Method and apparatus for inductive load control with current simulation

Abstract: A control for an inductive load (12) switches current on and off to regulate about a command value, a decaying recirculation current flowing through the load during the switch off periods. The current is sensed during the switch on periods and charges a capacitor (42) to provide a simulation signal representing the motor current. The capacitor is allowed to discharge through a resistor (44) during the switch off periods at the rate of the decaying recirculation current. The simulation signal is compared to the command value to control the switching. The simulation signal is sensed during a command value of zero current to determine offset errors for calibration purposes.

Description: This invention relates to method and apparatus for controlling the current to an inductive load and particularly to such method and apparatus for simulating the load current for feedback control purposes. When controlling current to an electric motor, a solenoid or other inductive load, it is frequently desired to control the current by rapidly switching the current on and off so that the average current meets a desired goal or command value. The current switching is generally accomplished by one or more switches in series with the inductive load and the power supply. When the current is switched on it increases at a rate limited by the inductive reactance of the inductive load. When the current is switched off it slowly decays at a rate also determined by the inductive reactance. During the current decay period a path must be provided for the current, known as induced or recirculation current. See, for example, US-A- 4,536,818. A common motor driver circuit is an H-bridge driver which has two arms connected from opposite sides of the electric motor to the power source and two more arms connected from opposite sides of the electric motor to ground. Each arm contains a switch such as a power MOSFET so that by selective switch control the electric motor can be driven in either direction by current flowing from the power source and through the electric motor to ground. It is convenient to use this type of driver in conjunction with a driver interface when using a microcomputer to control the electric motor. As is well known, load current feedback is often desirable for comparison to the command value to achieve closed loop control. The recirculation current as well as the applied current is required to be represented by the feedback. In the case of the H-bridge configuration, the motor current is difficult to sense because it is bidirectional and a sensor would yield negative voltages at times and much circuit complexity would be required to accommodate it. DE-A-3,701,985 discloses a series connected electronic device for a d.c. energisable winding in which the current through the winding is selectively applied and terminated on the basis of a comparison of a measure of the current passing through the winding and a reference value. When the winding current exceeds the reference value, current to the winding is immediately terminated and a capacitor in the circuit is immediately charged. When the winding current drops below the reference value, the capacitor discharges through a resistor. Once the capacitor has discharged by a sufficient amount, current is re-applied to the winding. EP-A-0,259,005 discloses a current driver circuit for an inductive load comprising two pairs of pulse-width modulated switches on opposite sides of the winding, each pair straddling the winding relative to the power supply. Each pair of switches is modulated in the different modes to control current during two different operating conditions, in a manner as to increase efficiency while reducing electromagnetic radiation. It is therefore an object of the invention to provide a method and apparatus to provide an electric motor or other inductive load control using a simple current feedback. It is a further object to provide such a control method and apparatus with a zero current calibration feature using the current feedback technique. The invention is carried out by the method of controlling current in an inductive load to a command value comprising the steps of applying current in one direction to the inductive load; charging a capacitor to a voltage simulating the applied current; terminating the applied current whereby an induced current flows through the inductive load after such termination, the induced current decaying at a rate determined by the inductive load; discharging the capacitor at a rate similar to the decay rate of the induced current to simulate said induced current, whereby the capacitor voltage simulates the load current for both the applied current and the induced current; and controlling the current to the inductive load by comparing the simulated value to the command value and applying and terminating current to maintain the simulated value close to the command value. The invention is further carried out by a circuit for controlling the current to an inductive load to a command value comprising generating means for generating a command value representing a desired load current; a power source; switch means for coupling the inductive load across the power source whereby an applied current flows in the inductive load and through the switch means when the switch means is closed and a recirculation current flows in the inductive load when the switch means is open; simulator means responsive to the applied current flowing through the switch means for generating a simulation signal representing the recirculation current as well as the applied current; and comparison means responsive to the command value and to the simulation signal for actuating the switch means to control the load current to the command value. The present invention will now be described, by way of example, with reference to the following description taken in conjunction with the accompanying drawings wherein like references refer to like parts and wherein:- Figure 1 is a block diagram of a control apparatus for an inductive load according to the invention, Figure 2 is a schematic diagram of a specific control apparatus according to the invention, Figure 3 is an alternate driver and motor configuration for use in the control apparatus of Figure 2; and Figure 4 is a set of current waveforms occurring in the load of Figure 3 when under regulation according to the invention. The description is directed to the control of a solenoid or an electric motor in an H-bridge configuration but it will be recognized that it is relevant to the control of current to any inductive load. Figure 1 shows a microcomputer 10 as the master control of current supplied to an inductive load 12 from a power source 14. A driver 16 (switch means) couples the power source (14) to the inductive load 12 and a current sensor 18 completes the return current path between driver 16 and the power source 14. A motor driver interface 20 receives a desired current command value in the form of digital signals from the microcomputer 10 and a feedback signal from the current sensor 18 and suitably switches the driver 16 to apply an average current to the inductive load 12 which corresponds to the command value. The motor driver interface 20 includes a D/A converter 22 which applies an analogue command value to a comparator 24 (comparison means). The microcomputer 10 and D/A converter 22 define generating means. A simulator circuit 26 (simulator means) receives a signal from the current sensor 18 and provides a simulated load current to an input of the comparator 24. The comparator 24 then produces an output to the driver 16 to control switching to maintain the load current near the value dictated by the command signal. Other inputs from the motor driver interface 20 to the driver 16 may be used in the case of an electric motor to determine motor direction. An A/D converter 28 encodes the simulated load current and supplies it to the microcomputer 10 which can use that information for calibration and diagnostics. The simulator circuit 26 is shown in Figure 2 and includes an amplifier 30 connected across the current sensor 18 which comprises a resistor, a level shift circuit 32, an amplifier 34 with a diode 36 at its output and a feedback from the cathode of the diode to the inverting input of the amplifier 34. The diode 36 is also coupled through a resistor 38 to a terminal 40. A filter circuit 41 comprising a capacitor 42 and a resistor 44 in parallel is connected between the resistor 38 and ground. A pull up resistor 46 is connected from the terminal 40 to a 5 volt source. The values of resistors 44, 46 are chosen to develop a voltage at terminal 40 equal to the level shift voltage. This provides the control apparatus with the capability to more accurately control the current through the inductive load 12. The terminal 40 carries the simulated load current signal and is connected to the A/D converter 28 and to an input of the comparator 24. The D/A converter 22 is connected through a level shift circuit 48 to the other input of the comparator 24. The purpose of the level shift circuits 32 and 48 is to maintain the comparator 24 at a discrete value above ground voltage to enhance its operation. In this example the inductive load 12 is a solenoid and the driver 16 is a single MOSFET with its rate coupled to the comparator 24 output; the inductive load 12, driver 16 and current sensor 18 are serially connected between voltage V of the power source and ground. A diode 50 is connected across the inductive load 12 and is poled to allow recirculation current. In operation, the comparator 24 compares the level shifted command value to the simulated load current signal at terminal 40. If the command value is larger than the current by some comparator hysteresis value, the output turns on the MOSFET to apply current from the source through the inductive load 12 and through the current sensor 18. A voltage proportional to the load current is developed across the current sensor 18 and is applied to the amplifier 30. The amplifier output is level shifted by 0.5 volt and is applied to the positive input of the amplifier 34. The amplifier 34 and the series diode 36 along with the feedback line to the inverting input of the amplifier 34 comprise a peak and hold circuit. Thus the voltage applied to the terminal 40 tracks the increasing load current but does not decrease when the load current decreases. The increasing voltage is stored on the capacitor 42 and is a measure of the load current. When the voltage at terminal 40 reaches a value above the command signal by a hysteresis amount the comparator 24 output turns off the driver (MOSFET) 16 to terminate the load current flowing through the current sensor 18. A current continues to flow in the inductive load 12 and recirculates through the diode 50. The recirculation current decays at a rate determined by the inductive load 12 but this current is not directly measured. Rather it is simulated by the capacitor 42 voltage which discharges through the resistor 44 at a rate determined by the time constant of capacitor 42 and resistor 44. The time constant is selected to effect a decay rate substantially the same as the decay rate of the recirculation current. While the rest of the circuit is suitably contained on an IC chip, the filter circuit 41 is preferably mounted externally so that the time constant can be readily tailored to the load characteristics of a particular application. Thus the voltage at the terminal 40 simulates the load current at all times. When the simulated load current signal decreases below the command level the comparator 24 again turns on the driver 16 to continue the current regulation process. The command signal may be varied by the microcomputer 10 to dictate a corresponding variation of the load current. For example, if the inductive load 12 is a solenoid it will require a high current to pull in the armature followed by a low holding current. Thus the command value may call for 8 amps for a few msec and then 3 amps for the remainder of the on period and finally zero current to turn off the solenoid. Another type of inductive load is illustrated in Figure 3 which shows an electric motor 12' driven by an H-bridge driver 16'. This inductive load and driver is substituted for the inductive load and driver of Figure 2. The H-bridge driver 16' has two upper arms 52 and 54 connected between the voltage V of a power source and opposite sides of the electric motor 12' and two lower arms 56 and 58 connected between the opposite sides of the electric motor and the current sensor 18. The arms 52 - 58 contain power MOSFETs 60 - 66 respectively for individually switching the arms to apply current to the electric motor 12'. The rates of the MOSFETs 60-66 are controlled by the motor driver interface 20 which has some additional logic to selectively turn on certain MOSFETs. Each MOSFET 60-66 has an internal diode or body diode 68 poled to pass current in the direction opposite to the MOSFET conduction. To drive the electric motor 12' forward the MOSFETs 60 and 66 are turned on so that the motor current I m , as shown in Figure 4, is initially equal to the current I fl which flows through the MOSFETs from V to ground. When the current exceeds the command value the MOSFET 66 is turned off but the MOSFET 60 remains on. Then the recirculation current I rec flows through the electric motor 12', the body diode 68 of MOSFET 62 and the MOSFET 60. This current is simulated in the simulator circuit 26. As shown in Figure 4 the MOSFET 66 is switched at a rate to control the rise and fall times of the load currents and thus minimize radio frequency interference. When the applied current I fl is turned off the motor current I m is the recirculation current I rec . When the current I m goes above or below the command value enough to switch the comparator 24, the MOSFET 66 is switched on or off to regulate the motor current. As is well known, reverse motor operation requires the MOSFETs 62 and 64 to be switched for applying I m in the opposite direction. The current regulation proceeds in the same way as for forward operation since the sensed load current always flows in the same direction through the current sensor 18. When the D/A converter 22 commands a zero current the lower MOSFETs 64 and 66 are turned off while the appropriate upper MOSFET 60 or 62 remains on to permit decay of the recirculation current. Then no load current flows through the current sensor 18. After enough time has elapsed for the simulated current signal to decay to essentially zero, the terminal 40 voltage is sampled by the microcomputer 10 via the A/D converter 28 to determine the zero current reading. This value can then be added to or subtracted from the simulated current signal when current is flowing resulting in a more accurate current value. This "calibrating" can be done on a regular basis, such as each software control loop while the electric motor 12' is turned off, to eliminate offset errors that may occur over time and with temperature changes. This calibration capability provides the control with improved accuracy over other types of current control circuits.

Claims: A method of controlling current in an inductive load (12) to a command value comprising the steps of applying current in one direction to the inductive load; and terminating the applied current whereby an induced current flows through the inductive load after such termination, the induced current decaying at a rate determined by the inductive load; characterised by the steps of charging a capacitor (42) to a voltage simulating said applied current, and discharging the capacitor at a rate similar to the decay rate of the induced current to simulate said induced current, whereby the capacitor voltage simulates the load current for both the applied current and the induced current, and controlling the current to the inductive load by comparing the simulated value to the command value and applying and terminating current to maintain the simulated value close to the command value. A method as claimed in Claim 1, wherein the applied current is terminated when the simulated value exceeds the command value; and wherein the current to the inductive load (12) is controlled by repeating the method steps each time the simulated value falls below the command value, whereby the load current is held close to the command value. A method as claimed in claim 1 or claim 2, including the steps of sampling the load current when the command value is for zero current to determine offset errors, and adjusting the command value for nonzero current conditions to compensate for the offset. Apparatus for controlling the current to an inductive load (12) to a command value comprising generating means (10,22,48) for generating a command value representing a desired load current; a power source (14); switch means (16) for coupling the inductive load across the power source whereby an applied current flows in the inductive load and through the switch means when the switch means is closed and a recirculation current flows in the inductive load when the switch means is open; characterised by simulator means (10,26) responsive to the applied current flowing through the switch means (16) for generating a simulation signal representing the recirculation current as well as the applied current; and comparison means (24) responsive to the command value and to the simulation signal for actuating the switch means to control the load current to the command value. Apparatus as claimed in claim 4, wherein the inductive load is an electric motor (12'); the switch means is an H-bridge driver (16'), the H-bridge driver (16') having four arms (52-58) with a power MOSFET (60-66) in each arm for controllably switching the electric motor into circuit with the power source (14) to input applied current to the electric motor and for allowing motor recirculation current to flow when the applied current is switched off; and further comprising a current sense resistor (18) in circuit with the power source and two of the MOSFETs in one side of the H-bridge driver so that a feedback voltage proportional to the motor current is developed when either of the said two MOSFETs is conducting; the simulator means (26) being responsive to the feedback voltage for simulating the motor current when the applied current is on as well as when it is off. Apparatus as claimed in claim 5, wherein the simulator means comprises a resistor (44) and capacitor (42) circuit (41) for storing a voltage representing the applied current and for permitting decay of the stored voltage at a rate representing the decay rate of the recirculation current so that the stored voltage simulates the motor current. Apparatus as claimed in claim 5 or claim 6, including means (22) for setting the command value to zero, whereby any variation of the simulated motor current from a value representing zero current reveals offset errors, and calibration means (28) in the generating means (10) responsive to the simulated motor current for compensating for zero offset errors.

Inventors: HACH LARRY RAYMOND, KELLEY GERARD FRANCIS, TALLANT II JAMES CHARLES, HACH, LARRY RAYMOND, KELLEY, GERARD FRANCIS, TALLANT II, JAMES CHARLES
Applicants: DELCO ELECTRONICS CORP, DELCO ELECTRONICS CORPORATION
Application year: 1990
Main classification: H01H47
IPC codes: H02P7, G05F1, H01H47