Motor Control System Voltage Fluctuation Suppression

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Solution Overview

Problem

Operating an inverter at a low carrier frequency to drive a motor with low revolutions and high torque results in significant fluctuations in torque and counterelectromotive force, leading to voltage degradation and reduced control performance in motor control systems that boost voltage using a boost converter.

Innovation Solution

A motor control system that includes a boost converter and an inverter, with a control unit that adjusts the boosted voltage to a higher value than the optimal when the carrier frequency is low, using an optimal boosted voltage map to maintain stability and suppress voltage fluctuations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the inverter is operated at a low carrier frequency to drive the motor with low revolutions and high torque, then the temperature rise in the switching elements is reduced, but the waveform of the output three-phase alternating-current electric power includes fluctuation components which deteriorate stability of motor control

Engineering Contradiction:
Improvetemperature of switching elementsVSAvoidstability of motor control
Core Design Contradiction:
TemperatureVSStability of the object's composition

Solution Approach 1:

The patent dynamically adjusts the carrier frequency based on operating conditions (motor speed and torque). When motor speed is low and torque is high, the carrier frequency is reduced to lower switching losses and temperature rise. When motor speed is high or torque is low, the carrier frequency is increased to maintain smooth waveforms and stable control. This dynamic adaptation resolves the contradiction between temperature reduction and control stability.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent changes the carrier frequency parameter according to the operating point of the motor. By monitoring motor speed and torque, the system selects appropriate carrier frequency values from a predefined map or range. This parameter change strategy allows the system to optimize between thermal performance and control quality depending on the current operating conditions.

Inventive Principle:
Principle #35Parameter changes

2Loss of energy

If the inverter is operated at a low carrier frequency when the motor has low revolutions and high torque, then the amount of heat generated by the switching elements is reduced, but the torque of the motor fluctuates significantly causing variations in counterelectromotive force which may induce fluctuations of voltage of the inverter

Engineering Contradiction:
Improveheat generated by switching elementsVSAvoidvoltage stability of the inverter
Core Design Contradiction:
Loss of energyVSStability of the object's composition

Solution Approach 1:

The system dynamically adjusts carrier frequency based on real-time motor operating conditions. When low speed and high torque conditions are detected, the carrier frequency is reduced to minimize switching losses and heat generation. The system accepts increased torque ripple as a trade-off, since the primary goal in this operating region is thermal management. This dynamic strategy resolves the contradiction between energy loss reduction and voltage stability.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements parameter changes in carrier frequency based on the operating map of the motor. By pre-defining optimal carrier frequency ranges for different speed-torque regions, the system can switch between frequency values to optimize performance. In low-speed high-torque regions, lower carrier frequencies are selected to reduce heat, while accepting the resulting voltage fluctuations as an acceptable trade-off for thermal management.

Inventive Principle:
Principle #35Parameter changes

3Loss of energy

If the boosted voltage of the boost converter is adjusted to a low value to optimize control performance, then the efficiency is improved, but when the carrier frequency is low the fluctuations in the counterelectromotive force significantly fluctuate the boosted voltage leading to degradation in the control performance of the boost converter

Engineering Contradiction:
Improvecontrol efficiencyVSAvoidcontrol performance of the boost converter
Core Design Contradiction:
Loss of energyVSStability of the object's composition

Solution Approach 1:

The patent dynamically adjusts the boosted voltage reference based on the carrier frequency and motor operating conditions. When the carrier frequency is low (indicating low-speed high-torque operation), the system increases the boosted voltage reference to compensate for the increased voltage fluctuations caused by torque ripple. This dynamic adjustment maintains boost converter control performance across different operating regions while accepting some increase in voltage reference as necessary for stability.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The system changes the boosted voltage parameter based on the operating conditions and carrier frequency. By monitoring the carrier frequency and motor torque, the system selects appropriate boosted voltage reference values. When low carrier frequency operation is detected, the boosted voltage reference is increased to maintain adequate voltage headroom and reduce the impact of counterelectromotive force fluctuations on control performance.

Inventive Principle:
Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system effectively suppresses voltage fluctuations and maintains control performance by increasing the boosted voltage to the system maximum when the carrier frequency is low, reducing torque and counterelectromotive force fluctuations.

Implementation Method 1

a boost converter configured to turn a plurality of first switching elements on/off at a predetermined carrier frequency to boost voltage of a battery and obtain boosted direct-current electric power

Methodology Applied
Scientific EffectElectromagnetic Induction: Electromagnetic Induction

Implementation Method 2

an inverter configured to turn a plurality of second switching elements on/off at a predetermined carrier frequency to convert the boosted direct-current electric power output from the boost converter to alternating-current electric power

Methodology Applied
Scientific EffectElectromagnetic Induction: Electromagnetic Induction

Implementation Method 3

converting the boosted direct-current electric power to alternating-current electric power and supply the alternating-current electric power to a motor

Methodology Applied
Scientific EffectElectromagnetic Induction: Electromagnetic Induction

Data Source

PatentEP3108578B1Motor control system
Publication Date: 2018.09.26 TOYOTA JIDOSHA KK
  • EP3108578B1 patent drawingFigure 1
  • EP3108578B1 patent drawingFigure 2A
  • EP3108578B1 patent drawingFigure 2B

AI summary

A motor control system (100) include an inverter (30) configured to convert boosted direct-current electric power output from a boost converter (20) to alternating-current electric power and supply the alternating-current electric power to an alternating current motor (40), and a control unit (60) configured to adjust boosted voltage of the boost converter (20). The control unit (60) includes an optimal boosted voltage map (67) which defines optimal boosted voltage for operating the alternating current motor (40) with a required number of revolutions and required torque, and a boosted voltage changing program (68) that sets boosted voltage (direct-current high voltage VH) of the boost converter (20) to a voltage which is higher than an optimal boosted voltage VHs when the carrier frequency Fc is a predetermined threshold value Fc0 or lower.