Motor drive device having failure detection function

A motor drive device includes an inverter configured to convert a DC voltage to an AC voltage by switching power devices, a current detector configured to detect a current output from the inverter, a current controller configured to generate a voltage command, a control signal generator configured to control switching of the power devices, a dynamic brake circuit provided with relays and configured to short-circuit an output side terminal of the inverter via resistances, a storage configured to store an initial current value and a first threshold value, and a failure determiner configured to compare a current value and an initial current value after a predetermined time has elapsed since detection of the initial current value, and determine presence or absence of a failure based on a result of comparing a change rate of the current value from the initial current value with the first threshold value.

This application is a new U.S. patent application that claims benefit of JP 2017-198612 filed on Oct. 12, 2017, the content of JP 2017-198612 is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a motor drive device, and more particularly relates to a motor drive device having a failure detection function.

2. Description of the Related Art

In the motor control device, a current controller which receives a current command sends a control signal for controlling (turning on/off) a power device to the power device, and controls the motor current to drive the motor. Further, a current detection circuit detects the motor current and feeds it back to the current controller, by which the current command and the actual motor current are compared, the current command is adjusted, and the control signal is adjusted.

In a case where any one of the power device, the motor, or the current detection circuit fails, the motor cannot be properly controlled, and problems may arise in which the motor performs abnormally.

Accordingly, methods of utilizing current fed back from a current detection circuit to detect failures or predict failures have been reported (for example, Japanese Unexamined Patent Publication (Kokai) No. JP 2004-350387 A).

SUMMARY OF THE INVENTION

However, in the related art, there is a problem that failures cannot be detected unless the motor is actually operated. Further, as no feedback current is generated unless the motor is connected to a motor drive device, there is a problem that failures cannot be detected in the motor drive device alone.

A motor drive device according to an example of the present disclosure includes an inverter provided with a plurality of power devices and configured to convert a direct current (DC) voltage to an alternative current (AC) voltage by switching the plurality of power devices; a current detector configured to detect a current output from the inverter; a current controller configured to generate a voltage command based on a current command and a value of the current detected by the current detector; a control signal generator configured to control switching of the plurality of power devices of the inverter based on the voltage command; a dynamic brake circuit provided with a plurality of relays and configured to short-circuit an output side terminal of the inverter via a plurality of resistances; a storage configured to store, when a current command is input to the current controller and at least two relays from among the plurality of relays are caused to conduct, an initial current value being an initial value of a current detected by the current detector and a first threshold value for determining presence or absence of a failure; and a failure determiner configured to compare, after a predetermined time has elapsed since detection of the initial current value, a current value and the initial current value, and determine presence or absence of a failure based on a result of comparing a change rate of the current value from the initial current value with the first threshold value, wherein the current value is a value of a current detected by the current detector when a current command is input to the current controller and at least two relays from among the plurality of relays are caused to conduct.

DETAILED DESCRIPTION

A motor drive device according to the present invention will be described below with reference to the drawings. However, it should be noted that the technical scope of the present invention is not limited to these embodiments, but includes the invention as disclosed in the claims and its equivalents.

The motor drive device according to a first embodiment will be described.FIG. 1illustrates a block diagram depicting a configuration of a motor drive device according to the first embodiment. The motor drive device101according to the first embodiment includes an inverter1, a current detector2, a current controller3, a control signal generator4, a dynamic brake circuit5, a storage6, and a failure determiner7.

The inverter1includes a plurality of power devices (not illustrated), and converts a DC voltage into an AC voltage by switching the plurality of power devices. For example, the inverter1includes a power device on each of an upper arm and a lower arm, and converts a DC voltage into an AC voltage by switching the power devices. By closing the relays (SA, SB, SC) of the dynamic brake circuit5, the converted AC voltage is applied to the dynamic break resistances (RbA, RbB, RbC) connected to each relay, and the R phase current, the S phase current, and the T phase current flow to the dynamic break circuit5. The DC voltage supplied to the inverter1can be obtained, for example, by converting an AC voltage supplied from an AC power supply (not illustrated) into a DC voltage by a rectifier, and smoothing the DC voltage with a smoothing capacitor. In the present embodiment, a case in a three-phase (R phase, S phase, T phase) inverter is used as the inverter1will be described as an example. In this case, for example, insulated gate bipolar transistors (IGBTs) can be used for the six power devices, and it is preferable to provide freewheeling diodes in anti-parallel to these power devices.

The current detector2detects a current output from the inverter1. In the example illustrated inFIG. 1, the current detector2includes a first current detector2aconfigured to detect an R phase current and a second current detector2bconfigured to detect an S phase current. However, such an example is not limiting, and the other two phase currents such as the R phase current and the T phase current may be detected, or three-phase currents may be detected. The R phase current IFBRwhich is the R phase current feedback (FB) detected by the first current detector2aand the S phase current IFBSwhich is the S phase current feedback (FB) detected by the second current detector2bare output to the current controller3and the storage6.

The current controller3generates a voltage command based on the current command and the value of the current detected by the current detector2. The current command is provided from outside of the motor drive device101. The generated voltage command is output to the control signal generator4.

The control signal generator4controls switching of the plurality of power devices of the inverter1based on the voltage command.

The dynamic brake circuit5includes a plurality of relays (SA, SB, SC) configured to short circuit an output side terminal of the inverter1via a dynamic brake resistor which is a plurality of resistances (RbA, RbB, RbC). In the example illustrated inFIG. 1, since a three-phase motor drive device is exemplified, an example is illustrated in which the dynamic brake circuit5is provided with three dynamic brake (DB) resistors and three relays respectively, but this example is not limiting. In addition, the opening and closing of the plurality of relays (SA, SB, SC) of the dynamic brake circuit5may be controlled by a control signal from the failure determiner7.

The storage6is configured to store, when a current command is input to the current controller3and at least two relays from among the plurality of relays are caused to conduct, an initial current value which is an initial value of a current detected by the current detector2and a first threshold value for determining the presence or absence of a failure. In the motor drive device according to the present embodiment, the presence or absence of a failure is determined with reference to the initial current value, which is the initial value of the current output from the inverter1. Accordingly, in a state in which two relays from among the plurality of relays of the dynamic brake circuit5are caused to conduct and a current flows in the dynamic brake circuit5, the current value initially detected by the current detection circuit2when the inverter1is operated is set as the initial current value. The storage6stores the initial current value. For example, it is possible to cause the relays SAand SBof the dynamic brake circuit5to conduct, and set the initial value of the detected R phase current or S phase current as the initial current value. As the initial current value, the initial value of any one of the R phase current, the S phase current, or the T phase current may be used as the initial current value. This is because, in cases where the values of the plurality of dynamic brake resistances (RbA, RbB, RbC) are equal and no failure has occurred in the motor drive device, the values of each of the R phase current, the S phase current, and the T phase current can be considered to be equal. It should be noted that a method for determining whether the initial current value is normal will be described later.

The failure determiner7is configured to compare, after a predetermined time has elapsed since detection of the initial current value, a current value, which is a value of a current detected by the current detector2when a current command is input to the current controller3and at least two relays from among the plurality of relays are caused to conduct, and the initial current value. The failure determiner7determines the presence or absence of a failure based on the result of comparing the change rate of the current value from the initial current value with the first threshold value. “After a predetermined time has elapsed” means that it is not simultaneous with the detection of the initial current value. The “predetermined time” can be arbitrarily set according to the elapsed time at which failure of the motor drive device is estimated to occur. After a predetermined time has elapsed since detection of the initial current value, in a state in which at least two relays from among the plurality of relays of the dynamic brake circuit5are caused to conduct and a current flows in the dynamic brake circuit5, the failure determiner7compares the current value detected by the current detection circuit2when the inverter1is operated with the initial current value stored in the storage6.

In addition, the storage6further stores a second threshold value that is smaller than the first threshold value. The failure determiner7may determine a failure when the absolute value of the change rate is greater than or equal to the first threshold value, and issue a warning when the absolute value of the change rate is greater than or equal to the second threshold value. In general, it is estimated that the absolute value of the change rate from the initial current value of the detected current value increases with time. For this reason, by issuing a warning before the motor drive device is determined to have failed, it is possible to prevent failures in advance. Accordingly, it is preferable that a second threshold value smaller than the first threshold value be set in advance and stored in the storage6, and a warning be issued when the absolute value of the change rate is greater than or equal to the second threshold value.

The failure determiner7may also be configured to cause the relays of at least two phases of the dynamic brake circuit5to conduct, detect the current value of one particular phase, and determine the presence or absence of a failure for the one particular phase based on a result of comparing a change rate of the detected current value of the one particular phase from the initial current value with the first threshold value. For example, the failure determiner7can determine the presence or absence of a failure based on the result of comparing the change rate of the detected R phase current value IFBRfrom the initial current value Iiniwith the first threshold value. In particular, when the absolute value of the change rate, which is the ratio of the difference between the R phase current value IFBRand the initial current value Iini(Iini−IFBR) with respect to the initial current value Iini, is greater than or equal to the first threshold value Th1, i.e., when Formula (1) below is satisfied, it may be determined that a failure has occurred in the path through which the R phase current of the motor drive device flows.
|(Iini−IFBR)/Iini|≥Th1(1)

The reason why the absolute value of the difference between the R phase current value IFBRand the initial current value Iini(Iini−IFBR) is used is that, as cases in which failure occurs, in addition to the cases where the detected current decreases due to disconnection, etc., the cases in which the detected current increases due to a short circuit, etc., are also possible.

Similarly in the case of generating warnings, when the absolute value of the change rate, which is the ratio of the difference between the R phase current value IFBRand the initial current value Iini(Iini−IFBR) with respect to the initial current value Iini, is greater than or equal to the second threshold value Th2(<Th1), i.e., when Formula (2) below is satisfied, a warning may be issued indicating that a failure may occur in the path through which the R phase current of the motor drive device flows.
|(Iini−IFBR)/Iini|Th2(2)

In the above description, an example was described in which attention was focused on the current of one phase, and generation of a warning or determination of the presence or absence of a failure was performed. However, generation of a warning or determination of the presence or absence of a failure may also be performed based on the detected currents of two phases. That is, the failure determiner7may be configured to cause the relays of at least two phases of the dynamic brake circuit5to conduct, detect current values of two particular phases, and determine the presence or absence of a failure based on a result of comparing a value obtained by dividing a difference between the detected current values of the two particular phases by a current value of one of the two particular phases with a third threshold value. In particular, when the absolute value of the change rate, which is the ratio of the difference between the R phase current value IFBRand the S phase current IFBS(IFBR−IFBS) with respect to the R phase current value IFBR, is greater than or equal to the third threshold value Th3, i.e., when Formula (3) below is satisfied, it may be determined that a failure has occurred in at least one of the paths through which the R phase current and the S phase current of the motor drive device flow.
|(IFBR−IFBS)/IFBR|=|1−IFBS/IFBR|≥Th3(3)

It should be noted that, in the above explanation, although an example was described in which failures were detected by paying attention to the difference between the R phase current value IFBRand the S phase current IFBS, a failure may be detected by paying attention to any two arbitrary currents from among the R phase current value, the S phase current, and the T phase current.

In the above description, an example was described in which generation of a warning or determination of the presence or absence of a failure was performed by comparing the detected current value with the initial current value or the current value of another phase. However, it is also possible to predict generation of a warning or determination of the presence or absence of a failure based on the temporal change of a detected current value. That is, the storage6may store the time when the current detection2detected the current value and the current value, and the failure determiner7may predict a timing of the failure based on the degree of temporal change of the current value.

As an example of the temporal changes of the detected current values, the case about linear changing with time is considered.FIG. 2illustrates an example of the temporal change of the absolute value of the difference between the initial current value and the detected current value in the motor drive device according to the first embodiment. For example, as illustrated inFIG. 2, in a case that a failure is determined when the absolute value of the difference between the initial current value and the detected current value is 20 mA, assume the absolute value of the difference between a current value detected one year after the initial current value is detected and the initial current value to be 5 mA. In this case, since the absolute value of the difference between the initial current value and the detected current value will reach 20 mA four years after the initial current value is detected, it can be predicted that a failure will occur three years after a point in time when the absolute value of the difference between the detected current value and the initial current value is 5 mA.

In addition, as an example of the temporal changes of the detected current values, the case about nonlinear changing with time is considered.FIG. 3illustrates another example of the temporal change of the absolute value of the difference between the initial current value and the detected current value in the motor drive device according to the first embodiment. For example, as illustrated inFIG. 3, consider a case where the absolute value of the difference between the initial current value and the detected current value is proportional to the square root of the elapsed time. In cases that a failure is determined when the absolute value of the difference between the initial current value and the detected current value is 20 mA, assume that the absolute value of the difference between a current value detected one year after the initial current value is detected and the initial current value is 5 mA. In this case, since the absolute value of the difference between the initial current value and the detected current value will reach 20 mA sixteen years after the initial current value is detected, it can be predicted that a failure will occur fifteen years after the point in time when the absolute value of the difference between the detected current value and the initial current value is 5 mA.

In the above description, an example was described in which the initial current value is used as a reference when determining the presence or absence of a failure. In cases where the initial current value itself is an abnormal value, it becomes difficult to accurately determine the presence or absence of a failure. For this reason, it is important to verify that the initial current value is normal. Accordingly, it is preferable for the storage6to store the resistance values of the plurality of resistances (RbA, RbB, RBC) of the dynamic brake circuit5, and for the failure determiner7to determine whether the initial current value is abnormal based on the difference between an ideal current value calculated from the resistance values and the initial current value. The ideal current value can be calculated from the resistance values of the plurality of resistances (RbA, RbB, RBC) of the dynamic brake circuit5and the applied voltage. In cases where the difference between the ideal current value and the initial current value exceeds an allowable range, the initial current value itself is considered to be abnormal. As a result, it is possible to prevent erroneously determining the presence or absence of a failure based on an abnormal initial current value when a power device has an initial defect, for example.

Next, a procedure will be described for determining the presence or absence of a failure based on the current of one phase by using the motor drive device according to the first embodiment.FIG. 4is a flowchart for explaining a procedure for detecting a failure in the motor drive device according to the first embodiment. In Step S101, the failure determiner7(seeFIG. 1) turns on the relays SBand SCof the dynamic brake circuit5.

Next, in Step S102, a current command is provided to the current controller3, the S phase current value that flows by controlling the switching of the power devices of the inverter1is detected, and the initial current value Iiniis stored in the storage6. It should be noted that the storage6also stores a first threshold value for determining the presence or absence of a failure.

Next, in Step S103, after a predetermined time has elapsed since detection of the initial current value, a current command is provided to the current controller3, and the S phase current value IFBSthat flows by controlling the switching of the power devices of the inverter1is detected.

Next, in Step S104, it is determined whether the absolute value of the change rate of the S phase current value IFBSfrom the initial current value Iiniis greater than or equal to the first threshold value.

In cases that the absolute value of the change rate of the S phase current value IFBSfrom the initial current value Iiniis greater than or equal to the first threshold value, in Step S105, it is determined that a failure has occurred in the path of the S phase current of the motor drive device.

In contrast, in cases that the absolute value of the change rate of the S phase current value IFBSfrom the initial current value Iiniis less than the first threshold value, in Step S106, it is determined that the path of the S phase current of the motor drive device is normal.

In the above description, an example was described in which the presence or absence of a failure is determined based on the S phase current. However, the presence or absence of a failure may be determined based on the R phase current or the T phase current.

Next, a procedure will be described for determining the generation of a warning or the presence or absence of a failure based on the current of one phase by using the motor drive device according to the first embodiment.FIG. 5is a flowchart for explaining a procedure for generating a warning and detecting a failure in the motor drive device according to the first embodiment. Steps S201to S205are steps for determining the presence or absence of a failure, and are the same as the above-mentioned steps S101to S105, so a detailed description will be omitted herein. It should be noted that the storage6stores a first threshold value for determining the presence or absence of a failure and a second threshold value for determining whether generation of a warning is necessary.

In Step S204, in cases that the absolute value of the change rate of the S phase current value IFBSfrom the initial current value Iiniis less than the first threshold value, in Step S206and the following steps, it is determined whether a warning should be generated.

In Step S206, it is determined whether the absolute value of the change rate of the S phase current value IFBSfrom the initial current value Iiniis greater than or equal to the second threshold value.

In cases that the absolute value of the change rate of the S phase current value IFBSfrom the initial current value Iiniis greater than or equal to the second threshold value, in Step S207, a warning is generated indicating that a failure may occur in the path of the S phase current of the motor drive device.

In contrast, in cases that the absolute value of the change rate of the S phase current value IFBSfrom the initial current value Iiniis less than the first threshold value, in Step S208, it is determined that the path of the S phase current of the motor drive device is normal.

In the above description, an example was described in which generation of a warning or determination of the presence or absence of a failure was performed based on the S phase current. However, generation of a warning or determination of the presence or absence of a failure may be performed based on the R phase current or the T phase current.

Next, a procedure will be described for determining the presence or absence of a failure based on the current of two phases by using the motor drive device according to the first embodiment.FIG. 6is a flowchart for explaining a procedure for detecting a failure from current detection values of two phases in the motor drive device according to the first embodiment. In Step S301, the failure determiner7turns on the relays SAand SBof the dynamic brake circuit.

Next, in Step S302, a current command is provided to the current controller3, and the S phase current value IFBSand the R phase current value IFBRthat flow by controlling the switching of the power devices of the inverter1are detected. It should be noted that the storage6also stores a third threshold value Th3for determining the presence or absence of a failure.

Next, in Step S303, it is determined whether the absolute value of the change rate, which is the ratio of the difference between the R phase current value IFBRand the S phase current IFBS(IFBR−IFBS) with respect to the R phase current value IFBR, is greater than or equal to the third threshold value Th3, i.e., whether the above mentioned Formula (3) is satisfied.

In cases that the absolute value of the ratio of the difference (IFBR−IFBS) with respect to the R phase current value IFBRis greater than or equal to the third threshold value Th3, then in Step S304, it is determined that a failure has occurred in at least one of the paths of the S phase current or the R phase current of the motor drive device.

In contrast, in cases that the absolute value of the ratio of the difference (IFBR−IFBS) with respect to the R phase current value IFBRis less than the third threshold value Th3, then in Step S305, it is determined that the paths of the S phase current and the R phase current of the motor drive device are normal.

In the above description, an example was described in which the presence or absence of a failure is determined based on a combination of the S phase current and the R phase current. However, the presence or absence of a failure may be determined based on a combination of an R phase current and a T phase current, or a combination of a T phase current and an S phase current.

As described above, according to the motor drive device of the first embodiment, it is possible to determine the presence or absence of a failure even for a motor drive device alone, not being connected with a motor.

Next, a motor drive device according to a second embodiment will be described.FIG. 7illustrates a block diagram depicting the configuration of a motor drive device according to the second embodiment. The motor drive device102according to the second embodiment is different from the motor drive device101according to the first embodiment in that it further includes a switch20for connecting or disconnecting the motor10to an output side terminal of the inverter1. As the other configurations of the motor drive device102according to the second embodiment are similar to those of the motor drive device101according to the first embodiment, a detailed description thereof will be omitted herein.

As illustrated inFIG. 7, the motor10can be approximated by a plurality of resistances (RmR, RmS, RmT) and a plurality of inductances (LmR, LmS, LmT). The switch20allows the motor10be connected to or disconnected from the motor drive device102.

As inductances (LmR, LmS, LmT) are included in the motor10, it is possible to determine whether the motor10is connected to the motor drive circuit102based on the temporal change in the current flowing through the motor10. That is, when the motor10is not connected to the motor drive circuit102, the detected current is constant. In contrast to this, when the motor10is connected to the motor drive circuit102, the current increases with time at a particular slope depending on the inductances (LmR, LmS, LmT) of the motor10. It is preferable that the value of the slope of the current for determining whether the motor10is connected to the motor drive circuit102is stored in advance in the storage6.

When the switch20is turned off and the motor10is disconnected from the motor drive device102, the presence or absence of a failure of the motor drive device102can be determined in the same manner as in the first embodiment. In contrast, when the switch20is turned on and the motor10is connected to the motor drive device102, it is possible to determine whether at least one of the motor10or the motor drive device102has a failure. In cases where the switch20is initially turned off, the presence or absence of a failure of the motor drive device102is determined, and it is found that the motor drive device102is normal, by subsequently turning on the switch20to determine the presence or absence of a failure, it is possible to determine the presence or absence of a failure only in the motor10.

As described above, according to the motor drive device of the second embodiment, it is possible to determine which one of the motor or the motor drive device has failed by determining the presence or absence of a failure while turning the switch20on and off.

According to the motor drive device according to an embodiment of the present disclosure, it is possible to detect a failure without actually operating the motor, and furthermore, failure detection can be performed by the motor drive device alone even when the motor is not connected to the motor drive device.