WO2020148173A1

WO2020148173A1 - Power supply control circuits for brushless dc (bldc) motors

Info

Publication number: WO2020148173A1
Application number: PCT/EP2020/050495
Authority: WO
Inventors: Juan CARRIÓN GONZÁLEZ; Carlos DOMINGO MÀS; Juan Francisco PARDO PERIS; Carlos SEVILLA PAVON; Carlos VERNICH GIMENO
Original assignee: Mahle International GmbH
Current assignee: Mahle International GmbH
Priority date: 2019-01-15
Filing date: 2020-01-10
Publication date: 2020-07-23
Anticipated expiration: 2021-07-15
Also published as: US20210344290A1; US11863106B2; CN113302504A; EP3683587A1

Abstract

A power supply control circuit (200) of a three-phase brushless DC (BLDC) motor (130), characterized in that the control circuit (200) comprises means for calculating the DC current consumption I _s based on a phase current signal I _shunt of the BLDC motor (130), the means comprising a shunt resistor (215) R _shunt, an amplifier (405) and a low pass filter (410). The amplifier (405) is configured to amplify a measured voltage V _shunt that corresponds to the current I _shunt across the resistor (215) R _shunt and perform an offset correction. The low pass filter (410) is configured to provide a filtered voltage V ₀ of the voltage V _shunt. The DC current I _s is calculated based on the voltage V ₀.

Description

POWER SUPPLY CONTROL CIRCUITS FOR BRUSHLESS DC (BLDC) MOTORS

DESCRIPTION

The present invention refers to power supply control circuits for BLDC motors having means to calculate a DC current consumption of the BLDC motor based on the processing of a phase current signal of the BLDC motor.

Background of the invention

The BLDC motor is becoming increasingly popular in sectors such as automotive (particularly electric vehicles (EV)), heating, ventilation, and air conditioning (HVAC), in white goods and industrial goods because it does away with the mechanical brush used in traditional motors. This characteristic makes the BLDC motors more reliable and increases its service life.

Another advantage of a BLDC motor is that it can be made smaller and lighter than a brush type motor with the same power output, making the BLDC motors suitable for applications where space is tight.

The microcontroller of the control circuit of the BLDC motor may be configured to energize the stator coils of the BLDC at the correct moment by implementing a control algorithm. Precise timing allows for accurate speed and torque control, as well as ensuring the BLDC motor runs at peak efficiency. In this respect, the microcontroller may receive system current values as inputs and signals from position sensors (as e.g. hall sensors that indicate the position of the motor rotor) to implement the control algorithm.

Current values can be measured and used as input for the control algorithm implemented by the microcontroller: Precise motor control performed by the control circuit of the BLDC represents a very significant condition for the correct performance of the BLDC motor. Whether for electronic power steering, electronic stability control, automatic braking systems, or for the self-driving vehicle, precise motor control may be required to ensure safe and efficient operation. Hence, currents can be measured to collect information primarily on the motor torque as the current measurements can be directly proportional to the motor torque.

Current measurements can also be used to determine the speed at which the motor is turning. Such speed information can be calculated by understanding how the control algorithm affects the current level applied in the BLDC motor. In this respect, the measurement of phase motor currents may be required as an input variable for the control algorithm implemented by the microcontroller. Therefore, the precise measurement of the phase motor currents can improve the motor control solution.

Furthermore, currents can be measured for fault protection: Current measurements may be used to detect when an overcurrent condition occurs allowing the system to take action to prevent a potential damage in the BLDC motor.

Current brushless DC motor control circuits may include 1 to 3 shunt resistors to measure the phase current that can be used as input for the control algorithm implemented by the microcontroller. Some algorithms may require the measurement of the DC current consumption I_s . In order to measure the current I_s , an additional shunt (101 , 102) can be included either in the positive battery input (A) or in the battery return (B) (i.e. in the DC link) as shown in figure 1 that represents a conventional power supply control circuit (100) of a BLDC motor. However, the type of shunt resistors (101 , 102) imply additional unwanted power consumption and heat dissipation in the system.

Furthermore, the power supply control circuit (100) of figure 1 can comprise a DC source (105), an input AC filter (103), in particular a LC filter, a microcontroller/PWM block (110) that represents a pulse width modulation (PWM) generator that generates a PWM signal to a three-phase inverter (120) and a microcontroller implementing a control algorithm that controls the input current in the brushless DC motor (130). The three-phase inverter (120) comprises six switches for high-power switching to feed current to the DC motor (130). Hence, the output from the block (110) comprises pulse width modulated (PWM) signals that determine the average voltage and average current applied to the three coils of the BLDC motor having a Ύ” formation as shown in figure 1 in order to control motor speed and motor torque. Furthermore, the BLDC motor (130) may use three hall-effect sensors not shown in the figure to indicate rotor position. The rotor itself uses several pairs of permanent magnets to generate the magnetic flux.

Hence, a power supply control circuit for a BLDC that uses a procedure for measuring the input DC current consumption I_s for the control algorithm other than using shunt resistors in the DC link and thus avoids additional power consumption and heat dissipation and maximizes the performance of the motor-control system is desired.

Description of the invention

The present invention proposes BLDC power supply control circuit that can measure the DC current consumption of the motor I_s without the requirement of establishing shunt resistors (101 , 102) in the DC link of the power supply in contrast to current implementations. In this respect, a measured phase current signal can be adequately processed in order to obtain the desired DC current consumption that can be used as input for a control algorithm implemented by a microcontroller of the power supply control circuit. Therefore, the proposed control circuit avoids additional power consumption ( )_> heat dissipation and PCB occupation

related to shunt resistors located in the DC link and maximizes the performance of the motor-control system. Furthermore, by getting rid of shunt resistors, in particular, shunt resistor (101) the addition of complex circuitry to measure a differential voltage value can also be avoided. Moreover, getting rid of the shunt resistors (101 , 102) may permit to ease the routing of conductive traces on a PCB supporting the control circuit.

Hence, in a main aspect of the present invention, it is proposed a power supply control circuit for a three-phase brushless DC (BLDC) comprising means for calculating a DC current consumption I_s based on a phase current signal I_shunt of the BLDC motor. The calculated DC current consumption I_s may be used by a control algorithm for controlling the BLDC motor control or reported to a master controller for performing additional actions as e.g. overcurrent protection. Hence, the means for calculating a DC current consumption I_s in the power supply control circuit comprises a shunt resistor R_shunt for phase current sensing having a voltage V_shunt that corresponds to a total phase current signal I_shunt of the three phase BLDC motor across the shunt resistor R_shunt. In particular, the shunt resistor Rs_hunt ^can be used to perform low-side phase current sensing as shown in figures 2 and 3. In this regard, low-side phase sensing allows for easier determination of the motor phase currents, but it is not an exact equivalent, an error is potentially introduced relative to the true phase current. Low-side phase sensing also introduces a ground variation of the motor relative to system ground.

Furthermore, the means for calculating a DC current consumption I_s in the power supply control circuit comprises an amplifier to amplify the input voltage V_shunt and perform an offset correction of the input voltage V_shunt .The power supply control circuit also comprises a low pass filter to filter the amplified voltage signal V_shunt to obtain a filtered output voltage V₀. The filtered output voltage V₀. may be fed into an analogue to digital converter (ADC) (which may or may not be included into the microcontroller itself) to calculate the input DC current consumption I_s from the voltage V₀. value.

Hence, the DC current consumption of the BLDC motor I_s can be obtained according to the following equation:

Where Gain is the amplification factor of the amplifier to amplify the input voltage V_Sflunf:.

Thus, shunt resistors (101 , 102) used to measure the DC current consumption of the BLDC motor I_s as shown in figure 1 are avoided.

In another aspect of the present invention, it is proposed a further example of a power supply control circuit for a BLDC comprising means for calculating a DC current consumption I_s according to the present disclosure. The power supply control circuit uses means for performing phase current sensing. The means comprises three shunt resistors, e.g. R_sh1 , R_sh2 and R_sh3. The means of the power supply control circuit also comprises means for shunt signal amplification and offset correction, means for summation of the three shunt signals and low-pass signal filter.

Hence, it is proposed an alternative BLDC motor power supply control circuit comprising means for calculating the DC current consumption I_s based on three phase current signals I_sh1 I_sh2 and I_sh3 of the BLDC motor.

Hence, the means of the power supply control circuit according to the second aspect of the present invention comprises three shunt resistors R_sh1 , R_sh2 and R_sh3 for the three phases of the BLDC motor. Furthermore, the means of the power supply control circuit comprises three amplifiers to amplify three measured voltage signals V_sh1, V_sh2 and V_sh3 corresponding to the phase current signals l_sh1, I_sh2 and I_sh3 of the BLDC motor across the shunt resistors R_sh1 , R_sh2 and R_sh3, respectively and perform an offset correction of the voltages V_sh1 V_sh2 and V_sh3. The total phase current signal can be calculated as I_shT = I_sh1 + I_sh2 + I_sh3.

The means of the power supply control circuit further comprises a summing amplifier to sum the three voltage signals V_sh1 V_sh2 and V_sh3 and a low pass filter that filters V_shT and obtains an output voltage V₀. Therefore V_shT = V_sh1 + V_sh2 + V_sh3.

The Gain_Total represents the total amplification factor of the three amplifiers to amplify three measured voltage signals V_sh1, V_sh2 and V_sh3 .

The R_Total is the equivalent resistance of R_sh1 , R_sh2 and R_sh3:

In some examples, the power supply control circuit comprises an AC filter comprising a capacitor and an inductance as shown in the figures.

In another aspect, it is proposed a method for calculating a DC current consumption I_s of a three phase brushless DC (BLDC) motor, the method performed by the motor microcontroller of the power supply control circuit. The method comprises a step for amplifying a voltage signal V_shunt corresponding to a total phase current signal I _shunt of the BLDC motor across a shunt resistor R_shunt. The shunt resistor R_shunt ^can measure low-side phase current. The method comprises a step for performing an offset correction of the voltage signal V_shunt. The method further comprises a step for obtaining an output voltage V₀ by low-pass filtering the amplified voltage signal V_shunt . Finally, the method comprises a step for obtaining the DC current consumption I_s based on the output voltage V₀ and according to equation 1. In an example, the motor microcontroller can be configured to implement a control algorithm for controlling the BLDC motor based at least on the calculated I_s. In another example, a master controller may use the calculated I_s for performing e.g. overcurrent protection.

In another aspect, it is proposed a second method for calculating a DC current consumption I_s of a three phase brushless DC (BLDC) motor, the method is also performed by the motor microcontroller of the power supply control circuit. The method comprises a step for amplifying three voltage signals V_sh1 V_sh2 and V_sh3 corresponding to three phase current signals I_sh1 I_sh2 I_Sh3 of the BLDC motor across shunt resistors R_sh1 , R_sh2 and R_sh3, respectively. In particular, the shunt resistors can measure low-side phase currents. The method comprises a step for performing offset correction of the three voltage signals V_sh1 V_sh2 and y_sh3. The method comprises obtaining a total tension V_shT by summing the three voltage signals V_sh1 V_sh2 and V_sh3 and obtaining a filtered voltage V₀ by low-pass filtering the total tension V_shT. Finally the DC current consumption I_s is obtained based on the output voltage V₀ and according to the equation 2. Brief description of the drawings

For a better understanding the above explanation and for the sole purpose of providing an example, some non-limiting drawings are included that schematically depict a practical embodiment.

Figure 1 shows a conventional BLDC power supply control circuit.

Figure 2 shows a first example of a BLDC power supply control circuit according to the present disclosure.

Figure 3 shows a second example of a BLDC power supply control circuit according to the present disclosure.

Figure 4 shows the first example of a BLDC power supply control circuit according to the present disclosure.

Figures 5 shows the second example of a BLDC power supply control circuit according to the present disclosure.

Description of a preferred embodiment

Figure 2 shows a power supply control circuit (200) for a BLDC (130) having a Ύ” formation. In another example, the BLDC (130) can have a“Delta” formation. The advantages of the configuration of the power supply control circuit (200) are cost reduction, the PCB area for placement of the control circuit is smaller compared to other configurations. Furthermore, one single ADC converters is needed. The control circuit (200) comprises a microcontroller/PWM control block (210) that generates a PWM signal for a power inverter (120) which produces an AC electric current that feeds the BLDC motor (130). The microcontroller/PWM block (210) controls current in the brushless DC motor (130) based on a control algorithm implemented by the microcontroller. The control circuit (200) comprises means for calculating a DC current consumption I_s based on a phase current signal I_shunt of the BLDC motor, the means comprises a R_shunt (215) for measuring low-side current sensing and an input AC filter (103). In order to obtain the DC current consumption I_s, the voltage V_shunt corresponding to the current l_shunt across R_shunt (215) is measured, amplified, offset corrected and filtered as shown in figure 4. The DC current consumption I_s is calculated according to equation 1.

Figure 3 shows a power supply control circuit (300) for the BLDC (130). The advantages of the configuration of the power supply control circuit (300) are that this configuration can obtain more precise phase currents readings and involve less acoustic noise and less total harmonic distortion (THD). Hence, the control algorithm can be improved when calculated DC current consumption I_s is used to implement the control algorithm. The control circuit (300) comprises a microcontroller/PWM generator control block (310) that generates six PWM signals for the power inverter (120) that feeds the DC motor (130). The microcontroller/PWM generator block (310) controls current in the brushless DC motor (130) based on the control algorithm. In some examples, the DC current consumption I_s of the BLDC motor (130) can be used as input to the control algorithm. The control circuit (300) comprises means for calculating the DC current consumption I_s based on a phase current signal I_ShTI_shunt, the means comprises a three shunt resistors R_sh1, R_sh2 and R_sh3 for measuring each phase current and an input AC filter (103). In order to obtain the DC current consumption I_s, three voltages V_sh1 V_sh2 and V_sh3 are measured that correspond to the currents I_sh1, I_sh2 and I_sh3 across the three shunt resistors R_sh1 , R_sh2 and R_sh3, respectively. The total phase current signal can be calculated as I_shT = I_sh1 + I_sh2 + I_sh3. Furthermore, the three voltages V_sh1 V_sh2 and V_sh3 are amplified, offset corrected, summed and filtered as shown in figure 5. The DC current consumption I_s is calculated according to equation 2.

Figure 4 shows the control circuit (200) previously shown in figure 2 comprising means for calculating a DC current consumption I_s , the means comprises signal processing elements to obtain the DC current consumption I_s of the BLDC motor (130). In this example, the DC current consumption I_s can be used as input for the microcontroller/PWM block (210) as shown in the figure. These signal processing elements comprise an amplifier (405) to amplify the voltage V_shunt and perform an offset correction and a low pass filter (410) to filter the voltage signal V_shunt from the amplifier (405). Hence, an output voltage V₀ is obtained from the low pass filter (410) and the DC current consumption of the BLDC motor I_s is obtained based on said voltage V₀ and according to the equation 1. Figure 5 shows the control circuit (300) previously shown in figure 3 further comprising means for calculating a DC current consumption I_s , the means comprises signal processing elements to obtain the DC current consumption I_s of the BLDC motor (130). In this example, the DC current consumption I_s can also be used as input for the microcontroller/PWM block (310) as in figure 4. As previously mentioned, the means for calculating a DC current consumption I_s comprises three shunt resistors R_sh1, R_sh2 and R_sh3. The signal processing elements comprise three amplifiers (505, 510, 515) to amplify three measured voltage levels V_sh1 V_sh2 and V_sh3 corresponding to the shunts resistors R_sh1 , R_sh2 and R_sh3, respectively and to perform an offset correction of the voltage levels. Furthermore, the signal processing elementscomprise a summation module as e.g. a summing amplifier (not drawn in the figure) but represented by reference (520) to obtain a total voltage V_shT = V_sh1 + V_sh2 + V_sh3. A low pass filter is also included as part of the control circuit (300) to filter the total voltage V_shT in order to obtain an output voltage V₀. Finally, the DC current consumption of the BLDC motor I_s is obtained based on said voltage V₀ and according to the equation 2.

Even though reference has been made to a specific embodiment of the invention, it is obvious for a person skilled in the art that the BLDC power supply control circuit architectures described herein are susceptible to numerous variations and modifications, and that all the details mentioned can be substituted for other technically equivalent ones without departing from the scope of protection defined by the attached claims.

Claims

1. A power supply control circuit (200) of a three-phase brushless DC (BLDC) motor (130), characterized in that the control circuit (200) comprises means for calculating the DC current consumption I_s based on a phase current signal I_shunt of the BLDC motor (130), the means comprising: a shunt resistor (215) R_shunt ;

an amplifier (405); and

a low pass filter (410),

wherein the amplifier (405) is configured to amplify and perform an offset correction of a voltage V_shunt that corresponds to the current I_shunt across the resistor (215)

R_shunt ;

wherein the low pass filter (410) is configured to provide a filtered voltage V₀ of the voltage V_shunt, and

wherein the DC current I_s is calculated according to the following equation:

wherein K = R_shunt * Gain and Gain is the amplification factor of the amplifier (405).

2. A power supply control circuit (300) of a three-phase brushless DC (BLDC) motor (130) characterized in that the control circuit (300) comprises means for calculating the DC current consumption I_s based on three phase current signals I_sh1 I_sh2 and I_sh3 of the BLDC motor (130), the means comprising: three shunt resistors (315, 320, 325) R_sh1 , R_sh2 and R_sh3 ;

three amplifiers (505, 510, 515);

a summing amplifier (520); and a low pass filter (525) wherein the three amplifiers (505, 510, 515) are configured to amplify and perform an offset correction of voltages V_sh1, V_sh2 and V_sh3 that correspond to the currents I_sh1 I_sh2 and I_sh3 across the three shunt resistors (315, 320, 325) R_sh1 , R_sh2 and Rsh3^’’

wherein the summing amplifier (520) is configured to provide a summed voltage

V_shT

wherein the low pass filter (525) is configured to provide a filtered voltage V₀ of the voltage V_shT, and

wherein the DC current consumption of the BLDC motor I_s is calculated according to the following equation:

wherein K = R_Total * Gain_Total R_Total is the equivalent resistance of resistors R_sh1 , R_sh2 and R_sh3 and Gain_Total is the total amplification factor of the three amplifiers (505, 510, 515).

3. The power supply control circuit according to any of the preceding claims further comprising an AC filter.

4. A method for calculating a DC current consumption I_s of a three phase brushless DC (BLDC), the method performed by a microcontroller of a power supply control circuit of the BLDC motor, the method comprising: amplifying a voltage signal V_shunt corresponding to a phase current signal I_shunt of the BLDC motor across a shunt resistor R_shunt for phase current sensing;

performing offset correction of the voltage signal V_shunt;

obtaining an output voltage V₀ by low-pass filtering the amplified voltage signal

V_shunt ; and

calculating the DC current consumption I_s according to the following equation:

5. The method according to claim 4, further comprising implementing a control algorithm for controlling the BLDC motor based at least on the calculated I_s.

6. A method for calculating a DC current consumption I_s of a three phase brushless DC (BLDC) motor, the method performed by a microcontroller of a power supply control circuit of the BLDC motor, the method comprising: amplifying three voltage signals V_sh1, V_sh2 and V_sh3 corresponding to three phase current signals I_sh1, I_sh2 and I_sh3 of the BLDC motor across three shunt resistors R_sh1, R_sh2 and R_sh3 for phase current sensing, respectively;

performing an offset correction of the three voltage signals V_sh1, V_sh2 and V_sh3 , obtaining a total tension V_shT by summing the three voltage signals V_sh1, V_sh2 and obtaining a filtered voltage V₀ by low-pass filtering the total tension V_shT ; and calculating the DC current consumption I_s according to the following equation:

wherein K = R_Total * Gain_Total,

wherein R_Total is the equivalent resistance of R_sh1 , R_sh2 and R_sh3 and Gain_Total is the total amplification factor of the three amplifiers (505, 510, 515).

7. The method according to claim 6, further comprising implementing a control algorithm for controlling the BLDC motor based at least on the calculated I_s.