A Novel PMSM Hybrid Sensorless Control Strategy for EV Applications Based on PLL and HFI

In this paper, a novel hybrid sensorless control strategy for Permanent Magnet Synchronous Machine (PMSM) drives applied to Electric Vehicles (EV) is presented. This sensorless strategy covers the EV full speed range and also has speed reversal capability. It combines a High Frequency Injection (HFI) technique for low and zero speeds, and a Phase-Locked Loop (PLL) for the medium and high speed regions. A solution to achieve smooth transitions between the PLL and the HFI strategies is also proposed, allowing to correctly detect the rotor position polarity when HFI takes part. Wide speed and torque four-quadrant simulation results are provided, which validate the proposed sensorless strategy for being further implemented in EV.Peer ReviewedPostprint (author's final draft

Low-cost, high-resolution, fault-robust position and speed estimation for PMSM drives operating in safety-critical systems

In this paper it is shown how to obtain a low-cost, high-resolution and fault-robust position sensing system for permanent magnet synchronous motor drives operating in safety-critical systems, by combining high-frequency signal injection with binary Hall-effect sensors. It is shown that the position error signal obtained via high-frequency signal injection can be merged easily into the quantization-harmonic-decoupling vector tracking observer used to process the Hall-effect sensor signals. The resulting algorithm provides accurate, high-resolution estimates of speed and position throughout the entire speed range; compared to state-of-the-art drives using Hall-effect sensors alone, the low speed performance is greatly improved in healthy conditions and also following position sensor faults. It is envisaged that such a sensing system can be successfully used in applications requiring IEC 61508 SIL 3 or ISO 26262 ASIL D compliance, due to its extremely high mean time to failure and to the very fast recovery of the drive following Hall-effect sensor faults at low speeds. Extensive simulation and experimental results are provided on a 3.7 kW permanent magnet drive

Improved speed estimation in sensorless PM brushless AC drives

The application of flux-observer-based sensorless control to permanent-magnet brushless AC motor drives is described. Current methods of speed estimation are assessed, both theoretically and experimentally, and an improved method, which combines the best features of methods in which speed is derived from the differential of rotor position and from the ratio of the electromotive force to excitation flux linkage, is proposed. Its performance is verified experimentally

Hybrid sensorless control of axial flux permanent magnet motor drives, including zero speed

Sensorless control of an axial flux permanent magnet motor drive is proposed and tested. The motor is not purposely designed for sensorless control and shows a very small inherent saliency. This significantly affects the saliency-based position estimation in the low speed region. Other non-idealities, such as the non-sinusoidal back-EMF waveforms and possible misalignment between stator and rotor make the control more challenging. A robust sensorless control scheme is proposed, able to deal with these non-idealities with a rather simple implementation. The position estimation is based on a closed loop hybrid observer of the permanent magnet flux linkage. Experimental results report torque and speed sensorless control

Some Permanent Magnet Synchronous Motor (PMSM) Sensorless Control Methods based on Operation Speed Area

This paper compares some sensorless Permanent Magnet Synchronous Motor (PMSM) controls for driving an electric vehicle in terms of operating speed. Sensorless control is a type of control method in which sensors, such as speed and position sensors, are not used to measure controlled variables.  The controlled variable value is estimated from the stator current measurement. Sensorless control performance is not as good as a sensor-based system. This paper aims are to recommend a control method for the PMSM sensorless controls that would be used to drive an electric vehicle. The methods that we will discuss are divided into four categories based on the operation speed area.  They are a startup, low speed, high speed, and low and high-speed areas. The low and high-speed area will be divided into with and without switching.  If PMSM more work at high speed, the most speed area that is used, we prefer to choose the method that works at high speed, that is, the modification or combination of two or more conventional methods

Hybrid sensorless control of PMSM in full speed range using HFI and back-EMF

The permanent magnet synchronous motors (PMSM) are more and more used because of their high performance compared with other AC motors. The present paper proposes a hybrid controller which consists of a high frequency injection estimator and a back-electromotive-force observer in full speed range for the sensorless control of PMSM. The aim objective of the study to prevent speed overshot in startup time of the motor and provides a better dynamic response in transient and permanent states using this structure. A hybrid algorithm is applied to realize a smooth transition from low to high speed. At standstill and very low speed region, HF injection technique is used to detect the rotor initial position. In this first step study, the position estimation is derived from a HF current injection by using only one filter. When the rotor speed goes up to a certain value where back-EMF can provide adequate information, a back-EMF observer will dominate. Thanks to this structure, the mechanical sensor can be engaged using the best estimates and the developed control method is fast, simple, and flexible. The effectiveness, superiority, and performance of the proposed control method and extensive simulation results are provided on a 1 kW permanent magnet synchronous motor drive, demonstrating the expected performances

Sensorless control for limp-home mode of EV applications

PhD ThesisOver the past decade research into electric vehicles’ (EVs) safety, reliability and availability has become a hot topic and has attracted a lot of attention in the literature. Inevitably these key areas require further study and improvement. One of the challenges EVs face is speed/position sensor failure due to vibration and harsh environments. Wires connecting the sensor to the motor controller have a high likelihood of breakage. Loss of signals from the speed/position sensor will bring the EV to halt mode. Speed sensor failure at a busy roundabout or on a high speed motorway can have serious consequences and put the lives of drivers and passengers in great danger. This thesis aims to tackle the aforementioned issues by proposing several novel sensorless schemes based on Model Reference Adaptive Systems (MRAS) suitable for limp-home mode of EV applications. The estimated speed from these schemes is used for the rotor flux position estimation. The estimated rotor flux position is employed for sensorless torque-controlled drive (TCD) based on indirect rotor field oriented control (IRFOC). The capabilities of the proposed schemes have been evaluated and compared to the conventional back-Electromotive Force MRAS (back-EMF MRAS) scheme using simulation environment and a test bench setup. The new schemes have also been tested on electric golf buggies. The results presented for the proposed schemes show that utilising these schemes provide a reliable and smooth sensorless operation during vehicle test-drive starting from standstill and over a wide range of speeds, including the field weakening region. Employing these new schemes for sensorless TCD in limp-home mode of EV applications increases safety, reliability and availability of EVs

An encoderless high-performance synchronous reluctance motor drive

This paper presents an encoderless high-performance synchronous reluctance motor drive for traction applications. The control system is based on the active flux concept and a hybrid rotor position estimation algorithm is used, being this algorithm based on the injection of high-frequency signals at low speeds and on the position of the active flux vector for medium and high-speeds. A smooth transition algorithm between the two rotor position estimation methods is provided. Moreover, in order to improve the efficiency of the overall drive system, a loss minimization algorithm is proposed in order to reduce the motor copper losses when operating in steady-state. Experimental results obtained in the laboratory confirm the validity and adequacy of the proposed algorithms for the developed drive system.info:eu-repo/semantics/publishedVersio

Hybrid Field Oriented and Direct Torque Control for Sensorless BLDC Motors Used in Aerial Drones

In this study, a sensorless hybrid control scheme for brushless direct current (BLDC) motors for use in multirotor aerial vehicles is introduced. In such applications, the control scheme must satisfy high-performance demands for a wide range of rotor speeds and must be robust to motor parameter uncertainties and measurement noise. The proposed controller combines field-oriented control (FOC) and direct torque control (DTC) techniques to take benefit of the advantages offered by each of these techniques individually. Simulation results demonstrate the effectiveness of the proposed control scheme over a wide range of rotor speeds as well as good robustness against parameter uncertainties within -5to + 10% for inductance and -5to + 5% for resistance parameters. The proposed hybrid controller is robust also against noise in voltage and current measurements. In order to verify the results from simulation, the proposed hybrid controller is implemented in hardware using the TI C2000 Piccolo Launchpad and TI BOOSTXL-DRV8305EVM BoosterPack. Testing is done with a Bull Running motor typically used in aerial drones. Testing experiments demonstrate that the hybrid controller reduces the rotor speed ripple when compared to DTC while operating in steady-state mode and decreases the response time to desired speed changes when compared to FOC