FPGA-based implementation of the back-EMF symmetric-threshold-tracking sensorless commutation method for brushless DC-machines

The operation of brushless DC permanent-magnet machines requires information of the rotor position to steer the semiconductor switches of the power-supply module which is commonly referred to as Brushless Commutation. Different sensorless techniques have been proposed to estimate the rotor position using current and voltage measurements of the machine. Detection of the back-electromotive force (EMF) zero-crossing moments is one of the methods most used to achieve sensorless control by predicting the commutation moments. Most of the techniques based on this phenomenon have the inherit disadvantage of an indirect detection of commutation moments. This is the result of the commutation moment occurring 30 electrical degrees after the zero-crossing of the induced back-emf in the unexcited phase. Often, the time difference between the zero crossing of the back-emf and the optimal current commutation is assumed constant. This assumption can be valid for steady-state operation, however a varying time difference should be taken into account during transient operation of the BLDC machine. This uncertainty degrades the performance of the drive during transients. To overcome this problem which improves the performance while keeping the simplicity of the back-emf zero-crossing detection method an enhancement is proposed. The proposed sensorless method operates parameterless in a way it uses none of the brushless dc-machine parameters. In this paper different aspects of experimental implementation of the new method as well as various aspects of the FPGA programming are discussed. Proposed control method is implemented within a Xilinx Spartan 3E XC3S500E board

Harjattoman tasavirtamoottorin arviointi opto-mekaanisessa paikkasäätösovelluksessa

This thesis evaluates the applicability of a micro-sized brushless direct current (DC) mo- tor in an opto-mechanical positioning application. Brushless DC motors are electronically commutated motors that use permanent magnets to produce the airgap magnetic field. The motor is powered through an inverter or switching power supply which produces an AC electric current to drive each phase of the motor. Optimal current waveforms are determined by the motor controller based on the desired torque, speed or position requirements. The benefits of a brushless motor over conventional brushed DC motors are a high power to weight ratio, low noise and a long operating life. The purpose of this thesis is to find out the performance potential of such motors and determine methods to achieve it. Firstly, a motor model and an exact motor classification is presented. A literature review is made to discuss state of the art control methods and hardware configurations for dynamic position control. Based on the literature review, a control scheme with field-oriented control based torque control and cascaded PI controlled speed and position loops was selected for further evaluation. Experimental positioning tests were executed for two motors with different power transmission setups. Tests were performed with both, a hardware and software implemented, motor controllers. Results show promising performance. It was shown that the required acceleration is feasible with both, geared and direct drive, transmissions. Field-oriented control was shown as a well performing method to control torque but special caution was needed to implement a reliable position sensing solution in a small size as the control algorithm is intolerant for inaccurate and noisy position data. The conventional PI based position controller was effective in cases with no feedback related harmonics or motor related torque ripple but was not capable in handling ripple caused by a non-ideal system. Quality variances were seen between motors which were originated from mechanical defects and non-idealities in the stator structure. Further research is needed to achieve a better settling performance through filtering undesired feedback harmonics, better tuning and thus minimizing undesired vibrations.Tämän diplomityön tarkoituksena on arvioida pienikokoisen harjattoman tasavirtamoottorin soveltuvuutta opto-mekaaniseen paikkasäätösovellukseen. Harjattomat tasavirtamoottorit ovat elektronisesti ohjattuja moottoreita, joissa ilmavälin magneettivuo luodaan kestomagneeteilla. Moottorille syötetään virtaa taajuusmuuttajalta, joka muodostaa halutunlaisen vaihtovirran jokaiselle moottorin vaiheelle. Syötettävää virtaa ohjataan moottorinohjaimelta määritettyjen vääntö-, nopeus- ja paikkavaatimusten perusteella. Harjattoman DC-moottorin edut verrattuna perinteiseen harjalliseen DC-moottoriin ovat hyvä teho-painosuhde, hiljainen käyntiääni ja pitkä käyttöikä. Diplomityön tavoitteena on kartoittaa kyseisen moottorityypin suorituskyky paikkasäädössä ja tutkia keinoja saavuttaa haluttu taso. Alan tutkimuksessa ja kirjallisuudessa tunnettuja suorituskykyisiä säätömenetelmiä ja laite- sekä komponenttikokoonpanoja on koostettu kirjallisuuskatsauksessa. Tämän perusteella kokeellisiin testeihin valittiin säätöarkkitehtuuri vektorisäätöön perustuvalla virransäädöllä sekä PI-pohjaisilla nopeus- ja paikkasäätimillä. Kokeellisilla paikoitustesteillä arvioitiin kahden moottorin suorituskykyä erilaisilla voimansiirtovaihtoehdoilla. Testit suoritettiin sekä ohjelmistopohjaisella että sovelluskohtaiseen mikropiiriin toteutetulla laitepohjaisella säätimellä. Tulokset osoittavat että vaaditun kiihtyvyyden saavuttaminen on mahdollista sekä vaihteellisella että suoravetoisella voimansiirrolla. Vektorisäätö osoittautui suorituskykyiseksi virransäätömenetelmäksi, mutta moottorin asentomittauksen luotettava toteutus vaati erityishuomiota, sillä vektorisäätöalgoritmi on herkkä paikkadatan tarkkuudelle. PI-säätimillä toteutettu paikkasäätö osoittautui toimivaksi, mutta herkäksi moottorin epäideaalisuuksille sekä häiriöille takaisinkytkennässä. Moottoreiden välillä havaittiin laatueroja mekaanisissa toleransseissa ja staattorin rakenteessa. Lopullisen asettumisajan saavuttaminen vaatii lisätutkimusta. Erityishuomiota on kiinnitettävä harmonisten komponenttien suodattamiseen sekä systeemin säätöön, jotta ei-toivotut värinät saadaan minimoitua

Positioning Control System for a Large Range 2D Platform with Submicrometre Accuracy for Metrological and Manufacturing Applications

The importance of nanotechnology in the world of Science and Technology has rapidly increased over recent decades, demanding positioning systems capable of providing accurate positioning in large working ranges. In this line of research, a nanopositioning platform, the NanoPla, has been developed at the University of Zaragoza. The NanoPla has a large working range of 50 mm × 50 mm and submicrometre accuracy. The NanoPla actuators are four Halbach linear motors and it implements planar motion. In addition, a 2D plane mirror laser interferometer system works as positioning sensor. One of the targets of the NanoPla is to implement commercial devices when possible. Therefore, a commercial control hardware designed for generic three phase motors has been selected to control and drive the Halbach linear motors.This thesis develops 2D positioning control strategy for large range accurate positioning systems and implements it in the NanoPla. The developed control system coordinates the performance of the four Halbach linear motors and integrates the 2D laser system positioning feedback. In order to improve the positioning accuracy, a self calibration procedure for the characterisation of the geometrical errors of the 2D laser system is proposed. The contributors to the final NanoPla positioning errors are analysed and the final positioning uncertainty (k=2) of the 2D control system is calculated to be ±0.5 µm. The resultant uncertainty is much lower than the NanoPla required positioning accuracy, broadening its applicability scope.<br /

Variable gain control of brushless DC motor control with low resolution sensors

In this work, feasibility of using low cost, low resolution sensor for high performance brushless dc (BLDC) motor speed control is investigated. Conventional control, using a tachometer or high resolution encoder, suffers from drawbacks such as high cost, large physical volume, and high sensor processing bandwidth. On the other hand, sensorless BLDC motor, appealing in its hardware simplicity, does not provide sufficient fast performance. Using a standard low resolution sensor, such as a hall sensor or commutation encoder, a compromise between cost and performance can be obtained. However, the use of a low resolution sensor does pose a challenge to the control design: the sensor signal is discrete and speed dependent. Together with the nonlinear drive voltage/speed characteristic of the motor, control of the BLDC motor requires a more advanced algorithm than fixed gain control. This thesis presents a speed dependent control scheme to produce optimal performance. The characteristics of the control scheme is first assessed by numerical simulation, based on the mathematical model of the BLDC motor. This is followed by experimental verification of the BLDC motor. From the available data, it is concluded that speed dependent control provides significant advantages over fixed gain control when low resolution sensor is used

Direct torque control of brushless DC drives with reduced torque ripple

The application of direct torque control (DTC) to brushless ac drives has been investigated extensively. This paper describes its application to brushless dc drives, and highlights the essential differences in its implementation, as regards torque estimation and the representation of the inverter voltage space vectors. Simulated and experimental results are presented, and it is shown that, compared with conventional current control, DTC results in reduced torque ripple and a faster dynamic response

2D positioning control system for the planar motion of a nanopositioning platform

A novel nanopositioning platform (referred as NanoPla) in development has been designed to achieve nanometre resolution in a large working range of 50 mm × 50 mm. Two-dimensional (2D) movement is performed by four custom-made Halbach linear motors, and a 2D laser system provides positioning feedback, while the moving part of the platform is levitating and unguided. For control hardware, this work proposes the use of a commercial generic solution, in contrast to other systems where the control hardware and software are specifically designed for that purpose. In a previous paper based on this research, the control system of one linear motor implemented in selected commercial hardware was presented. In this study, the developed control system is extended to the four motors of the nanopositioning platform to generate 2D planar movement in the whole working range of the nanopositioning platform. In addition, the positioning uncertainty of the control system is assessed. The obtained results satisfy the working requirements of the NanoPla, achieving a positioning uncertainty of ±0.5 µm along the whole working range

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

Positioning uncertainty of the control system for the planar motion of a nanopositioning platform

The novel nanopositioning platform (NanoPla) that is in development at the University of Zaragoza has been designed to achieve nanometre resolution in a large working range of 50 mm × 50 mm. The 2D movement is performed by four custom-made Halbach linear motors and a 2D laser system provides positioning feedback, while the moving part of the platform is levitating and unguided. As control hardware, this work proposes the use of a commercial solution, in contrast to other systems, where the control hardware and software were specifically designed for the purpose. In a previous work of this research, the control system of one linear motor implemented in the selected commercial hardware was presented. In this study, the developed control system is extended to the four motors of the nanopositioning platform to generate a 2D planar movement in the whole working range of the nanopositioning platform. In addition, the positioning uncertainty of the control system is assessed. The obtained results satisfy the working requirements of the NanoPla, achieving a positioning uncertainty of ±0.5 µm along the whole working range

Torque Controlled Drive for Permanent Magnet Direct Current Brushless Motors

This thesis describes the design and implementation of a simple variable speed drive (VSD) based on a brushless direct current (BLDC) machine and discrete logic circuits. A practical VSD was built, capable of operating a BLDC machine in two quadrants, motoring and regenerative braking. The intended applications are electric scooters and electric bicycles, where the recovered energy from braking extends the range of the vehicle. A conceptual four quadrant VSD, suitable for three and four wheelers requiring reverse operation, was designed and tested in simulation. Simplicity was emphasized in this design to help achieve a robust, easy to analyse system. The versatility of multi-function gate integrated circuits (ICs) made them ideal for implementing the commutation logic and keeping the system simple. The BLDC machine has sensors with a resolution of 60 ed to determine rotor position. An electronic commutator or phase switcher module interprets the position signals and produces a switching pattern. This effectively transforms the BLDC machine into a direct current (DC) brushed machine. A synchronous step down converter controls the BLDC machine current with a tolerance band scheme. This module treats the BLDC machine as if it was a DC machine. The leakage inductance of the electric machine is used as the inductive filter element. The unipolar switching scheme used ensures that current flows out of the battery only for motoring operation and into the battery only during regeneration. The current and torque are directly related in a DC brushed machine. The action of an electronic commutator or phase switcher creates that same relationship between torque and current in a BLDC machine. Torque control is achieved in the BLDC machine using a single channel current controller. The phase switcher current is monitored and used to control the duty ratio of the synchronous converter switches. Successful operation of the practical VSD was achieved in two quadrants: forwards motoring and forwards regenerating. The maximum tested power outputs were 236W in motoring mode and 158W in regenerating mode. The output torque could be smoothly controlled from a positive to a negative value. iv v Simulation of the conceptual four quadrant design was successful in all the motoring, generating and active braking zones. The required manipulation of logic signals to achieve this type of operation was done automatically while the machine was running. The resulting output torque is smoothly controlled in all of the operating zones. Commutation at certain speeds and torques are handled better by some topologies than others. Some current sensing strategies adversely affect instantaneous phase currents under certain conditions. The final design chose the method where phase currents experience no overshoot, minimizing component stress. The battery, or energy storage system, used in verifying the operation of the VSD in the practical electric bicycle was found to be the most limiting component. In regenerating mode, the low charge acceptance rate of the battery reduced the maximum retarding torque and energy recovery rate

Modelling and Detecting Faults of Permanent Magnet Synchronous Motors in Dynamic Operations

Paper VI is excluded from the dissertation until the article will be published.Permanent magnet synchronous motors (PMSMs) have played a key role in commercial and industrial applications, i.e. electric vehicles and wind turbines. They are popular due to their high efficiency, control simplification and large torque-to-size ratio although they are expensive. A fault will eventually occur in an operating PMSM, either by improper maintenance or wear from thermal and mechanical stresses. The most frequent PMSM faults are bearing faults, short-circuit and eccentricity. PMSM may also suffer from demagnetisation, which is unique in permanent magnet machines. Condition monitoring or fault diagnosis schemes are necessary for detecting and identifying these faults early in their incipient state, e.g. partial demagnetisation and inter-turn short circuit. Successful fault classification will ensure safe operations, speed up the maintenance process and decrease unexpected downtime and cost. The research in recent years is drawn towards fault analysis under dynamic operating conditions, i.e. variable load and speed. Most of these techniques have focused on the use of voltage, current and torque, while magnetic flux density in the air-gap or the proximity of the motor has not yet been fully capitalised. This dissertation focuses on two main research topics in modelling and diagnosis of faulty PMSM in dynamic operations. The first problem is to decrease the computational burden of modelling and analysis techniques. The first contributions are new and faster methods for computing the permeance network model and quadratic time-frequency distributions. Reducing their computational burden makes them more attractive in analysis or fault diagnosis. The second contribution is to expand the model description of a simpler model. This can be achieved through a field reconstruction model with a magnet library and a description of both magnet defects and inter-turn short circuits. The second research topic is to simplify the installation and complexity of fault diagnosis schemes in PMSM. The aim is to reduce required sensors of fault diagnosis schemes, regardless of operation profiles. Conventional methods often rely on either steady-state or predefined operation profiles, e.g. start-up. A fault diagnosis scheme robust to any speed changes is desirable since a fault can be detected regardless of operations. The final contribution is the implementation of reinforcement learning in an active learning scheme to address the imbalance dataset problem. Samples from a faulty PMSM are often initially unavailable and expensive to acquire. Reinforcement learning with a weighted reward function might balance the dataset to enhance the trained fault classifier’s performance.publishedVersio