Speed Error Mitigation for a DSP-Based Resolver-to-Digital Converter Using Auto-Tuning Filters

Modern resolver-to-digital converters (RDC) are typically implemented using DSP techniques to reduce hardware footprint and enhanced system accuracy. However, in such implementations, both resolver sensor and ADC channel unbalances introduce significant errors particularly in the speed output of the tracking loop. The frequency spectrum of the output error is variable depending on the resolver mechanical velocity. This paper presents the design of an auto-tuning output filter based on the interpolation of pre-computed filters for a DSP-based RDC with a type-II tracking loop. A fourth-order peak and a second-order high pass filter are designed and tested for an experimental RDC. The experimental results demonstrate significant reduction of the peak-to-peak error in the estimated speed

Rotary Position Sensors Comparative study of different rotary position sensors for electrical machines used in an hybrid electric vehicle application

Today, many projects about Electric Vehicles (EVs) and Hybrid Electric Vehicles (HEVs) are in progress within the automotive industry. Fuel-efficiency and reduction of carbon dioxide emissions from vehicles are the main targets. This thesis is within in one of these projects that is called electric All Wheel Drive(eAWD) at BorgWarner TorqTransfer Systems AB. A key parameter to perform an accurate and efficient control of an electric machine is the position sensor. The sensor measures the angular position of the rotor shaft and there are several ways and techniques to do this. This thesis aims to compare different common position sensors and identify ”new” sensor techniques by performing a literature study, model and simulate sensors and test an electric machine with different sensors implemented. Various enhancement methods to improve the position information and prediction are also evaluated. The electric motor prototype used in the eAWD project has different position sensors implemented and these are simulated in Matlab/Simulink together with the system model of the electric machine and control system. Tests are also performed and compared to the simulation results. The results show on best performance when using the resolver as position sensor. The Hall-effect sensor can be improved with an observer, but the observer is not suitable for this specific type of Torque Vectoring (TV) application. The Hall-effect sensor has a speed dependent torque ripple that leads to harmonics at frequencies that relates to the speed of the unit which may causes problems, such as mechanical resonances in the system. There are several ”new” sensor techniques based on the theory of eddy-currents that may be of interest since they are said to be more optimized for EV and HEV applications

High Frequency Injection Sensorless Control for a Permanent Magnet Synchronous Machine Driven by an FPGA Controlled SiC Inverter

As motor drive inverters continue to employ Silicon Carbide (SiC) and Gallium Nitride (GaN) devices for power density improvements, sensorless motor control strategies can be developed with field-programmable gate arrays (FPGA) to take advantage of high inverter switching frequencies. Through the FPGA’s parallel processing capabilities, a high control bandwidth sensorless control algorithm can be employed. Sensorless motor control offers cost reductions through the elimination of mechanical position sensors or more reliable electric drive systems by providing additional position and speed information of the electric motor. Back electromotive force (EMF) estimation or model-based methods used for motor control provide precise sensorless control at high speeds; however, they are unreliable at low speeds. High frequency injection (HFI) sensorless control demonstrates an improvement at low speeds through magnetic saliency tracking. In this work, a sinusoidal and square-wave high frequency injection sensorless control method is utilized to examine the impact an interior permanent magnet synchronous machine’s (IPMSM) fundamental frequency, injection frequency, and switching frequency have on the audible noise spectrum and electrical angle estimation. The audible noise and electrical angle estimation are evaluated at different injection voltages, injection frequencies, switching frequencies, and rotor speeds. Furthermore, a proposed strategy for selecting the proper injection frequency, injection voltage, and switching frequency is given to minimize the electrical angle estimation error

Metoda za estimaciju magnetskog toka rotora kaveznih asinkronih generatora bez mjernog člana brzine vrtnje temeljena na fazno spregnutoj petlji

This paper presents a new rotor flux estimation method for sensorless vector controlled squirrel-cage inductiongenerators used in wind power applications. The proposed method is based on a phase-locked loop (PLL) and theorthogonality between the rotor flux space vector and its back electromotive force (EMF) space vector. Rotor flux isestimated using stator voltage equations without integrating the back EMF components in the stationary referenceframe and the well-known difficulties with the implementation of pure integrators are thus avoided. Moreover, theproposed method ensures successful magnetization of a speed-sensorless squirrel-cage induction generator at nonzerospeeds which makes it suitable for wind power applications. Experimental results on a 560 kW squirrel-cageinduction generator are presented to confirm the effectiveness and the feasibility of the proposed method.U radu je predstavljena nova metoda za estimaciju magnetskog toka rotora vektorski upravljanih kaveznih asinkronih vjetrogeneratora. Predložena metoda se temelji na fazno spregnutoj petlji i ortogonalnosti između prostornog vektora magnetskog toka rotora i njemu pripadajućeg prostornog vektora induciranog napona. Magnetski tok rotora se estimira korištenjem naponskih jednadžbi statora u koordinatnom sustavu statora bez integracije komponenti induciranog napona čime su izbjegnuti dobro poznati problemi implementacije integratora. Osim toga, predložena metoda omogućava uspješno magnetiziranje pri vrtnji kaveznog asinkronog generatora bez mjernog člana brzine vrtnje pa je pogodna za primjenu na vjetrogeneratorima. U radu su prikazani eksperimentalni rezultati za kavezni asinkroni generator snage 560~kW koji potvrđuju izvedivost i učinkovitost predložene metode

Laboratory implementations of PMSM drive in hybrid electric vehicles applications

Field Programmable Gate Arrays (FPGAs) are one of the today\u27s most successful technologies for developing systems that require real time operation and providing additional flexibility to the designer. This research is focused on developing a control board for a permanent magnet synchronous machine (PMSM) using an FPGA module. The board is configured for individual use of an FPGA, digital signal processor (DSP) or in combination to control the PMSM by generating the required Pulse Width Modulator (PWM) to the inverter in order to drive and control the speed of the PMSM. Since, the exact rotor position and speed are required to control the motor; a useful method is developed digitally and implemented in the FPGA hardware module. The speed observer (SO), in which the Hall effect signals were used to calculate the speed and the angle of the rotor. In this thesis, three different techniques of PWM generation were developed and combined with rotor position and speed method. The project is implemented in Altera FPGA using Quartus II software V11.0 with VHDL as the supporting language. The design achieved high performance and accuracy of the detection estimation and control scheme for the Permanent Magnet Synchronous Machine. Error and design analysis has been done also --Abstract, page iii

A resolver-to-digital conversion method based on third-order rational fraction polynomial approximation for PMSM control

—In this paper, a cost-effective and highly accurate resolver-to-digital conversion (RDC) method is presented. The core of the idea is to apply a third-order rational fraction polynomial approximation (TRFPA) for the conversion of sinusoidal signals into the pseudo linear signals, which are extended to the range 0-360° in four quadrants. Then, the polynomial least squares method (PLSM) is used to achieve compensation to acquire the final angles. The presented method shows better performance in terms of accuracy and rapidity compared with the commercial available techniques in simulation results. This paper describes the implementation details of the proposed method and the way to incorporate it in digital signal processor (DSP) based permanent magnet synchronous motor (PMSM) drive system. Experimental tests under different conditions are carried out to verify the effectiveness for the proposed method. The obtained maximum error is about 0.0014° over 0-360° , which can usually be ignored in most industrial applications. Index Terms—Arc tangent function, Analog processing circuits, Pseudo linear signals, Resolver-to-digital conversion (RDC), Third-order rational fraction polynomial approximation (TRFPA)

A resolver-to-digital conversion method based on third-order rational fraction polynomial approximation for PMSM control

In this paper, a cost-effective and highly accurate resolver-to-digital conversion (RDC) method is presented. The core of the idea is to apply a third-order rational fraction polynomial approximation (TRFPA) for the conversion of sinusoidal signals into the pseudo linear signals, which are extended to the range 0-360° in four quadrants. Then, the polynomial least squares method (PLSM) is used to achieve compensation to acquire the final angles. The presented method shows better performance in terms of accuracy and rapidity compared with the commercial available techniques in simulation results. This paper describes the implementation details of the proposed method and the way to incorporate it in digital signal processor (DSP) based permanent magnet synchronous motor (PMSM) drive system. Experimental tests under different conditions are carried out to verify the effectiveness for the proposed method. The obtained maximum error is about 0.0014° over 0-360°, which can usually be ignored in most industrial application

ANALYSIS AND SYNTHESIS OF PRECISION RESOLVER SYSTEM

Ph.DDOCTOR OF PHILOSOPH

Sensorless Rotor Position Estimation For Brushless DC Motors

Brushless DC motor speed is controlled by synchronizing the stator coil current with rotor position in order to acquire an accurate alignment of stator rotating field with rotor permanent-magnet field for efficient transfer of energy. In order to accomplish this goal, a motor shaft is instantly tracked by using rotating rotor position sensors such as Hall effect sensors, optical encoders or resolvers etc. Adding sensors to detect rotor position affects the overall reliability and mechanical robustness of the system. Therefore, a whole new trend of replacing position sensors with sensorless rotor position estimation techniques have a promising demand. Among the sensorless approaches, Back-EMF measurement and high frequency signal injection is the most common. Back-EMF is an electromotive force, directly proportional to the speed of rotor revolutions per second, the greater the speed motor acquires the greater the Back-EMF amplitude appears against the motion of rotation. However, the detected Back-EMF is zero at start-up and does not provide motor speed information at this instant. There-fore, Back-EMF based techniques are highly unfavourable for low speed application specially near zero. On the other hand, signal injection techniques are comparatively developed for low or near zero motor speed applications and they also can estimate the on-line motor parameters exploiting the identification theory on phase voltages and currents signals. The signal injection approach requires expensive additional hardware to inject high frequency signal. Since, motors are typically driven with pulse width modulation techniques, high frequency signals are naturally already present which can be used to detect position. This thesis presents rotor position estimation by measuring the voltage and current signals and also proposes an equivalent permanent-magnet synchronous motor model by fitting thedata to a position dependent circuit model