The present invention relates to power steering apparatuses including an electric motor for generating an assist steering effort.
Japanese Patent Application Publication No. 2002-211425 discloses a power steering apparatus with an electric motor, in which a temperature sensor is provided at a motor drive section of a control unit. The temperature of the electric motor is estimated by: assuming an initial temperature of the electric motor to be equal to a temperature value detected by the temperature sensor when an ignition switch is turned on; computing an estimated temperature increase on the basis of a value of a motor current supplied to the electric motor; and adding the estimated temperature increase to the initial temperature. When the temperature sensor is judged as failed, then the motor current is limited to a motor current value with which both of the control unit and the electric motor can continuously operate without being overheated.
When the temperature sensor is failed in the power steering apparatus as disclosed in Japanese Patent Application Publication No. 2002-211425, the power steering apparatus may fail to control the assist steering effort as desired, because it is impossible to compute the initial temperature of the electric motor on the basis of the detected temperature value, and therefore to estimate the temperature of the electric motor.
Accordingly, it is desirable to provide a power steering apparatus including an electric motor for generating an assist steering effort, and a temperature sensor, wherein the power steering apparatus is capable of controlling the assist steering effort as desired even when the temperature sensor is abnormal or failed.
According to one aspect of the present invention, a power steering apparatus comprises: an electric motor for producing an assist steering effort in a steering system; a temperature sensor for measuring a temperature of a first portion subject to thermal influence of operation of the electric motor; and a control unit configured to: determine an estimated temperature of a second portion in accordance with a value of a motor current flowing through the electric motor, the second portion being subject to thermal influence of operation of the electric motor; determine a first upper limit value in accordance with the measured temperature; determine a second upper limit value in such a manner that when the estimated temperature is below a threshold temperature value, the second upper limit value is larger than or equal to a maximum value of the motor current, and that when the estimated temperature is above the threshold temperature value, the second upper limit value is smaller than the maximum value; determine whether the temperature sensor is normal or abnormal; limit the motor current to a smaller one of the first and second upper limit values, when determining that the temperature sensor is normal; limit the motor current to the second upper limit value, when determining that the temperature sensor is abnormal; and correct at least one of the estimated temperature and the threshold temperature value in such a manner that the estimated temperature increases with respect to the threshold temperature value, when determining that when the estimated temperature is below the threshold temperature value, the temperature sensor becomes abnormal. The control unit may be configured to determine the estimated temperature of the second portion by: determine an estimated amount of change of temperature of the second portion in accordance with the value of the motor current; and adding the estimated amount of change of temperature to a reference temperature value. The first portion may include a switching circuit for driving the electric motor. The second portion may include the electric motor. The control unit may be configured to: determine whether the determination of the estimated temperature is normal or abnormal; and limit the motor current to the first upper limit value, when determining that the temperature sensor is normal and that the determination of the estimated temperature is abnormal. The control unit may be configured to hold the estimated temperature constant, when determining that when the estimated temperature is above the threshold temperature value, the temperature sensor becomes abnormal. The control unit may be configured to set the first upper limit value to be larger than or equal to the maximum value of the motor current, when determining that the temperature sensor is abnormal. The control unit may be configured to correct the estimated temperature by adding a predetermined value, when determining that when the estimated temperature is below the threshold temperature value, the temperature sensor becomes abnormal. The control unit may be configured to correct the threshold temperature value by subtracting a predetermined value, when determining that when the estimated temperature is below the threshold temperature value, the temperature sensor becomes abnormal.
According to another aspect of the invention, a power steering apparatus comprises: an electric motor for producing an assist steering effort in a steering system; a temperature sensor for measuring a temperature of a portion subject to thermal influence of operation of the electric motor; and a control unit configured to: determine an estimated temperature of the portion in accordance with a value of a motor current flowing through the electric motor; determine a first upper limit value in accordance with the measured temperature; determine a second upper limit value in such a manner that when the estimated temperature is below a threshold temperature value, the second upper limit value is larger than or equal to a maximum value of the motor current, and that when the estimated temperature is above the threshold temperature value, the second upper limit value is smaller than the maximum value; determine whether the temperature sensor is normal or abnormal; limit the motor current to a smaller one of the first and second upper limit values, when determining that the temperature sensor is normal; limit the motor current to the second upper limit value, when determining that the temperature sensor is abnormal; and correct at least one of the estimated temperature and the threshold temperature value in such a manner that the estimated temperature increases with respect to the threshold temperature value, when determining that when the estimated temperature is below the threshold temperature value, the temperature sensor becomes abnormal.
According to a further aspect of the invention, a power steering apparatus comprises: an electric motor for producing an assist steering effort in a steering system; a temperature sensor for measuring a temperature of a first portion subject to thermal influence of operation of the electric motor; and a control unit configured to: determine an estimated temperature of a second portion in accordance with a value of a motor current flowing through the electric motor, the second portion being subject to thermal influence of operation of the electric motor; determine a first upper limit value in accordance with the measured temperature; determine a second upper limit value in such a manner that when the estimated temperature is within a first predetermined temperature range, the second upper limit value is larger than or equal to a maximum value of the motor current, and that when the estimated temperature is within a second predetermined temperature range, the second upper limit value is smaller than the maximum value; determine whether the temperature sensor is normal or abnormal; limit the motor current to a smaller one of the first and second upper limit values, when determining that the temperature sensor is normal; limit the motor current to the second upper limit value, when determining that the temperature sensor is abnormal; and reduce at least one of the first and second upper limit values, when determining that when the estimated temperature is within the first predetermined temperature range, the temperature sensor becomes abnormal.
According to a still further aspect of the invention, a power steering apparatus comprises: an electric motor for producing an assist steering effort in a steering system; a temperature sensor for measuring a temperature of a portion subject to thermal influence of operation of the electric motor; and a control unit configured to: determine an estimated temperature of the portion in accordance with a value of a motor current flowing through the electric motor; determine a first upper limit value in accordance with the measured temperature; determine a second upper limit value in such a manner that when the estimated temperature is within a first predetermined temperature range, the second upper limit value is larger than or equal to a maximum value of the motor current, and that when the estimated temperature is within a second predetermined temperature range, the second upper limit value is smaller than the maximum value; determine whether the temperature sensor is normal or abnormal; limit the motor current to a smaller one of the first and second upper limit values, when determining that the temperature sensor is normal; limit the motor current to the second upper limit value, when determining that the temperature sensor is abnormal; and reduce at least one of the first and second upper limit values, when determining that when the estimated temperature is within the first predetermined temperature range, the temperature sensor becomes abnormal.
According to another aspect of the invention, a power steering apparatus comprises: an electric motor for producing an assist steering effort in a steering system; a temperature sensor for measuring a temperature of a first portion subject to thermal influence of operation of the electric motor; and a control unit configured to: determine an estimated temperature of a second portion in accordance with a value of a motor current flowing through the electric motor, the second portion being subject to thermal influence of operation of the electric motor; determine a first upper limit value in accordance with the measured temperature; determine a second upper limit value in accordance with the estimated temperature; determine a third upper limit value in such a manner that the third upper limit value is smaller than or equal to the second upper limit value for each value of the estimated temperature; determine whether the temperature sensor is normal or abnormal; limit the motor current to a smaller one of the first and second upper limit values, when determining that the temperature sensor is normal; and limit the motor current to the third upper limit value, when determining that the temperature sensor is abnormal.
According to another aspect of the invention, a power steering apparatus comprises: an electric motor for producing an assist steering effort in a steering system; a temperature sensor for measuring a temperature of a first portion subject to thermal influence of operation of the electric motor; a control unit for controlling the electric motor, the control unit being configured to determine an estimated temperature of a second portion in accordance with a value of a motor current flowing through the electric motor, the second portion being subject to thermal influence of operation of the electric motor; and a circuit for supplying electric power to the control unit after the control unit is switched off, the circuit being configured to: determine in accordance with at least one of the measured temperature and the estimated temperature whether or not to supply electric power to the control unit after the control unit is switched off; correct the estimated temperature by adding a predetermined value, when determining that the temperature sensor is abnormal; and determine in accordance with the corrected estimated temperature whether or not to supply electric power to the control unit after the control unit is switched off, when determining that the temperature sensor is abnormal.
FIG. 1 is a schematic diagram showing system configuration of a power steering apparatus according to a first embodiment of the present invention.
FIG. 2 is control block diagram showing a control unit of the power steering apparatus according to the first embodiment.
FIG. 3 is a control block diagram showing a temperature-based torque limit computing section of the control unit according to the first embodiment.
FIG. 4 is a graph showing a function of computing a first torque limit according to the first embodiment.
FIG. 5 is a graph showing a function of computing a second torque limit according to the first embodiment.
FIG. 6 is a flow chart showing a main process to be performed by the control unit according to the first embodiment.
FIG. 7 is a flow chart showing a detailed process of computing the first torque limit according to the first embodiment.
FIG. 8 is a flow chart showing a detailed process of computing the second torque limit according to the first embodiment.
FIG. 9 is a flow chart showing a detailed process of computing a temperature-based torque limit according to the first embodiment.
FIG. 10 is a flow chart showing a detailed process of computing a command assist steering torque according to the first embodiment.
FIG. 11 is graph showing a function of computing the second torque limit according to the first embodiment, when a temperature sensor is abnormal.
FIGS. 12A and 12B are a set of time charts showing an example of how the power steering apparatus according to the first embodiment operates.
FIGS. 13A and 13B are a set of time charts showing another example of how the power steering apparatus according to the first embodiment operates.
FIG. 14 is a control block diagram showing a temperature-based torque limit computing section of a control unit of a power steering apparatus according to a second embodiment of the present invention.
FIG. 15 is a flow chart showing a detailed process of computing the second torque limit according to the second embodiment.
FIG. 16 is a flow chart showing a detailed process of computing the second torque limit according to a third embodiment of the present invention.
FIG. 17 is a graph showing a function of computing the second torque limit according to the third embodiment.
FIGS. 18A and 18B are a set of time charts showing an example of how the power steering apparatus according to the third embodiment operates.
FIG. 19 is a flow chart showing a detailed process of computing the second torque limit according to a fourth embodiment of the present invention.
FIG. 20 is a graph showing a function of computing the second torque limit according to the fourth embodiment.
FIGS. 21A and 21B are a set of time charts showing an example of how the power steering apparatus according to the fourth embodiment operates.
FIG. 22 is a control block diagram showing a temperature-based torque limit computing section of a control unit of a power steering apparatus according to a fifth embodiment of the present invention.
FIG. 23 is a graph showing a function of computing the first torque limit according to the fifth embodiment.
FIG. 24 is a graph showing a function of computing the second torque limit according to the fifth embodiment.
FIG. 25 is a graph showing a function of computing a third torque limit according to the fifth embodiment.
FIGS. 26A and 26B are a set of control block diagrams showing the temperature-based torque limit computing section according to the fifth embodiment under two different conditions.
FIG. 27 is a flow chart showing a main process to be performed by the control unit according to the fifth embodiment.
FIG. 28 is a flow chart showing a detailed process of computing the first torque limit according to the fifth embodiment.
FIG. 29 is a flow chart showing a detailed process of computing the second torque limit according to the fifth embodiment.
FIG. 30 is a flow chart showing a detailed process of computing the third torque limit according to the fifth embodiment.
FIG. 31 is a flow chart showing a detailed process of computing the temperature-based torque limit according to the fifth embodiment.
FIG. 32 is a flow chart showing a detailed process of computing the command assist steering torque according to the fifth embodiment.
FIGS. 33A, 33 B and 33 C are a set of time charts showing an example of how the power steering apparatus according to the fifth embodiment operates.
FIG. 34 is a graph showing a function of computing the third torque limit according to a sixth embodiment of the present invention.
FIGS. 35A, 35 B and 35 C are a set of time charts showing an example of how a power steering apparatus according to the sixth embodiment operates.
FIG. 36 is a control block diagram showing a temperature-based torque limit computing section of a control unit of a power steering apparatus according to a seventh embodiment of the present invention.
FIG. 37 is a control block diagram showing the temperature-based torque limit computing section under one exemplary condition according to the seventh embodiment.
FIG. 38 is a flow chart showing a detailed process of computing the third torque limit according to the seventh embodiment.
FIGS. 39A, 39 B and 39 C are a set of time charts showing an example of how the power steering apparatus according to the seventh embodiment operates.
FIG. 40 is a schematic diagram showing system configuration of a power steering apparatus according to an eighth embodiment of the present invention.
FIG. 41 is a control block diagram showing an ON-state holding circuit 18 of the power steering apparatus according to the eighth embodiment.
FIGS. 42A, 42 B and 42 C are a set of time charts showing an example of how the power steering apparatus according to the eighth embodiment operates.
FIG. 43 is a schematic diagram showing system configuration of a power steering apparatus to which the power steering apparatus according to the first to eighth embodiments may be applied.
The following describes a power steering apparatus according to a first embodiment of the present invention with reference to FIGS. 1 to 13. FIG. 1 shows system configuration of the power steering apparatus according to the first embodiment. As shown in FIG. 1, the power steering apparatus generally includes a steering input transmitting mechanism 1 , an assist steering torque generating mechanism 2 , a hydraulic fluid supplying mechanism 3 , and a control unit 4 . Steering input transmitting mechanism 1 is a mechanism constructed to receive and transmit a driver's steering torque (or driver's steering effort). Assist steering torque generating mechanism 2 is a mechanism constructed to generate an assist steering torque (or assist steering effort) in accordance with the driver's steering torque. Hydraulic fluid supplying mechanism 3 is a mechanism constructed to supply hydraulic fluids to assist steering torque generating mechanism 2 .
Steering input transmitting mechanism 1 includes a steering wheel 10 , a column shaft 11 , a universal joint 12 , an intermediate shaft 13 , a universal joint 14 , an input shaft 15 , and a pinion 17 connected in series, where a steering torque sensor 16 is provided at input shaft 15 for measuring a steering torque applied to steering input transmitting mechanism 1 .
Assist steering torque generating mechanism 2 includes a power cylinder 20 , a piston 21 , and a rack 22 . Piston 21 is mounted within power cylinder 20 for longitudinal motion, defining first and second cylinder chambers 23 and 24 on both sides thereof. Rack 22 is fixed to piston 21 for motion therewith.
Hydraulic fluid supplying mechanism 3 includes a hydraulic pump 30 , an electric motor 31 , first and second fluid passages 32 and 33 , and a failsafe valve 34 . Electric motor 31 drives hydraulic pump 30 for supplying hydraulic fluids. The hydraulic fluids are supplied to power cylinder 20 through first and second fluid passages 32 and 33 . First fluid passage 32 is connected between hydraulic pump 30 and first cylinder chamber 23 of power cylinder 20 , while second fluid passage 33 is connected between hydraulic pump 30 and second cylinder chamber 24 of power cylinder 20 . Failsafe valve 34 is a normally open valve, and is connected between first and second fluid passages 32 and 33 . Thus, electric motor 31 produces an assist steering torque in a steering system.
Control unit 4 is connected electrically to a vehicle speed sensor 5 , a battery 6 , steering torque sensor 16 , and electric motor 31 . Vehicle speed sensor 5 measures the vehicle speed of an automotive vehicle on which the power steering apparatus is mounted. Control unit 4 receives a signal indicative of the measured vehicle speed from vehicle speed sensor 5 , and a signal indicative of the measured steering torque from steering torque sensor 16 , and controls the assist steering torque on the basis of those signals by controlling the electric motor 31 to adjust the amount of the hydraulic fluids supplied to assist steering torque generating mechanism 2 .
Pinion 17 of steering input transmitting mechanism 1 meshes with rack 22 of assist steering torque generating mechanism 2 so that the driver's steering torque and the assist steering torque generated by assist steering torque generating mechanism 2 are transmitted to steerable vehicle wheels not shown through tie rods 7 and 7 .
Under normal operating conditions, control unit 4 shuts off fluid communication between first and second fluid passages 32 and 33 by closing the failsafe valve 34 . When steering wheel 10 is turned, and steering torque sensor 16 outputs a signal indicative of the measured steering torque to control unit 4 , then control unit 4 produces an assist steering torque in accordance with the measured steering torque by driving the hydraulic pump 30 through electric motor 31 .
When steering wheel 10 is turned left (counterclockwise from driver's viewpoint) as indicated by D 1 in FIG. 1, then the hydraulic pressure is supplied to first cylinder chamber 23 of power cylinder 20 through first fluid passage 32 , so as to boost the leftward steering effort. On the other hand, when steering wheel 10 is turned right as indicated by D 2 in FIG. 1, then the hydraulic pressure is supplied to second cylinder chamber 24 of power cylinder 20 through second fluid passage 33 , so as to boost the rightward steering effort.
Under failed operating conditions, control unit 4 allows fluid communication between first and second cylinder chambers 23 and 24 by opening the failsafe valve 34 , so as to allow manual steering operation.
FIG. 2 shows a control block diagram of control unit 4 . As shown in FIG. 2, control unit 4 includes a temperature sensor 40 , a section 41 (referred to as temperature sensor malfunction monitoring section), a section 42 (referred to as temperature-based torque limit computing section), a section 43 (referred to as assist steering torque computing section), a limiter 44 , a section 45 (referred to as motor position computing section), a section 46 (referred to as motor control section), a section 47 (referred to as motor drive section), and a current sensor 48 . Temperature sensor 40 measures the temperature of a portion of control unit 4 as measured temperature Tmsr (environmental temperature), and outputs a signal indicative of measured temperature Tmsr to temperature-based torque limit computing section 42 . The portion of control unit 4 is subject to thermal influence of operation of electric motor 31 . Naturally, electric motor 31 is also subject to thermal influence of operation of electric motor 31 . For example, temperature sensor 40 may measure the temperature of a switching circuit for driving electric motor 31 .
Temperature sensor malfunction monitoring section 41 monitors and detects malfunctions of temperature sensor 40 . Under abnormal conditions, temperature sensor 40 indicates extremely high or low temperatures existing out of a range of temperature within which temperature sensor 40 normally indicates temperatures. Accordingly, when temperature sensor 40 outputs a signal indicative of a temperature value existing out of the normal temperature range, then temperature sensor malfunction monitoring section 41 outputs a signal indicative of malfunction of temperature sensor 40 to temperature-based torque limit computing section 42 .
Temperature-based torque limit computing section 42 receives a signal indicative of the temperature of control unit 4 from temperature sensor 40 , a signal indicative of a motor current supplied to electric motor 31 from current sensor 48 , and a signal indicative of malfunction of temperature sensor 40 from temperature sensor malfunction monitoring section 41 .
Temperature-based torque limit computing section 42 computes an estimated temperature of electric motor 31 as estimated motor temperature Tmest on the basis of a measured value of the motor current flowing through electric motor 31 , computes, on the basis of measured temperature Tmsr of control unit 4 and estimated motor temperature Tmest, a value (referred to as temperature-based torque limit ATlim) to which the assist steering torque is limited, so as to bring control unit 4 and electric motor 31 into conditions of normal temperature range, and outputs a signal indicative of temperature-based torque limit ATlim to limiter 44 . Temperature-based torque limit computing section 42 is described in detail below with reference to FIG. 3.
Assist steering torque computing section 43 receives a signal indicative of the steering torque from steering torque sensor 16 , and a signal indicative of vehicle speed from vehicle speed sensor 5 , computes a desired assist steering torque ATdes, and outputs a signal indicative of desired assist steering torque ATdes to limiter 44 .
Limiter 44 receives a signal indicative of temperature-based torque limit ATlim from temperature-based torque limit computing section 42 , and a signal indicative of desired assist steering torque ATdes from assist steering torque computing section 43 , and outputs a signal indicative of a command assist steering torque ATcom to motor control section 46 in accordance with those inputted signals.
Motor position computing section 45 receives a signal indicative of the angular position of electric motor 31 from rotation sensor 35 , computes the angular position of electric motor 31 , and outputs a signal indicative of the angular position to motor control section 46 .
Motor control section 46 receives a signal indicative of the angular position of electric motor 31 from motor position computing section 45 , and a signal indicative of measured U-phase, V-phase and W-phase current values from current sensor 48 . Motor control section 46 converts the three-phase current values of U-phase, V-phase and W-phase into two-phase current values, generates motor drive signals (PWM signals) by feedback control such as PI control, and outputs the motor drive signals to motor drive section 47 .
Motor drive section 47 receives the motor drive signals from motor control section 46 . Motor drive section 47 includes power elements such as field-effect transistors (FETs). Motor drive section 47 performs switching operation for the power elements in accordance with the motor drive signals, and thereby supplies a motor current to electric motor 31 .
The following describes temperature-based torque limit computing section 42 with reference to FIG. 3. Temperature-based torque limit computing section 42 includes an A/D (Analog-to-Digital) converter 42 a , a first torque limit computing part 42 b , a motor temperature estimating part 42 c , a second torque limit computing part 42 d , and a minimum selecting part 42 e . A/D converter 42 a receives an analog signal indicative of the measured temperature from temperature sensor 40 , converts the analog signal into a digital signal, and outputs the digital signal to first torque limit computing part 42 b.
First torque limit computing part 42 b receives a signal indicative of the measured temperature, and a signal indicative of malfunction of temperature sensor 40 from temperature sensor malfunction monitoring section 41 , and computes a first upper limit value (referred to as first torque limit LIM 1 ) which is computed based on the temperature of control unit 4 for preventing overheating. First torque limit computing part 42 b outputs a signal indicative of first torque limit LIM 1 to minimum selecting part 42 e.
First torque limit computing part 42 b stores data indicative of a function of computing first torque limit LIM 1 as shown in FIG. 4. As shown in FIG. 4, according to the function of computing first torque limit LIM 1 , when measured temperature Tmsr (the temperature of control unit 4 ) is below a predetermined threshold temperature value (referred to as lowest assist-limiting temperature), then first torque limit LIM 1 is set to a maximum value (referred to as full-assist value ATf). The temperature range below the lowest assist-limiting temperature is referred to as full-assist range. On the other hand, when measured temperature Tmsr is above the lowest assist-limiting temperature, then first torque limit LIM 1 is set to decrease with increase in measured temperature Tmsr. The temperature range above the lowest assist-limiting temperature is referred to as assist-limiting range. Thus, a second upper limit value (LIM 2 ) is determined in such a manner that when the estimated temperature (Tmest) is below a threshold temperature value, the second upper limit value (LIM 2 ) is larger than or equal to a maximum value of the motor current, and that when the estimated temperature (Tmest) is above the threshold temperature value, the second upper limit value (LIM 2 ) is smaller than the maximum value.
Motor temperature estimating part 42 c receives a signal indicative of the motor current supplied to electric motor 31 from current sensor 48 , a signal indicative of malfunction of temperature sensor 40 from temperature sensor malfunction monitoring section 41 , and a signal indicative of measured temperature Tmsr of control unit 4 from temperature sensor 40 , estimates the temperature of electric motor 31 as estimated motor temperature Tmest, and outputs a signal indicative of estimated motor temperature Tmest to second torque limit computing part 42 d.
Second torque limit computing part 42 d receives a signal indicative of estimated motor temperature Tmest from motor temperature estimating part 42 c , computes a second upper limit value (referred to as second torque limit LIM 2 ) which is computed based on the temperature of electric motor 31 for preventing overheating, and outputs a signal indicative of second torque limit LIM 2 to minimum selecting part 42 e.
Second torque limit computing part 42 d stores data indicative of a function of computing second torque limit LIM 2 as shown in FIG. 5. As shown in FIG. 5, according to the function of computing second torque limit LIM 2 , when estimated motor temperature Tmest is lower than a temperature value (referred to as lowest assist-limiting temperature) (estimated motor temperature Tmest is within the full-assist range), then second torque limit LIM 2 is set to full-assist value ATf. On the other hand, when estimated motor temperature Tmest is above the lowest assist-limiting temperature (estimated motor temperature Tmest is within the assist-limiting range), then second torque limit LIM 2 is set to decrease with increase in estimated motor temperature Tmest.
Minimum selecting part 42 e receives a signal indicative of first torque limit LIM 1 from first torque limit computing part 42 b , and a signal indicative of second torque limit LIM 2 from second torque limit computing part 42 d , compares first torque limit LIM 1 with second torque limit LIM 2 , and outputs the smaller one of them as temperature-based torque limit ATlim.
According to the first embodiment, the power steering apparatus monitors the temperature of control unit 4 and electric motor 31 , in order to prevent control unit 4 and electric motor 31 from overheating. The temperature of control unit 4 is directly monitored by temperature sensor 40 . On the other hand, the temperature of electric motor 31 is monitored as follows. Motor temperature estimating part 42 c estimates or computes an amount of generated heat on the basis of a value of the current supplied to electric motor 31 , and estimates an amount of change of temperature of electric motor 31 on the basis of the computed amount of generated heat, and adds the estimated amount of change of temperature to a reference temperature value T 0 to produce estimated motor temperature Tmest.
As described above, according to the related art, when a temperature sensor is judged as failed, then a motor current is limited to a motor current value with which both of a control unit and an electric motor can continuously operate without being overheated. However, it is possible that when the temperature sensor is failed, even if the temperature of electric motor 31 is sufficiently low, the motor current is suppressed so that the driver's steering torque is required to be large. In contrast, according to the first embodiment, even when temperature sensor 40 is failed, then temperature-based torque limit ATlim is provided on the basis of the estimated temperature of electric motor 31 .
The following describes a process performed by control unit 4 with reference to FIG. 6. At Step S 1 , control unit 4 computes first torque limit LIM 1 on the basis of the temperature of control unit 4 , and then proceeds to Step S 2 . The operation of computing first torque limit LIM 1 is described in detail below with reference to FIG. 7.
At Step S 2 , control unit 4 computes second torque limit LIM 2 on the basis of the temperature of electric motor 31 , and then proceeds to Step S 3 . The operation of computing second torque limit LIM 2 is described in detail below with reference to FIG. 8.
At Step S 3 , control unit 4 computes temperature-based torque limit ATlim on the basis of first torque limit LIM 1 and second torque limit LIM 2 , and then proceeds to Step S 4 . The operation of computing temperature-based torque limit ATlim is described in detail below with reference to FIG. 9.
At Step S 4 , control unit 4 computes command assist steering torque ATcom on the basis of desired assist steering torque ATdes and temperature-based torque limit ATlim, and then exits from this process. The operation of computing command assist steering torque ATcom is described in detail below with reference to FIG. 10.
The following describes a process of computing first torque limit LIM 1 with reference to FIG. 7. At Step S 11 , control unit 4 reads and obtains measured temperature Tmsr from temperature sensor 40 , and then proceeds to Step S 12 .
At Step S 12 , control unit 4 judges whether or not temperature sensor 40 is normal, on the basis of presence or absence of the signal indicative of malfunction of temperature sensor 40 outputted from temperature sensor malfunction monitoring section 41 . When judging temperature sensor 40 as normal, then control unit 4 proceeds to Step S 13 . When judging temperature sensor 40 as abnormal or failed, control unit 4 proceeds to Step S 14 .
At Step S 13 , control unit 4 computes first torque limit LIM 1 on the basis of measured temperature Tmsr using the function of computing first torque limit LIM 1 shown in FIG. 4. Specifically, when measured temperature Tmsr (the temperature of control unit 4 ) is lower than the lowest assist-limiting temperature, then control unit 4 sets first torque limit LIM 1 to full-assist value ATf. On the other hand, when measured temperature Tmsr is above the lowest assist-limiting temperature, then control unit 4 sets first torque limit LIM 1 to decrease with increase in measured temperature Tmsr.
At Step S 14 , control unit 4 sets first torque limit LIM 1 to the maximum, or to full-assist value ATf, and then exits from this process. As described in detail below, temperature-based torque limit ATlim is set to the smaller one of first torque limit LIM 1 and second torque limit LIM 2 . When temperature sensor 40 is abnormal, temperature-based torque limit ATlim is set to second torque limit LIM 2 , because first torque limit LIM 1 is set to the maximum at Step S 14 .
The following describes a process of computing second torque limit LIM 2 with reference to FIG. 8. At Step S 21 , control unit 4 computes estimated motor temperature Tmest of electric motor 31 on the basis of the torque current and field current supplied to electric motor 31 , and then proceeds to Step S 22 . Control unit 4 estimates or computes an amount of generated heat on the basis of a value of the current supplied to electric motor 31 , and estimates an amount of change of temperature of electric motor 31 on the basis of the computed amount of generated heat, and adds the estimated amount of change of temperature to a reference temperature value T 0 to produce estimated motor temperature Tmest.
At Step S 22 , control unit 4 judges whether or not temperature sensor 40 is normal, on the basis of presence or absence of the signal indicative of malfunction of temperature sensor 40 outputted from temperature sensor malfunction monitoring section 41 . When judging temperature sensor 40 as normal, then control unit 4 proceeds to Step S 27 . When judging temperature sensor 40 as abnormal, control unit 4 proceeds to Step S 23 .
At Step S 23 , control unit 4 judges whether or not a flag (referred to as temperature sensor malfunction flag) is set. When judging the temperature sensor malfunction flag as set, control unit 4 proceeds to Step S 27 . When judging the temperature sensor malfunction flag as not set, control unit 4 proceeds to Step S 24 . The temperature sensor malfunction flag is a data set flag for condition that temperature sensor 40 is abnormal.
At Step S 24 , control unit 4 judges whether or not second torque limit LIM 2 is equal to full-assist value ATf. When judging second torque limit LIM 2 as equal to full-assist value ATf, control unit 4 proceeds to Step S 25 . When judging second torque limit LIM 2 as not equal to full-assist value ATf, control unit 4 proceeds to Step S 27 .
At Step S 25 , control unit 4 corrects estimated motor temperature Tmest to be equal to the lowest assist-limiting temperature, and then proceeds to Step S 26 . Estimated motor temperature Tmest is updated at Step S 21 by adding, to the preceding value of estimated motor temperature Tmest, the amount of generated heat of electric motor 31 computed on the basis of the torque current and field current. If estimated motor temperature Tmest is increased in the following control cycle, the assist steering torque is limited to second torque limit LIM 2 which is below full-assist value ATf, because estimated motor temperature Tmest is corrected to be equal to the lowest assist-limiting temperature at Step S 25 in the current control cycle. Thus, estimated motor temperature Tmest is corrected by adding a predetermined value, when it is determined that when estimated motor temperature Tmest is below the lowest assist-limiting temperature, temperature sensor 40 becomes abnormal.
At Step S 26 , control unit 4 sets the temperature sensor malfunction flag, and then proceeds to Step S 27 .
At Step S 27 , control unit 4 computes second torque limit LIM 2 on the basis of estimated motor temperature Tmest computed at Step S 21 and corrected at Step S 25 , and then exits from this process. Second torque limit LIM 2 is computed using the function of computing second torque limit LIM 2 shown in FIG. 5. Specifically, when estimated motor temperature Tmest is below the lowest assist-limiting temperature, control unit 4 sets second torque limit LIM 2 to full-assist value ATf. On the other hand, when estimated motor temperature Tmest is above the lowest assist-limiting temperature, control unit 4 sets second torque limit LIM 2 to decrease with increase in estimated motor temperature Tmest.
The following describes a process of computing temperature-based torque limit ATlim with reference to FIG. 9. At Step S 31 , control unit 4 compares first torque limit LIM 1 with second torque limit LIM 2 , and then judges whether or not first torque limit LIM 1 is smaller than second torque limit LIM 2 . When judging first torque limit LIM 1 as smaller than second torque limit LIM 2 , control unit 4 proceeds to Step S 32 . When judging first torque limit LIM 1 as not smaller than second torque limit LIM 2 , control unit 4 proceeds to Step S 33 .
At Step S 32 , control unit 4 sets temperature-based torque limit ATlim to be equal to first torque limit LIM 1 , and then exits from this process.
At Step S 33 , control unit 4 sets temperature-based torque limit ATlim to be equal to second torque limit LIM 2 , and then exits from this process.
The following describes a process of computing command assist steering torque ATcom with reference to FIG. 10. At Step S 41 , control unit 4 judges whether or not desired assist steering torque ATdes is smaller than temperature-based torque limit ATlim. When judging desired assist steering torque ATdes as smaller than temperature-based torque limit ATlim, control unit 4 proceeds to Step S 42 . When judging desired assist steering torque ATdes as not smaller than temperature-based torque limit ATlim, control unit 4 proceeds to Step S 43 .
At Step S 42 , control unit 4 sets command assist steering torque ATcom to be equal to desired assist steering torque ATdes, and then proceeds to Step S 44 .
At Step S 43 , control unit 4 sets command assist steering torque ATcom to be equal to temperature-based torque limit ATlim, and then proceeds to Step S 44 .
At Step S 44 , control unit 4 implements command assist steering torque ATcom which is set at Step S 42 or S 43 , and then exits from this process.
FIG. 11 illustrates the foregoing method of setting second torque limit LIM 2 for the case where temperature sensor 40 is abnormal.
According to the first embodiment, even when temperature sensor 40 provided at control unit 4 is abnormal, the power steering apparatus sets temperature-based torque limit ATlim on the basis of estimated motor temperature Tmest, and generates an assist steering torque within temperature-based torque limit ATlim. Motor temperature estimating part 42 c of control unit 4 can estimate accurately the amount of increase in temperature based on heat generation by electric motor 31 , although using no environmental temperatures and no measured temperature of electric motor 31 .
For example, it is supposed that when temperature sensor 40 is abnormal, estimated motor temperature Tmest is equal to a temperature value T 1 which is below the lowest assist-limiting temperature Ta, or within the full-assist range, as indicated by F 111 in FIG. 11. In such a case, estimated motor temperature Tmest is corrected or increased to be equal to lowest assist-limiting temperature Ta in the direction to increase a margin for safety, as indicated by F 112 in FIG. 11. After that, the current supplied to electric motor 31 is controlled on the basis of the modified estimated motor temperature Tmest which is updated by motor temperature estimating part 42 c.
On the other hand, it is supposed that when temperature sensor 40 is abnormal, estimated motor temperature Tmest is equal to a temperature value T 2 which is above the lowest assist-limiting temperature Ta, or within the assist-limiting range. In such a case, estimated motor temperature Tmest is maintained to be equal to temperature value T 2 .
The following describes an example of how the power steering apparatus according to the first embodiment operates, in which temperature sensor 40 becomes abnormal under condition of the full-assist range, with reference to FIGS. 12A and 12B. FIG. 12A shows how estimated motor temperature Tmest changes with time, while FIG. 12B shows how command assist steering torque ATcom changes with time.
As shown in FIG. 12B, until time t 0 after time t 0 , command assist steering torque ATcom is set to be equal to desired assist steering torque ATdes, because desired assist steering torque ATdes is smaller than temperature-based torque limit ATlim. Accordingly, as shown in FIG. 12A, until time t 0 after time t 0 , estimated motor temperature Tmest increases with increase in desired assist steering torque ATdes.
Temperature sensor 40 is assumed to become abnormal at time t 1 . At time t 1 , estimated motor temperature Tmest is equal to temperature value T 1 . Estimated motor temperature Tmest is corrected to be equal to lowest assist-limiting temperature Ta, because temperature value T 1 is within the full-assist range.
After time t 1 , estimated motor temperature Tmest becomes above lowest assist-limiting temperature Ta, so that temperature-based torque limit ATlim is set to decrease with increase in estimated motor temperature Tmest. Until time t 2 after time t 0 , command assist steering torque ATcom is still set to be equal to desired assist steering torque ATdes, because desired assist steering torque ATdes is still smaller than temperature-based torque limit ATlim. Accordingly, as shown in FIG. 12A, until time t 2 , estimated motor temperature Tmest continues to increase with increase in desired assist steering torque ATdes.
After time t 2 , command assist steering torque ATcom is set to be equal to temperature-based torque limit ATlim, because desired assist steering torque ATdes exceeds temperature-based torque limit ATlim at time t 2 .
Thus, when temperature sensor 40 becomes abnormal, and motor temperature estimating part 42 c estimates an increase in estimated motor temperature Tmest, second torque limit LIM 2 is set so as to limit the assist steering torque. Therefore, it is possible to produce a sufficient assist steering torque for steering operation, while preventing control unit 4 and electric motor 31 from overheating.
The following describes an example in which temperature sensor 40 becomes abnormal under condition of the assist-limiting range with reference to FIGS. 13A and 13B. FIG. 13A shows how estimated motor temperature Tmest changes with time, while FIG. 13B shows how command assist steering torque ATcom and temperature-based torque limit ATlim change with time.
As shown in FIG. 13B, until time t 3 after time t 0 , command assist steering torque ATcom is set to be equal to desired assist steering torque ATdes, because desired assist steering torque ATdes is smaller than temperature-based torque limit ATlim. Accordingly, as shown in FIG. 13A, until time t 3 after time t 0 , estimated motor temperature Tmest increases with increase in desired assist steering torque ATdes.
As shown in FIG. 13A, at time t 3 , estimated motor temperature Tmest exceeds lowest assist-limiting temperature Ta, so that temperature-based torque limit ATlim is set to decrease with increase in estimated motor temperature Tmest.
Temperature sensor 40 is assumed to become abnormal at time t 4 . At time t 4 , estimated motor temperature Tmest is equal to temperature value T 2 . After time t 4 , estimated motor temperature Tmest is held constant, i.e. maintained to be equal to temperature value T 2 , because temperature value T 2 is within the assist-limiting range.
Until time t 5 after time t 3 , command assist steering torque ATcom is still set to be equal to desired assist steering torque ATdes, because desired assist steering torque ATdes is still smaller than temperature-based torque limit ATlim. Accordingly, as shown in FIG. 13A, estimated motor temperature Tmest continues to increase with increase in desired assist steering torque ATdes until time t 4 .
After time t 5 , command assist steering torque ATcom is set to be equal to temperature-based torque limit ATlim, because desired assist steering torque ATdes exceeds temperature-based torque limit ATlim at time t 5 .
Accordingly, second torque limit LIM 2 is maintained below full-assist value ATf. Thus, it is possible to produce a sufficient assist steering torque for steering operation, while preventing control unit 4 and electric motor 31 from overheating.
As described above, when temperature sensor 40 is abnormal, first torque limit LIM 1 is set to the maximum or full-assist value ATf. Temperature-based torque limit LIM is constantly set to be equal to second torque limit LIM 2 , because temperature-based torque limit ATlim is set to be equal to the smaller one of first torque limit LIM 1 and second torque limit LIM 2 .
Thus, even after temperature sensor 40 becomes abnormal, it is possible to provide temperature-based torque limit ATlim on the basis of estimated motor temperature Tmest. Therefore, it is possible to produce a sufficient assist steering torque for steering operation, while preventing control unit 4 and electric motor 31 from overheating.
As described above, according to the first embodiment, motor temperature estimating part 42 c computes the estimated temperature of electric motor 31 by estimating the amount of generated heat of electric motor 31 on the basis of the current supplied to electric motor 31 , and computes the estimated temperature of electric motor 31 on the basis of the amount of generated heat. Alternatively, motor temperature estimating part 42 c may estimate the amount of generated heat of control unit 4 on the basis of the current supplied to electric motor 31 , and compute an estimated temperature of control unit 4 .
Moreover, temperature sensor 40 may be configured to measure the temperature of electric motor 31 , instead of the temperature of control unit 4 . Also, in this alternative configuration, it is sufficient to compute first torque limit LIM 1 on the basis of the measured temperature of temperature sensor 40 . This alternative configuration is effective similarly as in the first embodiment.
In general, it is difficult to attach a temperature sensor to an electric motor. The temperature of control unit 4 changes in correlation with that of electric motor 31 , because control unit 4 drives electric motor 31 . Accordingly, according to the first embodiment, temperature sensor 40 is provided in control unit 4 for detecting a temperature correlated with the temperature of electric motor 31 .
The following describes a power steering apparatus according to a second embodiment of the present invention with reference to FIGS. 14 and 15. As described above, the power steering apparatus according to the first embodiment is configured to: monitor malfunction of temperature sensor 40 ; and when temperature sensor 40 becomes abnormal, set temperature-based torque limit ATlim to be equal to second torque limit LIM 2 so as to limit desired assist steering torque ATdes. In contrast, as described in detail below, the power steering apparatus according to the second embodiment is further configured to: monitor malfunction of motor temperature estimating part 42 c ; and when motor temperature estimating part 42 c becomes abnormal, set temperature-based torque limit ATlim to be equal to first torque limit LIM 1 so as to limit desired assist steering torque ATdes.
In the following, the corresponding components are given the same reference characters as in the first embodiment. FIG. 14 shows a control block diagram of temperature-based torque limit computing section 42 . Temperature-based torque limit computing section 42 further includes a motor temperature estimation malfunction monitoring part 42 f.
Motor temperature estimation malfunction monitoring part 42 f monitors malfunction of motor temperature estimating part 42 c ; and when judging motor temperature estimating part 42 c as abnormal, outputs a signal indicative of malfunction of motor temperature estimating part 42 c to second torque limit computing part 42 d . Second torque limit computing part 42 d receives a signal indicative of estimated motor temperature Tmest from motor temperature estimating part 42 c , and a signal indicative of malfunction of motor temperature estimation from motor temperature estimation malfunction monitoring part 42 f , computes second torque limit LIM 2 , and outputs a signal indicative of second torque limit LIM 2 to minimum selecting part 42 e.
Although the second embodiment is based on the first embodiment, the second embodiment differs from the first embodiment in the operation of computing second torque limit LIM 2 as follows.
The following describes a process of computing second torque limit LIM 2 with reference to FIG. 15. At Step S 51 , control unit 4 computes estimated motor temperature Tmest of electric motor 31 on the basis of the torque current and field current supplied to electric motor 31 , and then proceeds to Step S 52 . Control unit 4 estimates or computes an amount of generated heat on the basis of a value of the current supplied to electric motor 31 , and estimates an amount of change of temperature of electric motor 31 on the basis of the computed amount of generated heat, and adds the estimated amount of change of temperature to a reference temperature value T 0 to produce estimated motor temperature Tmest.
At Step S 52 , control unit 4 judges whether or not temperature sensor 40 is normal, on the basis of presence or absence of the signal indicative of malfunction of temperature sensor 40 outputted from temperature sensor malfunction monitoring section 41 . When judging temperature sensor 40 as normal, then control unit 4 proceeds to Step S 58 . When judging temperature sensor 40 as abnormal, control unit 4 proceeds to Step S 53 .
At Step S 53 , control unit 4 judges whether or not a flag (referred to as temperature sensor malfunction flag) is set. When judging the temperature sensor malfunction flag as set, control unit 4 proceeds to Step S 57 . When judging the temperature sensor malfunction flag as not set, control unit 4 proceeds to Step S 54 . The temperature sensor malfunction flag is a data set flag for condition that temperature sensor 40 is abnormal.
At Step S 54 , control unit 4 judges whether or not second torque limit LIM 2 is equal to full-assist value ATf. When judging second torque limit LIM 2 as equal to full-assist value ATf, control unit 4 proceeds to Step S 55 . When judging second torque limit LIM 2 as not equal to full-assist value ATf, control unit 4 proceeds to Step S 57 .
At Step S 55 , control unit 4 corrects estimated motor temperature Tmest to be equal to the lowest assist-limiting temperature, and then proceeds to Step S 56 . Estimated motor temperature Tmest is updated at Step S 51 by adding, to the preceding value of estimated motor temperature Tmest, the amount of generated heat of electric motor 31 computed on the basis of the torque current and field current. If estimated motor temperature Tmest is increased in the following control cycle, the assist steering torque is limited to second torque limit LIM 2 which is below full-assist value ATf, because estimated motor temperature Tmest is set to the lowest assist-limiting temperature at Step S 55 in the current control cycle.
At Step S 56 , control unit 4 sets the temperature sensor malfunction flag, and then proceeds to Step S 57 .
At Step S 57 , control unit 4 computes second torque limit LIM 2 on the basis of estimated motor temperature Tmest computed at Step S 51 and corrected at Step S 55 , and then exits from this process. Second torque limit LIM 2 is computed using the function of computing second torque limit LIM 2 shown in FIG. 5. Specifically, when estimated motor temperature Tmest is below the lowest assist-limiting temperature, control unit 4 sets second torque limit LIM 2 to full-assist value ATf. On the other hand, when estimated motor temperature Tmest is above the lowest assist-limiting temperature, control unit 4 sets second torque limit LIM 2 to decrease with increase in estimated motor temperature Tmest.
At Step S 58 , control unit 4 judges whether or not motor temperature estimating part 42 c is normal. When judging motor temperature estimating part 42 c as normal, then control unit 4 proceeds to Step S 57 . When judging motor temperature estimating part 42 c as abnormal, control unit 4 proceeds to Step S 59 .
At Step S 59 , control unit 4 sets first torque limit LIM 1 to the maximum value, or to full-assist value ATf, and exits from this process. According to this, when motor temperature estimating part 42 c is abnormal and temperature sensor 40 is normal, temperature-based torque limit ATlim is constantly set to be equal to first torque limit LIM 1 , because temperature-based torque limit ATlim is set to the smaller one of first torque limit LIM 1 and second torque limit LIM 2 .
Thus, even after motor temperature estimating part 42 c becomes abnormal, it is possible to provide temperature-based torque limit ATlim on the basis of measured temperature Tmsr. Therefore, it is possible to produce a sufficient assist steering torque for steering operation, while preventing control unit 4 and electric motor 31 from overheating.
The following describes a power steering apparatus according to a third embodiment of the present invention with reference to FIGS. 16 to 18B. As described above, the power steering apparatus according to the first embodiment is configured to correct estimated motor temperature Tmest to increase, when determining that when estimated motor temperature Tmest is within the full-assist range, temperature sensor 40 becomes abnormal. In contrast, as described in detail below, the power steering apparatus according to the third embodiment is configured to correct the lowest assist-limiting temperature of the function of computing second torque limit LIM 2 to decrease, when determining that when estimated motor temperature Tmest is within the full-assist range, temperature sensor 40 becomes abnormal.
In the following, the corresponding components are given the same reference characters as in the first embodiment. The third embodiment differs from the first embodiment in the operation of computing second torque limit LIM 2 as follows.
The following describes a process of computing second torque limit LIM 2 with reference to FIG. 16. At Step S 61 , control unit 4 computes estimated motor temperature Tmest of electric motor 31 on the basis of the torque current and field current supplied to electric motor 31 , and then proceeds to Step S 62 . Control unit 4 estimates or computes an amount of generated heat on the basis of the value of the current supplied to electric motor 31 , and estimates an amount of change of temperature of electric motor 31 on the basis of the computed amount of generated heat, and adds the estimated amount of change of temperature to a reference temperature value T 0 to produce estimated motor temperature Tmest.
At Step S 62 , control unit 4 judges whether or not temperature sensor 40 is normal, on the basis of presence or absence of the signal indicative of malfunction of temperature sensor 40 outputted from temperature sensor malfunction monitoring section 41 . When judging temperature sensor 40 as normal, then control unit 4 proceeds to Step S 67 . When judging temperature sensor 40 as abnormal, control unit 4 proceeds to Step S 63 .
At Step S 63 , control unit 4 judges whether or not a flag (referred to as temperature sensor malfunction flag) is set. When judging the temperature sensor malfunction flag as set, control unit 4 proceeds to Step S 67 . When judging the temperature sensor malfunction flag as not set, control unit 4 proceeds to Step S 64 . The temperature sensor malfunction flag is a data set flag for condition that temperature sensor 40 is abnormal.
At Step S 64 , control unit 4 judges whether or not second torque limit LIM 2 is equal to full-assist value ATf. When judging second torque limit LIM 2 as equal to full-assist value ATf, control unit 4 proceeds to Step S 65 . When judging second torque limit LIM 2 as not equal to full-assist value ATf, control unit 4 proceeds to Step S 67 .
At Step S 65 , control unit 4 reduces the lowest assist-limiting temperature of the function of computing second torque limit LIM 2 , and then proceeds to Step S 66 . The function indicated by broken lines in FIG. 17 is normally employed to compute second torque limit LIM 2 . On the other hand, at Step S 65 , the function indicated by solid lines in FIG. 17 is employed, which is provided by reducing the lowest assist-limiting temperature from Ta to Tb. Thus, the lowest assist-limiting temperature is corrected by subtracting a predetermined value, when it is determined that when estimated motor temperature Tmest is below the lowest assist-limiting temperature, temperature sensor 40 becomes abnormal.
At Step S 66 , control unit 4 sets the temperature sensor malfunction flag, and then proceeds to Step S 27 .
At Step S 67 , control unit 4 computes second torque limit LIM 2 on the basis of estimated motor temperature Tmest computed at Step S 61 , using the corrected function, and then exits from this process.
The following describes an example of how the power steering apparatus according to the third embodiment operates with reference to FIGS. 18A and 18B. FIG. 18A shows how estimated motor temperature Tmest changes with time, while FIG. 18B shows how command assist steering torque ATcom changes with time.
In the following, estimated motor temperature Tmest when temperature sensor 40 becomes abnormal is assumed to be equal to a temperature value T 11 . Temperature value T 11 is below the lowest assist-limiting temperature Ta of the function of computing second torque limit LIM 2 for condition that temperature sensor 40 is normal, and is above the lowest assist-limiting temperature Tb of the function of computing second torque limit LIM 2 for condition that temperature sensor 40 is abnormal, as shown in FIG. 17.
As shown in FIG. 18B, until time t 11 after time t 0 , command assist steering torque ATcom is set to be equal to desired assist steering torque ATdes, because desired assist steering torque ATdes is smaller than temperature-based torque limit ATlim. Accordingly, as shown in FIG. 18A, until time t 11 after time t 0 , estimated motor temperature Tmest increases with increase in desired assist steering torque ATdes.
Temperature sensor 40 is assumed to become abnormal at time t 11 . At time t 11 , estimated motor temperature Tmest is equal to temperature value T 11 . At time t 11 , the lowest assist-limiting temperature is shifted from Ta to Tb, so that estimated motor temperature Tmest exceeds lowest assist-limiting temperature Tb as shown in FIG. 18A. Thus, as shown in FIG. 18B, after time t 11 , temperature-based torque limit ATlim is lower than desired assist steering torque ATdes, so that command assist steering torque ATcom is set to be equal to temperature-based torque limit ATlim.
As shown in FIG. 18A, until time t 12 after time t 11 , estimated motor temperature Tmest continues to decrease, while temperature-based torque limit ATlim increases with decrease in estimated motor temperature Tmest. After time t 12 , command assist steering torque ATcom is set to be equal to desired assist steering torque ATdes, because temperature-based torque limit ATlim exceeds desired assist steering torque ATdes at time t 12 .
Thus, when temperature sensor 40 becomes abnormal, and motor temperature estimating part 42 c estimates an increase in estimated motor temperature Tmest, second torque limit LIM 2 is set so as to limit the assist steering torque. Therefore, it is possible to produce a sufficient assist steering torque for steering operation, while preventing control unit 4 and electric motor 31 from overheating.
The third embodiment may be combined with the first embodiment. Specifically, the power steering apparatus may correct one or both of estimated motor temperature Tmest and the lowest assist-limiting temperature in such a manner that estimated motor temperature Tmest increases with respect to the lowest assist-limiting temperature, when determining that when estimated motor temperature Tmest is below the lowest assist-limiting temperature, temperature sensor 40 becomes abnormal.
The following describes a power steering apparatus according to a fourth embodiment of the present invention with reference to FIGS. 19 to 21B. As described above, the power steering apparatus according to the first embodiment is configured to correct estimated motor temperature Tmest to increase, when determining that when estimated motor temperature Tmest is within the full-assist range, temperature sensor 40 becomes abnormal. In contrast, as described in detail below, the power steering apparatus according to the fourth embodiment is configured to correct the value of the function of computing second torque limit LIM 2 to decrease, when determining that when estimated motor temperature Tmest is within the full-assist range, temperature sensor 40 becomes abnormal.
In the following, the corresponding components are given the same reference characters as in the first embodiment. The fourth embodiment differs from the first embodiment in the operation of computing second torque limit LIM 2 as follows.
The following describes a process of computing second torque limit LIM 2 with reference to FIG. 19. At Step S 71 , control unit 4 computes estimated motor temperature Tmest of electric motor 31 on the basis of the torque current and field current supplied to electric motor 31 , and then proceeds to Step S 72 . Control unit 4 estimates or computes an amount of generated heat on the basis of the value of the current supplied to electric motor 31 , and estimates an amount of change of temperature of electric motor 31 on the basis of the computed amount of generated heat, and adds the estimated amount of change of temperature to a reference temperature value T 0 to produce estimated motor temperature Tmest.
At Step S 72 , control unit 4 judges whether or not temperature sensor 40 is normal, on the basis of presence or absence of the signal indicative of malfunction of temperature sensor 40 outputted from temperature sensor malfunction monitoring section 41 . When judging temperature sensor 40 as normal, then control unit 4 proceeds to Step S 77 . When judging temperature sensor 40 as abnormal, control unit 4 proceeds to Step S 73 .
At Step S 73 , control unit 4 judges whether or not a flag (referred to as temperature sensor malfunction flag) is set. When judging the temperature sensor malfunction flag as set, control unit 4 proceeds to Step S 77 . When judging the temperature sensor malfunction flag as not set, control unit 4 proceeds to Step S 74 . The temperature sensor malfunction flag is a data set flag for condition that temperature sensor 40 is abnormal.
At Step S 74 , control unit 4 judges whether or not second torque limit LIM 2 is equal to full-assist value ATf. When judging second torque limit LIM 2 as equal to full-assist value ATf, control unit 4 proceeds to Step S 75 . When judging second torque limit LIM 2 as not equal to full-assist value ATf, control unit 4 proceeds to Step S 77 .
At Step S 75 , control unit 4 reduces the value of the function of computing second torque limit LIM 2 , and then proceeds to Step S 76 . The function indicated by broken lines in FIG. 20 is normally employed to compute second torque limit LIM 2 . In contrast, at Step S 75 , the function indicated by solid lines in FIG. 20 is employed, which is provided by reducing the value of second torque limit LIM 2 .
At Step S 76 , control unit 4 sets the temperature sensor malfunction flag, and then proceeds to Step S 77 .
At Step S 77 , control unit 4 computes second torque limit LIM 2 on the basis of estimated motor temperature Tmest computed at Step S 71 , using the corrected function, and then exits from this process.
The following describes an example of how the power steering apparatus according to the fourth embodiment operates with reference to FIGS. 21A and 21B. FIG. 21A shows how estimated motor temperature Tmest changes with time, while FIG. 22B shows how command assist steering torque ATcom changes with time.
In the following, estimated motor temperature Tmest when temperature sensor 40 becomes abnormal is assumed to be equal to a temperature value T 21 . Temperature value T 21 is below the lowest assist-limiting temperature Ta of the function of computing second torque limit LIM 2 , as shown in FIG. 20.
As shown in FIG. 21B, until time t 21 after time t 0 , command assist steering torque ATcom is set to be equal to desired assist steering torque ATdes, because desired assist steering torque ATdes is smaller than temperature-based torque limit ATlim. Accordingly, as shown in FIG. 21A, until time t 21 after time t 0 , estimated motor temperature Tmest increases with increase in desired assist steering torque ATdes.
Temperature sensor 40 is assumed to become abnormal at time t 21 . At time t 21 , temperature-based torque limit ATlim is set to a reduced value, as shown in FIG. 21B. Until time t 22 after time t 21 , desired assist steering torque ATdes is below temperature-based torque limit ATlim, so that command assist steering torque ATcom is set to be equal to desired assist steering torque ATdes.
After time t 22 , command assist steering torque ATcom is set to temperature-based torque limit ATlim, because desired assist steering torque ATdes exceeds temperature-based torque limit ATlim at time t 22 . Thus, when temperature sensor 40 becomes abnormal, and motor temperature estimating part 42 c estimates an increase in estimated motor temperature Tmest, second torque limit LIM 2 is set so as to limit the assist steering torque. Therefore, it is possible to produce a sufficient assist steering torque for steering operation, while preventing control unit 4 and electric motor 31 from overheating.
The following describes a power steering apparatus according to a fifth embodiment of the present invention with reference to FIGS. 22 to 33C. As described above, the power steering apparatus according to the first embodiment is configured to correct estimated motor temperature Tmest to increase, when determining that when estimated motor temperature Tmest is within the full-assist range, temperature sensor 40 becomes abnormal. In contrast, as described in detail below, the power steering apparatus according to the fifth embodiment is configured to employ a function of computing a third torque limit LIM 3 where third torque limit LIM 3 is below second torque limit LIM 2 for each value of estimated motor temperature Tmest, when determining that when estimated motor temperature Tmest is within the full-assist range, temperature sensor 40 becomes abnormal.
In the following, the corresponding components are given the same reference characters as in the first embodiment. The following describes temperature-based torque limit computing section 42 with reference to FIG. 22. Temperature-based torque limit computing section 42 includes an A/D (Analog-to-Digital) converter 42 a , a first torque limit computing part 42 b , a motor temperature estimating part 42 c , a second torque limit computing part 42 d , a minimum selecting part 42 e , a third torque limit computing part 42 g , and a switch 42 h . A/D converter 42 a receives an analog signal indicative of the measured temperature from temperature sensor 40 , converts the analog signal into a digital signal, and outputs the digital signal to first torque limit computing part 42 b.
First torque limit computing part 42 b receives a signal indicative of the measured temperature, and computes a value (referred to as first torque limit LIM 1 ) which is computed based on the temperature of control unit 4 for preventing overheating. First torque limit computing part 42 b outputs a signal indicative of first torque limit LIM 1 to minimum selecting part 42 e.
First torque limit computing part 42 b stores data indicative of a function of computing first torque limit LIM 1 as shown in FIG. 23. As shown in FIG. 23, according to the function of computing first torque limit LIM 1 , when measured temperature Tmsr (the temperature of control unit 4 ) is lower than a temperature value (referred to as lowest assist-limiting temperature), then first torque limit LIM 1 is set to a maximum value (referred to as full-assist value ATf). The range below the lowest assist-limiting temperature is referred to as full-assist range. On the other hand, when measured temperature Tmsr is above the lowest assist-limiting temperature, then first torque limit LIM 1 is set to decrease with increase in measured temperature Tmsr. The range above the lowest assist-limiting temperature is referred to as assist-limiting range.
Motor temperature estimating part 42 c receives a signal indicative of the motor current supplied to electric motor 31 from current sensor 48 , and a signal indicative of measured temperature Tmsr of control unit 4 from temperature sensor 40 , estimates the temperature of electric motor 31 as estimated motor temperature Tmest, and outputs a signal indicative of estimated motor temperature Tmest to second torque limit computing part 42 d.
Second torque limit computing part 42 d receives a signal indicative of estimated motor temperature Tmest from motor temperature estimating part 42 c , computes a value (referred to as second torque limit LIM 2 ) which is computed based on the temperature of electric motor 31 for preventing overheating, and outputs a signal indicative of second torque limit LIM 2 to minimum selecting part 42 e.
Second torque limit computing part 42 d stores data indicative of a function of computing second torque limit LIM 2 as shown in FIG. 24. As shown in FIG. 24, according to the function of computing second torque limit LIM 2 , when estimated motor temperature Tmest is lower than a temperature value (referred to as lowest assist-limiting temperature) (within the full-assist range), then second torque limit LIM 2 is set to full-assist value ATf. On the other hand, when estimated motor temperature Tmest is above the lowest assist-limiting temperature (within the assist-limiting range), then second torque limit LIM 2 is set to decrease with increase in estimated motor temperature Tmest.
Minimum selecting part 42 e receives a signal indicative of first torque limit LIM 1 from first torque limit computing part 42 b , and a signal indicative of second torque limit LIM 2 from second torque limit computing part 42 d , compares first torque limit LIM 1 with second torque limit LIM 2 , and outputs the smaller one of them as temperature-based torque limit ATlim to switch 42 h.
Third torque limit computing part 42 g receives a signal indicative of estimated motor temperature Tmest from motor temperature estimating part 42 c , computes third torque limit LIM 3 on the basis of estimated motor temperature Tmest, and outputs a signal indicative of third torque limit LIM 3 to switch 42 h.
Third torque limit computing part 42 g stores data indicative of a function of computing third torque limit LIM 3 as shown in FIG. 25. In FIG. 25, the function of second torque limit LIM 2 is indicated by broken lines, while the function of third torque limit LIM 3 is indicated by solid lines. As shown in FIG. 25, third torque limit LIM 3 is set to be lower than second torque limit LIM 2 for any value of estimated motor temperature Tmest. Specifically, the maximum value for third torque limit LIM 3 in the full-assist range is lower than that for second torque limit LIM 2 . In this embodiment, third torque limit LIM 3 is thus determined by reducing second torque limit LIM 2 for each value of estimated motor temperature Tmest.
Switch 42 h receives a signal indicative of one of first torque limit LIM 1 and second torque limit LIM 2 from minimum selecting part 42 e , a signal indicative of third torque limit LIM 3 from third torque limit computing part 42 g , and a signal indicative of malfunction of temperature sensor 40 from temperature sensor malfunction monitoring section 41 . Switch 42 h selectively outputs the one of first torque limit LIM 1 and second torque limit LIM 2 or third torque limit LIM 3 in accordance with the temperature sensor malfunction flag.
FIGS. 26A and 26B show temperature-based torque limit computing section 42 under two different conditions. FIG. 26A shows a condition in which the temperature sensor malfunction flag is equal to zero, while FIG. 26B shows a condition in which the temperature sensor malfunction flag is equal to one. When the temperature sensor malfunction flag is equal to zero, that is, when temperature sensor 40 is normal, switch 42 h outputs one of first torque limit LIM 1 and second torque limit LIM 2 outputted from minimum selecting part 42 e , as shown in FIG. 26A. On the other hand, when the temperature sensor malfunction flag is equal to one, that is, when temperature sensor 40 is abnormal, switch 42 h outputs third torque limit LIM 3 outputted from third torque limit computing part 42 g , as shown in FIG. 26B. Switch 42 h implements the switch from one of first torque limit LIM 1 and second torque limit LIM 2 to third torque limit LIM 3 gradually over a predetermined period of time.
The following describes a process performed by control unit 4 with reference to FIG. 27. At Step S 81 , control unit 4 computes first torque limit LIM 1 on the basis of the temperature of control unit 4 , and then proceeds to Step S 82 . The operation of computing first torque limit LIM 1 is described in detail below with reference to FIG. 28.
At Step S 82 , control unit 4 computes second torque limit LIM 2 on the basis of the temperature of electric motor 31 , and then proceeds to Step S 83 . The operation of computing second torque limit LIM 2 is described in detail below with reference to FIG. 29.
At Step S 83 , control unit 4 computes third torque limit LIM 3 on the basis of the temperature of electric motor 31 , and the proceeds to Step S 84 . The operation of computing third torque limit LIM 3 is described in detail below with reference to FIG. 30.
At Step S 84 , control unit 4 computes temperature-based torque limit ATlim on the basis of first torque limit LIM 1 , second torque limit LIM 2 , and third torque limit LIM 3 , and then proceeds to Step S 85 . The operation of computing temperature-based torque limit ATlim is described in detail below with reference to FIG. 31.
At Step S 85 , control unit 4 computes command assist steering torque ATcom on the basis of desired assist steering torque ATdes and temperature-based torque limit ATlim, and then exits from this process. The operation of computing command assist steering torque ATcom is described in detail below with reference to FIG. 32.
The following describes a process of computing first torque limit LIM 1 with reference to FIG. 28. At Step S 91 , control unit 4 reads and obtains measured temperature Tmsr from temperature sensor 40 , and then proceeds to Step S 92 .
At Step S 92 , control unit 4 computes first torque limit LIM 1 on the basis of measured temperature Tmsr using the function of computing first torque limit LIM 1 shown in FIG. 23. Specifically, when measured temperature Tmsr (the temperature of control unit 4 ) is lower than the lowest assist-limiting temperature, then control unit 4 sets first torque limit LIM 1 to full-assist value ATf. On the other hand, when measured temperature Tmsr is above the lowest assist-limiting temperature, then control unit 4 sets first torque limit LIM 1 to decrease with increase in measured temperature Tmsr.
The following describes a process of computing second torque limit LIM 2 with reference to FIG. 29. At Step S 101 , control unit 4 computes estimated motor temperature Tmest of electric motor 31 on the basis of the torque current and field current supplied to electric motor 31 , and then proceeds to Step S 102 . Control unit 4 estimates or computes an amount of generated heat on the basis of the value of the current supplied to electric motor 31 , and estimates an amount of change of temperature of electric motor 31 on the basis of the computed amount of generated heat, and adds the estimated amount of change of temperature to a reference temperature value T 0 to produce estimated motor temperature Tmest.
At Step S 102 , control unit 4 computes second torque limit LIM 2 on the basis of estimated motor temperature Tmest computed at Step S 101 , and then exits from this process. Second torque limit LIM 2 is computed using the function of computing second torque limit LIM 2 shown in FIG. 24. Specifically, when estimated motor temperature Tmest is below the lowest assist-limiting temperature, control unit 4 sets second torque limit LIM 2 to full-assist value ATf. On the other hand, when estimated motor temperature Tmest is above the lowest assist-limiting temperature, control unit 4 sets second torque limit LIM 2 to decrease with increase in estimated motor temperature Tmest.
The following describes a process of computing third torque limit LIM 3 with reference to FIG. 30. At Step S 110 , control unit 4 computes estimated motor temperature Tmest of electric motor 31 on the basis of the torque current and field current supplied to electric motor 31 , and then proceeds to Step S 11 . Control unit 4 estimates or computes an amount of generated heat on the basis of the value of the current supplied to electric motor 31 , and estimates an amount of change of temperature of electric motor 31 on the basis of the computed amount of generated heat, and adds the estimated amount of change of temperature to a reference temperature value T 0 to produce estimated motor temperature Tmest.
At Step S 111 , control unit 4 computes third torque limit LIM 3 on the basis of estimated motor temperature Tmest computed at Step S 110 , and then exits from this process. Third torque limit LIM 3 is computed using the function of computing third torque limit LIM 3 shown in FIG. 25. Specifically, when estimated motor temperature Tmest is below the lowest assist-limiting temperature, control unit 4 sets third torque limit LIM 3 to full-assist value ATf. On the other hand, when estimated motor temperature Tmest is above the lowest assist-limiting temperature, control unit 4 sets third torque limit LIM 3 to decrease with increase in estimated motor temperature Tmest.
The following describes a process of computing temperature-based torque limit ATlim with reference to FIG. 31. At Step S 121 , control unit 4 judges whether or not the malfunction flag of temperature sensor 40 is equal to one. When judging the temperature sensor malfunction flag as equal to one, then control unit 4 proceeds to Step S 122 . When judging the temperature sensor malfunction flag as not equal to one, or as equal to zero, then control unit 4 proceeds to Step S 123 .
At Step S 122 , control unit 4 sets temperature-based torque limit ATlim to be equal to third torque limit LIM 3 , and then exits from this process. At Step S 123 , control unit 4 compares first torque limit LIM 1 with second torque limit LIM 2 , and then judges whether or not first torque limit LIM 1 is smaller than second torque limit LIM 2 . When judging first torque limit LIM 1 as smaller than second torque limit LIM 2 , control unit 4 proceeds to Step S 124 . When judging first torque limit LIM 1 as not smaller than second torque limit LIM 2 , control unit 4 proceeds to Step S 125 .
At Step S 124 , control unit 4 sets temperature-based torque limit ATlim to be equal to first torque limit LIM 1 , and then exits from this process. At Step S 125 , control unit 4 sets temperature-based torque limit ATlim to be equal to second torque limit LIM 2 , and then exits from this process.
The following describes a process of computing command assist steering torque ATcom with reference to FIG. 32. At Step S 131 , control unit 4 judges whether or not desired assist steering torque ATdes is smaller than temperature-based torque limit ATlim. When judging desired assist steering torque ATdes as smaller than temperature-based torque limit ATlim, control unit 4 proceeds to Step S 132 . When judging desired assist steering torque ATdes as not smaller than temperature-based torque limit ATlim, control unit 4 proceeds to Step S 133 .
At Step S 132 , control unit 4 sets command assist steering torque ATcom to be equal to desired assist steering torque ATdes, and then proceeds to Step S 134 .
At Step S 133 , control unit 4 sets command assist steering torque ATcom to be equal to temperature-based torque limit ATlim, and then proceeds to Step S 134 .
At Step S 134 , control unit 4 implements command assist steering torque ATcom which is set at Step S 132 or S 133 , and then exits from this process.
The following describes an example of how the power steering apparatus according to the fifth embodiment operates with reference to FIGS. 33A, 33 B and 33 C. FIG. 33A shows how estimated motor temperature Tmest changes with time, FIG. 33B shows how command assist steering torque ATcom changes with time, and FIG. 33C shows how the temperature sensor malfunction flag changes with time.
In the following, estimated motor temperature Tmest when temperature sensor 40 becomes abnormal is assumed to be equal to a temperature value T 31 . Temperature value T 31 is below the lowest assist-limiting temperature Tc of the function of computing second torque limit LIM 2 or the function of computing third torque limit LIM 3 , as shown in FIG. 25.
As shown in FIG. 33B, until time t 31 after time t 0 , command assist steering torque ATcom is set to be equal to desired assist steering torque ATdes, because desired assist steering torque ATdes is smaller than temperature-based torque limit ATlim. Accordingly, as shown in FIG. 33A, until time t 31 after time t 0 , estimated motor temperature Tmest increases with increase in desired assist steering torque ATdes.
At time t 31 , temperature sensor 40 becomes abnormal, so that the temperature sensor malfunction flag is set to one. Over a predetermined period from time t 31 to time t 33 , temperature-based torque limit ATlim changes from one of first torque limit LIM 1 and second torque limit LIM 2 , which is outputted when the temperature sensor malfunction flag is equal to zero, to third torque limit LIM 3 , which is outputted when the temperature sensor malfunction flag is equal to one.
Until time t 32 after time t 31 , command assist steering torque ATcom is set to be equal to desired assist steering torque ATdes, because desired assist steering torque ATdes is still below temperature-based torque limit ATlim. After time t 32 , command assist steering torque ATcom is set to be equal to temperature-based torque limit ATlim, because temperature-based torque limit ATlim is smaller than desired assist steering torque ATdes.
Thus, when temperature sensor 40 becomes abnormal, and motor temperature estimating part 42 c estimates an increase in estimated motor temperature Tmest, third torque limit LIM 3 is set so as to limit the assist steering torque. Therefore, it is possible to produce a sufficient assist steering torque for steering operation, while preventing control unit 4 and electric motor 31 from overheating.
The following describes a power steering apparatus according to a sixth embodiment of the present invention with reference to FIGS. 34 to 35C. As described above, the power steering apparatus according to the fifth embodiment is configured to employ the function of third torque limit LIM 3 for setting temperature-based torque limit ATlim to be smaller than the function of second torque limit LIM 2 , when determining that temperature sensor 40 becomes abnormal. In contrast, as described in detail below, the power steering apparatus according to the sixth embodiment is configured to employ another function of computing third torque limit LIM 3 which has a lowest assist-limiting temperature lower than the function of computing second torque limit LIM 2 , when determining that temperature sensor 40 becomes abnormal.
In the following, the corresponding components are given the same reference characters as in the fifth embodiment. The sixth embodiment differs from the fifth embodiment in the operation of computing third torque limit LIM 3 as follows.
FIG. 34 shows a function of computing third torque limit LIM 3 according to the sixth embodiment. In FIG. 34, the function of computing second torque limit LIM 2 is indicated by broken lines, while the function of computing third torque limit LIM 3 is indicated by solid lines. The function of computing third torque limit LIM 3 has a lowest assist-limiting temperature Td than the function of computing second torque limit LIM 2 (Tc).
When temperature sensor 40 becomes abnormal, the function employed to compute temperature-based torque limit ATlim is shifted gradually over a predetermined period for transition from one of the function of computing first torque limit LIM 1 and the function of computing second torque limit LIM 2 to the function of computing third torque limit LIM 3 . The predetermined period is set to vary in accordance with the maximum difference in the torque limit value between the function o