Dynamic Supply Current Estimation for Electric Motor Drives

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Solution Overview

Problem

Existing electric systems that employ active power management struggle to accurately estimate supply current in dynamic states without the need for additional current sensors, which adds cost and complexity.

Innovation Solution

The method involves using a state observer and a simplified plant model of the power circuit to estimate the power supply current based on input voltage and current, eliminating the need for a current sensor by simplifying the power input circuit model to include only a common mode choke and bulk capacitor, allowing for real-time dynamic supply current estimation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a current sensor is added to measure supply current directly, then measurement precision is improved, but device complexity and cost increase

Engineering Contradiction:
Improvesupply current measurement accuracyVSAvoidsystem complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent introduces an intermediary estimation approach using a state observer and simplified plant model to infer supply current from measurable quantities (input voltage and inverter current). This mediator (the estimation algorithm) bridges the gap between available measurements and the desired supply current information without requiring direct sensing of the supply current itself.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the physical current sensor (mechanical/electrical measurement device) with a computational estimation system. Instead of using a hardware sensor to directly measure supply current, the system uses mathematical models and algorithms (state observer, plant model) to compute the supply current from other measurements, substituting physical measurement with computational inference.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If a full detailed model of the power input circuit is used, then measurement precision is improved, but device complexity increases

Engineering Contradiction:
Improvesupply current estimation accuracyVSAvoidmodel complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts only the essential dynamic elements (common mode choke and bulk capacitor) from the complete power input circuit model, removing unnecessary complexity while retaining the critical dynamics needed for accurate supply current estimation. This selective extraction maintains estimation precision while simplifying the model structure.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of using a complex detailed model to achieve accuracy, the patent inverts the approach by using a simplified model that captures only the essential dynamics. The inversion lies in recognizing that fewer, more carefully selected model elements can achieve the same or better estimation accuracy by focusing on the dominant dynamic characteristics of the system.

Inventive Principle:
Principle #13The other way round (Inversion)

Data Source

PatentUS10833620B2Dynamic estimation of supply current for electric motor drive
Publication Date: 2020.11.10 STEERING SOLUTIONS IP HOLDING CORP
  • US10833620B2 patent drawing
  • US10833620B2 patent drawing
  • US10833620B2 patent drawing

AI summary

According to one or more embodiments of the technical solutions described herein, an example method includes determining an input voltage (Vinv) of an inverter in a power circuit. The method further includes measuring an input current (Ii) of the inverter. The method further includes estimating a power supply current from a power supply of the power circuit based on the input voltage and the input current using a state observer and a plant model of the power circuit, the power supply current estimated at a non-steady state. The method further includes performing an active power management of a motor that receives electric power via the inverter.