Apparatus and method for controlling brushless electric motors and position encoders and indicating position thereof

Abstract

A brushless direct current motor is energized by a power stage. Switches of the power stage are selectively switched by an electronic control device. In order to determine the correct commutation pattern, without using rotor position indicators such as Hall effect devices, the control device is arranged to sample the power fed to the motor. The samples, each responsive to a test signal or normal energization pulses received by the motor, in a ordered sequence define an analogue function whose parameters can be determined by mathematical analysis. The analysis applied to the samples derives the necessary commutation information and the energization signals in a rapid manner by employing a vector or complex number addition based on functions dependent on variable inductance in the operation of the motor.

1. Apparatus for controlling a brushless electric motor having motor coils, the apparatus comprising:
 a power stage having a plurality of switching means, and output terminals for supplying power to the motor coils of a motor to be controlled; and  
 control means coupled to the power stage and arranged to apply commutation signals to the power stage to selectively switch said switching means whereby power is selectively applied to said motor by way of said switching means, and wherein the control means is arranged to receive sequence of samples of a component of the power fed to the motor, the control means further comprising means for determining parameters of a function depending on variable inductance in the motor and defined by the sequence of samples, including means for performing a vector addition or a complex number addition for each set of a plurality of the samples, wherein the parameter determining means operates repeatedly for multiple successive applications of power to the motor and from the parameters determines position-dependent and/or inductance-dependent electrical motor values.  
 
     
     
       2. The apparatus according to  claim 1 , wherein the parameter determining means includes means for determining parameters of inductance of at least one motor winding as position dependent electrical motor values. 
     
     
       3. The apparatus according to  claim 2 , further including a rotor and a magnetic circuit in the motor affected by and affecting the at least one motor winding, the magnetic circuit being of a type to approach magnetic saturation during a rotor movement of 360° el. 
     
     
       4. The apparatus according to  claim 2  or  claim 3 , wherein the motor comprises a plurality of permanent magnets having pole faces that have magnetic fluxes that vary sufficiently across the pole faces to provide rotor-position-dependent variations of inductance of the at least one motor winding. 
     
     
       5. The apparatus according to  claim 2  or  claim 3 , wherein a preliminary current is supplied to the one winding to produce a pre-magnetization state. 
     
     
       6. The apparatus according to  claim 2  or  claim 3 , wherein the current path to the one winding is arranged to facilitate the determination of the inductance of the one winding. 
     
     
       7. The apparatus according to  claim 2  or  claim 3 , wherein the control means including means for determining the parameters of inductances of at least two windings as functions of rotor position, determining a combined function of the inductance-rotor position functions, and electronically storing the combined function as a table of values. 
     
     
       8. The apparatus according to  claim 7 , including means for interpolating between values in the table of values to provide further values for storage in the table of values. 
     
     
       9. The apparatus according to  claim 8 , wherein the means for interpolating provides a spline interpolation. 
     
     
       10. The apparatus according to  claim 8 , wherein the means for interpolating provides an interpolation based on a sin-cos series expansion. 
     
     
       11. The apparatus according to  claim 8 , wherein the control means adjusts the application of commutation signals in response to a determination of rotor position for which the decision criterion is the similarity of functions, which functions are based on at least one of measured energization current pulses to the winding and on the function defined by the electronically stored table of values. 
     
     
       12. The apparatus according to  claim 11 , wherein the similarity of functions is based upon the method known as sum of least squares or the method known as sum of smallest absolute amounts. 
     
     
       13. The apparatus according to  claim 2  or  claim 3 , wherein the position dependent electrical motor values are applied to determine rotor position, the control means including means for multiplying the individual measured current values by associated directional components thereof and adding the products on a directional basis to assist in the determination of position. 
     
     
       14. The apparatus according to  claim 13 , wherein the directional components have directions separated by so-called integral angles, which are respective ones of the angles 0=360°/n, wherein n=1, 2, 3 etc. 
     
     
       15. The apparatus according to  claim 14 , wherein the addition of products on a directional basis is a vector addition. 
     
     
       16. The apparatus according to  claim 13 , wherein the control means establishes a test mode including planned, incremental movements of the rotor, and the determining and electronically storing means determines and electronically stores the associated directional components of the currents. 
     
     
       17. The apparatus according to  claim 12 , wherein the control means sets a desired rotor position, compares it with the determined rotor position to provide an error signal, and applies the error signal via proportional-integral-derivative negative feedback to reduce the error signal. 
     
     
       18. The apparatus according to  claim 11 , wherein the control means schedules a start-up mode for the motor according to a schedule in which the period duration of the applied current pulses is shortened progressively to approach a normal operating mode. 
     
     
       19. The apparatus according to  claim 18 , wherein the control means provides a linear shortening of the period duration of the applied current pulses. 
     
     
       20. The apparatus according to  claim 13 , wherein the control means, in determining rotor position, determines a phase of a fundamental oscillation of at least some of the functions, which are repeatedly determined. 
     
     
       21. The apparatus according to  claim 20 , wherein the control means determines the amplitude and phase of the fundamental oscillation by a centroid analysis. 
     
     
       22. The apparatus according to  claim 11 , wherein the control means further adjusts the application of commutation signals and the determination of rotor position based up an electronically stored table of correction values that are specific to the brushless electric motor. 
     
     
       23. The apparatus according to  claim 11 , wherein, for the application of commutation signals, the control means includes, in series toward the motor, a commutation logic unit, a commutation control unit, a current detection unit, a counter, an attenuator, a voltage comparison unit, and a signal delay unit, the current detection unit including current sensors and a sample and hold device, the voltage comparison unit including inputs for voltages from the coils, the control means further including an input to which an interrupt request may be applied. 
     
     
       24. The apparatus according to  claim 23 , wherein the motor includes at least three coils and the control means provides at least three commutation signals. 
     
     
       25. The apparatus according to  claim 11 , wherein the control means, in determining rotor position, determines a phase of a fundamental oscillation of at least some of the functions, which are repeatedly determined. 
     
     
       26. The apparatus according to  claim 7 , wherein the brushless electric motor is operated at no load. 
     
     
       27. The apparatus according to  claim 13 , wherein the brushless electric motor is operated at no load. 
     
     
       28. The apparatus according to  claim 20 , wherein the control means determines phases and amplitudes of oscillatory functions of the at least some functions by Fourier transform analysis. 
     
     
       29. The apparatus according to  claim 17 , comprising additional control means that provides a desired rotor position, compares it with the determined rotor position to provide an error signal, and applies the error signal via proportional-integral-derivative negative feedback to reduce the error signal. 
     
     
       30. A brushless direct current motor, comprising:
   a stator including at least three stator coils;        a rotor which is mounted for rotation about an axis with respect to said stator and which includes a permanent magnetic member, wherein an air gap is defined between adjacent surface of said permanent magnetic member and said at least three stator coils;        a plurality of switches operatively electrically connected to said stator coils, said switches allowing power to be supplied to said stator coils during operation of said motor; and        a switch controller electrically connected to said plurality of switches, said switch controller applying commutation signals to said plurality of switches to selectively switch said switches thereby selectively applying power to said stator coils during operation of said motor, said switch controller including,        a first circuit mounted stationary with respect to said stator and operatively connected to said stator coils, said first circuit generating a sequence of samples of a component of power fed to said stator coils which are generally representative of the rotational position of said rotor with respect to said stator, and        a second circuit electrically connected to said first circuit, wherein said second circuit determines parameters of a function based upon a variable inductance in the motor and said sequence of samples, and wherein said second circuit generates said commutation signals based upon said parameters of a function.     
     
     
       31. The brushless direct current motor of  claim 30 , wherein said second circuit further comprises a memory electrically connected to said first and second circuits, said memory storing said sequence of samples to allow an adjustable offset in time to be applied to said commutation signals. 
     
     
       32. A brushless direct current motor, comprising:
   a stator including at least three stator coils;        a rotor which is mounted for rotation about an axis with respect to said stator and which includes a permanent magnetic member, wherein an air gap is defined between adjacent surface of said permanent magnetic member and said at least three stator coils;        a plurality of switches operatively electrically connected to said stator coils, said switches allowing power to be supplied to said stator coils during operation of said motor; and        a switch controller electrically connected to said plurality of switches, said switch controller applying commutation signals to said plurality of switches to selectively switch said switches thereby selectively applying power to said stator coils during operation of said motor, said switch controller including,        a first circuit mounted stationary with respect to said stator and operatively connected to said stator coils, said first circuit generating a sequence of samples of a component of power fed to said stator coils which are generally representative of the rotational position of said rotor with respect to said stator, and        a second circuit electrically connected to said first circuit, wherein said second circuit includes a memory electrically connected to said first circuit, said memory storing said sequence of samples to allow an adjustable offset in time to be applied to said commutation signals.     
     
     
       33. The brushless direct current motor of  32  wherein said second circuit determines parameters of a function based upon a variable inductance in the motor and said sequence of samples, and wherein said second circuit generates said commutation signals based upon said parameters of a function.