U.S. patent application number 11/614239 was filed with the patent office on 2007-09-20 for motor speed estimation system and method using hybrid model reference adaptive system.
This patent application is currently assigned to ROCKWELL AUTOMATION TECHNOLOGIES, INC.. Invention is credited to Haihui Lu, Wei Qian.
Application Number | 20070216337 11/614239 |
Document ID | / |
Family ID | 37863837 |
Filed Date | 2007-09-20 |
United States Patent
Application |
20070216337 |
Kind Code |
A1 |
Lu; Haihui ; et al. |
September 20, 2007 |
MOTOR SPEED ESTIMATION SYSTEM AND METHOD USING HYBRID MODEL
REFERENCE ADAPTIVE SYSTEM
Abstract
Motor drives, motor speed controllers, motor speed estimation
systems, and methods are presented for controlling motor speed and
for estimating motor speed, in which a speed estimate controller
provides a rotor speed estimate based on a first error term from a
torque-based MRAS component for a first range of motor speeds and
based on a second error term from a rotor flux-based MRAS component
for a second range of speeds.
Inventors: |
Lu; Haihui; (Shanghai,
CN) ; Qian; Wei; (Shanghai, CN) |
Correspondence
Address: |
ROCKWELL AUTOMATION, INC./FAY
ATTENTION: SUSAN M. DONAHUE, E-7F19, 1201 SOUTH SECOND STREET
MILWAUKEE
WI
53204
US
|
Assignee: |
ROCKWELL AUTOMATION TECHNOLOGIES,
INC.
Mayfield Heights
OH
|
Family ID: |
37863837 |
Appl. No.: |
11/614239 |
Filed: |
December 21, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11375800 |
Mar 14, 2006 |
7193387 |
|
|
11614239 |
|
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Current U.S.
Class: |
318/800 ;
318/609 |
Current CPC
Class: |
H02P 2203/05 20130101;
H02P 2203/09 20130101; H02P 2207/01 20130101; H02P 21/141 20130101;
Y10S 388/917 20130101; H02P 21/26 20160201; H02P 21/32 20160201;
H02P 21/0021 20130101; H02P 21/20 20160201; H02P 31/00 20130101;
Y10S 388/906 20130101; H02P 21/0017 20130101; H02P 21/18 20160201;
H02P 21/34 20160201 |
Class at
Publication: |
318/800 ;
318/609 |
International
Class: |
H02P 27/04 20060101
H02P027/04 |
Claims
1. A motor drive system, comprising: a switching system including a
plurality of switching devices coupled between a power source and a
motor and operative according to a corresponding plurality of
switch control signals; and a motor startup control system for
controlling the motor speed during startup, the motor startup
control system comprising: a hybrid model reference adaptive system
(MRAS) component including: a torque-based MRAS component providing
a first error term at least partially according to a calculated
torque value and an estimated torque value; and a rotor flux-based
MRAS component providing a second error term at least partially
according to a calculated rotor flux and an estimated rotor flux; a
speed estimate controller providing a rotor speed estimate
according to a controller error input; a motor controller providing
a motor controller output for controlling the motor speed during
startup according to a desired startup speed profile and according
to the rotor speed estimate; a switch control circuit providing the
switch control signals to the switching system during startup of
the motor according to the controller output; and an error selector
operatively coupled with the hybrid MRAS component and with the
speed estimate controller to provide the error input to the speed
estimate controller, the error selector providing the first error
term as the controller error input when the rotor speed estimate is
in a first speed range and providing the second error term as the
controller error input when the rotor speed estimate is in a second
speed range.
2. The motor drive system of claim 1, further comprising bypass
switches operative to selectively bypass the switching system by
connecting the motor leads to the power source according to a
bypass control signal; and a bypass control component receiving the
rotor speed estimate from the speed estimate controller and
providing the bypass control signal to bypass the switching system
when the rotor speed estimate is in a third speed range.
3. The motor drive system of claim 1, wherein the first speed range
is from zero to about 80% of the rated full speed of the motor.
4. The motor drive system of claim 1: wherein the motor startup
control system evaluates stator equations to derive a calculated
rotor flux according to current and voltage feedback values, and
evaluates rotor equations to derive an estimated rotor flux
according to current and voltage feedback values and according to
the rotor speed estimate; wherein the torque-based MRAS component
computes a calculated torque value according to the calculated
rotor flux, computes an estimated torque value according to the
estimated rotor flux, and provides the first error term as the
difference between the calculated and estimated torque values; and
wherein the rotor flux-based MRAS component provides the second
error term as a vector product of the calculated rotor flux and the
estimated rotor flux.
5. The motor drive system of claim 4: wherein the motor startup
control system computes one of a stator flux modulus and a rotor
flux modulus; wherein the speed estimate controller is a
proportional integral (PI) controller with proportional and
integral gains K.sub.I and K.sub.P, respectively; and wherein the
speed estimate controller adjusts K.sub.I and K.sub.P according to
a reciprocal of the square of the stator or rotor flux modulus.
6. The motor drive system of claim 5, further comprising bypass
switches operative to selectively bypass the switching system by
connecting the motor leads to the power source according to a
bypass control signal; and a bypass control component receiving the
rotor speed estimate from the speed estimate controller and
providing the bypass control signal to bypass the switching system
when the rotor speed estimate is greater than a second
threshold.
7. The motor drive system of claim 4, further comprising bypass
switches operative to selectively bypass the switching system by
connecting the motor leads to the power source according to a
bypass control signal; and a bypass control component receiving the
rotor speed estimate from the speed estimate controller and
providing the bypass control signal to bypass the switching system
when the rotor speed estimate is greater than a second
threshold.
8. The motor drive system of claim 1: wherein the motor startup
control system computes one of a stator flux modulus and a rotor
flux modulus; wherein the speed estimate controller is a
proportional integral (PI) controller with proportional and
integral gains K.sub.I and K.sub.P, respectively; and wherein the
speed estimate controller adjusts K.sub.I and K.sub.P according to
a reciprocal of the square of the stator or rotor flux modulus.
9. The motor drive system of claim 8, further comprising bypass
switches operative to selectively bypass the switching system by
connecting the motor leads to the power source according to a
bypass control signal; and a bypass control component receiving the
rotor speed estimate from the speed estimate controller and
providing the bypass control signal to bypass the switching system
when the rotor speed estimate is in a third speed range.
10. The motor drive system of claim 1, wherein at least one gain
value in the speed estimate controller is adjusted at least in part
according to one of a stator flux modulus and a rotor flux
modulus.
11. A control system for controlling the speed of an electric
motor, comprising: a speed estimate controller providing a rotor
speed estimate according to a controller error input; a hybrid
model reference adaptive system (MRAS) component, including a
torque-based MRAS component providing a first error term based on a
calculated torque value and an estimated torque value, and a rotor
flux-based MRAS component providing a second error term based on a
calculated rotor flux and an estimated rotor flux; an error
selector operatively coupled with the hybrid MRAS component and
with the speed estimate controller to provide the error input to
the speed estimate controller, the error selector providing the
first error term as the controller error input when the rotor speed
estimate is in a first speed range and providing the second error
term as the controller error input when the rotor speed estimate is
in a second speed range; and a motor controller providing a
controller output for controlling the motor speed according to a
desired speed profile and according to the rotor speed
estimate.
12. The control system of claim 11, wherein the first speed range
is from zero to about 80% of the rated full speed of the motor.
13. The control system of claim 11, wherein the control system
evaluates stator equations to derive a calculated rotor flux
according to current and voltage feedback values, and evaluates
rotor equations to derive an estimated rotor flux according to
current and voltage feedback values and according to the rotor
speed estimate, wherein the torque-based MRAS component computes a
calculated torque value according to the calculated rotor flux,
computes an estimated torque value according to the estimated rotor
flux, and provides the first error term as the difference between
the calculated and estimated torque values, and wherein the rotor
flux-based MRAS component provides the second error term as a
vector product of the calculated rotor flux and the estimated rotor
flux.
14. The control system of claim 11, wherein the control system
computes one of a stator flux modulus and a rotor flux modulus,
wherein the speed estimate controller is a proportional integral
(PI) controller with proportional and integral gains K.sub.I and
K.sub.P, respectively, and wherein the speed estimate controller
adjusts K.sub.I and K.sub.P according to a reciprocal of the square
of either the stator flux modulus or the rotor flux modulus.
15. The control system of claim 11, wherein at least one gain value
in the controller is adjusted according to a stator flux modulus or
a rotor flux modulus.
16. A hybrid model reference adaptive system (MRAS) motor speed
estimation system for estimating the speed of an electric motor,
comprising: a speed estimate controller providing a rotor speed
estimate according to a controller error input; a torque-based MRAS
component providing a first error term based at least partially on
a calculated torque value and an estimated torque value; a rotor
flux-based MRAS component providing a second error term based at
least partially on a calculated rotor flux and an estimated rotor
flux; and an error selector providing the error input to the speed
estimate controller according to the first error term when the
rotor speed estimate is in a first speed range and providing the
error input according to the second error term when the rotor speed
estimate is in a second speed range.
17. The motor speed estimation system of claim 16, wherein the
torque-based MRAS component computes the calculated torque value
and the estimated torque value, and provides the first error term
as the difference between the calculated and estimated torque
values, and wherein the rotor flux-based MRAS component provides
the second error term as a vector product of the calculated rotor
flux and the estimated rotor flux.
18. The motor speed estimation system of claim 16, wherein the
speed estimate controller is a proportional integral (PI)
controller with proportional and integral gains K.sub.I and
K.sub.P, respectively, and wherein the speed estimate controller
adjusts K.sub.I and K.sub.P according to either the stator flux
modulus or the rotor flux modulus.
19. A method of controlling the speed of an electric motor, the
method comprising: providing a rotor speed estimate according to a
controller error input; providing a controller output according to
the rotor speed estimate and according to a desired speed profile;
controlling the motor speed according to the controller output;
computing a first error term at least partially according to a
calculated torque value and an estimated torque value; computing a
second error term at least partially according to a calculated
rotor flux and an estimated rotor flux; and providing the
controller error input according to the first error term when the
rotor speed estimate is in a first speed range and providing the
error input according to the second error term when the rotor speed
estimate is in a second speed range.
20. The method of claim 19, further comprising adjusting at least
one gain factor of the controller at least in part according to a
stator flux modulus or a rotor flux modulus.
Description
REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of, and claims priority
to and the benefit of, co-pending U.S. patent application Ser. No.
11/375,800, filed Mar. 14, 2006, entitled SYSTEM AND METHOD FOR
MOTOR SPEED ESTIMATION USING HYBRID MODEL REFERENCE ADAPTIVE
SYSTEM, the entirety of which is hereby incorporated by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to electric
induction motors and more particularly to estimating motor speed
using hybrid model reference adaptive systems.
BACKGROUND OF THE INVENTION
[0003] Motor control systems are widely used to control various
aspects of motor performance in a broad spectrum of applications in
which electric motors drive loads. Induction motors are
asynchronous AC motors having a stator with stator windings
providing a rotating AC stator field, with a rotor attached to the
motor shaft to rotate within the stator field. Induction motors
generally include a so-called squirrel cage rotor with the rotor
rotating at a speed less than the rotational speed of the rotating
stator field. The rotation of the stator magnetic field induces a
current in the rotor conductors, in turn creating a rotor magnetic
field that causes the rotor to turn in the direction the stator
field is rotating. For many electric motor applications, control of
the motor speed is important, particularly where the shaft load
varies. In this regard, speed control during startup is
particularly important in many motor control applications.
[0004] To regulate the motor performance according to a desired
speed, it is necessary to measure or estimate the actual rotational
speed of the rotor at any given time. In certain induction motor
control architectures, moreover, soft-starters are used to energize
the stator windings during startup, with the soft startup controls
being bypassed once the motor reaches the normal operating speed,
in order to minimize steady state heat generation. Many
conventional motor control systems employ some form of tachometer
or other sensor device mechanically coupled to the motor shaft to
produce a feedback signal representing the motor speed, to
facilitate closed loop startup speed control. However, such
external sensors add cost to the motor drive system, and require
maintenance.
[0005] Sensorless systems have been proposed and introduced, often
employing model-based estimation or speed estimation based on
measuring stator current harmonic content. However, actual motor
startup times using these systems often varies with line voltage
and motor load, which makes it difficult to coordinate motor
startup with other equipment in various automated systems.
Model-based approaches in particular suffer from variance in motor
parameters and weak signals during motor startup.
Stator-current-harmonics-based approaches require complex signal
processing and the measured harmonics are related to the rotor
structure, whereby the speed estimate cannot be updated quickly.
Thus, there is a continuing need for improved motor controls and
sensorless speed estimation techniques and systems for motor
control applications, particularly for controlling motor speeds
during startup.
SUMMARY OF INVENTION
[0006] One or more aspects of the invention are now summarized to
facilitate a basic understanding of the invention, wherein this
summary is not an extensive overview of the invention, and is
intended neither to identify certain elements of the invention, nor
to delineate the scope thereof. The primary purpose of the summary,
rather, is to present some concepts of the invention in a
simplified form prior to the more detailed description that is
presented hereinafter. The present invention involves hybrid Model
Reference Adaptive System (MRAS)-based speed estimation and motor
control techniques that are particularly useful in controlling AC
induction motor speed during startup without the need for
tachometers or other speed sensors. The invention employs a
torque-based MRAS error term over a first speed range, such as from
zero to about 80% of full speed, and then a rotor-flux-based MRAS
error term for a second speed range, wherein the hybrid MRAS
components and closed loop controller are used in providing an
estimated speed that is compared with a threshold to determine when
the speed estimation switches from torque to flux-based MRAS. In
certain embodiments, one of the MRAS error terms is provided to a
regulating speed estimate controller, such as a
proportional-integral (PI) controller, where the speed estimate
controller generates the speed estimate with at least one speed
estimate controller gain factor (e.g., K.sub.I and/or K.sub.P)
being adjusted inversely with respect to the stator or rotor flux
modulus, wherein the hybrid MRAS technique is less sensitive to
motor parameter inaccuracy or variations compared with previous
sensorless motor startup approaches, while retaining the cost and
maintenance advantages of sensorless control.
[0007] In accordance with one or more aspects of the invention, a
motor drive system is provided for operating an induction motor.
The drive system includes a switching system for selectively
coupling the motor leads to an AC power source, as well as a motor
startup control system for controlling and estimating the motor
speed during startup. The motor startup control system includes a
hybrid MRAS component, a motor controller with an output driving a
switch control circuit and speed estimate controller providing a
rotor speed estimate, with an error selector to provide a speed
estimate controller error input from a torque-based MRAS component
when the rotor speed estimate is less than or equal to a first
threshold or from a rotor flux-based MRAS component when the
estimated speed is above the threshold. The torque-based MRAS
component provides a first error term representing a difference
between a calculated torque value and an estimated torque value,
while the flux-based MRAS component provides a second error term
based on a difference between a calculated rotor flux and an
estimated rotor flux, which can be computed as a vector product.
The speed estimate controller provides the speed estimate during
startup according to the selected controller error input, with one
or more speed estimate controller gain factors being adapted or
adjusted based on the stator or rotor flux modulus.
[0008] In one embodiment, the control system evaluates stator
equations to derive a calculated rotor flux according to current
and voltage feedback values, and evaluates rotor equations to
derive an estimated rotor flux according to current feedback values
and according to the most recent rotor speed estimate. The
torque-based MRAS component computes a calculated torque value
according to the calculated rotor flux and computes an estimated
torque value according to the estimated rotor flux, and then
provides the first error term as the difference between the
calculated and estimated torque values. In this example, the rotor
flux-based MRAS component provides the second error term as a
vector product of the calculated rotor flux and the estimated rotor
flux from the stator and rotor equations. The motor drive system
may also include bypass switches to selectively to connect the
motor leads to the AC power source bypassing the switching system,
with a bypass controller to activate the bypass switches when the
rotor speed exceeds a second threshold value.
[0009] Further aspects of the invention provide a system for
controlling the speed of an electric motor during startup. The
system is comprised of a speed estimate controller providing a
rotor speed estimate according to a controller error input and a
motor controller providing a controller output for controlling the
motor speed during startup according to a desired startup speed
profile and according to the estimated motor speed. The system
further includes a hybrid model reference adaptive system (MRAS)
component, with a torque-based MRAS component providing a first
error term representing a difference between a calculated torque
value and an estimated torque value, and a rotor flux-based MRAS
component providing a second error term representing a difference
between a calculated rotor flux and an estimated rotor flux. An
error selector is operatively coupled with the hybrid MRAS
component and with the speed estimate controller to provide the
error input to the speed estimate controller, where the first error
term is provided as the controller error input when the rotor speed
estimate is less than or equal to a first threshold and the second
error term is provided as the controller error input when the rotor
speed estimate is greater than the first threshold.
[0010] Other aspects of the invention relate to a hybrid model
reference adaptive system (MRAS) motor speed estimation system for
estimating the speed of an electric motor. The hybrid MRAS system
includes a speed estimate regulator or controller, torque and flux
based MRAS components, and an error selector, where the speed
estimate controller provides a rotor speed estimate according to a
controller error input, and the controller includes one or more
gain factors that are adjusted at least partially based on a stator
or rotor flux modulus. The torque-based MRAS component provides a
first error term representing a difference between a calculated
torque value and an estimated torque value, and the rotor
flux-based MRAS component provides a second error term representing
a difference between a calculated rotor flux and an estimated rotor
flux. The error selector provides the error input to the speed
estimate controller according to the first error term when the
rotor speed estimate is in a first speed range and provides the
error input according to the second error term when the rotor speed
estimate is in a second speed range.
[0011] Further aspects of the invention relate to a method for
controlling the speed of an electric motor. The method includes
providing a rotor speed estimate according to a controller error
input, computing a first error term as the difference between a
calculated torque value and an estimated torque value, computing a
second error term as a vector product of a calculated rotor flux
and an estimated rotor flux, and providing the error input to the
controller according to the first error term when the rotor speed
estimate is in a first speed range and providing the error input
according to the second error term when the rotor speed estimate is
in a second speed range. In certain embodiments, the method also
includes adjusting at least one gain factor of the controller at
least in part according to a stator or rotor flux modulus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The following description and drawings set forth certain
illustrative implementations of the invention in detail, which are
indicative of several exemplary ways in which the principles of the
invention may be carried out. The illustrated examples, however,
are not exhaustive of the many possible embodiments of the
invention. Other objects, advantages and novel features of the
invention will be set forth in the following detailed description
of the invention when considered in conjunction with the drawings,
in which:
[0013] FIG. 1 is a detailed schematic diagram illustrating an
exemplary motor drive system for driving an induction motor,
including a hybrid MRAS-based startup control system for
controlling and estimating motor speed during startup and a bypass
system for operating the motor at full speed;
[0014] FIG. 2 is a schematic diagram illustrating further details
of the speed estimation system of the MRAS-based startup control
system of FIG. 1;
[0015] FIG. 3 is a graph of motor speed vs. time during startup,
showing control of the motor speed in first and second ranges in
the system of FIGS. 1 and 2 according to a threshold;
[0016] FIG. 4 is a flow diagram illustrating an exemplary method
for motor startup control and speed estimation using a first error
term from a torque-based MRAS system in a first speed range and
using a second error term from a rotor-flux-based MRAS in a second
speed range; and
[0017] FIGS. 5A-5C are detailed flow diagrams illustrating
exemplary speed estimate update operation using a hybrid torque and
rotor flux-based MRAS system.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Referring now to the figures, several embodiments or
implementations of the present invention are hereinafter described
in conjunction with the drawings, wherein like reference numerals
are used to refer to like elements throughout, the invention is
hereinafter illustrated and described in the context of startup
control for a three-phase induction motor, although the invention
is not limited to the illustrated examples and can be employed in
controlling AC motors of any number of phases. The embodiments
illustrated below employ closed-loop control of motor speed during
startup, in which an error value used by a regulating controller is
obtained using a torque-based MRAS component for a first range of
speeds, and then the error is obtained for a second speed rage
using a rotor flux-based MRAS component, thereby providing hybrid
MRAS speed estimation and control. The inventors have found that
the hybrid MRAS approach can be easily implemented in existing
motor control apparatus, including soft starters and other motor
control devices, and may facilitate uniform speed tracking
performance throughout a motor startup process wherein certain
motor control drives can be upgraded to implement various features
of the invention by software updates in order to implement the
hybrid MRAS concepts illustrated and described herein. For
instance, where the stator resistance is known or can be measured,
the hybrid MRAS systems can be implemented to yield good speed
estimation and control performance to facilitate linear ramp
control or any other form of desired speed control profile desired
by a user.
[0019] While not wishing to be tied to any particular theory, the
inventors take advantage of the fact that the flux linkages of a
motor can be calculated from a set of stator equations and a set of
rotor equations, as shown in FIGS. 5B and 5C below, wherein the
stator equations do not involve motor speed and can thus be
regarded as a reference model. The rotor equations, however,
include speed and are thus used as an adjustable model, where the
motor speed (e.g., rotor speed) is a parameter in the adjustable
model. Moreover, the inventors have appreciated that the estimated
torque changes proportionally with the speed estimation error
throughout a significant major portion of the startup process,
i.e., over a first speed range, wherein a torque-based MRAS
component can be successfully used to provide a closed loop
control/estimation error term in this first range of speeds.
However, the inventors have further found that this relationship
does not hold for higher speeds (e.g., in a second speed range),
wherein the speed estimation error has almost no impact on rotor
flux estimation until the motor speed is in this second (higher)
range. The invention uses these discoveries in providing control
based on the torque MRAS for low speeds and then using flux-based
MRAS components to generate the error term in a second higher speed
range, which can be used in motor startup control for implementing
any desired speed control profile or operating mode, including but
not limited to current limiting mode, soft start mode, current
limit with kickstart mode, soft start with kickstart mode, etc.,
for both no load and loaded operation. The exemplary hybrid MRAS
techniques illustrated and described below employ a threshold speed
value defining the boundary between the first and second speed
ranges, where any suitable threshold value may be used. In one
example, the threshold may be set at about 80% of the motor's full
speed, with torque-based MRAS being used for 0 to about 80% of
rated speed, and rotor-flux-based MRAS being employed for the
second 80%-100% speed range, where the estimated speed is used for
switching between the two control ranges.
[0020] In these examples, moreover, the adaptive regulator or
controller gain is auto-adjusted to be inversely proportional to
the square of the stator or rotor flux modulus. In the illustrated
examples below, leakage inductance is removed from the reference
model in the torque-based stage, where the calculated torque is
essentially accurate since stator resistance R.sub.S is the only
motor parameter in the reference model, and Rs has been found to be
fairly constant during the startup process. The stator equations
yield the stator flux term .psi..sub.S and the proportional and
integral gains K.sub.P and K.sub.I of a PI type controller are
adjusted based on the reciprocal of the square of the stator flux
1/|.psi..sub.S|.sup.2 (or based on the reciprocal of the square of
the rotor flux 1/|.psi..sub.r|.sup.2) such that the adjustment of
the controller gains is essentially free of motor parameter
variations since its calculation involves only stator resistance
Rs, which can be considered constant during startup, where R.sub.S
can be measured or estimated using any suitable techniques in
constructing the stator equations. In the rotor-flux-based control
range, the motor is approaching full speed, wherein the remaining
motor parameters approach normal values, by which the speed
estimation provides an accurate speed value until well after the
motor transitions into steady-state operation.
[0021] FIGS. 1 and 2 show an exemplary motor drive system 2 for
driving a polyphase induction motor 4 using power from a three
phase AC power source 6. The system 2 includes a switching system
10 with three pairs of SCR switching devices 10a, 10b, 10c coupled
between power supply lines A, B, and C of the AC power source 6 and
leads R, S, and T of the motor 4, respectively, with the individual
switching devices operating to selectively couple a corresponding
motor lead to the AC power source according to a corresponding
switch control signal 22. In this manner portions of the power
supply voltages can be applied to the motor windings to
generate/create motor phase currents I.sub.R, I.sub.S, and I.sub.T.
Each phase coupling also includes a bypass switch 12a, 12b, and
12c, respectively, to selectively bypass the switching system 10
and the switch pairs 10a, 10b, and 10c thereof by connecting the
motor leads R, S, and T to the AC power source lines A, B, and C
according to a bypass control signal 16 from a bypass control
component 14. The switching system 10 is operated by a hybrid
MRAS-based startup control system 20 for controlling motor speed
during startup, which includes a hybrid MRAS-based speed estimation
system 20a for providing a speed estimate .omega.'r using torque
and rotor flux-based MRAS components 34 and 36. While illustrated
with SCR type switches 10a-10c, any type of electrical switching
devices may be used in the system 10 and for the bypass switches
12.
[0022] The startup control system 2 and the speed estimation system
20a thereof can be implemented as any suitable hardware, software,
and/or combinations thereof, where the control system 20 includes a
switch control circuit 24 with circuitry for providing a plurality
of switch control signals 22 to control operation of the switching
devices 10a, 10b, and 10c of the switching system 10 during startup
of the motor 4 according a control output signal 25a from a motor
controller 25, which can be any suitable controller or regulator 25
by which the motor is controlled according to drive process
feedback 18 and an estimated motor speed signal .omega.'r from the
speed estimation system 20a. In addition, the motor controller 25
can be operated in a number of different modes or control schemes,
including controlling torque, speed, etc., wherein the exemplary
motor controller 25 operates to control the speed of the induction
motor 4 during startup according to a user defined startup speed
profile 28. The switch control circuit 24 provides appropriate
switching signals 22 to operate the motor 4 in accordance with the
motor control output 25a, which may include pulse width modulation
or other switch timing control.
[0023] The hybrid MRAS speed estimation system 20a includes a PI
controller 26 providing the speed estimate .omega.'r in radians per
second, revolutions per minute, or other suitable units, which is
indicative of the speed of the motor 4 at any given time. In this
regard, the speed estimation may be performed at a rather high
sampling rate such as every 100 us in one example, whereas the
speed control of motor controller 25 may in certain embodiments be
carried out at a slower rate, such as every 50 ms. The PI
controller 26 in the speed estimation system 20a provides the speed
estimate .omega.'r during startup and thereafter according to a
controller error input e. The speed estimation system 20a also
includes a hybrid model reference adaptive system (MRAS) component
38 with a torque-based MRAS component 34 providing a first error
term .epsilon..sub.1 representing the difference or error between a
calculated torque value 34b (torque T in FIG. 2), and an estimated
torque value 34a (T' in FIG. 2). The hybrid MRAS component 38 also
includes a rotor flux-based MRAS component 36 providing a second
error term .epsilon..sub.2 representing the difference or error
between a calculated rotor flux 36b (.psi..sub.rd, .psi..sub.rq in
FIG. 2) and an estimated rotor flux 36a (.psi.'.sub.rd,
.psi.'.sub.rq in FIG. 2), which may be computed as a vector product
with the calculated and estimated polyphase flux terms
.psi..sub.rd, .psi..sub.rq and .psi.'.sub.rd, .psi.'.sub.rq being
represented in the arbitrary dual axis reference frame (d-q frame).
These two MRAS components 34 and 36 provide the respective error
terms .epsilon..sub.1 and .epsilon..sub.2 to an error selector 40
providing a comparison function 44 and a switching function 46
(FIG. 2) to provide the error input e to the speed estimate PI
controller 26 as the first error term .epsilon..sub.1 when the
rotor speed estimate .omega.'r is less than or equal to a first
threshold TH1 42 (a first speed range) or as the second error term
.epsilon..sub.2 when the rotor speed estimate is greater than the
threshold 42 (a second speed range). Any threshold TH1 42 can be
used, for example, about 80% of the rated full speed of the motor 4
in one embodiment.
[0024] The speed estimate controller 26 operates in generally
continuous fashion to provide the motor speed estimate .omega.'r,
with the switching system 10 providing feedback current and voltage
values 18 from the motor drive process to the control system 20,
such as phase or line voltages, stator current values, etc. The
speed estimation system 20a includes stator equations 32 and rotor
equations 30, as well as known or estimated values (e.g.,
resistances, inductances, number of poles P, etc.) for computing
calculated and estimated flux and torque values using the current
and voltage feedback 18 as inputs, where the calculated and
estimated flux values .psi. may also be represented in the d-q
frame format. As shown in FIG. 1, the rotor speed estimate
.omega.'r is provided by the Pi speed estimate controller 26 to the
rotor equations 30, and also to the motor controller 25 and the
bypass control component 14, which selectively provides the bypass
control signal 16 to bypass the switching system 10 when the rotor
speed estimate .omega.'r is greater than a second threshold TH2
14a. As best shown in FIG. 2, moreover, the solutions X to the
stator equations 30 (e.g., calculated rotor flux values .psi.rd,
.psi.rq) are provided as inputs to the torque-based MRAS component
34 and to the rotor-flux based MRAS component 36. In addition, the
reciprocal of the square of the stator flux modulus
1/|.psi..sub.S|.sup.2 (e.g., or the reciprocal of the square of the
rotor flux modulus 1/|.psi..sub.r|.sup.2) is provided from the
stator equations 32 to the speed estimate controller 26 for
adjustment of the Pi controller gains K.sub.I and K.sub.P.
[0025] In operation, the speed estimation system 20a in the motor
startup control system 20 evaluates the stator equations 32 to
derive a calculated rotor flux 36b (.psi..sub.rd, .psi..sub.rq in
the d-q reference frame, as shown best in FIG. 2) according to the
current and voltage feedback values 18, and evaluates the rotor
equations 30 to derive an estimated rotor flux 36a (.psi.'.sub.rd,
.psi.'.sub.rq) according to the feedback values 18 and according to
the rotor speed estimate .omega.'r. The system 20a also computes
either the stator flux modulus |.psi..sub.S|.sup.2 or the rotor
flux modulus |.psi..sub.r|.sup.2. The torque-based MRAS component
34, in turn computes a calculated torque value T according to the
calculated rotor flux 36b (.psi..sub.rd, .psi..sub.rq) and computes
an estimated torque value T' according to the estimated rotor flux
36a (.psi.'.sub.rd, .psi.'.sub.rq). The torque-based MRAS component
34 then provides the first error term .epsilon..sub.1 as the
difference between the calculated and estimated torque values 36b
and 36a, respectively (.epsilon..sub.1=T-T'). The rotor flux-based
MRAS component 36 provides the second error term .epsilon..sub.2 as
a vector product of the calculated rotor flux 36b (.psi..sub.rd,
.psi..sub.rq) and the estimated rotor flux 36a (.psi.'.sub.rd,
.psi.'.sub.rq).
[0026] Referring also to FIG. 3, a plot 52 is provided in a graph
50 showing motor speed .omega.'r vs. time t, wherein the system 2
provides for torque MRAS based speed estimation and speed control
using the first error term .epsilon..sub.1 in a first speed range
54 from zero to a first threshold speed value TH1 (threshold 42 in
FIGS. 1 and 2). When the estimated speed .omega.'r exceeds the
threshold TH1 in a second speed range 56, the speed estimate
controller 26 uses the second error term .epsilon..sub.2 (rotor
flux-based MRAS control) until the speed .omega.'r exceeds the
second (bypass) threshold TH2 (TH2 14a in FIG. 1), at which time
the bypass control 14 provides the bypass control signal 16 to
activate bypass switches 12a-12c, wherein the bypass threshold TH2
is typically above the first threshold TH1, and preferably near the
full speed FS rating for the motor 4. The control system 20 can be
employed for dual range control and/or speed estimation techniques
using a hybrid MRAS approach to achieve a substantially uniform
speed tracking performance throughout the startup speed range
without the need for external tachometers or other sensors, and
without suffering from noise associated with conventional harmonic
measurement estimation techniques. Thus, the system 20 facilitates
advanced sensorless control of startup speed profile in soft
starters and other motor control applications.
[0027] Referring now to FIGS. 4-5C, the motor control and speed
estimation aspects of the hybrid MRAS approach are further
illustrated in a flow diagram 70 in FIG. 4 showing an exemplary
method for motor startup control and speed estimation using a first
error term .epsilon..sub.1 from a torque-based MRAS system (e.g.,
34 above) in a first speed range (range 54 in FIG. 3) and using a
second error term .epsilon..sub.2 from a rotor-flux-based MRAS (36)
in a second speed range (56). Although illustrated as a single
flow, it will be appreciated that the speed estimation and motor
control loops can be processed separately at different update
rates, for instance, wherein the speed control loop will typically
be processed at a lower rate than the speed estimation loop.
Moreover, the hybrid MRAS-based speed estimation process can
continue operating even after the startup process is complete
(e.g., during bypass operation), in order to provide sensorless
speed value feedback for steady state motor control or data
acquisition. The process 70 begins at 72, in which the rotor speed
is estimated using a first error term .epsilon..sub.1 from a
torque-based MRAS system (MRAS 34), and the motor phase switches
(e.g., switches 10a, 10b, and 10c in FIG. 1) are controlled at 74
according to the desired motor startup speed profile (speed profile
28 in FIG. 1) and the speed estimate .omega.'r. A determination is
made at 76 as to whether the estimated rotor speed .omega.'r is
greater than the threshold TH1 (e.g., greater than about 80% of
rated speed in one example). If not (NO at 76), the method 70
returns to 74 to continue motor control and torque-based MRAS speed
estimation according to error term .epsilon..sub.1. Once the speed
.omega.'r exceeds TH1 (YES at 76), the second speed range (e.g.,
range 56 in FIG. 3) is entered, and the startup process continues
to 78 in FIG. 4, where the rotor speed .omega.'r is estimated using
a second error term E2 from a rotor flux-based MRAS system (MRAS
36) and the motor switching is controlled according to the desired
speed profile and the speed estimate .omega.'r. The speed estimate
.omega.'r is compared to a second (e.g., bypass) threshold TH2 at
80 (e.g., bypass threshold 14a in FIG. 1), and if the speed is
still in the second range (NO at 80), the method 70 returns to 78
to continue rotor flux-based MRAS speed estimation according to
error term .epsilon..sub.2 and corresponding motor speed control.
When the speed estimate .omega.'r exceeds TH2 (YES at 80), the
startup control switches are bypassed at 82 and the motor leads are
connected to the power leads (e.g., bypassed) to complete the motor
startup process 70 at 84.
[0028] FIGS. 5A-5C illustrate an example of the speed estimate
update operation 100 using a hybrid torque and flux-based MRAS
system 20a. The speed estimate update process 100 begins at 102,
wherein the most recent current and voltage feedback values are
obtained at 104 for use at 106 and 108 in evaluating or solving
stator and rotor equations (e.g., equations 32 and 30 in the
controller 20 of FIG. 1 above). At 106, the stator equations are
evaluated using the feedback values to obtain calculated rotor flux
and torque values .psi..sub.rd, .psi..sub.rq 36b and T 34b,
respectively. As best shown in FIG. 5B, the stator equations 32 are
evaluated at 106a using the feedback values 18 for the motor
terminal voltages V.sub.D, V.sub.Q and stator currents I.sub.D,
I.sub.Q as well as the mutual inductance L.sub.m, the rotor and
stator inductances L.sub.r and L.sub.s, and the stator resistance
R.sub.s, to obtain the calculated rotor flux value .psi..sub.rd,
.psi..sub.rq, where the values for L.sub.m, L.sub.r, L.sub.s, and
R.sub.s can be measured values or may be estimated or otherwise
specified based on the particular motor 4 being controlled. The
torque-based MRAS component 34 then computes the calculated torque
value T 34b at 106b based on the calculated rotor flux values
.psi..sub.rd, .psi..sub.rq 36b, the feedback values 18, and the
stator resistance R.sub.S. Referring back to FIG. 5A, the rotor
equations 30 are evaluated at 108 using the current feedback values
18 and the most recent rotor speed estimate .omega.'r to obtain
estimated rotor flux and torque values 36a and 34a (.psi.'.sub.rd,
.psi.'.sub.rq, and T' in FIG. 1). As best shown in FIG. 5C, the
rotor equations 30 employ the feedback values 18 (I.sub.D, and
I.sub.Q) along with the speed estimate .omega.'r and the motor
parameters L.sub.m, L.sub.r, and R.sub.r at 108a from which the
flux values 36a .psi.'.sub.rd, .psi.'.sub.rq can be computed. At
108b, the torque-based MRAS component 34 then computes the
estimated torque value T' using the motor parameters L.sub.m,
L.sub.r, and the estimated rotor flux values 36a .psi.'.sub.rd,
.psi.'.sub.rq.
[0029] Referring again to FIG. 5A, once the calculated and
estimated flux and torque values have been obtained from evaluation
of the stator and rotor equations 32 and 30 at 106 and 108,
respectively, the speed estimate update process 100 continues at
110, where the first error term .epsilon..sub.1 is computed (e.g.,
by the torque-based MRAS component 34) from the calculated and
estimated torque values T 34b and T' 34a, respectively, wherein
.epsilon..sub.1 is computed as T-T' in the illustrated embodiment.
At 112, the second error term .epsilon..sub.2 is computed (e.g., by
the flux-based MRAS component 36) from the calculated and estimated
rotor flux values .psi..sub.rd, .psi..sub.rq 36b and .psi.'.sub.rd,
.psi.'.sub.rq 36a, respectively. In this example, the second error
term .epsilon..sub.2 is computed as a vector product
.psi..sub.rq*.psi.'.sub.rd-.psi..sub.rd*.psi.'.sub.rq. At 113, a
flux modulus is calculated for use by the estimation controller,
which can be either the stator flux modulus |.psi..sub.S| or the
rotor flux modulus |.psi..sub.r|, The current speed is then
estimated at 114 using one of the error terms .epsilon..sub.1 and
.epsilon..sub.2, where the controller 26 (FIG. 1) generates a new
estimate of the speed .omega.'r based on the controller gain
parameters K.sub.P 26a and K.sub.I 26b (FIG. 1), the reciprocal of
the square of either the stator flux modulus 1/|.psi..sub.S|.sup.2
or the rotor flux modulus 1/|.psi..sub.r|.sup.2, and the controller
error input e (selected as either .epsilon..sub.1 or
.epsilon..sub.2 based on the current speed estimate .omega.'r from
the last update cycle), and the estimate update is completed at
116. In the illustrated example, the gain parameters K.sub.P 26a
and K.sub.I 26b are modified according to the flux modulus by the
modified PI control output equation
.omega.'r=(K.sub.P+(K.sub.I/S))*e/(|.psi..sub.S|.sup.2), where
e=.epsilon..sub.1 for .omega.'r less than or equal to TH1 and
e=.epsilon..sub.2 for .omega.'r greater than TH1. In this manner,
the controller 26 provides the motor speed estimate .omega.'r using
a dual range hybrid MRAS technique based on either torque or
flux-based MRAS components with K.sub.I and K.sub.P being modified
or adapted according to the reciprocal of the square of the flux
modulus.
[0030] The above examples are merely illustrative of several
possible embodiments of various aspects of the present invention,
wherein equivalent alterations and/or modifications will occur to
others skilled in the art upon reading and understanding this
specification and the annexed drawings. In particular regard to the
various functions performed by the above described components
(assemblies, devices, systems, circuits, and the like), the terms
(including a reference to a "means") used to describe such
components are intended to correspond, unless otherwise indicated,
to any component, such as hardware, software, or combinations
thereof, which performs the specified function of the described
component (i.e., that is functionally equivalent), even though not
structurally equivalent to the disclosed structure which performs
the function in the illustrated implementations of the invention.
In addition, although a particular feature of the invention may
have been disclosed with respect to only one of several
implementations, such feature may be combined with one or more
other features of the other implementations as may be desired and
advantageous for any given or particular application. Also, to the
extent that the terms "including", "includes", "having", "has",
"with", or variants thereof are used in the detailed description
and/or in the claims, such terms are intended to be inclusive in a
manner similar to the term "comprising".
* * * * *