Artificial Neural Network-based error compensation procedure for low-cost encoders

An Artificial Neural Network-based error compensation method is proposed for improving the accuracy of resolver-based 16-bit encoders by compensating for their respective systematic error profiles. The error compensation procedure, for a particular encoder, involves obtaining its error profile by calibrating it on a precision rotary table, training the neural network by using a part of this data and then determining the corrected encoder angle by subtracting the ANN-predicted error from the measured value of the encoder angle. Since it is not guaranteed that all the resolvers will have exactly similar error profiles because of the inherent differences in their construction on a micro scale, the ANN has been trained on one error profile at a time and the corresponding weight file is then used only for compensating the systematic error of this particular encoder. The systematic nature of the error profile for each of the encoders has also been validated by repeated calibration of the encoders over a period of time and it was found that the error profiles of a particular encoder recorded at different epochs show near reproducible behavior. The ANN-based error compensation procedure has been implemented for 4 encoders by training the ANN with their respective error profiles and the results indicate that the accuracy of encoders can be improved by nearly an order of magnitude from quoted values of ~6 arc-min to ~0.65 arc-min when their corresponding ANN-generated weight files are used for determining the corrected encoder angle.Comment: 16 pages, 4 figures. Accepted for Publication in Measurement Science and Technology (MST

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

Type-III resolver-to-digital converter using synchronous demodulation / Tipo-III conversor resolver-para-digital utilizando a desmodulação síncrona

Resolver is an angular position sensor widely used in applications such as electric/hybrid vehicles, CNCs, antennas and robotics. However, the estimation of the angular position from resolver outputs is more difficult than the analysis of encoder signals, and it is still an open question. Most algorithms proposed in literature are based on type-I or type-II angle tracking ob- servers. Some type-III observers were proposed, but they require a high sampling frequency. This paper explores the use of synchronous demodulation of the resolver outputs to simplify the implementation of a type-III angle tracking observer. The resolver outputs are sampled at the peaks and valleys of the excitation resolver signal, being easy to get sine and cosine of the angular position. The proposed approach reduces the computational cost and the required sampling frequency to implement the type-III observer. Simulation and experimental results prove the accuracy of the proposed approach.

New Rotor Position Redundancy Decoding Method Based on Resolver Decoder

In view of the frequent safety problems of electric vehicles, the research on accurately obtaining the rotor position of the motor through the resolver is an important means to improve the functional safety of the system. The commonly used resolver decoding method involves the resolver decoding chip method and software decoding method, but few studies integrate the two decoding methods. A single method of motor rotor position acquisition cannot meet the requirements of system functional safety. To fill this gap, this paper proposes a method to simultaneously integrate hardware decoding and software decoding in the motor control system. The decoding chip and software decoding obtain the angle data at the same time, and they provide redundancy to improve the functional safety of the electronic control system. Finally, the effectiveness of the proposed simultaneous operation of hardware decoding and software decoding is verified by experiments

Controller Platform Design and Demonstration for an Electric Aircraft Propulsion Driv

With the growth in the aerospace industry there has been a trend to optimize the performance of an aircraft by reducing fuel consumption and operational cost. Recent advancements in the field of power electronics have pushed towards the concepts of hybrid electric aircraft also known as more electrical aircrafts. In this work, a custom controller board for an electric aircraft propulsion drive was designed to drive a permanent magnet synchronous motor. Design of the controller board required knowledge of the topology selection and power module selections. Simulations of the system were performed using MATLAB/Simulink to analyze the overall performance of the selected topology. Implementation of the control algorithm was tested on the hardware prototype of a three-phase, two-level voltage source inverter. Complete testing of the system at high power was accomplished; thus, demonstrating the inverter’s ability to operate at the desired power level

Control of the interaction of a gantry robot end effector with the environment by the adaptive behaviour of its joint drive actuators

The thesis examines a way in which the performance of the robot electric actuators can be precisely and accurately force controlled where there is a need for maintaining a stable specified contact force with an external environment. It describes the advantages of the proposed research, which eliminates the need for any external sensors and solely depends on the precise torque control of electric motors. The aim of the research is thus the development of a software based control system and then a proposal for possible inclusion of this control philosophy in existing range of automated manufacturing techniques.The primary aim of the research is to introduce force controlled behaviour in the electric actuators when the robot interacts with the environment, by measuring and controlling the contact forces between them. A software control system is developed and implemented on a robot gantry manipulator to follow two dimensional contours without the explicit geometrical knowledge of those contours. The torque signatures from the electric actuators are monitored and maintained within a desired force band. The secondary aim is the optimal design of the software controller structure. Experiments are performed and the mathematical model is validated against conventional Proportional Integral Derivative (PID) control. Fuzzy control is introduced in the software architecture to incorporate a sophisticated control. Investigation is carried out with the combination of PID and Fuzzy logic which depend on the geometrical complexity of the external environment to achieve the expected results

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

Simulink modeling and design of an efficient hardware-constrained FPGA-based PMSM speed controller

The aim of this paper is to present a holistic approach to modeling and FPGA implementation of a permanent magnet synchronous motor (PMSM) speed controller. The whole system is modeled in the Matlab Simulink environment. The controller is then translated to discrete time and remodeled using System Generator blocks, directly synthesizable into FPGA hardware. The algorithm is further refined and factorized to take into account hardware constraints, so as to fit into a low cost FPGA, without significantly increasing the execution time. The resulting controller is then integrated together with sensor interfaces and analysis tools and implemented into an FPGA device. Experimental results validate the controller and verify the design

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

Implementation of a motor control system for electric bus based on DSP

© 2017 IEEE. Motor control system may be the most important part of electric vehicles. To implement the control strategies, a lot of practical problems need to be taken into account. In this paper, an induction motor control system for electric bus is developed based on digital signal processor (DSP). The control strategy is based on field-oriented control and space vector pulse width modulation. Over-modulation, field weakening control, PI controller and fault diagnosis are also applied in this DSP algorithm. As a practical product running on a real electric bus with an 100 kW induction motor, communication with vehicle control unit (VCU) by controller area network (CAN bus), control system safety and PC software designed for experiment at lab are also discussed. The transient and steady-state performances of this motor control system are analyzed by experiments. Its performance is satisfactory when applied to the real electric bus