Over-loading monitoring system for electric motor in automotive engine simulating apparatus

Abstract: An over-loading detection system periodically samples motor operating parameter, e.g. a revolution speed and an output torque at a predetermined relatively short sampling period. Based on the sampled motor operating parameter, ratio of the output torque and a predetermined over-load rating torque is derived and stored. Over-load detection is performed with respect to a plurality of sampled ratio of the output torque and the over-load rating torque by deriving a running average and comparing the derived running average value with a predetermined threshold.

Description: BACKGROUND OF THE INVENTION Field of the Invention The present invention relates generally to a control system for controlling operation of an electric motor, particularly for a motor applied for simulating an automotive internal combustion engine for testing engine driven vehicular components, such as an automatic power transmission, an automatic transaxle, a differential gear unit and so forth. More specifically, the invention relates to a system for monitoring an electric motor being driven at over-loaded state. Description of the Background Art An automatic power transmission testing apparatus employing an electric motor has recently been proposed with an engine output characteristics simulating system. Such system is called a transient-dynamometer (TR-DY), in which high or great inertia in the electric motor has been compensated for simulating the automotive engine driving characteristics with satisfactorily high response. In such a system, a direct-current motor is employed as a driving torque source. The direct-current motor employed in such a system tends to be driven in over-loaded condition in view of the capacity defined in continuous rating. In general, the rating of the electric motor is defined by the following conditions: (1) it should not become over-loaded for nominal rating torque which is temporary maximum output; (2) 25%ED rating should be standard, which 25%ED means in the cyclic drive in a given pattern, 25% is driven at the nominal rating torque and remaining 75% is driven at no-load condition; and (3) continous drive is possible when RMS value (square-average) in each cycle is lower than or equal to 50% of the nominal rating torque. As seen froM Fig. 3, assuming that the torque at respective cycles of Δt 1 to Δt 3 are respectively T 1 to T 3 , the RMS value and the condition (3) can be expressed by: RMS = T 1 2 · Δt 1 + T 2 2 · Δt 2 + T 3 2 · Δt 3 Δt 1 + Δt 2 + Δt 3 ≦ 50%·T 0 By dividing both sides by T 0 and setting T 1 /T 0 = T a and T 2 /T 0 = T b and T 3 /T 0 = T c , the foregoing equation (1) can be modified as Ta 2 · Δt 1 + Tb 2 · Δt 2 + Tc 2 · Δt 3 Δt 1 + Δt 2 + Δt 3 ≦ 50% On the other hand, driving at 25%ED is expressed by RMS value by the following equation RMS = (T0/T0) 2 · Δt 4 · Δt = 5o% From the foregoing, it should be appreciated that the value representative of RMS value at 25%ED becomes 50% of the nominal rating torque. For the motor which is expected to be driven in over-loaded condition, a driving pattern is set so that the magnitude of over-loading cannot be greater than a predetermined limit. In the prior art, a thermal relay or a temperature switch is used for detecting over-heating due to excessive load for protecting the motor from excessive over-loading condition. From US-A-4246622, against which claim 1 is delimited, an overload protective device of electric motors is known. According to this document, a static type overload relay is used to protect a motor against overload. The overload relay comprises an integrator for integrating the difference between the motor current and a continuous current carrying capacity of the motor. When the output of the integrator exceeds a predetermined value, a circuit breaker connected in series with the motor is tripped. Furthermore, from US-A-4468958, a control system for an automatic transmission testing device is known, which is used in automobiles and comprises a torque controlling feedback loop for controlling the torque applied to the input shaft of the transmission under test, and a speed controlling feedback loop for controlling the speed of the output shaft of the transmission under test, whereby the circumstances in an actual automobile application can be simulated to allow testing of the automatic transmission. However, none of the conventionally attempt ways for detecting overloading conditions are successfully in view of accuracy and response time required for detection of excessive load. Therefore, it is an object of the present invention to provide an improved over-loading monitoring system. This object is achieved by the features of the independent claim 1. Preferred embodiments are specified in the dependent claims. In order to accomplish the aforementioned and other objects, an over-loading detection system, according to the present invention, periodically samples the revolution speed and the output torque of the motor at a predetermined relatively short sampling period. Based on the sampled signals, the ratio of the output torque and a predetermined over-load rating torque can be derived and stored. Over-load detection can be performed with respect to a plurality of sampled ratio of the output torque and the over-load rating torque by deriving a running RMS average and comparing the derived running RMS average value with a predetermined threshold. In practice, calculation of the running RMS average and over-load detection can be done by the following formula: wherein Tsi represents the sampled instantaneous output torque. In the alternative, calculation of the running RMS average and over-load detection can also be done by the following formula: wherein Ti represents a ratio of the sampled instantaneous output torque and a predetermined over-load rating torque. BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be understood more fully from the detailed description given herebelow and from the accompanying drawings of the preferred embodiment of the invention, which, however, should not be taken to limit the invention to the specific embodiment but for explanation and understanding only. In the drawings: Fig 1 is a schematic illustration of a bench testing apparatus for an automotive automatic power transmission, in which is employed an electric motor in a low inertia power plant and the preferred embodiment of an over-loading monitoring system, according to the invention; Fig. 2 is a flowchart showing process implementing the preferred embodiment of over-load monitoring according to the invention; and Fig. 3 is a chart showing variation of driving torque in one cycle. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings, particularly to Fig. 1, there is illustrated a bench testing apparatus For an automotive power transmission. The apparatus employs a low inertia power plant 1 which included an electric motor. The electric motor in the low inertia power plant is coupled with a speed increasing device or any appropriate device which can compensate high inertia of the electric motor in order to simulate an automotive engine. The low inertia power plant 1 is connected to an automatic power transmission 3 to be tested, via a torque meter 2. A dummy load 4 such as a dynamometer for absorbing driving torque is connected to the output shaft of the automatic power transmission. A computer based controller 6 is connected to a revolution speed sensor 5 which monitors revolution speed of the motor to produce an engine speed simulated revolution speed signal. The controller 6 is also connected to the torque meter to receive therefrom an output torque indicative signal which represents the output torque of the low inertia power plant 1. The controller 6 includes a sampling stage 7 for sampling the input signals and an over-load detecting section 8. The over-load detecting section 8 processes the input data for deriving square-average of the torque and compare the derived average value with a predetermined over-load criterion to make judgement of over-loading condition. The controller 6 is connected to a display monitor 9 for displaying the result of monitoring. A process to be implemented for detecting over-loading condition of the electric motor will be discussed herebelow with reference to Fig. 2. At First, the low inertia power plant 1 is started to supply the output torque to the automatic power transmission. Then, the revolution speed sensor 5 and the torque meter 2 become active to produce the revolution speed indicative signal Ni and the output torque indicative signal Tsi. The revolution speed indicative signal Ni and the output torque indicative signal Tsi are sampled by the sampling stage 7. In the shown embodiment, the sampling stage samples the input signals at given intervals, e.g. every 0.1 sec. Also, in the shown embodiment. an unit period for detecting over-loading condition on the electric motor is set at 5 min. Therefore, in each sampling cycle, 3000 sample data may be obtained. The over-loading detecting section compares each sampled revolution speed data Ni(1 - 1 ÷ 3000) with a revolution speed criterion N B which is set at a weak filed criterion. If the revolution speed data Ni is smaller than or equal to the revolution speed criterion N B , a ratio Ti between the output torque Tsi and a predetermined over-load rating torque T NB is derived. On the other hand, when the revolution speed data Ni is greater than the revolution speed criterion N B , the ratio Ti is derived between the output torque Tsi and a over-load rating torque T. The over-load rating torque T is derived based on the revolution speed and, in practice set in a memory. Therefore, the over-load rating torque may be derived by table or map look-up in terms of the revolution speed Ni. The ratio Ti thus derived is stored in a memory (not shown). The foregoing sampling process is performed at each sampling timing and thus repeated for 3000 times in each over-load detection cycle. If necessary, RMS derivation process can be performed with respect to each sampling data with the already sampled data, for protecting the motor from excess over-loading. When 3000 or more data are sampled. the sampled data are processed for deriving a running average. At the sample time, data shifting in the memory is performed for erasing the old data which was sampled more than 3000 cycles ahead so that the memory can hold the 3000 most recently sampled data. Then, sampled data is processed for deriving the RMS value. Here, assuming the sampled data is Tk, the RMS value can be derived through the following equation: The RMS value thus derived is compared with a predetermined criterion value, e.g. 0.5 (50%). If the RMS value is greater than the criterion value, an excess over-loading detecting signal is output. Otherwise, the process returns to repeat the foregoing process with respect to the next sample. The excess over-loading detecting signal is fed to the display 9 for indicating excessive over-loading condition of the motor. With the shown embodiment, the objects and advantages sought therefore can be fulfilled. While the present invention has been discussed in terms of the preferred embodiment of the invention, the invention should not be understood to be limited to the specific embodiment set forth above but includes all possible embodiments and modifications which can be implemented without departing from the scope of the invention as defined in the appended claims.

Claims: An excess over-load detection system for an electric motor comprising: sensor means comprising a sensor (2) for monitoring an output torque of said motor and for producing a signal indicative of said output torque; means for deriving a signal in response to the output torque indicative signal; means for processing said derived signal over a period for deriving a motor load indicative data and comparing said motor load indicative data with a predetermined load criterion to output an over-load detection signal when the motor load indicative data is greater than said predetermined load criterion characterized in that said sensor means further comprises a sensor (5) for monitoring the revolution speed of said electric motor and for producing a signal indicative of said revolution speed; said means for deriving a signal in response to the output torque indicative signal comprises means (7) for periodically sampling said revolution speed indicative signal and said output torque indicative signal at a predetermined sampling period and is adapted for producing said derived signal on the basis of at least said sampled output torque indicative signal; and said means for processing said derived signal is adapted for processing the signals derived over a predetermined over-loading detection period which is set substantially longer than that of said sampling period so that a predetermined number of derived signals can be produced therein and for deriving said motor load indicative data as an RMS average of the derived signal. An excess over-load detection system according to claim 1, wherein said processing means is adapted for deriving said RMS average as a running RMS average. An excess over-load detection system according to claim 1 or 2, wherein said deriving means is adapted to derive a ratio of the actual torque represented by said sampled output torque indicative signal and a predetermined torque criterion. An excess over-load detection system according to any of the previous claims, wherein said predetermined over-loading detection period is set so that an integer number of samples can be sampled therein. An excess over-load detection system according to claim 4, wherein said integer number of samples equals 3000. A bench testing apparatus for testing vehicular components intended to be associated with an automotive internal combustion engine, including a low inertia power plant (1) having an electric motor as prime mover for driving said vehicular components, characterized in that, said bench testing apparatus comprises an excess over-load detection system for the electric motor in accordance with one of the preceeding claims. A bench testing apparatus according to claim 6, wherein the electric motor is controlled for providing an output torque simulating the characteristics of an automotive engine.

Inventors: GOTO TAKASHI, MARUKI TOSHIMITSU, MIZUSHINA FUMIO, NAGANUMA YUKIO, SANO KAORU, GOTO, TAKASHI, MARUKI, TOSHIMITSU, MIZUSHINA, FUMIO, NAGANUMA, YUKIO, SANO, KAORU
Applicants: MEIDENSHA ELECTRIC MFG CO LTD, KABUSHIKI KAISHA MEIDENSHA
Application year: 1990
Main classification: H02H7
IPC codes: G01R31, H02H7, G01M13