Magnet management in electric machines

A magnet management method of controlling a ferrite-type permanent magnet electrical machine includes receiving and/or estimating the temperature permanent magnets; determining if that temperature is below a predetermined temperature; and if so, then: selectively heating the magnets in order to prevent demagnetization and/or derating the machine. A similar method provides for controlling magnetization level by analyzing flux or magnetization level. Controllers that employ various methods are disclosed. The present invention has been described in terms of specific embodiment(s), and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to commonly assigned U.S. patent application Ser. No. 14/064,547, entitled “SYSTEM AND METHOD FOR HEATING FERRITE MAGNET MOTORS FOR LOW TEMPERATURES”, currently pending, the contents which are incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

Embodiments of the invention relate generally to electrical machines and the heating of magnets in ferrite-type magnet motors to prevent demagnetization and, more particularly, to magnet management of these heating methodologies and/or motors that may be used in electric and/or hybrid electric vehicles, as well as other applications.

The usage of electrical machines in various industries has continued to become more prevalent in numerous industrial, commercial, and transportation industries over time. In an attempt to realize high performance in electric machines, the choice of using permanent magnet (PM) materials is becoming more popular for many applications. In such machines, the PMs can either replace electromagnets in traditional designs, or novel topologies can be developed to make the best use of the properties and characteristics of PMs.

One PM electrical machine topology that has been developed is referred to as “stator permanent magnet machines,” which are electrical machines that are designed such that the PMs in the machine are positioned on the stator. Stator permanent magnet machines can thus refer to, but are not limited to, permanent magnet flux switching machines, permanent magnet flux reversal machines, and doubly-salient permanent magnet machines. Another PM electrical machine topology that has been developed is referred to as “interior permanent magnet (IPM) machines,” which are electrical machines that are designed such that the PMs in the machine are embedded inside the laminations of a rotor. IPM machines can thus refer to IPM motors or generators widely used in a variety of applications, including aircraft, automobiles and industrial usage.

One issue that is taken into consideration when constructing and operating a PM electrical machine is demagnetization of the PMs. Depending on the type of PMs employed, demagnetization of the PMs can occur if the electrical machine is exposed to extremely high or extremely low temperatures. For example, if the PMs are rare earth magnets, exposure of the PMs to extremely high temperatures can make the PMs more susceptible to demagnetization. Conversely, if the PMs are ferrite magnets, exposure of the PMs to low temperatures (e.g., −40° to 60° C.) can make the PMs more susceptible to demagnetization.

It is recognized that the use of ferrite magnets in PM electrical machines can provide cost savings as compared to the use of rare earth magnets, and thus the use of ferrite magnets may be desirable in some PM electrical machines. While ferrite magnets are more prone to demagnetization at lower temperatures compared to rare earth magnets, they are less prone to demagnetization at higher temperatures than rare earth magnets. Thus, if solutions can be provided for preventing demagnetization of ferrite magnets at low temperatures, ferrite magnet PM machines can be a desirable alternative to rare earth magnet PM machines.

As a result, the aforementioned referenced patent application provides for various systems and methods for preventing the demagnetization of ferrite magnets in a PM machine. This leads to a ferrite magnet PM machine that is useable over a wider range of ambient temperatures and that exhibits improved resistance to corrosion and improved stability. The improved PM machine may then lead to enhanced opportunities for a wide range of applications including, for example, with vehicle applications.

Accordingly, there is an opportunity to improve upon the operation, for example, of vehicles (and in other applications) that include motors that utilize these ferrite-type magnet methods and systems in their PM machine(s).

BRIEF DESCRIPTION

The present invention overcomes at least some of the aforementioned drawbacks by providing a method of controlling a ferrite-type permanent magnet electrical machine that mitigates the degradation of machine performance due to demagnetization of the magnets at low temperatures. More specifically, the present invention is directed to a control module, or controller, that provides for magnet management instructions in various applications such as, but not limited, in electric or hybrid electric vehicles.

Therefore, in accordance with one aspect of the invention, a method of controlling a ferrite-type permanent magnet electrical machine, the method comprising: one of receiving and estimating a temperature of a plurality of permanent magnets; determining if the temperature is below a predetermined temperature; and if the temperature is below the predetermined temperature, at least one of: selectively heating the plurality of ferrite-type permanent magnets in order to prevent demagnetization of the plurality of permanent magnets; and derating the electrical machine.

In accordance with another aspect of the invention, a controller comprising programming instructions to: one of receive and estimate a temperature of a plurality of ferrite-type permanent magnets in an electrical machine; compare the temperature with a predetermined temperature; and send current injection information to an operating controller of the electrical machine, wherein the current injection information comprises instructions configured to prevent demagnetization of the plurality of ferrite-type permanent magnets.

In accordance with another aspect of the invention, a controller comprising programming instructions to: receive or estimate a back-emf of a ferrite-type permanent magnet machine, said ferrite-type permanent magnet machine having a plurality of ferrite-type permanent magnets; compare the received or estimated back-emf with a predetermined back-emf; and send current injection information to an operating controller of the ferrite-type permanent machine, wherein the current injection information comprises instructions configured to prevent demagnetization of the plurality of ferrite-type permanent magnets.

In accordance with another aspect of the invention, a method of controlling a ferrite-type permanent magnet electrical machine, the method comprising: one of receiving and estimating a magnetization level of a plurality of permanent magnets; determining if the magnetization level is above a predetermined level; and if the magnetization level is above the predetermined level, at least one of: selectively heating the plurality of ferrite-type permanent magnets in order to prevent demagnetization of the plurality of permanent magnets; and derating the electrical machine.

In accordance with another aspect of the invention, a controller comprising programming instructions to: inject one of a current or a voltage to a ferrite-type permanent magnet machine, said ferrite-type permanent magnet machine having a plurality of ferrite-type permanent magnets; estimate impedance based on the injecting; selectively heat the plurality of ferrite-type permanent magnets based on the estimated impedance; and limit current to the machine.

DETAILED DESCRIPTION

Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art with respect to the presently disclosed subject matter. The terms “first”, “second”, and the like, as used herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “a”, “an”, and “the” do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item, and the terms “front”, “back”, “bottom”, and/or “top”, unless otherwise noted, are used for convenience of description only, and are not limited to any one position or spatial orientation.

If ranges are disclosed, the endpoints of all ranges directed to the same component or property are inclusive and independently combinable (e.g., ranges of “up to about 25 wt. %,” is inclusive of the endpoints and all intermediate values of the ranges of “about 5 wt. % to about 25 wt. %,” etc.). The modified “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the degree of error associated with measurement of the particular quantity). Accordingly, the value modified by the term “about” is not necessarily limited only to the precise value specified.

As used herein, “ferrite-type magnet” means both ferrite-based magnets as well as types of magnets and/or magnet compositions' now known or later developed′ that exhibit temperature-related behaviors similar to the ferrite-based magnets discussed herein. For example, but not by limitation, certain embodiments of ferrite-type magnets could conceivably include magnets and/or magnet compositions that, in fact, contact no, or only trace amounts, of iron.

As used herein, “low temperature” means at or below temperatures that can make ferrite-type permanent magnets more susceptible to demagnetization. For example, but not by limitation, it could be in the range from about −40° C. to about 60° C. However, the low temperature may be different than the aforementioned range. For example, the range could differ for a variety of reasons including the motor size and configuration; pressure; motor application; and/or other factors.

As referenced above, the present invention is related and extends from aspects of commonly assigned U.S. patent application Ser. No. 14/063,547, entitled “SYSTEM AND METHOD FOR HEATING FERRITE MAGNET MOTORS FOR LOW TEMPERATURES”, the contents which are incorporated herein by reference in its entirety. In general, but not by limitation, this invention provides for further application of the methods and systems of the earlier invention. These applications include, but are not limited to, the operation of vehicles that may have one or more motors that have ferrite-type magnets therein.

Aspects of the present invention provide for a Magnet Management Module (MMM), or controller, that is configured to aid in the prevention of demagnetization of ferrite-type magnets at or during lower temperatures. The MMM may reside in a motor control module. The MMM introduces the concept of rotor or stator heating to ensure that the ferrite-type magnet temperature is above the demagnetizing temperature. The MMM has the magnet temperature as a controllable variable to ensure the magnets are not demagnetized. Demagnetization of the magnets can affect the operating flux density and field strength of the magnets of the ferrite-type magnet. Demagnetization can ultimately result in degraded motor performance and/or a destroyed motor. The MMM may observe the remanence and coercivity from at least one of the flux linkage and output torque of the motor.

Referring concurrently to theFIGS. 1-3, the figures illustrate a schematic diagram of a magnet management environment (FIG. 1) and two flowcharts (FIGS. 2 and 3) of methods of operation, respectively, according to aspects of the present invention. As shown, a magnet management module (MMM)10resides within a control module20that is used to operate a motor, or electrical machine,50that includes a plurality of ferrite-type magnets52therein. Depending on the application of the motor50, the environment may reside further within a vehicle60. Depending on the application, the MMM10receives instructions and/or information and sends instructions and/or information ultimately preventing the demagnetization of the magnets52due to low temperatures.

The MMM10may receive information including one of: temperature information12and/or flux, or magnetization, information18from the motor50and back-emf information14from an operating point control module30that is in communication with the motor50. The operating point control module30may be receiving at least one of current, voltage, and/or position information34and sending inverter signals32to the motor50. The inverter signals32sent to the motor50may be based, in part, on current injection information16.

The MMM10comprises a control module or controller that comprises programming instructions. The programming instructions comprise instructions to receive the temperature information12of the plurality of ferrite-type permanent magnets52residing in the electrical machine50. In addition, or alternatively, the MMM10may estimate a temperature of the plurality of ferrite-type permanent magnets52. The MMM10also may compare the received and/or estimated temperature to one, or more, predetermined temperatures. Based on the comparison, the MMM10sends current injection information16to the operating point control module30of the electrical machine50so as to prevent demagnetization of the magnets52.

As further shown, the back-emf information14from the operating point control module30may be derived from one of the current, voltage, and position34of the machine50. Contrastingly, the MMM10sends current injection information16to the operating point control module30that, in turn, leads to inverter signals32sent to the motor50so as to prevent demagnetization of the magnets52therein. The current injection information16includes instructions to selectively heat the plurality of ferrite-type permanent magnets52by at least one of: heating the magnets52for a fixed duration; heating the magnets52to a predetermined temperature; and, heating the magnets52to a predetermined rate of rise in temperature of the magnets52. In an embodiment, the current injection information16further comprises instructions to also derate operation of the motor50and/or delay operation of the motor50. One way to derate and/or delay operation is to limit the current to the motor50and, in the case of delaying operation, reduce the current to zero to the motor50.

Depending on the embodiment, there are a variety of instructions that can be sent so as to delay operation of the motor50so as to prevent demagnetization of the magnets52. For example, but without limitation, the delay in the operation of the motor50could be one or more of the following: simply inactivating operation of the motor50; delaying operation of the motor50for a set period of time; delaying operation of the motor50until a predetermined temperature in the magnets52is reached; and/or delaying operation of the motor50until a predetermined rate of rise in the temperature increase is reached.

Referring to the flowchart inFIG. 2, a method100for controlling a ferrite-type magnet electrical machine50is depicted. The method100may comprise receiving and/or estimating a temperature of the plurality of ferrite-type permanent magnets at110. The MMM10(FIG. 1) then, at112, determines if the received and/or estimated temperature is below a predetermined temperature. If at112, the answer is “NO” (i.e., the received and/or estimated temperature is not below the predetermined temperature), then the method could stop; or, alternatively, the MMM10may continue receiving and/or estimating temperatures of the magnets52(i.e., resume back to110).

If at112, the answer is “YES” (i.e., the received and/or estimated temperature is below the predetermined temperature), then the method100proceeds to one or both of114and116. At114, the method100continues with the MMM10selectively heating the magnets52so as to prevent demagnetization of the magnets52. Alternatively, or additionally, at116the method100continues with the MMM10derating the motor50. Upon the completion of either or both of114and116, the method100may end. Alternatively, the method100may optionally return either of continuing to receive and/or estimate temperatures of the magnets52(i.e.,110) and/or determining if the received and/or estimated temperature is below the predetermined temperature, at112.

In embodiments of the method100, the selective heating (i.e.,114) may further comprise one or more types of selective heating including heating for a predetermined period of time; heating until the magnets52reach a certain, predetermined setpoint temperature; and/or, heating until a predetermined rate of rise temperature rate is attained.

In embodiments of the method100, the determining (i.e.,112) may further comprise determining if a time delay is available prior to operation of the machine50in a situation where112answers “YES”. For example, the time delay may include a determination if the vehicle60user can, or cannot, accept immediate use of the motor50and vehicle60. If a time delay is not available, then the motor50may be derated (i.e.,116) or the motor50may be made inoperable, until the predetermined temperature is reached so as to not demagnetize the magnets52. Contrastingly, if a time delay is available, then the selective heating, at114, can take place. The derating at116may be accomplished by limiting the current available to the motor50.

Referring to110in the method100, there are a variety of ways to receive and/or estimate the magnet temperature.

According to an embodiment, the estimating of the temperature of the plurality of the permanent magnets52can include estimating by indirectly measuring the temperature of the magnets52. That is temperatures information of element(s) other than measuring the actual temperature of the magnets52proper may be obtained. From this indirect measurement, then the temperature of the magnets52may be estimated and/or derived. For example, the temperature of one or more of the lamination temperature, ambient temperature, housing temperature, and winding temperature may be measured. Additional information may optionally be used in addition to the indirect temperatures to derive an estimate of the magnet temperature. For example, a thermal model of the electrical machine50and/or information related to the heat in the machine50may be applied to the indirect temperature information of the machine50to then estimate the temperature of the magnets52.

According to an embodiment, the estimating of the temperature of the plurality of the permanent magnets52can additionally or alternatively include estimating based on one or more of the motor terminal quantities of the machine50. The motor terminal quantities may include, for example, voltage and/or current. For example, the machine50may be run with zero current as an open circuit spinning and short circuit testing.

According to an embodiment, the estimating of the temperature of the plurality of the permanent magnets52can additionally or alternatively include estimating the temperature using injected test voltage and/or test current to the machine50and then estimating the small signal impedance and/or estimating the magnetization level.

It should be apparent that in embodiments of the method, that various repeating of step(s) is possible without diverting from the invention. For example, the receiving, estimating, determining, and heating could each, or all, could be continually repeating, intermittently repeating, discretely occurring, automatically occurring, or operational by the user of the vehicle60and/or motor50.

Referring to the flowchart inFIG. 3, another embodiment of a method200for controlling a ferrite-type magnet electrical machine50is depicted. The method200may comprise receiving and/or estimating a magnetization level, or flux level, of the plurality of ferrite-type permanent magnets at210. The MMM10(FIG. 1) then, at212, determines if the received or estimated flux level is above a predetermined level. If at212, the answer is “NO” (i.e., the received and/or estimated flux level is not above the predetermined level), then the method could stop; or, alternatively, the MMM10may continue receiving and/or estimating flux levels of the magnets52(i.e., resume back to210).

If at212, the answer is “YES” (i.e., the received and/or estimated flux level is above the predetermined level), then the method200proceeds to one or both of214and216. At214, the method200continues with the MMM10selectively heating the magnets52so as to prevent demagnetization of the magnets52. Alternatively, or additionally, at216the method200continues with the MMM10derating the motor50. Upon the completion of either, or both, of214and216, the method200may end. Alternatively, the method200may optionally return either of continuing to receive and/or estimate flux levels of the magnets52(i.e.,210) and/or determining if the received and/or estimated flux level is above the predetermined level, at212.

In embodiments of the method200, the selective heating (i.e.,214) may further comprise one or more types of selective heating including heating for a predetermined period of time; heating until the magnets52reach a certain, predetermined setpoint temperature; and/or, heating until a predetermined rate of rise temperature rate is attained.

In embodiments of the method200, the determining (i.e.,212) may further comprise determining if a time delay is available prior to operation of the machine50in a situation where212answers “YES”. For example, the time delay may include a determination if the vehicle60user can, or cannot, accept immediate use of the motor50and vehicle60. If a time delay is not available, then the motor50may be derated (i.e.,216) or the motor50may be made inoperable, until the predetermined temperature is reached so as to not demagnetize the magnets52. Contrastingly, if a time delay is available, then the selective heating, at214, can take place. The derating at216may be accomplished by limiting the current available to the motor50.

Referring to210in the method200, there are a variety of ways to receive and/or estimate the flux level.

According to an embodiment, the estimating of the flux level of the plurality of the permanent magnets52can include estimating flux level based on one or more of the motor terminal quantities of the machine50. The motor terminal quantities may include, for example, voltage and/or current. For example, the machine50may be run with zero current as an open circuit spinning and short circuit testing.

According to an embodiment, the estimating of the flux level of the plurality of the permanent magnets52can additionally or alternatively include estimating the flux level using injected test voltage and/or test current to the machine50and then estimating the small signal impedance and/or estimating the flux level.

It should be apparent that in embodiments of the method, that various repeating of step(s) is possible without diverting from the invention. For example, the receiving, estimating, determining, and heating could each, or all, could be continually repeating, intermittently repeating, discretely occurring, automatically occurring, or operational by the user of the vehicle60and/or motor50.

Referring toFIG. 4depicting the variation of current limits imposed on the machine the permanent magnet flux linkage, or magnetization level, against temperature, andFIG. 5depicting impedance and current limits imposed on the machine against flux linkage in the machine, respectively.

AsFIG. 4illustrates at300, the current limit of a machine is shown as Imax. As shown, below a certain temperature, the current limit of the machine is derated (i.e., sloping graph). Similarly, the permanent magnet flux linkage, or magnetization level, is shown as λpm. The y-axis shows the received or estimated magnet temperature, as T.

AsFIG. 5illustrates at400, the current limits of the machine are a function of the magnetization level. Embodiments of only three possible current limits are shown at Ia, Ib, and Ic. The current limit may be virtually any function of the magnetization level. For example, at Icthe function may be linear; at Ibthe function may be curved downward; and, at Iathe function may be level and then linear below a certain value. As shown, a small signal impedance (voltage or current) may be injected. From the injection, the impedance may be estimated.

While the embodiments illustrated and described herein may be used with an electrical machine such as a traction motor in an electric vehicle or hybrid electric vehicle aspects of the present invention can be used in other electric machine applications without departing from the scope of the invention. For example and without limitation, the electric machine could be a stationary motor used in a cold temperature environment, a non-traction motor on a vehicle, and the like.

Therefore, in accordance with one aspect of the invention, a method of controlling a ferrite-type permanent magnet electrical machine, the method comprising: one of receiving and estimating a temperature of a plurality of permanent magnets; determining if the temperature is below a predetermined temperature; and if the temperature is below the predetermined temperature, at least one of: selectively heating the plurality of ferrite-type permanent magnets in order to prevent demagnetization of the plurality of permanent magnets; and derating the electrical machine.

In accordance with another aspect of the invention, a controller comprising programming instructions to: one of receive and estimate a temperature of a plurality of ferrite-type permanent magnets in an electrical machine; compare the temperature with a predetermined temperature; and send current injection information to an operating controller of the electrical machine, wherein the current injection information comprises instructions configured to prevent demagnetization of the plurality of ferrite-type permanent magnets.

In accordance with another aspect of the invention, a controller comprising programming instructions to: receive or estimate a back-emf of a ferrite-type permanent magnet machine, said ferrite-type permanent magnet machine having a plurality of ferrite-type permanent magnets; compare the received or estimated back-emf with a predetermined back-emf; and send current injection information to an operating controller of the ferrite-type permanent machine, wherein the current injection information comprises instructions configured to prevent demagnetization of the plurality of ferrite-type permanent magnets.

In accordance with another aspect of the invention, a method of controlling a ferrite-type permanent magnet electrical machine, the method comprising: one of receiving and estimating a magnetization level of a plurality of permanent magnets; determining if the magnetization level is above a predetermined level; and if the magnetization level is above the predetermined level, at least one of: selectively heating the plurality of ferrite-type permanent magnets in order to prevent demagnetization of the plurality of permanent magnets; and derating the electrical machine.

In accordance with another aspect of the invention, a controller comprising programming instructions to: inject one of a current or a voltage to a ferrite-type permanent magnet machine, said ferrite-type permanent magnet machine having a plurality of ferrite-type permanent magnets; estimate impedance based on the injecting; selectively heat the plurality of ferrite-type permanent magnets based on the estimated impedance; and limit current to the machine.

While only certain features of the invention have been illustrated and/or described herein, many modifications and changes will occur to those skilled in the art. Although individual embodiments are discussed, the present invention covers all combination of all of those embodiments. It is understood that the appended claims are intended to cover all such modification and changes as fall within the intent of the invention.