehicle.

<Configuration Example of Electric Motor Device>
As shown in FIG. 1, the electric motor device includes an electric motor 1, a control device 2 for controlling the electric motor 1, a power supply device 3, and various command means. The various command means includes motor operation command means 4 and maximum power consumption limiting means 5.

The motor operation command means 4 is, for example, a target command value (motor) for operating the electric motor 1 such as the position (angle) of the rotor of the electric motor, the speed (angular velocity) of the rotor, load (torque, load, etc.) The operation command is output to the control device 2. Alternatively, the motor operation command means 4 may output to the control device 2 a plurality of operation commands among the position, speed and load, and operation mode commands etc. indicating what kind of operation is to be performed. The motor operation command means 4 may be, for example, a host ECU such as a vehicle integrated control unit (VCU) or a test apparatus sequencer, or may be an operation interface such as a brake pedal or an operation volume.

The maximum power consumption limiting means 5 has a function of command-outputting the maximum value of the power that can be consumed by the electric motor 1 (maximum power consumption limit value Pmax) to the control device 2. The maximum power consumption limiting unit 5 may be a host ECU or an operation interface that is the same as or similar to the motor operation command unit 4, or may be a dedicated power management system such as a battery manager or a power breaker. Alternatively, as the maximum power consumption limiting means 5, a predetermined power limiting condition may be implemented by a program or the like in the control device 2 in advance without providing such an external command means.

When the electric motor 1 is constituted by a permanent magnet synchronous motor, space saving and high efficiency and high torque are preferable. For example, a DC motor using a brush or a reluctance motor not using a permanent magnet, an induction motor or the like is applied You can also

The electric motor 1 is provided with an angle sensor Sa that detects the angle of rotation of the electric motor 1. As the angle sensor Sa, for example, using a resolver or a magnetic encoder is preferable because of high accuracy and high reliability, but various sensors such as an optical encoder can also be applied. Instead of using the angle sensor Sa, for example, it is possible to use angle sensorless estimation in which the motor angle is estimated from the relationship between the voltage and the current of the electric motor 1 or the like in the control device 2 described later. In addition, various sensors such as a thermistor may be separately provided as elements not shown based on requirements for safety etc. according to the requirements.

<About control device 2>
The control device 2 includes various control computing units that perform control computations, a motor driver 6 as a drive circuit, and sensors. The various control computing units include a torque command computing unit 7, a motor output limiter 8 as an output limiting function unit, a voltage estimator 9, a current estimator 10, a current command computing unit 11, a motor current controller 12, and a control power supply 13. , A current estimator 14 and a rotational motion estimator 15 as angular velocity estimation means. The sensors include current sensors 16 and 17, a voltage sensor 18, and the like.

The rotational motion estimator 15 has a function of estimating parameters such as an angle, an angular velocity, an electrical angle phase, and the like used for control calculation from a sensor that detects the motion of the electric motor 1 such as the angle sensor Sa. What is used for estimation of the parameter may be, for example, a Calculus process such as differentiating an angle to obtain an angular velocity, or a state estimation observer using an actuator motion equation for calculation, or these The combination of Alternatively, the rotational motion estimator 15 may be, for example, a sensorless estimator that estimates the electrical angular velocity or the electrical angle phase from the voltage and current of the electric motor 1 as described above. The rotational motion estimator 15 can also include the function of a disturbance observer, such as, for example, estimation of a motor reaction force.

The current sensors 16 and 17 are sensors for detecting the current of the electric motor 1 and are, for example, a sensor comprising an amplifier for detecting a voltage across the shunt resistor, or a noncontact type for detecting a magnetic flux or the like around the current path. A sensor or the like can be used. The current estimators 10 and 14 have a function of estimating the current used for the control calculation from the values detected by the current sensors 17 and 16.

The voltage sensor 18 is a sensor that detects the voltage of the electric motor 1, and can be configured inexpensively by using, for example, a voltage dividing resistor. A noise reduction process using a capacitor or the like may be used as appropriate. Alternatively, the voltage sensor 18 can directly observe the voltage without using a voltage dividing resistor if the hardware withstand voltage of the A / D converter of the computing unit is sufficient.

The voltage estimator 9 has a function of estimating the voltage used for the control calculation from the value detected by the voltage sensor 18. Alternatively, when the electric motor 1 is driven by a predetermined fixed voltage (when it is not necessary to consider battery voltage fluctuation etc.), the voltage sensor 18 and the voltage estimator 9 are not provided, and the program etc. You may use the voltage value implemented by.

The torque command calculator 7 has a function of converting a command value input from the motor operation command means 4 into a torque command value. Alternatively, the torque command calculator 7 may perform predetermined control calculation from command values such as angular velocity, angle, or load (torque, load) to derive a torque command value, and in that case, The angular velocity angle or load (torque, load) or the like may be feedback calculated. The above-mentioned function shall be suitably defined according to what kind of application this electric motor device is applied to.

Based on a predetermined condition including the angular velocity estimated by the rotational motion estimator 15, the motor output limiter 8 limits the torque command value so as not to exceed the threshold and outputs it as a limited value. The motor output limiter 8 reduces the torque command value when the power consumption of the electric motor 1 estimated by the power calculation unit 19 which is a power consumption estimation function unit and the power calculation unit 19 is larger than a predetermined value. And a variable limiting unit 20 that adjusts the restricted value.

The power calculation unit 19 has a function of deriving the power consumption of the electric motor 1 from the voltage and current of the primary side (input side) of the motor driver 6 described later. The variable limiting unit 20 is a torque limiting value coupling unit that combines the output results of a plurality of (the first and second in this example) torque limiting units (limiting units) 21 and 22 and the plurality of torque limiting units 21 and 22 (Limit value coupling unit) 23, and has a function of deriving a torque command value that achieves predetermined power consumption.

The first torque limiting unit 21 has a torque limiting function in which the output is relatively large, and the second torque limiting unit 22 has a torque limiting function in which the output is relatively small. Generally, current conditions for exerting a predetermined torque are uniquely set based on motor characteristics previously determined from test or simulation results, but in actuality, resistance value, inductance, rotor magnetic flux, etc. The power consumption for the current condition is often different due to the solid-state difference and the characteristic fluctuation of the

At that time, for example, when the resistance value increases with a temperature rise or the like, power consumption under a predetermined torque, that is, current condition increases. Alternatively, if the power factor changes with the change of the inductance and the rotor magnetic flux, the power consumption under a predetermined current condition fluctuates. At this time, by making the maximum power consumption adjustable by the first and second torque limiters 21 and 22, it is possible to limit to a predetermined maximum power consumption regardless of the motor characteristic fluctuation.

The output change width of the first and second torque limiters 21 and 22 will be described. For example, the maximum torque can be applied to the electric motor device, which is determined based on motor coil current density, heat radiation characteristics of coil heat generation, heat capacity, current capacity of motor drive element, etc. A torque limiter based on the maximum output under current conditions. The second torque limiting unit 22 is defined as a torque limiting unit based on the maximum output under the current condition where the maximum power consumption is achieved under the condition of the power factor or the predetermined maximum power factor.

As described above, when the output change width of the first and second torque limiters 21 and 22 is determined, the power consumption can be adjusted as much as possible with respect to any characteristic change. Alternatively, the output change widths of the first and second torque limiters 21 and 22 may be appropriately set based on characteristic fluctuations that may occur in the electric motor device.

Further, for example, even when the predetermined maximum power consumption in steady state and the instantaneous maximum power consumption in a certain period of time are determined as different maximum consumption conditions, the first and second torque limiters 21 and 22 are appropriate. Can be limited to the maximum power consumption. At this time, for example, the first and second torque limiters 21 and 22 can be used as the torque limiter including the difference between the predetermined maximum power consumption and the instantaneous maximum power consumption in the steady state.

The torque limiting unit coupling unit 23 couples the first and second torque command values limited by the first and second torque limiting units 21 and 22 based on a predetermined relationship, and a final torque limiting value It has the function of (restricted value). For example, when the power consumption Pm calculated by the power calculation unit 19 exceeds the maximum power consumption limit value Pmax, the predetermined relationship sets the torque limit value to a second torque limit value at which the output becomes relatively small. In the case where the power consumption calculated by the power calculation unit 19 is smaller than the limit value of the maximum power consumption, the processing may be made to approach the first torque limit value.

Specifically, for example, using the limit value Pmax of the maximum power consumption, the power consumption Pm derived by the power calculation unit 19, and the predetermined gain Ka, the first torque limit value T1 and the second torque limit value T2 are obtained. Alternatively, the final torque limit value T may be set as follows.
T = α · T1 + (1−α) · T2 (α = Ka · (Pmax−Pm), 0 ≦ α ≦ 1)
The gain Ka may be linear, or may be a non-linear gain that changes based on a deviation (Pmax−Pm) or the like. Also, for example, α may be calculated using differentiation or integration of the deviation (Pmax−Pm). In addition, the actual operation may not be the above equation but may be an operation process that is substantially equivalent to the above equation.

In addition to the first and second torque limiters 21 and 22, the motor output limiter 8 has, for example, a third further torque limiter for nonlinear interpolation of the first and second torque limits, and a fourth A torque limiter or the like may be provided. In addition, the motor output limiter 8 may be provided with different first and second or additional torque limiters in power running and regeneration, respectively.

Finally, when the torque command value input to the motor output limiter 8 exceeds the torque limit value T, the torque command value is limited to the torque limit value T. When the torque command value does not exceed the torque limit value T, torque is output. The command value is transmitted to the subsequent functional block (the current command calculation unit 11 in the example of FIG. 1) without limitation. The term "restriction" means to limit the magnitude regardless of the sign of the torque.

The current command calculation unit 11 has a function of converting, for example, a torque command value or a torque limit value into a current value that generates the torque based on a predetermined motor characteristic. For example, it is preferable to reduce the calculation load if a LUT or the like of current values according to motor angular velocity and torque is provided in the storage area. Further, the conversion can be a desired torque using, for example, a calculation formula for obtaining a current using a predetermined torque and angular velocity as arguments, or a motor phase resistance or a phase inductance using a convergence calculation formula such as Newton-Rapson method It can also be determined by a predetermined calculation equation such as a calculation equation for obtaining the current condition.

The current command value determined by the current command calculation unit 11 may be, for example, an orthogonal current (d-axis current, q-axis current) with respect to a predetermined electrical angle phase, and is an alternating current having a predetermined phase and frequency. It may be. Alternatively, it may be a current command value in consideration of the slip angle in the induction motor, or may be a DC current command of a brushed DC motor.

The motor current controller 12 has a function of controlling the electric motor current so as to follow the current command value given from the current command calculation unit 11. The current estimator 14 estimates the electric motor current used for the control calculation from the value detected by the current sensor 16. For this current control, for example, current feedback control may be used, feed forward control may be used based on predetermined motor characteristics, and these may be used in combination as appropriate.

The motor driver 6 converts DC power of the power supply 3 into AC power used for driving the electric motor 1 based on a current command given from the motor current controller 12. The motor driver 6 constitutes a half bridge circuit including switching elements such as FETs, and is preferably inexpensive and has high performance if it is configured to perform PWM control to determine a motor applied voltage with a predetermined duty ratio. Alternatively, a transformer circuit or the like (not shown) may be provided to perform PAM control. The control power supply 13 supplies power to various control computing units and low-power systems such as the motor driver 6 and the like.

The functions not shown in FIG. 1 are separately provided as necessary. For example, when limiting the motor output, output saturation compensation may be required in the control computing unit, and a compensator for performing the output saturation compensation may be provided as appropriate. Alternatively, for example, a redundant system may be separately provided to limit or stop the output at a temperature rise or an overcurrent.

In addition, FIG. 1 shows the concept of the functional configuration to the last, and elements not shown are appropriately provided according to the requirements. Also, each functional block is provided for the sake of convenience, and can be appropriately integrated or divided according to the convenience of mounting. Moreover, the connection form of each function is shown as an example, and can be changed in the range which does not disturb the above-mentioned function.

<Operation Example of Electric Motor Device>
FIGS. 2A and 2B show an example of positioning to a predetermined motor angle using the electric motor device. In FIG. 2A and FIG. 2B, the operation example of the electric motor apparatus of a prior art example is shown by a dotted line, and the operation example of the electric motor apparatus of embodiment is shown by a continuous line.

FIG. 2A shows a case where the loss increases more than a predetermined assumed value in the electric motor having the characteristic variation. In the electric motor device of the conventional example, the maximum power consumption exceeds the limit value as the motor loss increases. However, in the electric motor device of the embodiment, the predetermined maximum consumption particularly by the motor output limiter 8 (FIG. 1) Limited to power.

FIG. 2B shows a case where the loss is relatively small in the electric motor having the characteristic variation. In the electric motor device according to the embodiment, the response speed of the electric motor decreases as a result of adjusting the maximum power consumption not to exceed the predetermined limit value for the characteristic variation in the electric motor device of the conventional example. In particular, the motor output limiter 8 (FIG. 1) increases the power consumption and improves the response of the electric motor 1 (FIG. 1).

<Configuration Example of Electric Brake Device>
FIG. 3 is a block diagram showing a configuration example of an electric brake device DB using the electric motor device according to the embodiment. The electric brake device DB includes an electric motor device DM and a friction brake BR. The electric brake system includes a plurality of electric brake devices DB.

The power supply device 3 may be, for example, a battery, a DC / DC converter, or a combination of these as appropriate. For example, in an EV, HEV, etc., a high voltage battery of about 200 V to 300 V, a DC / DC converter for reducing the high battery voltage to 12 V, and a 12 V battery are provided. The configuration to be used may be used.

The brake command means 4A is a means for giving a braking force to the integrated control device 24, and for example, a brake pedal can be used. Alternatively, the brake command unit 4A may be another command unit such as a joystick or a volume, or may be a command unit that does not depend on the driver of the vehicle, such as a predetermined brake command unit in an autonomous driving vehicle.

The integrated control device 24 includes a power supply capacity calculator 25, a braking force distribution calculator 26, and a power distribution calculator 27 as power distribution means. For example, the integrated control device 24 may be a vehicle integrated control device (VCU), or one or more of the brake control devices 2A described later may have the integrated control device 24.

The power supply capacity calculator 25 has a function of determining the power that can be used for the electric brake device DB from the output capacity and state of the power supply device 3. The detection and diagnosis functions of the state of the power supply device 3 may be, for example, the remaining amount detection function such as% SOC in the case of a battery, and in the case of a DC / DC converter The self-diagnosis function of or a combination of these may be used. In addition, the power supply capacity computing unit 25 obtains the power consumption state of an electric device (not shown) such as an electric steering device other than the electric brake device, and determines the maximum power consumption taking this power consumption state into consideration. It is also good. Alternatively, in the case where the electric brake device DB preferentially uses electric power, it may have a function of notifying the electric power consumption of the electric brake device DB to an electric device not shown.

The braking force distribution computing unit 26 outputs a braking force command value to each brake control device 2A in accordance with the braking force required by the braking command unit 4A. The brake force command value may be, for example, a predetermined fixed ratio such as a front / rear brake ratio in a four-wheeled vehicle, for example, a braking state or a turning state of the vehicle is estimated from an acceleration sensor not shown. It may be a variable value according to one or both of the states.

In addition, the braking force distribution computing unit 26 may include a wheel speed estimating unit 28, a slip state estimating unit 29, an antiskid control function unit 30, and a skid prevention control function unit 31. The wheel speed estimation means 28 estimates a wheel speed which is a rotational speed of each wheel on which the plurality of electric brake devices DB are mounted. The slip state estimation means 29 estimates the slip state of each wheel using the wheel speed of each wheel estimated by the wheel speed estimation means 28, the longitudinal acceleration of the vehicle, vehicle position information (GPS), and the like.

The anti-skid control function unit 30 adjusts the braking force (braking force) of the electric brake device DB so that the slip state is suppressed when the slip state estimated by the slip state estimation means 29 exceeds the threshold value. I do. In other words, the anti-skid control function unit 30 performs anti-skid control to adjust the braking force regardless of the operation of the brake pedal or the like in order to prevent an excessive slip state at the time of braking. The skid prevention control function unit 31 estimates the slip state of each wheel as described above, and performs skid prevention control based on the turning state of the vehicle and the like.

The power distribution calculator 27 has a function of determining the maximum power consumption of each of the electric brake devices DB from the power consumption of the electric brake device DB determined by the power source capacity calculator 25. The maximum power consumption may be a value changed based on a predetermined distribution condition for each of the electric brake devices DB, or may be the same value. In particular, for example, in the case of applying an electric brake device DB having different braking force capacities such as the front wheel brake and the rear wheel brake in a four-wheeled vehicle, the power distribution computing unit 27 distributes according to the brake force capacity (front wheel Preferably, the distribution of the fork brakes is large and the distribution of the rear wheel brakes is small.

Further, the power distribution computing unit 27 may have a power variable function unit 27a that changes the maximum power distribution of each of the electric brake devices DB according to the power condition. For example, when there is an allowance in the drive power of a predetermined electric brake device DB and there is no margin in the drive power of another electric brake device DB, the surplus electric power of the predetermined electric brake device DB is It may be a process to consume.

The power condition may be determined based on, for example, comparison between a power limit value in a predetermined electric brake device DB and drive power. If the drive power is equal to or close to the power limit value, the electric brake device DB is considered to be an emergency operating condition requiring a relatively large drive power. If the drive power is smaller than the power limit value by a predetermined amount or more, it is considered that the electric brake device DB is in a situation where the drive power is relatively unnecessary. That is, when the electric brake device DB requiring driving power and the electric brake device DB not requiring driving power coexist, the electric power variable function unit 27a performs the electric braking device DB in an emergency operation state requiring driving power. The responsiveness of the electric brake device DB can be improved by increasing the limit power value (limit value) of the above.

The power condition of the electric brake device DB may be determined based on, for example, whether or not a predetermined electric brake device DB is in anti-skid control. The electric brake device DB in anti-skid control requires high-speed brake operation, and the other electric brake devices DB do not relatively require high-speed brake operation. Therefore, in the case where the electric brake device DB performing antiskid control and the electric brake device DB not performing antiskid control among the plurality of electric brake devices DB are mixed, the power variable function unit 27a is By setting the power limit value of the electric brake device DB not performing anti-skid control relatively small and improving the power limit value of the electric brake device DB under anti-skid control with the surplus, anti-skid control performance can be achieved. It can be improved.

In addition to the function of the control device 2 (FIG. 1) described above, the brake control device 2A has a function of following control of the braking force to a desired command value. The electric actuator 1A includes friction member operating means such as a screw mechanism or a ball ramp mechanism for operating a friction member of the friction brake BR described later, in addition to the electric motor 1 (FIG. 1) described above. In addition, the electric actuator 1A may be provided with a load sensor or the like for detecting the pressing force of the friction member in order to control the braking force. The friction brake BR (described later) includes a brake rotor 32 that rotates in synchronization with the wheels, and a friction member 33 that abuts on the brake rotor 32 to generate a braking force.

<Operation Example of Electric Brake Device>
FIG. 4A and FIG. 4B show an operation example of the electric brake system in a four-wheeled vehicle. In the same figure, F1 and F2 show the operation of the electric brake system for the left and right front wheels, and R1 and R2 show the operation of the electric brake system for the left and right rear wheels.

FIG. 4A shows an operation example of this electric brake system (configuration of FIG. 3). The section in the figure in which F1 operates differently to F2 indicates that anti-skid control is being performed. At this time, the power distribution computing unit 27 (FIG. 3) performs high-precision antiskid control by temporarily increasing the maximum power consumption of F1 while keeping the sum of all the maximum power consumptions constant. It shows that it can do.

In the power distribution computing unit 27 (FIG. 3), the determination to temporarily increase the maximum power consumption of F1 may be made based on whether anti-skid control is being performed or not, and the power consumption of F1 is large, F2,. You may judge from the power consumption of R1 and R2 being small. FIG. 4B shows an example in which the maximum power consumption is always constant in the conventional electric brake system.

<About schematic configuration of electric brake device DB>
As shown in FIG. 5, the electric brake device DB includes an electric actuator 1A and a friction brake BR. The friction brake BR includes a brake rotor 32 that rotates in conjunction with the wheels of the vehicle, and a friction member 33 that contacts the brake rotor 32 to generate a braking force. The friction member 33 is disposed near the brake rotor. A mechanism may be used in which the friction member 33 is operated by the electric actuator 1A and pressed against the brake rotor 32, and a braking force is generated by the frictional force. The brake rotor 32 and the friction member 33 may be, for example, a disk brake device using a brake disk and a caliper, or may be a drum brake device using a drum and a lining.

The electric actuator 1A has an electric motor 1, a reduction mechanism 34, a direct acting mechanism 35 which is a friction member operating means, and a parking brake mechanism PB. The reduction mechanism 34 is a mechanism that reduces the rotation of the electric motor 1 and includes a primary gear 36, an intermediate gear 37, and a tertiary gear 38. In this example, the reduction mechanism 34 reduces the rotation of the primary gear 36 attached to the rotor shaft 1 a of the electric motor 1 by the intermediate gear 37 and transmits it to the tertiary gear 38 fixed to the end of the rotating shaft 39 It is possible.

The linear motion mechanism 35 is a mechanism that converts the rotational motion output from the speed reduction mechanism 34 into linear motion of the linear motion portion 40 by the feed screw mechanism, and causes the friction member 33 to contact and separate from the brake rotor 32. The linear motion portion 40 is detentated and supported movably in the axial direction indicated by the arrow mark A1. A friction member 33 is provided at the outboard side end of the linear movement portion 40. By transmitting the rotation of the electric motor 1 to the linear motion mechanism 35 via the reduction mechanism 34, the rotational motion is converted into a linear motion, which is converted into the pressing force of the friction member 33 to generate a braking force. .

For example, a linear solenoid is applied as the actuator 41 of the parking brake mechanism PB. The locking member 42 is advanced by the actuator 41 and engaged by being fitted into a locking hole (not shown) formed in the intermediate gear 37, and the rotation of the intermediate gear 37 is prohibited to thereby obtain a parking lock state. Make it By disengaging the lock member 42 from the locking hole, the rotation of the intermediate gear 37 is allowed to be in the unlocked state.

<Function effect>
According to the configuration described above, the motor output limiter 8 limits the torque command value given from the torque command calculator 7 so as not to exceed the threshold value based on the angular velocity and the like. As a result, the electric motor 1 can be used to the maximum usable output, and the output performance of the electric motor 1 can be improved. Therefore, it is possible to prevent the responsiveness of the electric brake device DB and the like from being lowered undesirably. When the power consumption under a predetermined current condition fluctuates, the maximum power consumption can be adjusted by the first and second torque limiters 21 and 22 to limit the power consumption to a predetermined maximum power consumption regardless of motor characteristic fluctuation. be able to. Further, the configuration of the motor output limiter 8 shown in FIG. 1 is preferable in strictly treating the motor power consumption. For example, when a control system such as an angle or angular velocity is provided on the upper side, saturation compensation control accompanying motor output limitation is facilitated. Be superior in terms of The power calculation unit 19 of FIG. 1 is advantageous in managing power consumption more directly because the power consumption of the electric motor 1 is derived from the voltage and current of the primary side of the motor driver 6.

<Other Embodiments>
In the following description, the portions corresponding to the items described in advance in each embodiment are denoted by the same reference numerals, and the redundant description will be omitted. When only a part of the configuration is described, the other parts of the configuration are the same as those described in the preceding embodiment unless otherwise stated. The same function and effect can be obtained from the same configuration. Not only the combination of the portions specifically described in the embodiments but also the embodiments may be partially combined if any problem does not occur in the combination.

FIG. 6 shows an example in which the motor output limiter 8 as the output limiting function unit is provided between the current command calculator 11 and the motor current controller 12. With respect to the example of FIG. 1, the motor output limiter 8 in the example of FIG. The variable limiting unit 20 includes first and second current limiting units (limiting units) 21A and 22A, and a current limiting value coupling unit (limit value coupling unit) 23A.

The first current limiting unit 21A has a current limiting function in which the current value is relatively large, and the second current limiting unit 22A has a current limiting function in which the current value is relatively small. The first and second current limiters 21A and 22A can be set in the same manner as the first and second torque limiters 21 and 22 in FIG.

As shown in FIG. 6, for example, the first current limiting portion 21A has an abnormality in the electric motor apparatus determined based on motor coil current density, heat radiation characteristics of coil heat generation, heat capacity, current capacity of motor drive element, etc. Alternatively, the second current limiter 22A may be a maximum current limit that provides maximum power consumption under conditions of a power factor or a predetermined maximum power factor. Alternatively, the first and second current limiters 21A and 22A may be appropriately set to an arbitrary relationship in which the maximum current value differs by a predetermined amount based on the characteristic fluctuation that may occur in the electric motor device.

The power computing unit 19 has the same function as the power computing unit 19 of FIG. 1. Also, as shown in FIG. 6, the current limit value coupling unit 23A differs from the torque limit value coupling unit 23 of FIG. 1 only in that it handles current limitation instead of torque limitation, and the other points are the same as in FIG. It has a function.

Therefore, also in the configuration of FIG. 6, the output performance of the electric motor 1 can be improved by appropriately limiting the maximum motor power consumption regardless of the motor characteristic fluctuation and the like and using the power within the allowable range to the maximum. it can. Further, the configuration of motor output limiter 8 of FIG. 6 is preferable in order to handle power consumption and heat load of electric motor 1 more strictly, for example, based on the first and second current limit values strictly based on motor characteristic fluctuation. It is superior when deciding.

FIG. 7 shows an example in which a power operation unit 19 having a function of calculating power from the current and the output voltage is provided without the voltage estimator 9 and the like in the example of FIG. The power may be, for example, a function of obtaining active power from coaxial voltage and current using orthogonally axis converted voltage and current at a predetermined electrical angle phase, and obtains active power from alternating current voltage and current It may be a function. Also, the power calculation unit 19 having the function of FIG. 7 can be applied to FIG. 6 or other embodiments. The configuration for estimating power from the phase current and voltage of FIG. 7 is superior to the configurations of FIGS. 1 and 6 in reducing sensors and the like.

FIG. 8 shows an example in which the motor output limiter 8 is provided downstream of the motor current limiter 12. The motor output limiter 8 in this example includes a power computing unit 19 and a voltage limiting unit 43 as a variable limiting unit. The power calculating unit 19 has a function of calculating power from the current and the output voltage, as in the power calculating unit 19 of FIG. 7. The power may be, for example, a function of obtaining active power from coaxial voltage and current using orthogonally axis converted voltage and current at a predetermined electrical angle phase, and obtains active power from alternating current voltage and current It may be a function.

The voltage limiting unit 43 has a function of limiting the output voltage such that the active power of the power computing unit 19 is equal to or less than the limit value of the maximum power consumption. At this time, when the output voltage is d-axis or q-axis voltage, the voltage limiting unit 43 may limit one of the d-axis and q-axis voltages, for example. The d-axis and q-axis voltages may be restricted so as to reduce the norm with equal voltage vector angles at the same ratio.

The voltage limiting unit 43 evaluates the output estimation formula when the d-axis and q-axis voltages are applied using the d-axis and q-axis voltages as variables, the active power as a constraint, and the phase resistance and inductance characteristics, etc. The d-axis and q-axis voltages can also be determined by a convergence operation method such as the Newton-Rapson method.

When the output voltage is a three-phase voltage, for example, the voltage limiting unit 43 may limit the voltage amplitude or may limit the voltage phase. Alternatively, the voltage limiting unit 43 uses the voltage amplitude and phase as variables, and the active power as a constraint, and uses an output estimation equation when applying the voltage amplitude and phase as the variables based on phase resistance and inductance characteristics as an evaluation function, The voltage amplitude and phase can also be determined by a convergence operation method such as the Newton-Rapson method. The configuration of FIG. 8 is advantageous in more strictly managing the power consumption of the electric motor 1.

FIG. 9 shows an example of direct feedback calculation using power as a control amount. The power calculation unit 19 has the same function as the power calculation unit 19 according to any of the above-described embodiments. The output adjustment amount computing unit 44 as the variable limiting unit has a function of comparing the maximum power consumption with the power consumption computed by the power computing unit 19 and outputting a predetermined adjustment amount. The predetermined adjustment amount may be, for example, a result of multiplying the excess amount (excess) by a predetermined feedback gain when the output exceeds the maximum power consumption.

The sign of the adding unit 45 in FIG. 9 indicates adjustment to decrease the magnitude of the output, and the sign of the actual physical quantity may be appropriately determined according to the driving situation of the electric motor 1. Do. Further, FIG. 9 shows an example in which an adjustment amount is applied to the output of the torque command computing unit 7, ie, the torque command value, but the adjustment is performed by inputting the torque command computing unit 7, ie, the command input Adjustments can also be applied to other functions, such as the output or current command value, and the output or output voltage of the motor current controller 12. The configuration of FIG. 9 is advantageous in terms of resource constraints such as a memory since a limitation LUT and the like are not necessary.

The embodiment of FIGS. 1 and 6 to 9 can be selected by a designer based on any design concept, or can be used in combination as appropriate.

The electric motor device may be a drive device for driving a vehicle. For example, as shown in FIG. 10A, the electric motor system may be applied to an in-wheel motor drive type vehicle as an electric motor system including a plurality (two in this example) of electric motor devices. As shown in FIG. 10B, the electric motor system may be applied to a two-motor on-board type vehicle as an electric motor system including a plurality of (two in this example) electric motor devices.

Although not shown, the electric motor system can also be applied to a vehicle electrical system including an electric steering and an electric brake, an attitude control actuator system of a robot, an actuator system of an aircraft or a ship, and the like.

As described above, although the preferred embodiments have been described with reference to the drawings, various additions, modifications, and deletions can be made without departing from the spirit of the present invention. Therefore, such is also included in the scope of the present invention.

1 ... electric motor 2 ... control device 6 ... motor driver (drive circuit)
8 ... Motor output limiter (output limiting function part)
15: Rotational motion estimator (angular velocity estimation means)
19 ... Power calculation unit (power consumption estimation function unit)
20 ... variable limiting portion 21 ... first torque limiting portion (first limiting portion)
21A ... first current limiting unit (first limiting unit)
22 ... 2nd torque limiting section (second limiting section)
22A ... second current limiter (second limiter)
23 ... Torque limit value junction (limit value junction)
23A ... Current limit value junction (limit value junction)
27 Power distribution computing unit (power distribution means)
27a: Power variable function unit 28: Wheel speed estimation means 29: Slip state estimation means 30: Anti-skid control function unit 32: Brake rotor 33: Friction member 35: Linear movement mechanism (friction member operation means)
43 ... Voltage limiter (variable limiter)
DM: Electric motor device

Claims (9)

1. An electric motor apparatus comprising an electric motor and a control device for controlling the electric motor,
   The controller is
   A power consumption estimation function unit that estimates current and voltage of the electric motor and estimates power consumption of the electric motor from the estimated current and voltage;
   Angular velocity estimation means for estimating the angular velocity of the electric motor;
   At least one of a torque command value, a current command value, and a voltage command value generated from the motor operation command given to the control device is a determined condition including the angular velocity estimated by the angular velocity estimating means. Based on the output limit function unit which limits the threshold value so as not to exceed the threshold value and outputs it as a restricted value,
   A drive circuit for driving the electric motor based on the limited value given from the output limitation function unit;
   The output limiting function unit is a variable limiting unit that adjusts the restricted value so that the command value decreases to a defined value when the power consumption estimated by the power consumption estimating function is larger than the defined value. An electric motor device having
2. The electric motor apparatus according to claim 1, wherein the variable limiting unit of the output limiting function unit determines the command value when the power consumption estimated by the power consumption estimating function unit is smaller than a predetermined value. An electric motor arrangement for adjusting the restricted value to increase to a value.
3. The electric motor apparatus according to claim 1 or 2, wherein the variable limiting unit of the output limiting function unit includes a first limiting unit, and power consumption becomes smaller than that of the first limiting unit. A limit value combining unit that derives a value obtained by combining the output limiting values by the second limiting unit and the first and second limiting units according to a defined ratio as the final output value from the output limiting function unit And the limit value coupling unit adjusts the determined ratio based on the power consumption estimated by the power consumption estimation function unit.
4. The electric motor apparatus according to claim 1 or 2, wherein the variable limiting unit of the output limiting function unit is a maximum consumption from the determined maximum power consumption and the current estimated by the power consumption estimating unit. The electric motor apparatus which derives | leads-out the voltage value which may become electric power, and restrict | limits the voltage applied to the said electric motor to the derived said voltage value.
5. The electric motor apparatus according to claim 1 or 2, wherein the variable limiting unit of the output limiting function unit is configured to calculate an excess of the power consumption estimated by the power consumption estimating function unit with respect to the determined maximum power consumption. An electric motor apparatus, wherein a value obtained through a gain is applied to any one of the torque command value, the current command value, and the voltage command value as an adjustment amount for reducing the command value.
6. An electric motor system comprising a plurality of electric motor devices according to any one of claims 1 to 5, comprising:
   An electric motor system comprising power distribution means for determining the maximum power consumption of each electric motor device so that the sum of estimated power consumption in the plurality of electric motor devices does not exceed a predetermined system maximum power consumption.
7. The electric motor system according to claim 6, wherein the power distribution unit is a degree of power consumption that is a degree of power consumption of the electric motor device based on comparison of maximum power consumption and estimated power consumption in the electric motor device. Have the ability to
   When the electric motor apparatus having the power consumption degree higher than the reference value and the electric motor apparatus having the power consumption degree lower than the reference value among the plurality of electric motor apparatuses are mixed, the power distribution unit An electric motor setting the maximum power consumption of the electric motor device having a high power consumption degree larger than a predetermined value and setting the maximum power consumption of the electric motor device having a low power consumption degree smaller than a predetermined value; system.
8. The electric motor device according to any one of claims 1 to 5, a brake rotor, a friction member generating a braking force by contacting the brake rotor, and the friction member being operable by the electric motor And a friction member operating means for
   An electric brake provided with a power variable function unit that makes the maximum power consumption of the electric brake device variable, and based on the maximum power consumption given from the power variable function unit, the restricted value in the output limiting function unit is adjusted apparatus.
9. An electric brake system comprising a plurality of electric brake devices according to claim 8, comprising:
   Power distribution means for determining the maximum power consumption of each of the electric brake devices such that the sum of the estimated power consumption of the plurality of electric brake devices does not exceed a predetermined maximum power consumption of the electric brake system;
   A wheel speed estimation means for estimating a wheel speed which is a rotational speed of a plurality of wheels on which each of the plurality of electric brake devices is mounted;
   Slip state estimation means for estimating slip states of individual wheels using information including a plurality of wheel speeds estimated by the wheel speed estimation means;
   The anti-skid control function unit performs anti-skid control to adjust the braking force of the electric brake device so that the slip state is suppressed when the slip state estimated by the slip state estimation means exceeds a threshold.
   The electric power distribution means performs antiskid control when the electric brake device performing antiskid control and the electric brake device not performing antiskid control are mixed among the plurality of electric brake devices. An electric brake system in which the maximum power consumption of the electric brake device is set larger than a predetermined value, and the maximum power consumption of the electric brake device not performing antiskid control is smaller than the predetermined value.

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