Physical quantity detecting device and electric power steering apparatus using same

The present invention relates to a physical quantity detecting device having a physical quantity detector configured to detect physical quantities such as a torque and an angle and a controller configured to receive the detected physical quantity and an electric power steering apparatus using the physical quantity detecting device.

For example, in a conventional electric power steering apparatus, a steering torque detected by a torque sensor as a physical quantity detecting unit is supplied to a control device as a control unit, and a current flowing in an electric motor configured to transmit a steering assist force to a steering apparatus is controlled on the basis of the steering torque by the control device.

In such an electric power steering apparatus, abnormality of the torque sensor is detected since the current to be supplied to the electric motor is controlled on the basis of the steering torque detected by the torque sensor.

In order to detect abnormality of such a torque sensor, a magnetostrictive torque sensor including failure detecting means for detecting a failure on the basis of detection results of torque detecting means and an electric power steering apparatus including the magnetostrictive torque sensor have been proposed (for example, see PTL 1).

There has been proposed a torque detecting device including a torque sensor disposed in a rotating shaft and outputting a predetermined electrical signal corresponding to a torque applied to the rotating shaft, a sensor circuit outputting the predetermined electrical signal outputted from the torque sensor as a sensor circuit signal, and an output signal processing circuit processing the output of the sensor circuit and outputting the processed signal as a torque detection signal, wherein the signal processing circuit is provided in parallel with an abnormality state monitoring circuit that operates in response to the sensor circuit signal and that monitors occurrence of an abnormal operation in the signal output from the sensor circuit such that the abnormality state monitoring circuit outputs an abnormality occurrence signal of a high level or a low level to a power steering controller when the abnormality state monitoring circuit determines that a signal involved in the sensor circuit signal is in an oscillating state (for example, see PTL 2).

Patent Literature

PTL 1: Japanese Patent No. 4572227

PTL 2: Japanese Patent No. 3791253

Technical Problem

In the conventional examples described in PTL 1 and PTL 2, a failure is detected on the basis of the detection result of the torque detecting means or signal abnormality of the output sensor circuit is detected using the predetermined electrical signal outputted from the torque sensor as the sensor circuit signal.

However, in the above-mentioned conventional examples, abnormality of the torque calculated in the torque sensor or the torque detecting device is detected, there is an unsolved problem in that abnormality of a transmission line through which the torque detection signal of the torque sensor or the torque detecting device is supplied to the control device cannot be detected.

Therefore, the present invention is made in consideration of the unsolved problem of the above-mentioned conventional examples, and an object thereof is to provide a physical quantity detecting device that can detect abnormality of a signal transmission system between a physical quantity detector and a controller and an electric power steering apparatus using the physical quantity detecting device.

Solution to Problem

In order to achieve the above-mentioned object, a first aspect of a physical quantity detecting device according to the present invention includes a physical quantity detector configured to detect a physical quantity and to output a physical quantity detection signal; and a controller configured to receive the physical quantity outputted from the physical quantity detector via a transmission line and to perform a control operation on the basis of the physical quantity, wherein the physical quantity detector outputs a diagnostic signal for detecting abnormality of a transmission system between the controller and the physical quantity detector and the controller includes an abnormality determining unit configured to determine the abnormality of the transmission system on the basis of the diagnostic signal when receiving the diagnostic signal.

In a second aspect of the physical quantity detecting device according to the present invention, the physical quantity detector includes a signal switch configured to switch between the physical quantity detection signal and the diagnostic signal.

In a third aspect of the physical quantity detecting device according to the present invention, the physical quantity detector outputs the diagnostic signal for a predetermined period of time at a time of power-up.

In a fourth aspect of the physical quantity detecting device according to the present invention, the physical quantity detector outputs the diagnostic signal for a predetermined period of time at a fixed period of time.

In a fifth aspect of the physical quantity detecting device according to the present invention, the physical quantity detector outputs a signal distinguishable from the physical quantity detection signal as the diagnostic signal.

In a sixth aspect of the physical quantity detecting device according to the present invention, the controller is configured to output a diagnostic signal output request to the physical quantity detector, and the physical quantity detector outputs the diagnostic signal to the transmission line when receiving the diagnostic signal output request.

In a seventh aspect of the physical quantity detecting device according to the present invention, the physical quantity detector outputs a pulse-width modulated signal with a pulse width corresponding to the physical quantity as the physical quantity detection signal, and the diagnostic signal is set to have a duty ratio out of an effective range of the pulse-width modulated signal.

In an eighth aspect of the physical quantity detecting device according to the present invention, the physical quantity detector outputs the physical quantity detection signal to the controller via a noise filter, and the abnormality determining unit determines whether or not the noise filter is abnormal by detecting a change of at least one of a rise and a fall of the received diagnostic signal.

A first aspect of an electric power steering apparatus according to the present invention includes the physical quantity detecting device according to any one of the first to eighth aspects, wherein the physical quantity detecting device detects at least one physical quantity necessary for calculating a steering torque command value and outputs the physical quantity detection signal and the diagnostic signal, and wherein the controller calculates the steering torque command value on the basis of the physical quantity detection signal of the physical quantity detecting device, and controls an electric motor generating a steering assist force on the basis of the calculated steering torque command value, and the abnormality determining unit determines whether or not the transmission system is abnormal when receiving the diagnostic signal.

Advantageous Effects of Invention

According to the present invention, the diagnostic signal in addition to the physical quantity detection signal is outputted from the physical quantity detector to the controller via the transmission line, and the controller performs control process on the basis of the physical quantity detection signal and determines abnormality of the transmission system when receiving the diagnostic signal. Accordingly, it is possible to determine abnormality of the physical quantity detection signal and to accurately detect signal transmission abnormality of the transmission system, thereby improving reliability of the physical quantity detecting device.

FIG. 1 is a diagram schematically illustrating a configuration of an electric power steering apparatus according to the present invention;

FIG. 2 is a block diagram illustrating configurations of a torque sensor and a controller according to an embodiment of the present invention;

FIG. 3 is a flowchart illustrating an example of a signal switching procedure performed by a calculating unit of the torque sensor;

FIG. 4 is a flowchart illustrating an example of a steering assist control procedure performed by a micro control unit of a steering assist control device;

FIG. 5 is a block diagram illustrating configurations of a torque sensor and a controller according to a second embodiment of the present invention;

FIG. 6 is a flowchart illustrating an example of a signal switching procedure in the second embodiment;

FIG. 7 is a flowchart illustrating an example of a steering assist control procedure in the second embodiment;

FIG. 8 is a flowchart illustrating an example of a steering assist control procedure in a third embodiment;

FIG. 9 is a flowchart illustrating a specific example of a diagnostic signal receiving process illustrated in FIG. 8 ;

FIG. 10 is a waveform diagram illustrating a reception state of a diagnostic signal which is used to describe operations in the third embodiment; and

FIG. 11 is a waveform diagram illustrating a reception state of a received signal during disconnection.

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

FIG. 1 is a diagram illustrating an example of the whole configuration of an electric power steering apparatus according to a first embodiment of the present invention.

In the electric power steering apparatus, a steering effort which is applied to a steering wheel 1 by a driver is transmitted to a steering shaft 2 including an input shaft 2 a and an output shaft 2 b . One end of the input shaft 2 a of the steering shaft 2 is linked to the steering wheel 1 and the other end is linked to one end of the output shaft 2 b via a torque sensor 3 as a detection unit of a physical quantity detecting device.

The steering effort transmitted to the output shaft 2 b is transmitted to a lower shaft 5 via a universal joint 4 and is then transmitted to a pinion shaft 7 via a universal joint 6 . The steering effort transmitted to the pinion shaft 7 is transmitted to tie rods 9 via a steering gear 8 to turn steered wheels not illustrated. Here, the steering gear 8 employs a rack-and-pinion type including a pinion 8 a linked to the pinion shaft 7 and a rack 8 b engaging with the pinion 8 a , and converts a rotational motion transmitted to the pinion 8 a into a linear motion by the use of the rack 8 b.

A steering assist mechanism 10 that transmits a steering assist force to the output shaft 2 b is linked to the output shaft 2 b of the steering shaft 2 . The steering assist mechanism 10 includes a deceleration mechanism 11 linked to the output shaft 2 b and an electric motor 12 linked to the deceleration mechanism 11 to generate the steering assist force to be applied to the steering apparatus.

The torque sensor 3 is configured to detect the steering torque applied to the steering wheel 1 and transmitted to the input shaft 2 a and includes, for example, a sensor unit 3 a of a pulse width modulation (PWM) output type. The sensor unit 3 a includes a torque sensor unit 3 b , a calculating unit 3 c , a signal output unit 3 d , and a power supply circuit 3 e.

The torque sensor unit 3 b converts the steering torque into a torsion angle displacement of a torsion bar (not illustrated) interposed between the input shaft 2 a and the output shaft 2 b , converts the torsion angle displacement, for example, into a current variation, and outputs the current variation. For example, as disclosed in JP 2006-267045 A, the torque sensor unit 3 b includes plural elongated protrusions that are formed on the outer circumferential surface of any one of the input shaft 2 a and the output shaft 2 b so as to extend in an extension direction, a cylindrical member that is fixed to the other of the input shaft 2 a and the output shaft 2 b so as to face the elongated protrusions and that has a rectangular window in the circumferential direction, at least two detection coils of which impedance varies in the opposite directions depending on a torque generated in a rotating shaft fixed to the outer circumference of the cylindrical member, a bridge circuit having resistors individually connected in series to the two detection coils so as to detect impedance variations of the detection coils, and an AC signal source that supplies an AC signal to the bridge circuit. The torque sensor unit amplifies a voltage across the detection coils of the bridge circuit, A/D converts the amplified voltage, and outputs the converted voltage as a digital voltage signal.

The calculating unit 3 c receives the digital voltage signal outputted from the torque sensor unit 3 b , performs a predetermined torque computing process on the basis of the received digital voltage signal to calculate a torque detection value, and generates a pulse-width modulated (PWM) signal St as a torque detection signal with a pulse width of a duty ratio in a predetermined effective range (for example, 5% to 95%) depending on the calculated torque detection value.

The calculating unit 3 c generates a diagnostic signal Sd instead of the pulse-width modulated signal as the torque detection signal for a predetermined period of time after a supply of a power supply voltage from a power supply circuit 3 e is started. The diagnostic signal Sd is set to have a duty ratio of 1% to 4% or a duty ratio of 96% to 99% which is out of the effective range of the pulse-width modulated signal as the torque detection signal, and is distinguishable from the pulse-width modulated signal St as the torque detection signal.

The calculating unit 3 c includes a signal switching unit 3 ca that switches between the pulse-width modulated signal St and the diagnostic signal Sd. The signal switching unit 3 ca selects the diagnostic signal Sd for a predetermined period of time after the supply of the power supply voltage from the power supply circuit 3 e is started, and selects the pulse-width modulated signal St after the predetermined period of time elapses.

The calculating unit 3 c performs a signal switching process illustrated in FIG. 3 when the supply of power is started. In the signal switching process, first, as the initialization process of step S 1 , a diagnostic period flag F 1 is set to “1”, the diagnostic period flag F 1 indicating that a predetermined diagnostic period after the time of power-up does not elapse, and a variable N for counting the diagnostic period is cleared to “0”.

Subsequently, it is determined in step S 2 whether or not the diagnostic period flag F 1 is set to “1”. When it is determined that the diagnostic period flag F 1 is set to “1”, the diagnostic signal generated as a pulse-width modulated (PWM) signal which is set to have any of a duty ratio of 1% to 4% and a duty ratio of 96% to 99% which are out of the effective range of the above-mentioned pulse-width modulated (PWM) signal is outputted to the signal output unit 3 d in step S 3 and then the process goes to step S 4 .

In step S 4 , the variable N for counting the diagnostic period increases by “1” and it is determined in step S 5 whether or not the variable N reaches a predetermined number Ns. When it is determined that “N<Ns”, the process returns to step S 2 . When it is determined that “N≧Ns”, the diagnostic period flag F 1 is reset to “0” in step S 6 and then the process returns to step S 2 .

On the other hand, when it is determined in step S 2 that the diagnostic period flag F 1 is “0”, the digital voltage signal outputted from the torque sensor unit 3 b is read in step S 7 and then the process goes to step S 8 .

In step S 8 , a torque detection value calculating process is performed. In the torque detection value calculating process, a torque detection value is calculated by calculating difference signals of the read digital voltage signals, full-wave rectifying and averaging the difference signals, and adjusting a neutral voltage thereof.

Subsequently, in step S 9 , a duty ratio is calculated, for example, by referring to a duty ratio calculation map on the basis of the calculated torque detection value, the pulse-width modulated signal St with the calculated duty ratio is outputted to the signal output unit 3 d , and then the process returns to step S 2 .

The signal switching process illustrated in FIG. 3 corresponds to the signal switching unit 3 ca.

The signal output unit 3 d outputs the pulse-width modulated signal outputted from the calculating unit 3 c as the torque detection signal to the output terminal tso via a noise filter 3 f.

The power supply circuit 3 e converts a power supply voltage, which is supplied from the steering assist control device 20 as the control unit to be described later via a noise filter 3 g , into a voltage used in the calculating unit 3 c and the signal output unit 3 d and outputs the converted voltage to the calculating unit 3 c and the signal output unit 3 d.

The torque detection signal T outputted from the torque sensor 3 is inputted to the steering assist control device 20 .

The steering assist control device 20 operates with a supply of power from an in-vehicle battery 21 and controls driving of an electric motor 12 including, for example, a three-phase brushless motor applying a steering effort to the steering apparatus. The negative electrode of the battery 21 is grounded, and the positive electrode thereof is linked to the steering assist control device 20 via an ignition switch 22 for starting an engine and is also connected directly to the steering assist control device 20 without interposing the ignition switch 22 .

As illustrated in FIG. 2 , the steering assist control device 20 receives the torque detection signal T detected by the torque sensor 3 via a noise filter 23 and receives a vehicle velocity detection value Vs detected by the vehicle velocity sensor 24 via a vehicle controller area network (CAN) 25 which is a network connecting controllers in a vehicle.

The steering assist control device 20 includes a micro control unit (MCU) 31 as a control unit constituted of, for example, a microcomputer. The steering assist control device 20 includes a motor drive circuit 32 , an FET gate drive circuit 33 , and a motor current detecting circuit 34 .

The micro control unit 31 calculates phase voltage command values for causing the electric motor 12 to generate the steering assist force on the basis of the detection signals of various sensors and generates a pulse-width modulated (PWM) control signal on the basis of the calculated phase voltage command values.

The motor drive circuit 32 includes field effect transistors (FET) that drive the electric motor 12 .

The FET gate drive circuit 33 controls gate voltages of the field effect transistors of the motor drive circuit 32 on the basis of the PWM control signal outputted from the micro control unit 31 .

The motor current detecting circuit 34 detects phase currents supplied for phases of the electric motor 12 .

The motor current detecting circuit 34 detects motor currents of a U phase, a V phase, and a W phase from the voltages across motor current detection resistors inserted into the negative electrodes of a U-phase arm, a V-phase arm, and a W-phase arm of an inverter circuit constituting the motor drive circuit 32 .

The steering assist control device 20 includes a power supply relay 35 that supplies power from the battery 21 to the motor drive circuit 32 . The ON/OFF state of the power supply relay 35 is controlled by the micro control unit 31 . The steering assist control device 20 includes a CAN interface circuit 36 that receives the vehicle velocity detection value Vs by performing an interface process with the vehicle CAN 25 .

Furthermore, the steering assist control device 20 includes the power supply circuit 37 that is linked to the battery 21 via the ignition switch 22 and that is linked to the battery via the power supply relay 35 . The power supply circuit 37 includes a regulator that lowers a battery voltage (for example, 12 V) to an internal voltage (for example, 5 V) necessary for the micro control unit 31 or the FET gate drive circuit 33 .

The internal voltage outputted from the power supply circuit 37 is supplied as an internal power to the micro control unit 31 , the FET gate drive circuit 33 , the motor current detecting circuit 34 , the CAN interface circuit 36 , and the like, and is supplied to the torque sensor 3 via a power supply output terminal tpo.

Additionally, as illustrated in FIG. 2 , the micro control unit 31 includes an abnormality determining unit 31 a that determines abnormality of a signal transmission line to the torque sensor 3 . The micro control unit 31 performs a steering assist control process illustrated in FIG. 4 .

The steering assist control process is started when the ignition switch 22 is turned on and power is supplied to the micro control unit 31 from the power supply circuit 27 .

That is, first, in step S 11 , an initialization process is performed to set the diagnostic state flag F 2 to “1”, to clear the variable N 2 for counting the diagnostic signal reception number to “0”, to set a timer to start counting of the diagnostic period, and to control the power supply relay 35 so as to be turned on.

Subsequently, in step S 12 , it is determined whether or not the diagnostic state flag F 2 is set to “1”. When it is determined that the diagnostic state flag F 2 is set to “1”, the process goes to step S 13 .

In step S 13 , it is determined whether or not the diagnostic signal with a predetermined duty ratio outputted from the calculating unit 3 c of the above-mentioned torque sensor 3 is received. When it is determined that the diagnostic signal is received, the variable N 2 indicating the diagnostic signal reception number increases by “1” in step S 14 and then the process goes to step S 15 . When it is determined that the diagnostic signal is not received, the process immediately goes to step S 15 .

In step S 15 , it is determined whether or not the diagnostic period counted by the timer is up. When it is determined that the diagnostic period is not up, the process returns to step S 12 . When it is determined that the diagnostic period is up, it is determined in step S 16 whether or not the variable N 2 reaches a predetermined value N 2 s.

When it is determined in step S 16 that “N 2 ≧N 2 s ”, it is determined that the signal transmission line between the torque sensor 3 and the micro control unit 31 is normal, the diagnostic state flag F 2 is reset to “0”, and the process returns to step S 12 .

When it is determined that “N 2 <N 2 s ”, it is determined that the signal transmission line between the torque sensor 3 and the micro control unit 31 is abnormal and the process goes to step S 18 .

In step S 18 , a torque sensor abnormality alarm signal is outputted to an alarm circuit 40 , a torque sensor abnormality alarm including sound, light, image information, or the like is issued from the alarm circuit 40 , and then the steering assist control process is terminated. Here, when it is determined that the torque sensor is abnormal, a controlling value may be switched to a known alternative torque value and then the assist operation may be continued.

On the other hand, when it is determined in step S 12 that the diagnostic state flag F 2 is reset to “0”, detection values of various sensors such as the torque sensor 3 , the vehicle velocity sensor 24 , and the motor current detecting circuit 34 are read in step S 19 . Then, in step S 20 , a steering assist current command value Iref is calculated by referring to a steering assist current command value calculation map indicating the relationship between the steering torque and the steering assist current command value using the vehicle velocity as a parameter on the basis of the steering torque T and the vehicle velocity detection value Vs and the process goes to step S 21 .

In step S 21 , a d-q axis current command value computing process is performed on the basis of the calculated steering assist current command value Iref to calculate a d-axis current command value Idref and a q-axis current command value Iqref. Then, in step S 22 , a two-phase to three-phase transformation process is performed to calculate three-phase motor current command values Iuref to Iwref.

Subsequently, current deviations ΔIu to ΔIw are calculated by subtracting the motor currents Iu to Iw from the motor current command values Iuref to Iwref in step S 23 , voltage command values Vuref to Vwref are calculated by performing a PI control process on the current deviations ΔIu to ΔIw in step S 24 , and then the process goes to step S 25 .

In step S 25 , the duty ratio is calculated on the basis of the calculated voltage command values Vuref to Vwref and a pulse width modulating process is performed to generate a gate control signal. Then, in step S 26 , the generated gate control signal is outputted to the FET gate drive circuit 33 and then the process returns to step S 19 .

In the procedure illustrated in FIG. 4 , the processes of steps S 11 to S 18 correspond to the abnormality determining unit 31 a.

The power supply relay 35 is returned to the OFF state after various control processes of the micro control unit 31 are terminated.

Operations in the first embodiment will be described below.

When it is assumed that a vehicle stops, the ignition switch 22 is turned off, and the power supply relay 35 is in the OFF state, power from the battery 21 is not supplied to the power supply circuit 37 of the steering assist control device 20 in this state and thus the internal voltage is not outputted from the power supply circuit 37 . Accordingly, the micro control unit 31 , the motor drive circuit 32 , the FET gate drive circuit 33 , the motor current detecting circuit 34 , and the alarm circuit 40 are in a deactivated state and the electric motor 12 is also in a non-rotating state.

Similarly, in the torque sensor 3 , since the internal power is not supplied to the power supply circuit 3 e from the power supply circuit 37 of the steering assist control device 20 , the torque sensor unit 3 b , the calculating unit 3 c , and the signal output unit 3 d are in a deactivated state.

When a driver starts an engine by turning on the ignition switch 22 in this state, power from the battery 21 is supplied to the power supply circuit 37 via the ignition switch 22 . Accordingly, for example, the internal voltage of 5 V is supplied to the micro control unit 31 , the FET gate drive circuit 33 , the motor current detecting circuit 34 , and the alarm circuit 40 from the power supply circuit 37 and these units are switched to an activated state.

At the same time, the internal voltage outputted from the power supply circuit 37 is supplied to the power supply circuit 3 e of the torque sensor 3 via the power supply output terminal tpo, the power supply input terminal tpi, and the noise filter 3 g . Accordingly, the internal voltage is outputted from the power supply circuit 3 e to the torque sensor unit 3 b , the calculating unit 3 c , and the signal output unit 3 d and these units are switched to an activated state.

At this time, the signal switching procedure described with reference to FIG. 3 is started by the calculating unit 3 c of the torque sensor 3 . First, the initialization process is performed to set the diagnostic period flag F 1 to “1” and to clear the variable N for counting the diagnostic period to “0” (step S 1 ).

Subsequently, since the diagnostic period flag F 1 is set to “1”, the process goes from step S 2 to step S 3 and the diagnostic signal with a predetermined duty ratio which is out of the effective range of the pulse-width modulated (PWM) signal indicating a normal steering torque detection value is outputted to the signal output unit 3 d.

Thereafter, the variable N for counting the diagnostic period increases by “1” (step S 4 ), it is then determined whether or not the diagnostic period variable N reaches a predetermined number Ns (step S 5 ), and the output of the diagnostic signal is repeated until the diagnostic period variable N reaches the predetermined number.

On the other hand, in the steering assist control device 20 , the steering assist control procedure illustrated in FIG. 4 is similarly started by the micro control unit 31 . In the initialization process, the diagnostic state flag F 2 is set to “1”, the variable N 2 indicating the diagnostic signal reception number is cleared to “0”, and furthermore, the timer for setting the diagnostic period is set (step S 11 ).

Subsequently, since the diagnostic state flag F 2 is set to “1”, the process goes from step S 12 to step S 13 and it is determined whether or not the diagnostic signal with a predetermined duty ratio is received from the torque sensor 3 . At this time, when it is determined that the diagnostic signal is received, the variable N 2 indicating the diagnostic signal reception number increases by “1” and then it is determined whether or not the diagnostic period counted by the timer is up. Since the timer is set just before, the process returns to step S 12 .

The process of counting the diagnostic signal reception number from steps S 12 to S 15 are repeatedly performed until the diagnostic period counted by the timer is up, that is, until the diagnostic period set by the calculating unit 3 c of the torque sensor 3 elapses.

When the diagnostic period elapses, the diagnostic period flag F 1 is reset to “0” in the torque computing process performed by the calculating unit 3 c of the torque sensor 3 (step S 6 ), the process goes from step S 2 to step S 7 , and the torque detection value computing process is performed. In the torque detection value computing process, the torque detection value is calculated by reading the output voltages of the bridge circuit from the normal torque sensor unit 3 b , full-wave rectifying and averaging the difference voltages of the output voltages, and adjusting the neutral voltage (step S 8 ).

The duty ratio depending on the torque detection value is calculated by referring to the duty ratio calculation map on the basis of the calculated torque detection value, the pulse-width modulated (PWM) signal with the calculated duty ratio is outputted to the signal output unit 3 d , and the pulse-width modulated (PWM) signal is outputted as the torque detection signal from the signal output unit 3 d to the output terminal tso.

Similarly, the micro control unit 31 of the steering assist control device 20 repeatedly performs a diagnostic signal receiving process for the diagnostic period from the time of power-up and increases the variable N 2 indicating the diagnostic signal reception number every time the diagnostic signal is received. Accordingly, when the signal transmission system between the sensor unit 3 a of the torque sensor 3 and the micro control unit 31 of the steering assist control device 20 is not abnormal, the variable N 2 indicating the diagnostic signal reception number becomes equal to or greater than a predetermined value N 2 s . Accordingly, when the diagnostic period counted by the timer is up, the process goes from step S 15 to step S 17 via step S 16 and the diagnostic state flag F 2 is reset to “0”.

Therefore, when the process returns to step S 12 , the process goes from step S 12 to step S 19 , the torque detection signal T, the vehicle velocity detection value Vs, the motor current detection value, and the like are read, and the steering assist current command value Iref is calculated by referring to the steering assist current command value calculation map on the basis of the read torque detection signal T and the read vehicle velocity detection value Vs (step S 20 ).

The d-q axis command value computing process is performed on the basis of the calculated steering assist current command value Iref to calculate the d-axis current command value Idref and the q-axis current command value Iqref (step S 22 ), and the calculated d-axis current command value Idref and the calculated q-axis current command value Iqref are processed by using a two-phase to three-phase transformation to calculate the three-phase motor current command values Iuref to Iwref (step S 23 ).

Subsequently, the motor current detection values Iu to Iw are subtracted from the calculated motor current command values Iuref to Iwref, respectively, to calculate the current deviations ΔIu to ΔIw (step S 23 ), the PI control process is performed on the calculated current deviations ΔIu to ΔIw to calculate the voltage command values Vuref to Vwref (step S 24 ), the pulse width modulating process is performed on the basis of the calculated voltage command values Vuref to Vwref to generate the gate control signal (step S 25 ), and the generated gate control signal is outputted to the FET gate drive circuit 33 (step S 26 ).

Accordingly, the gate control signal is outputted from the FET gate drive circuit 33 to the motor drive circuit 32 and the three-phase motor currents Iu to Iw are outputted from the motor drive circuit 32 to the electric motor 12 . Therefore, the electric motor 12 is driven to rotate so as to generate a steering assist torque depending on the steering torque detection value, and the generated steering assist torque is transmitted to the output shaft 2 b of the steering shaft 2 via the deceleration mechanism 11 . As a result, it is possible to steer the steering wheel 1 with a small steering effort.

On the other hand, when the variable N 2 indicating the diagnostic signal reception number is less than a predetermined value N 2 s in the diagnosis process at the time of power-up, it is determined that abnormality occurs in the signal transmission system between the calculating unit 3 c of the torque sensor 3 and the micro control unit 31 of the steering assist control device 20 .

Accordingly, when the diagnostic period counted by the timer is up and the diagnostic period elapses, the process goes from step S 16 to step S 18 , the torque sensor abnormality alarm signal is outputted to the alarm circuit 40 , and then the steering assist control process is terminated. The alarm circuit 40 issues an alarm using sound, light, image information, or the like to notify a driver of the abnormality of the torque detection value transmission system. When it is determined that the torque sensor is abnormal, the controlling value may be switched to the known alternative torque value and then the assist operation may be continued.

As a result, it is possible to surely prevent the steering assist control process from being performed in a state where the steering torque detection signal read by the micro control unit 31 is abnormal.

In this way, according to the first embodiment, the calculating unit 3 c of the torque sensor 3 generates and outputs the diagnostic signal to the micro control unit 31 as a control unit of the steering assist control device 20 at least at the time of starting the supply of power, and it is determined whether or not the micro control unit 31 normally receives the diagnostic signal. Accordingly, it is possible to accurately detect the abnormality of the signal transmission system including the noise filters 3 f and 14 between the calculating unit 3 c of the torque sensor 3 and the micro control unit 31 , thereby improving reliability of the electric power steering apparatus.

In addition, since the diagnostic signal used to detect abnormality uses a duty ratio of 1% to 4% or a duty ratio of 96% to 99% out of the effective range (duty ratio of 5% to 95%) of the pulse-width modulated (PWM) signal in which a normal torque detection signal is outputted, it is possible to accurately determine whether or not the diagnostic signal is received at the time of the diagnostic process of the micro control unit 31 .

Furthermore, even when the diagnostic signal is erroneously outputted from the calculating unit 3 c of the torque sensor 3 in the normal operation, the micro control unit 31 does not recognize the erroneous diagnostic signal as the torque detection signal and it is thus possible to avoid the possibility of occurrence of an erroneous operation.

Additionally, since the output computing process of a diagnostic signal and the reception computing process of a diagnostic signal are performed as the respective software processes, the present invention can be easily applied to an existing electric power steering apparatus not having a signal transmission system diagnosing function by only changing programs of the calculating unit 3 c of the torque sensor 3 and the micro control unit 31 of the steering assist control device 20 .

In the first embodiment, the descriptions are given for a case where the diagnostic signal is outputted from the calculating unit 3 c of the torque sensor 3 at the time of power-up and the diagnostic signal is received by the micro control unit 31 of the steering assist control device 20 , but the present invention is not limited to this case.

That is, the calculating unit 3 c of the torque sensor 3 may set the diagnostic period flag F 1 to “1”, perform the diagnostic signal output process (steps S 2 to S 6 ), and output the diagnostic signal for a predetermined period of time, at a fixed period of time T 1 after the time of power-up.

Then, the micro control unit 31 of the steering assist control device 20 performs the diagnostic signal determining process (steps S 12 to S 18 ) for a predetermined period of time by setting the diagnostic state flag F 2 to “1” and setting the timer, at a fixed period of time T 1 equal to that in the calculating unit 3 c after the time of power-up.

In the diagnostic signal determining process, it may be determined whether or not abnormality occurs in the signal transmission system between the calculating unit 3 c of the torque sensor 3 and the micro control unit 31 of the steering assist control device 20 on the basis of the reception state of the diagnostic signal. In this case, the output period of the diagnostic signal is preferably set to a short period so as to reduce an influence on the steering assist control by the continuously-output torque detection signals.

A second embodiment of the present invention will be described below with reference to FIG. 5 .

In the second embodiment, the steering assist control device 20 can request the torque sensor 3 to transmit a diagnostic signal.

That is, in the second embodiment, a signal transmission line 41 for transmitting a diagnostic signal transmission request signal is provided between the micro control unit 31 of the steering assist control device 20 and the calculating unit 3 c of the torque sensor 3 as illustrated in FIG. 5 .

In the signal switching process which is performed by the calculating unit 3 c of the torque sensor 3 , step S 31 is performed after step S 9 as illustrated in FIG. 6 . In step S 31 , it is determined whether or not the diagnostic signal transmission request signal is received from the micro control unit 31 of the steering assist control device 20 is performed.

When it is determined in step S 31 that the diagnostic signal transmission request signal is not received, the process returns to step S 2 . When it is determined that the diagnostic signal transmission request signal is received, the diagnostic period flag F 1 is set to “1” in step S 32 and then the process returns to step S 2 .

Furthermore, in the steering assist control process which is performed by the micro control unit 31 of the steering assist control device 20 , step S 41 is add after step S 26 as illustrated in FIG. 7 . In step S 41 , it is determined whether or not the steering torque detection value is “0” or a value within a dead zone in the vicinity of “0”.

When it is determined in step S 41 that the steering torque detection value is not “0” nor a value within a dead zone in the vicinity of “0”, a variable N 3 to be described later is cleared to “0” in step S 42 and then the process returns to step S 19 . On the other hand, when it is determined that the steering torque detection value is “0” or a value within a dead zone in the vicinity of “0”, it is determined that the steering is held at a neutral position, the variable N 3 for counting the duration of the steering-held state increases by “1” in step S 43 , and then the process goes to step S 44 .

In step S 44 , it is determined whether or not the variable N 3 reaches a predetermined value N 3 s . When it is determined that “N 3 <N 3 s ”, the process returns to step S 19 . When it is determined that “N 3 ≧N 3 s ”, the diagnostic signal transmission request signal is transmitted to the signal transmission line 41 in step S 45 . Subsequently, in step S 46 , the diagnostic state flag F 2 is set to “1”, the timer is set, and then the process returns to step S 12 .

According to the second embodiment, similarly to the first embodiment, initial abnormality diagnostic process is performed at the time of power-up. In the abnormality diagnostic process, the abnormality of the signal transmission line between the calculating unit 3 c of the torque sensor 3 and the micro control unit 31 of the steering assist control device 20 is diagnosed. Furthermore, in the steering assist control process of the micro control unit 31 of the steering assist control device 20 , when the state where the steering torque detection value is “0” or a value within a dead zone in the vicinity of “0” is maintained for a predetermined period of time, the micro control unit 31 transmits the diagnostic signal transmission request signal to the calculating unit 3 c of the torque sensor 3 so as to cause the calculating unit 3 c to transmit the diagnostic signal.

Accordingly, it is possible to diagnose the abnormality of the signal transmission system between the calculating unit 3 c of the torque sensor 3 and the micro control unit 31 of the steering assist control device 20 during operation of the steering assist control device 20 and also to diagnose the abnormality even after the time of power-up, thereby further improving reliability.

In the second embodiment, the descriptions are given for a case where the diagnostic signal transmission request signal is transmitted to the calculating unit 3 c of the torque sensor 3 via the signal transmission line 41 when the torque detection signal is “0” or a value within a dead zone in the vicinity of “0”, but the present invention is not limited to this case.

That is, in the present invention, a steering angle sensor that detects a steering angle of the steering wheel 1 may be provided, and the diagnostic signal transmission request signal may be transmitted when a state where the steering angle is located at the neutral position (=“0”) indicating straight traveling is maintained for a predetermined period of time. In brief, the diagnostic signal transmission request signal may be transmitted during the period in which the transmitting does not affect on the steering assist control process. The diagnostic signal transmission request signal may be transmitted at a fixed period of time.

A third embodiment of the present invention will be described below with reference to FIGS. 8 and 9 .

In the third embodiment, the abnormality of the noise filters 3 f and 23 interposed between the torque sensor unit 3 a of the torque sensor 3 and the micro control unit 31 of the steering assist control device 20 is detected.

That is, in the third embodiment, the abnormality determining unit 31 a of the micro control unit 31 illustrated in FIG. 2 in the first embodiment is used to detect the abnormality of the noise filters 3 f and 23 .

That is, the micro control unit 31 performs a steering assist control process illustrated in FIG. 8 .

The steering assist control process includes step S 50 . In step S 50 , a diagnostic signal receiving process is performed instead of the processes of steps S 13 and S 14 in the steering assist control process illustrated in FIG. 4 .

In the diagnostic signal receiving process of step S 50 , as illustrated in FIG. 9 , it is first determined in step S 51 whether or not the received signal rises from 0 V. When it is determined that the received signal does not rise, the diagnostic signal receiving process is terminated without performing any process and then the process goes to step S 15 illustrated in FIG. 8 .

When it is determined in step S 51 that the received signal rises, a rise counter including a software counter is activated to start a counting in step S 52 , so as to count at a constant a cycle shorter than the rise time of the received signal.

Subsequently, in step S 53 , it is determined whether or not the received signal level reaches a set level of, for example, 5 V which is the power supply voltage. When it is determined in step S 53 that the received level does not reach the set level, the process waits until the received level reaches the set level. When it is determined that the received level reaches the set level, the process goes to step S 54 .

The count value Tn 1 of the rise counter is read in step S 54 , and it is determined in step S 55 whether or not the read count value Tn 1 is smaller than a set count value Tns previously set to a value smaller than the count value in a state where both of the noise filters 3 f and 23 are normal.

The determination of step S 55 is to determine whether or not the rising of the received signal is rapid. That is, since the noise filters 3 f and 23 are generally constituted of a low-pass filter and serve as an integration element, the received signal rises at a relatively slow change rate as indicated by a dotted line in FIG. 10 when the noise filters 3 f and 23 are normal. However, when the noise filters 3 f and 23 are abnormal and cannot serve as a filter, the integration elements do not operate and thus the received signal rides rapidly as indicated by a solid line in FIG. 10 .

Therefore, by causing the rise counter to count the period of time in which the received signal rides from 0 V to the set level of 5 V, it is possible to determine whether or not the noise filters 3 f and 23 are normal on the basis of the count value.

When it is determined that “Tn 1 <Tns”, it is determined that abnormality occurs in any one of the noise filters 3 f and 23 , a filter abnormality flag FNA 1 indicating that the noise filters 3 f and 23 are abnormal is set to “1” in step S 56 , and then the process goes to step S 58 . When it is determined that “Tn 1 ≧Tns”, it is determined that the noise filters 3 f and 23 are normal, the filter abnormality flag FNA 1 is reset to “0” in step S 57 , and then the process goes to step S 58 .

In step S 58 , it is determined whether or not the received signal falls. When it is determined that the received signal does not fall, the process waits until the received signal falls. When it is determined that the received signal falls, the process goes to step S 59 .

A fall counter including a software counter is activated to start a counting in step S 59 so as to count at a constant cycle shorter than the fall time of the received signal, the counting of the rise counter is stopped in step S 60 , and then the process goes to step S 61 . By stopping the counting of the rise counter at the time of falling of the received signal, the count value of the rise counter indicates the duration Ton of the ON section of the received signal.

In step S 61 , it is determined whether or not the received signal level reaches 0 V. When it is determined that the received signal level does not reach 0 V, the process waits until the received signal level reaches 0 V. When it is determined that the received signal level reaches 0 V, the process goes to step S 62 .

The count value Tn 2 of the fall counter is read in step S 62 , and it is determined in step S 63 whether or not the read count value Tn 2 is smaller than a set count value Tns previously set to a value smaller than the count value in a state where both of the noise filters 3 f and 23 are normal.

The determination of step S 63 is to determine whether or not the fall of the received signal is rapid. That is, when the noise filters 3 f and 23 are normal, the received signal falls at a relatively slow change rate as indicated by a dotted line in FIG. 10 . However, when the noise filters 3 f and 23 are abnormal and cannot serve as a filter, the integration elements do not operate and thus the received signal falls rapidly as indicated by a solid line in FIG. 10 .

Therefore, by causing the fall counter to count the period of time in which the received signal falls from 5 V as the power supply voltage to 0 V, it is possible to determine whether or not the noise filters 3 f and 23 are normal on the basis of the count value.

When it is determined that “Tn 2 <Tns”, it is determined that abnormality occurs in any one of the noise filters 3 f and 23 , a filter abnormality flag FNA 2 indicating that the noise filters 3 f and 23 are abnormal is set to “1” in step S 64 , and then the process goes to step S 66 . When it is determined that “Tn 2 ≧Tns”, it is determined that the noise filters 3 f and 23 are normal, the filter abnormality flag FNA 2 is reset to “0” in step S 65 , and then the process goes to step S 66 .

In step S 66 , it is determined whether or not the received signal rises again. When it is determined that the received signal does not rise, the process waits until the received signal rises. When it is determined that the received signal rises, the process goes to step S 67 .

The counting of the fall counter is stopped in step S 67 and then the process goes to step S 68 . The count value Tn 2 of the fall counter indicates the duration Toff of the OFF section of the received signal.

In step S 68 , the duty ratio D of the received signal is calculated according to Expression (1) on the basis of the duration Ton of the ON section of the received signal indicated by the count value Tn 1 of the stopped rise counter and the duration Toff of the OFF section of the received signal indicated by the count value Tn 2 of the stopped fall counter, and then the process goes to step S 69 .

D=T on/( T on+ T off)  (1)

In step S 69 , it is determined whether or not the received signal is a diagnostic signal by determining whether or not the calculated duty ratio D corresponds to the set duty ratio of the diagnostic signal Sd. When it is determined that the received signal is not a diagnostic signal, the diagnostic signal receiving process is terminated and the process goes to step S 15 of FIG. 8 .

On the other hand, when it is determined in step S 69 that the received signal is a diagnostic signal, it is determined in step S 70 whether or not any one of the filter abnormality flags FNA 1 and FNA 2 is set to “1”. When it is determined that any one of the filter abnormality flags FNA 1 and FNA 2 is set to “1”, an alarm signal indicating abnormality of the noise filter is outputted to the alarm circuit 40 in step S 71 and then the process goes to step S 72 . When it is determined that both of the filter abnormality flags FNA 1 and FNA 2 are reset to “0”, the process immediately goes to step S 72 .

The variable N 2 indicating the diagnostic signal reception number increases by “1” in step S 72 , the diagnostic signal receiving process is terminated, and then the process goes to step S 15 of FIG. 8 .

According to the third embodiment, in the diagnostic signal receiving process illustrated in FIG. 9 at the time of power-up, the rise time Tn 1 of the received signal is measured in steps S 51 to S 54 , and the fall time Tn 2 of the received signal is measured in steps S 58 to S 62 .

The rise time Tn 1 and the fall time Tn 2 indicate the change rates, that is, slopes, of the rise and the fall of the received signal. Therefore, when the noise filters 3 f and 23 are normal and the received signal is received, as indicated by the dotted line in FIG. 10 , the rise and the fall of the received signal are slow, the change rates thereof are small, the rise time Tn 1 and the fall time Tn 2 are longer than the set time Tns, and thus it can be determined that the noise filters 3 f and 23 are normal.

However, for example, when both of the noise filters 3 f and 23 are abnormal, the rise and the fall of the received diagnostic signal become rapider as indicated by the solid line in FIG. 10 , the count value Tn 1 of the rise counter read in step S 54 is smaller than the set count value Tns, and the count value Tn 2 of the fall counter read in step S 62 is smaller than the set count value Tns.

Accordingly, the filter abnormality flag FNA 1 is set to “1” in step S 56 , and the filter abnormality flag FNA 2 is set to “1” in step S 64 .

Thereafter, when the received signal rises again, the process goes from step S 66 to step S 67 , the fall counter is stopped, the duty ratio D is calculated according to Expression (1) on the basis of the count value Tn 1 , that is, the ON time Ton, of the stopped rise counter and the count value Tn 2 , that is, the OFF time Toff, of the stopped fall counter in step S 68 .

When the calculated duty ratio D is out of the effective range of the duty ratio of the pulse-width modulated signal St in which the torque detection signal is outputted, it can be determined that the received signal is the diagnostic signal. When it is determined that the received signal is the diagnostic signal, it is determined in step S 70 whether or not the filter abnormality flag FNA 1 or FNA 2 is set to “1”. When it is determined that any one of the filter abnormality flags FNA 1 and FNA 2 is set to “1”, the alarm signal indicating the abnormality of the noise filter is outputted to the alarm circuit 40 to issue an alarm in step S 71 .

When both of the filter abnormality flags FNA 1 and FNA 2 are reset to “0”, it is determined that the noise filters 3 f and 23 are normal.

On the other hand, when the received signal does not rise from 0 V as indicated by a solid line in FIG. 11 , the diagnostic signal receiving process is terminated without performing any process after step S 51 . Accordingly, when the state where the received signal does not rise is maintained, the variable N 2 indicating the diagnostic signal reception number is maintained in “0”, and thus it can be determined that the transmission line between the torque sensor unit 3 a and the micro control unit 31 of the steering assist control device 20 is in a disconnected state.

In the third embodiment, in order to determine whether or not the noise filters 3 f and 23 are normal, the time until the received signal rises to the set voltage 5 V from 0 V as the rising state of the received signal is measured, and the time until the received signal reaches 0 V from the set voltage 5 V as the falling state of the received signal is measured. However, the present invention is not limited to the above-mentioned configuration. A voltage after a predetermined time elapses from the time point at which the rise or fall is detected may be detected to determine the rising state and the falling state of the received signal, or the period of time in which the received signal rises to a predetermined voltage and the period of time in which the received signal falls to a predetermined voltage may be measured. In brief, values corresponding to the change rates of the rise and the fall of the received signal have only to be detected. The present invention is not limited to the case where both the rising state and the falling state of the received signal are measured, but any one thereof may be measured.

In the third embodiment, the descriptions are given for a case where the process of determining abnormality of the noise filters is applied to the first embodiment, but the process of determining abnormality of the noise filters may be applied to the second embodiment.

In the first to third embodiments, the descriptions are given for a case where the torque detection value is outputted in the form of a pulse-width modulated (PWM) signal from the calculating unit 3 c of the torque sensor 3 , but the present invention is not limited to this case.

That is, the present invention may employ any signal transmitting method such as using an analog or digital voltage signal corresponding to the torque detection value or using a pulse signal with a pulse interval corresponding to the torque detection value.

In the first to third embodiments, the descriptions are given for a case where the abnormality of the signal transmission system is detected by causing the calculating unit 3 c of the torque sensor 3 and the micro control unit 31 of the steering assist control device 20 to generate the diagnostic signal and to receive the generated diagnostic signal by a software process.

The present invention is not limited to the above-mentioned configuration, but the torque sensor 3 may be provided with a test signal forming circuit that outputs a test signal and a signal switching circuit that switches between the diagnostic signal of the test signal forming circuit and the torque detection signal calculated by the calculating unit 3 c . Similarly, the calculating unit 3 c and the micro control unit 31 may be constructed by hardware.

In the first to third embodiments, the descriptions are given for a case where only the steering torque is detected as the physical quantity, but the present invention is not limited to this case. When a steering angel sensor that detects a steering angle as the physical quantity is provided, the sensor unit 3 a may be applied to the steering angle sensor. Alternatively, two or more types of physical quantities may be detected by physical quantity sensors and the detected physical quantities may be supplied to the steering assist control device in a time division manner. The physical quantities to be detected are not limited to the steering torque and the steering angle, but the present invention may be used to detect arbitrary physical quantities such as a current, a voltage, a pressure, and a liquid level.

In the above-mentioned embodiments, the descriptions are given for a case where the physical quantity detecting device according to the present invention is applied to the electric power steering apparatus, but the present invention is not limited to this case. The present invention may be applied to a physical quantity detecting device including a detection unit that detects a physical quantity and a control unit that performs a control operation on the basis of the physical quantity detected by the detection unit, or a control device that controls any control target using the physical quantity detecting device.

1 : steering wheel

2 : steering shaft

3 : torque sensor

3 a : sensor unit

3 b : torque sensor unit

3 c : calculating unit

3 d : signal output unit

3 e : power supply circuit

3 f , 3 g : noise filter

10 : steering assist mechanism

11 : deceleration mechanism

12 : electric motor

20 : steering assist control device

21 : battery

22 : ignition switch

23 : noise filter

24 : vehicle velocity sensor

25 : vehicle CAN

31 : micro control unit (MCU)

31 a : abnormality determining unit

32 : motor drive circuit

33 : FET gate drive circuit

34 : motor current detecting circuit

35 : power supply relay

36 : CAN interface

37 : power supply circuit

40 : alarm circuit

41 : signal transmission line