WO2021195189A1

WO2021195189A1 - An electric motor drive system for a vehicle

Info

Publication number: WO2021195189A1
Application number: PCT/US2021/023850
Authority: WO
Inventors: Lixin Tang; Geng NIU
Original assignee: Karma Automotive Llc
Priority date: 2020-03-25
Filing date: 2021-03-24
Publication date: 2021-09-30
Also published as: US20210376776A1; US11621656B2; US11159108B2; CN115315370A; EP4126586A1; US20210305920A1; EP4126586A4

Abstract

An electrical drive system for a vehicle. The system includes a plurality of electric propulsion motors and a plurality of corresponding inverter circuits. The system also includes an auxiliary motor for driving an auxiliary device located in the vehicle. The auxiliary motor is connected to the propulsion motors and is driven by the inverter circuits. The system does not include a separate inverter for driving the auxiliary motor.

Description

AN ELECTRIC MOTOR DRIVE SYSTEM FOR A VEHICLE

BACKGROUND

[0001] The present disclosure relates to a method of using at least one primary inverter to partially or completely replace the functionality of an auxiliary inverter, thereby reducing the hardware requirements for a motor drive system.

[0002] Electric vehicles employ auxiliary power systems (i.e., auxiliary drives) to provide power to auxiliary loads. These auxiliary power systems differ from the vehicle propulsion system which typically employs a traction drive inverter having a much higher power rating. The power rating of the auxiliary loads are typically less lOkW. These auxiliary loads may include air compressors, cooling system oil/water pumps, and electric power steering systems. Figure 1 shows a conventional auxiliary motor drive system 200 including an inverter. The inverter includes six power switches 220 and a DC bus capacitor 210. The system may also include a gate drive board and controller. The inverter may need active cooling in most cases and the inverter-related hardware adds weight/volume/cost to the system. The inverter provides power to auxiliary loads such as, for example, an electric motor 230.

[0003] It is desirable to find a means to meet the power requirements of auxiliary systems without the use of additional hardware.

SUMMARY

[0004] Disclosed herein is a method of using at least one primary or traction motor inverter to partially or completely replace the functionality of an auxiliary motor inverter, thereby reducing the hardware requirements for a motor drive system.

[0005] The disclosed system provides a different auxiliary drive circuit to eliminate the auxiliary inverter hardware requirements, totally or partially and includes unique control algorithms for all the affected circuits.

[0006] According to a disclosed embodiment an electrical drive system for a vehicle is disclosed. The system includes first, second and third electric propulsion motors for driving the vehicle, wherein each of the propulsion motors includes three primary phase wires, and wherein each of the propulsion motors include a neutral point between the three primary phase wires. The system also includes first, second and third inverter circuits, wherein each of the inverter circuits is controlled by a controller and is paired with one of the electric propulsion motors so that each inverter circuit provides a plurality of phase voltages to one of the propulsion motors across the plurality of primary phase wires in order to drive the propulsion motor. The system also includes a three phase auxiliary motor for driving an auxiliary device located in the vehicle wherein the auxiliary motor includes three auxiliary phase wires. One of three auxiliary phase wires is connected to the neutral point of the first propulsion motor, and a second one of the three auxiliary phase wires is connected to the neutral point of the second propulsion motor, and a third one of the three auxiliary phase wires is connected to the neutral point of the third propulsion motor. The controller for each of the inverter circuits is configured to generate a zero-sequence voltage at the neutral point and in the connected auxiliary phase wire to thereby create the phase voltage in the auxiliary phase wire required for driving the auxiliary motor.

[0007] According to another disclosed embodiment, an electrical drive system for a vehicle is disclosed. The system includes first, second and third electric propulsion motors for driving the vehicle, wherein each of the propulsion motors includes three primary phase wires, and wherein each of the propulsion motors include a neutral point between the three primary phase wires.

The system further includes first, second and third inverter circuits, wherein each of the inverter circuits is controlled by a controller and is paired with one of the electric propulsion motors so that each inverter circuit provides a plurality of phase voltages to one of the propulsion motors across the plurality of primary phase wires in order to drive the propulsion motor. A two phase auxiliary motor for driving an auxiliary device is located in the vehicle. The auxiliary motor includes three auxiliary phase wires. One of two auxiliary phase wires is connected to the neutral point of the first propulsion motor, and a second one of the two auxiliary phase wires is connected to the neutral point of the second propulsion motor. A neutral point of the auxiliary motor is connected to the neutral point of the third propulsion motor. The ontroller for each of the inverter circuits for the first and second propulsion motors is configured to generate a zero- sequence voltage at the neutral point and in the connected auxiliary phase wire to thereby create the phase voltage in the auxiliary phase wire required for driving the two phase auxiliary motor.

[0008] According to yet another disclosed embodiment, an electrical drive system for a vehicle is disclosed. The system includes first and second electric propulsion motors for driving the vehicle, wherein each of the propulsion motors includes three primary phase wires, and wherein each of the propulsion motors include a neutral point between the three primary phase wires.

The system also includes first and second inverter circuits, wherein each of the inverter circuits is controlled by a controller and is paired with one of the electric propulsion motors so that each inverter circuit provides a plurality of phase voltages to one of the propulsion motors across the plurality of primary phase wires in order to drive the propulsion motor. The first inverter circuit includes an additional inverter leg including a pair of switches, wherein the additional inverter leg is not connected to any of the plurality primary phase wires. The system includes three phase auxiliary motor for driving an auxiliary device located in the vehicle wherein the auxiliary motor includes three auxiliary phase wires. One of three auxiliary phase wires is connected to the neutral point of the first propulsion motor. A second one of the three auxiliary phase wires is connected to the neutral point of the second propulsion motor. A third one of the three auxiliary phase wires is connected to the additional inverter leg of the first inverter circuit. The controller for each of the two inverter circuits is configured to generate a zero-sequence voltage at the neutral point and in the connected auxiliary phase wire to thereby create the phase voltage in auxiliary phase wire required for driving the auxiliary motor, wherein the controller for the first inverter circuit is configured to generate a voltage in the additional inverter leg and in one of the auxiliary phase wires for driving the auxiliary motor.

[0009] According to still another disclosed embodiment, an electrical drive system for a vehicle is disclosed. The system includes first and second electric propulsion motors for driving the vehicle, wherein each of the propulsion motors includes three primary phase wires. Each of the propulsion motors include a neutral point between the three primary phase wires. The system further also includes first and second inverter circuits, wherein each of the inverter circuits is controlled by a controller and is paired with one of the electric propulsion motors so that each inverter circuit provides a plurality of phase voltages to one of the propulsion motors across the plurality of primary phase wires in order to drive the propulsion motor. The first inverter circuit includes an additional inverter leg including a pair of switches, wherein the additional inverter leg is not connected to any of the plurality primary phase wires. A two phase auxiliary motor is provided for driving an auxiliary device located in the vehicle wherein the auxiliary motor includes three auxiliary phase wires. One of two auxiliary phase wires is connected to the neutral point of the first propulsion motor, and a second one of the two auxiliary phase wires is connected to the additional inverter leg of the first inverter circuit. A neutral point of the auxiliary motor is connected to the neutral point of the second propulsion motor. The controller for first inverter circuit is configured to generate a zero-sequence voltage at the neutral point and in the connected auxiliary phase wire to thereby create the phase voltage in the connected auxiliary phase wire required for driving the auxiliary motor. The controller for the first inverter circuit is configured to generate a voltage in the additional inverter leg and in the connected auxiliary phase wire for driving the auxiliary motor.

[0010] Other aspects, features, and techniques will be apparent to one skilled in the relevant art in view of the following detailed description of the embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The features, objects, and advantages of the disclosed embodiments will become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference characters identify correspondingly throughout and wherein:

[0012] FIG. 1 is a circuit diagram of an exemplary embodiment of a previously established inverter for controlling an auxiliary motor.

[0013] FIG. 2 is a circuit diagram of an exemplary embodiment of a multi -inverter drive system, wherein a plurality of primary inverters provide power for an auxiliary motor by using the zero- sequence voltage of a plurality of primary motors powered by the primary inverters.

[0014] FIG. 3 is a circuit diagram of an exemplary embodiment of a multi -inverter drive system, wherein a plurality of primary inverters provide power for an auxiliary motor by using the zero- sequence voltage of a plurality of primary motors powered by the primary inverters.

[0015] FIG. 4 is a circuit diagram of an exemplary embodiment of a multi -inverter drive system, wherein a plurality of primary inverters provide power for an auxiliary motor by using the zero- sequence voltage of a plurality of primary motors powered by the primary inverters, in conjunction with a dedicated inverter leg.

[0016] FIG. 5 is a circuit diagram of an exemplary embodiment of a multi -inverter drive system, wherein a plurality of primary inverters provide power for an auxiliary motor by using the zero- sequence voltage of a plurality of primary motors powered by the primary inverters, in conjunction with a dedicated inverter leg. DETAILED DESCRIPTION

[0017] One aspect of the disclosure is directed to a method of using at least one primary motor inverter to partially or completely replace the functionality of an auxiliary motor inverter, thereby reducing the hardware requirements for a motor drive system.

[0018] References throughout this document to “one embodiment,” “certain embodiments,” “an embodiment,” or similar term mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of such phrases in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner on one or more embodiments without limitation. For example, two or more of the innovative methods described herein may be combined in a single method, but the application is not limited to the specific exemplary combinations of methods that are described herein.

[0019] As used herein, the terms “a” or “an” shall mean one or more than one. The term “plurality” shall mean two or more than two. The term “another” is defined as a second or more. The terms “including” and/or “having” are open ended (e.g., comprising). The term “or” as used herein is to be interpreted as inclusive or meaning any one or any combination. Therefore, "A, B or C" means "any of the following: A; B; C; A and B; A and C; B and C; A, B and C". An exception to this definition will occur only when a combination of elements, functions, steps or acts are in some way inherently mutually exclusive.

[0020] The character "N" refers hereinafter to the last member of a set or the total count of members in a set. The character "X" refers hereinafter to a variable member of a set. The characters "A", "B", "C", etc. refer to a specific but otherwise undefined member of a set.

[0021] A detailed description of various embodiments is provided; however, it is to be understood that the disclosed embodiments are merely exemplary and may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the disclosed embodiments. [0022] FIG. 2 shows a power system for an electric vehicle. The system includes a circuit 300A, in which three (3) inverters 320A_I-A₃ are used to drive three star-connected motors 330A_I-A₃ in an electric vehicle. Each of the inverters is connected to the same or different DC bus (Vdc). The DC bus is supplied power by a battery, generator or other source of electrical power. The circuit 300A may be employed in an electric vehicle that includes three inverters 320 in its powertrain for providing power to two or more propulsion motors 330. Each of these traction motors 330A_I- _A3 is driven by three phase voltages, wherein each phase voltage is carried across a phase wire.

In one embodiment, each phase wire corresponds to a pair of inverter switches, wherein the activity of the pair of inverter switches provides a voltage signal/phase voltage to the phase wire, and the phase voltage in turn drives the operation of the motor.

[0023] In the main motors 330, power is transmitted by magnetic flux passing through an air gap, which has a very low magnetic permeability, which can limit performance of the motor.

The configuration shown in Fig. 2 allows for the voltage of the phase wires of an auxiliary motor 335 to be driven by a zero-sequence voltage of the main motors. This configuration avoids using additional inverter leg, thus saves cost/weight/volume of the auxiliary inverter.

[0024] In one embodiment, shown in Fig. 2, at least one phase wire of the auxiliary motor 335A is driven by a zero-sequence voltage of a main (e.g., a traction) motor 330A instead of a pair of inverter switches. As used in this application, the term “auxiliary motor” refers to a motor not used to directly propel the vehicle. The auxiliary motor is used to drive an auxiliary device located in the vehicle. The auxiliary device or load typically has a power rating of less than lOkW. These devices may include air compressors, cooling system oil/water pumps, and electric power steering systems, each of which may include one or more auxiliary motors.

[0025] The zero-sequence voltage of a motor is the voltage of the motor between its neutral point and ground. The neutral point of the motor 330A is the point within the motor 330A at which the three phase wires meet. In one embodiment, shown in Fig. 2, the neutral points of the motors 1, 2, and 3 (330A_I-A₃) are connected to phase wires R, S, and T (respectively) of the auxiliary motor 335A. Each of the motors is controlled by a controller. The controller for Motor 1 is configured to generate a zero-sequence voltage of VR. The controller for Motor 2 is configured to generate a zero-sequence voltage of Vs. The controller for Motor 3 is configured to generate a zero-sequence voltage of V_T. Each of the motors may have a dedicated controller or a single controller may control one or more motors.

[0026] The three phase voltages of V_R, V_S, V_T are provided to drive auxiliary motor 335A. The current of auxiliary motor phase R is shared equally among the three phase wires U, V and W of motor 1 330A_I, due to the same voltage and zero-sequence impedance of motor 1 330A_I. This configuration will not generate any air-gap flux linkage in motor 1 330A_I and, as a result, will not affect the torque generation of motor 1 330A_I. In the same manner as described above for the phase R of the auxiliary motor 335A, the current in phase S of the auxiliary motor is share equally among the three phase wires A, B and C of motor 2 330A₂, due to the same voltage and zero-sequence impedance of motor 2 330A₂. This configuration will not generate any air-gap flux linkage in motor 2 330A₂ and, as a result, will not affect the torque generation of motor 2 330A₂. Similarly, the current in phase T of the auxiliary motor is share equally among the three phase wires X, Y and Z of motor 3 330A₃, due to the same voltage and zero-sequence impedance of motor 3 330A₃. This configuration will not generate any air-gap flux linkage in motor 3 330A₃ and, as a result, will not affect the torque generation of motor 3 330A₃.

[0027] FIG. 3 shows the proposed circuit B 300_B. The circuit includes three inverters 320. The inverters 320 and motors 330 may be the same or similar to the inverters and motors described above. In one embodiment, the neutral point of motor 1 330_BI is connected to the neutral point of a two-phase auxiliary motor 335_B, while the neutral point of motor 2 330_B2 is connected to phase wire R and the neutral point of motor 3 330_B3 is connected to phase wire S.

[0028] The controller for Motor 1 is configured to generate a zero-sequence voltage of 0. The controller for Motor 2 is configured to generate a zero-sequence voltage of V_R. The controller for Motor 3 is configured to generate a zero-sequence voltage of Vs. The voltages (V_R, V_S) drive the rotation of the auxiliary motor 335_B.

[0029] FIG. 4 shows proposed circuit C 300c, in which two inverters 320C_I-C₂ and their corresponding main propulsion motors 330C_I-C₂ are configured to drive a three-phase auxiliary motor 335c. The inverters 320 and motors 330 may be the same or similar to the inverters and motors described above. One of the inverters 320ci may include an additional inverter leg. The additional inverter leg 325ci_{, R} is connected to the phase wire R of the auxiliary motor 335c, while the neutral point of motor 1 330ci is connected to phase wire S and the neutral point of motor 2330c₂ is connected to phase wire T. The controller for Motor 1 is configured to generate a zero-sequence voltage Vs in the phase winding S of the auxiliary motor 335c. The controller for Motor 2 is configured to generate a zero-sequence voltage of VT in the phase winding T of the auxiliary motor 335c.

[0030] FIG. 5 shows proposed circuit D 300_D, in which a two-phase auxiliary motor 335_D is driven by two inverters configured to drive the main propulsion motors. One of the inverters may include an additional inverter leg. The additional inverter leg 325_DI,

is connected to the phase wire R of the auxiliary motor 335_D. The neutral point of motor 1 330_DI is connected to phase wire S. The controller for Motor 1 is configured to generate a zero-sequence voltage of Vs in the phase winding or wire S. The neutral point of motor 2 330_D2 is connected to the neutral point of the auxiliary motor 335_D. The controller for Motor 2 is configured to generate a zero- sequence voltage of 0 is configured to generate a zero-sequence voltage of zero.

[0031] The provision of the circuits A 300A and B 300_B, allows for the dedicated auxiliary inverter including all of the associated hardware (e.g., power switches, capacitor, gate drive board and micro-controller board) used in FIG. 1 can be replaced. In addition, the provision of the circuits C 300c and D 300_D, similarly allow for a portion of the auxiliary inverter to be eliminated. These two circuits include an auxiliary leg integrated into one or more of the main inverters driving the main propulsion motors.

[0032] The control methodology for the circuits A 300A and B 300_B are described further below. The following definitions are provided for the associated voltages: for the auxiliary motor 335A to reach desirable speed and generate reference torque, the auxiliary motor needs rotating voltage u_aA and Up_A to be provided in the stationary reference frame; these voltages in the auxiliary motor require corresponding voltages in motor 1 of ii_al and Up and voltages in motor 2 of u_a2 and Up₂ „ for motor 3, it needs u_a3 and Up_3.

[0033] For the auxiliary motor 335A, the phase R, S, and T voltages can be calculated as below in equation (1). In one embodiment, the power invariant Alpha-beta inverse transformation is used to find the necessary phase voltages to achieve the desired auxiliary motor rotating voltages and zero- sequence voltage. [0034] The voltage of inverter 1 320A_I phases U, V, and W can be calculated as below in equation (2). In one embodiment, the zero-sequence voltage u_R is generated from inverter 1 320A_I for auxiliary motor 335A. In one embodiment, inverter 1 320A_I does not only generate the positive-sequence voltage to drive motor 1 330A_I, it also generates the zero-sequence voltage for phase R of auxiliary motor 335A, wherein the auxiliary motor phase R current is shared equally among the three phase windings/wires of motor 1 330A_I and the U, V, and W phases of the inverter 1 320_AI.

[0035] Similarly, for inverter 2 320A₂, the phase A, B, and C voltages can be calculated as below in equation (3). In one embodiment, zero-sequence voltage u_s is generated from inverter 2320A₂ for auxiliary motor 335A.

[0036] In inverter 3 320A₃, the phase X, Y, and Z voltages can be calculated as below in equation (4). Zero-sequence voltage u_T is generated from inverter 3 320A₃ for auxiliary motor 335A.

[0037] All the afore-mentioned equations indicate the control of the auxiliary motor 335A via inverter 1~3 320AI-A₃. AS mentioned above, the exemplary embodiments shown in Figs. 2-5 allow for the dedicated inverter for the auxiliary motor to be eliminated.

[0038] The control algorithm for circuit B 300B can be developed as described below. For example, the voltage of inverter 1 320BI phase U, V, and W can be calculated as below in equation (5). Zero-sequence voltage 0 is generated from inverter 1 320BI for auxiliary motor 335B. However, it has to take the total current of Phase R and S of the auxiliary motor 335B.

[0039] In inverter 2 320B2, the phase A, B, and C voltages can be calculated as below in equation (6). In one embodiment, the zero-sequence voltage u_R is generated from inverter 2320B2 for auxiliary motor 335B. In one embodiment, inverter 2320B2 supplies the phase R current of the auxiliary motor 335B.

[0040] In inverter 3 320B₃, the phase X, Y, and Z voltages can be calculated as below in equation (7). Zero-sequence voltage u_s is generated from inverter 3 320B₃ for auxiliary motor 335B.

[0041] Control laws for circuits C 300c and D 300D can be developed similarly.

[0042] While this disclosure makes reference to exemplary embodiments, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the claimed embodiments.

Claims

WHAT IS CLAIMED IS:

1. An electrical drive system for a vehicle, comprising: first, second and third electric propulsion motors for driving the vehicle, wherein each of the propulsion motors includes three primary phase wires, and wherein each of the propulsion motors include a neutral point between the three primary phase wires; first, second and third inverter circuits, wherein each of the inverter circuits is controlled by a controller and is paired with one of the electric propulsion motors so that each inverter circuit provides a plurality of phase voltages to one of the propulsion motors across the plurality of primary phase wires in order to drive the propulsion motor; and a three phase auxiliary motor for driving an auxiliary device located in the vehicle wherein the auxiliary motor includes three auxiliary phase wires; wherein each of the three auxiliary phase wires is supplied with a voltage by one of the inverter circuits; and wherein the controller for each of the inverter circuits is configured to generate a zero- sequence voltage in one of the auxiliary phase wires required for driving the auxiliary motor.

2. The electrical drive system of claim 1, wherein one of three auxiliary phase wires is connected to the neutral point of the first propulsion motor, and a second one of the three auxiliary phase wires is connected to the neutral point of the second propulsion motor, and a third one of the three auxiliary phase wires is connected to the neutral point of the third propulsion motor; and wherein the controller for each of the inverter circuits is configured to generate a zero- sequence voltage at the neutral point and in the auxiliary phase wire connected to the neutral point of the propulsion motor paired with the inverter circuit to thereby create the phase voltage in the auxiliary phase wire required for driving the auxiliary motor.

3. The electrical drive system of claim 1, wherein the first inverter circuit includes an additional inverter leg including a pair of switches, wherein the additional inverter leg is not connected to any of the plurality primary phase wires; wherein one of three auxiliary phase wires is connected to the neutral point of the first propulsion motor, and a second one of the three auxiliary phase wires is connected to the neutral point of the second propulsion motor, and a third one of the three auxiliary phase wires is connected to the additional inverter leg of the first inverter circuit; wherein the controller for each of the two inverter circuits is configured to generate a zero-sequence voltage at the neutral point and in the connected auxiliary phase wire to thereby create the phase voltage in auxiliary phase wire required for driving the auxiliary motor, wherein the controller for the first inverter circuit is configured to generate a voltage in the additional inverter leg and in one of the auxiliary phase wires for driving the auxiliary motor.

4. An electrical drive system for a vehicle, comprising: first, second and third electric propulsion motors for driving the vehicle, wherein each of the propulsion motors includes three primary phase wires, and wherein each of the propulsion motors include a neutral point between the three primary phase wires; first, second and third inverter circuits, wherein each of the inverter circuits is controlled by a controller and is paired with one of the electric propulsion motors so that each inverter circuit provides a plurality of phase voltages to one of the propulsion motors across the plurality of primary phase wires in order to drive the propulsion motor; and a two phase auxiliary motor for driving an auxiliary device located in the vehicle wherein the auxiliary motor includes three auxiliary phase wires, wherein each of the two auxiliary phase wires is supplied with a voltage by one of the inverter circuits; and wherein the controller for two of the inverter circuits is configured to generate a zero- sequence voltage in one of the auxiliary phase wires required for driving the auxiliary motor.

5. The electrical drive system of claim 4, wherein one of two auxiliary phase wires is connected to the neutral point of the first propulsion motor, and a second one of the two auxiliary phase wires is connected to the neutral point of the second propulsion motor; wherein a neutral point of the auxiliary motor is connected to the neutral point of the third propulsion motor; and wherein the controller for each of the inverter circuits for the first and second propulsion motors is configured to generate a zero-sequence voltage at the neutral point and in the connected auxiliary phase wire to thereby create the phase voltage in the auxiliary phase wire required for driving the two phase auxiliary motor.

6. The electrical drive system of claim 4, wherein the first inverter circuit includes an additional inverter leg including a pair of switches, wherein the additional inverter leg is not connected to any of the plurality primary phase wires; wherein one of two auxiliary phase wires is connected to the neutral point of the first propulsion motor, and a second one of the two auxiliary phase wires is connected to the additional inverter leg of the first inverter circuit; wherein a neutral point of the auxiliary motor is connected to the neutral point of the second propulsion motor; and wherein the controller for first inverter circuit is configured to generate a zero-sequence voltage at the neutral point and in the connected auxiliary phase wire to thereby create the phase voltage in the connected auxiliary phase wire required for driving the auxiliary motor, wherein the controller for the first inverter circuit is configured to generate a voltage in the additional inverter leg and in the connected auxiliary phase wire for driving the auxiliary motor.