Protection of motor drive systems from current sensor faults

1. A method for detecting a phase current sensor fault in a multi-phase electrical machine, the method comprising:

receiving an input torque command T* and measuring a set of feedback signals of the electrical machine including a phase current Ix for each phase thereof;

generating direct and quadrature command phase currents Id*, Iq* for the machine corresponding to the value of an input torque command T*;

determining a total command current Is=f(Id*, Iq*);

generating a negative sequence current Ineg =f(Ix);

combining Ineg and Is to provide a normalized negative sequence current Inn=Ineg/Is;

comparing the normalized negative sequence current Inn to a predetermined threshold value INN* to determine the presence of a phase current sensor fault; and

executing a control action when Inn>INN*, wherein the control action comprises reducing the phase currents Ix flowing to the machine or reducing a phase voltages Vx applied to the machine.

2. The method of claim 1 , wherein the control action includes setting a fault flag when Inn>INN*.

3. The method of claim 2 , wherein the control action includes setting a diagnostic code indicating the nature of the fault.

4. A method for detecting a phase current sensor fault in a three-phase electrical motor, the method being executable via a motor controller adapted for controlling the electric motor, and comprising:

measuring an input torque command T* and set of feedback signals of the electrical motor including a phase current Ia, Ib, Ic for each of the three phases of the electric motor, and using the controller;

generating direct and quadrature command phase currents Id*, Iq* for the motor corresponding to a value of the input torque command T*;

determining a total command current Is =[(Iq*) 2 +(Id*) 2 ] 1/2 ;

generating a negative sequence current Ineg =(⅓)[Ia+(α 2 )Ib +(α)Ic], where α=e j2π/3 , and wherein (i) “e” is a mathematical constant named Euler's number, with the natural logarithm of “e” being equal to one, (ii) “j” represents an imaginary number equal to the square root of negative one, and (iii) “π” is the ratio of the circumference of any circle to the diameter of that circle;

combining Ineg and Is to provide a normalized negative sequence current Inn =Ineg/Is;

comparing the normalized negative sequence current Inn to a predetermined threshold value INN* to determine the presence of a phase current sensor fault; and

executing a control action when Inn>INN*, wherein the control action comprises reducing one or more of the phase currents flowing to the motor or reducing voltages Va, Vb, Vc applied to the motor.

5. The method of claim 4 , further comprising, setting a fault flag when Inn>INN*.

6. The method of claim 5 , further comprising, also setting a diagnostic code indicating the nature of the fault.

7. A method for protecting an electric propulsion system from malfunction of one or more current sensors that measure phase currents into windings Wa, Wb, Wc of a drive motor, the current sensors providing indicated motor phase current signals Ia, Ib, Ic, the method comprising:

receiving from the current sensors indicated motor phase current signals Ia, Ib, Ic;

receiving a motor torque command T* from a command input source;

receiving a motor rotation speed ωr from the motor;

receiving a direct current (dc) voltage Vdc from a dc source supplying the drive currents to the motor windings Wa, Wb, Wc;

using T*, ωr, and Vdc, obtaining values for time varying direct axis command current Id* and quadrature axis command current Iq*;

determining values for total command current Is =((Id*) 2 +(Iq*) 2 ) 1/2 ;

determining values for negative current In =(⅓)*(Ia+α 2 Ib +αIc) where α=e j2π/3 , and wherein (i) “e” is a mathematical constant named Euler's number, with the natural logarithm of “e” being equal to one, (ii) “j” represents an imaginary number equal to the square root of negative one, and (iii) “π” is the ratio of the circumference of any circle to the diameter of that circle;

determining values for normalized negative current Inn=In/Is; and

comparing Inn to a predetermined threshold value INN*, and if Inn>INN*, executing a control action*, wherein the control action comprises setting an error flag or an error diagnostic code in memory.

8. The method of claim 7 , further comprising, if Inn>(INN*), reducing the drive current flowing to the motor windings Wa, Wb, Wc.

9. The method of claim 8 , wherein the drive current flowing to the motor windings Wa, Wb, Wc is obtained from the dc voltage source by converting the voltage Vdc into three time varying voltages Va, Vb, Vc of different phases A, B, C each applied to a respective winding Wa, Wb, Wc of the motor, and wherein the drive currents flowing to the motor windings Wa, Wb, Wc are reduced by reducing Va, Vb, Vc.

10. The method of claim 9 , wherein the three time varying voltages Va, Vb, Vc of different phases A, B, C, each applied to a respective motor winding Wa, Wb, Wc depend upon the torque command T*, and if Inn>(INN*), overriding T* to reduce Va, Vb, Vc.

11. The method of claim 10 , wherein the torque command T* is derived at least in part from an operator actuated throttle position.

12. The method of claim 7 , further comprising, when Inn>INN*, setting a fault flag or indicator and then reducing the phase voltages Va, Vb, Vc.

13. The method of claim 7 , further comprising, when Inn>INN*, reducing one or more phase currents into windings Wa, Wb, Wc.

14. The method of claim 7 , further comprising, when Inn>INN*, turning off the drive motor.