Theory and Simulation of the Brushless DC 120° Inverter System

The brushless dc motor- inverter system is becoming increasingly popular in servo and variable speed applications. One type of inverter, the 120° inverter, does not require rotor position sensing hardware. In this thesis, a theory of the brushless dc motor with a 120° inverter is set forth and used to create a fast simulation procedure for steady state operation. This simulation is well suited for evaluation of torque speed curves since the effects of changes of system parameters can be rapidly assessed. Furthermore, it was found that the system operation may be classified into a finite number of distinct operating modes. The properties of these modes and physical reason for their existence is discussed. Classifying the operation into modes provides a powerful tool for understanding system behavior. The theory presented and classification scheme are then used to formulate an approximate analytical method for the steady-state torque, which is quite accurate for normal operating conditions. The approximations presented are suitable for control system design

A Hybrid Observer for High Performance Brushless DC Motor Drives

Brushless DC motor drive systems are used in a wide variety of applications. These drives may be classified as being one of two types: sinusoidal drives in which there are no low-frequency harmonics in the current waveforms and no low-frequency torque ripple; and nonsinusoidal drives in which there is considerable low-frequency harmonic content, both in the current and torque waveforms. Although sinusoidal drives feature superior performance, they are generally more expensive since rotor position must be sensed on a continuous basis, thus requiring an optical encoder or a resolver, whereas relatively inexpensive Hall-effect sensors may be used for nonsinusoidal drives. In this paper, a straightforward hybrid observer is set forth which enables rotor position to be estimated on a continuous basis using information available from the Hall-effect sensors. The proposed observer is experimentally shown to perform just as well as an optical encoder for steady-state conditions and nearly as well as the optical encoder during transient conditions. The proposed scheme provides designers with a new option for rotor position sensing, one which offers an excellent compromise between accuracy and expense

A field-extrema hysteresis loss model for high-frequency ferrimagnetic materials

We present a new field-extrema hysteresis loss model (FHM) for high-frequency ferrimagnetic materials, along with a parameter identification procedure. The model does not involve solving an ordinary differential equation (ODE) and is asymmetric in that it works well under dc bias conditions. In the proposed model, the loss calculations are based on the extrema values of the fields. The model includes the effects of magnetic saturation as well as frequency effects. The model is comparable in accuracy to the ODE-based Jiles-Atherton model, but retains the convenience and computational efficiency of an empirical model. We demonstrate a procedure to characterize the model parameters using the Jiles-Atherton model. We compare magnetic hysteresis loss calculated by our new model with a full time-domain solution, as well as an empirical model, for a sample high-frequency ferrite. We demonstrate the use of the model, and validate the model, by calculating magnetic loss in an EI core inductor operating as the filter inductor in a buck converter. The model and identification procedure are being endorsed as a useful framework for computing magnetic loss in the context of automated magnetic device design

A Flux-weakening Strategy for Current-Regulated Surface-mounted Permanent-magnet Machine Drives

Permanent-magnet synchronous machines fed from current-regulated converters feature nearly ideal performance at low-to-moderate speeds. However, as rotor speed increases the back emf rises which results in loss of current regulation and decreased torque. In buried-magnet machine drives, flux weakening is often used to extend the speed range. This paper sets forth a flux-weakening control specifically designed for surface-mounted permanent-magnet machines which is simple and does not require knowledge of the machine or system parameters. The proposed method is demonstrated both experimentally and through the use of computer simulatio

Performance Characteristics of a Cascaded Two-level Converter

A cascaded two-level power converter is proposed which utilizes two six-transistor inverters and is capable of producing voltages which are identical to those of three-level and four-level converters. Since the machine voltages are the same, the converter performance is the same as is verified through laboratory tests. The advantages and disadvantages of the proposed cascaded converter are explored. The proposed converter is simpler to construct and offers more nonredundant switching states per number of active semiconductors than standard multi-level converter

Analysis of a Current-Regulated Brushless DC Drive

Current-regulated brushless DC machines are used in a wide variety of applications including robotics, actuators, electric vehicles, and ship propulsion systems. When conducting system analysis of this or any other type of drive, average-value reduced-order models are invaluable since they provide a means of rapidly predicting the electromechanical dynamics and are readily linearized for control system synthesis. In this paper, a highly accurate average-value reduced-order model of a hysteresis current-regulated brushless DC drive is set forth. In so doing it is demonstrated that the drive exhibits five distinct operating modes. The physical cause of each of these modes is explained and a mathematical model for each mode is set forth. The mathematical models are verified both experimentally and through the use of computer simulation. It has been found that the model set fourth herein is on the order of 300 times faster than a detailed computer simulation in calculating electromechanical transient

Thermal Characterization of Magnetic Components

Thermal limits are crucial constraints in the design of power magnetic components. As the power density of magnetic components continues to increase, cooling becomes more critical. Our research focuses on solving for the amount of cooling needed for a particular magnetic component. During the research process, a low-velocity wind tunnel designed and built from the ground up is used to form uniform and controlled conditions for the test components. Thermal Equivalent Circuit (TEC) and parameter identification techniques are used in conjunction to yield temperature distribution results. The expected result is temperature data on various areas of the component under different cooling air flow. Temperature data will aid developers to optimize their component designs. Future work on different types of cooling systems, such as liquid cooled, will be considered

Transient and Dynamic Average-Value Modeling of Synchronous Machine Fed Load-Commutated Converters

A new average-value model of a synchronous machine fed load-commutated converter is set forth in which the stator dynamics are combined with the DC link dynamics. This model is shown to he extremely accurate in predicting system transients and in predicting frequency-domain characteristics such as the impedance looking into the synchronous machine fed load-commutated converter. The model is verified against a detailed computer simulation and against a hardware test system, thus providing a three-way comparison. The proposed model is shown to be much more accurate than models in which the stator dynamics are neglecte

Wide-Bandwidth Multi-Resolutional Analysis of a Surface-Mounted PM Synchronous Machine

Advances in power semiconductor devices have led to inverters with unprecedented voltage edge rates. This has decreased inverter switching losses and enabled the use of increasingly higher switching frequencies. However, faster edge rates and higher switching frequencies increase electromagnetic compatibility (EMC) problems, machine insulation stress, bearing currents, and other aspects of system design. Typical computer simulations used to design and evaluate proposed electric drive systems cannot be used to predict these high-frequency effects. A wide-bandwidth multi-resolutional analysis that allows designers to anticipate and quantify high-frequency effects is detailed in this paper. The approach is specifically applied to permanent magnet synchronous machine drives, and is validated experimentally

Behavioral IGBT Modeling for Predicting High Frequency Effects in Motor Drives

A first-order behavioral IGBT/gate drive model is proposed together with a procedure for deriving all model parameters. Despite the simplicity of the proposed model, comparison of model predictions with hardware measurements demonstrate the model to be accurate in predicting turn-on and turn-off transients