high performance controllers based on real …experimental characterization 22 august 2013 • data...

UNCLASSIFIED

UNCLASSIFIED

HIGH PERFORMANCE CONTROLLERS BASED ON REAL

PARAMETERS TO ACCOUNT FOR PARAMETER

VARIATIONS DUE TO IRON SATURATION

Jorge G. Cintron-Rivera, Shanelle N. Foster,

Wesley G. Zanardelli and Elias G. Strangas

22 August 2013 UNCLASSIFIED: Distribution Statement A. Approved for public release.

Report Documentation Page Form ApprovedOMB No. 0704-0188

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1. REPORT DATE 12 AUG 2013

2. REPORT TYPE Briefing Charts

3. DATES COVERED 07-04-2013 to 10-08-2013

4. TITLE AND SUBTITLE HIGH PERFORMANCE CONTROLLERS BASED ON REALPARAMETERS TO ACCOUNT FOR PARAMETER VARIATIONSDUE TO IRON SATURATION

5a. CONTRACT NUMBER

5b. GRANT NUMBER

5c. PROGRAM ELEMENT NUMBER

6. AUTHOR(S) Jorge Cintron-Rivera; Wesley Zanardelli; Shanelle Foster; Elias Strangas

5d. PROJECT NUMBER

5e. TASK NUMBER

5f. WORK UNIT NUMBER

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) U.S. Army TARDEC,6501 East Eleven Mile Rd,Warren,Mi,48397-5000

8. PERFORMING ORGANIZATIONREPORT NUMBER #24095

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) U.S. Army TARDEC, 6501 East Eleven Mile Rd, Warren, Mi, 48397-5000

10. SPONSOR/MONITOR’S ACRONYM(S) TARDEC

11. SPONSOR/MONITOR’S REPORT NUMBER(S) #24095

12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited

13. SUPPLEMENTARY NOTES GROUND VEHICLE SYSTEMS ENGINEERING AND TECHNOLOGY SYMPOSIUM (GVSETS), SETFOR AUG. 21-22, 2013

14. ABSTRACT Briefing Charts

15. SUBJECT TERMS

16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT

Public Release

18. NUMBEROF PAGES

25

19a. NAME OFRESPONSIBLE PERSON

a. REPORT unclassified

b. ABSTRACT unclassified

c. THIS PAGE unclassified

Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18

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Outline

• Motivation

• Problem Statement

– Experimental and FEA results comparison

• Proposed method

– Linear Approximation Methods

• Performance Simulation

– Based on experimental data.

– Controllers based on different parametric data

• Conclusion

22 August 2013

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Motivation

22 August 2013

• There is an increasing demand for high performance motor controllers.

• Military ground vehicles

• On-board vehicle power (125-160kW)

• Electrification of vehicle loads (cooling fan, HVAC, etc...)

• Transportation

• Automotive industry

• Mass transportation drives, etc.

• Better energy generation and utilization

• Smart Grid

• Renewable energy

• The efficiency of a motor drive is dependent on the parameters used in the motor controller.

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Motor Model

22 August 2013

• Motor Types, (Surface PMSM and Interior PMSM)

• Windings are distributed in a balanced 3 phase configuration.

• Rotor magnets, induce a balanced 3 phase back EMF.

Stator Windings

Rotor Magnets

Shaft

Surface PMSM Interior PMSM

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Three phase model

22 August 2013

abM

ai

ˆa pme

aL

bcM

bi

b pme bL

ci

c pme cL

acM

sr

sr

sr

• Electrical model:

• Back EMF voltages, 𝑒𝑎,𝑏,𝑐, are produced by rotational magnetic induction.

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Transformation into the dq axis

model

22 August 2013

• Using Park’s transformation matrix:

• To transform from 3 phase abc to 3 equivalent axes dq0:

• Under balanced condition zero sequence quantities are nullified.

𝑃 =2

3

cos 𝜃 cos 𝜃 −2𝜋

3cos 𝜃 +

2𝜋

3

sin 𝜃 sin 𝜃 −2𝜋

3sin 𝜃 +

2𝜋

3

0.5 0.5 0.5

𝑥𝑑𝑞0 = 𝑃 ⋅ 𝑥𝑎𝑏𝑐

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dq motor Model

22 August 2013

• The motor model:

sRdL

di

dv

sR qLqie d

qv

e pm

e q

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Problem Statement

22 August 2013

• The real situation, saturation:

, ( ) ( , )d d q d d d dq d q q pmi i L i i L i i i

, ( ) ( , )q d q q q q qd d q di i L i i L i i i

x

xi

,0 ( )x x x x x x xi i L i i

( , ) ( )x x y x x x xy yi i L i i L i

xy yL i

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Experimental Setup

22 August 2013

• Schematic diagram

PMSM

shaft

Inver

ter

&

gat

e-dri

ver

ai

bi

ci

Park’s

,d qi i

* *,d qi i regulator

PI* *,d qv v

Inverse Park’s

*

abcvabc

dq

dq

abc

DYNAMOMETER

OR

ENGINE

Controller

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Experimental Setup with

Dynamometer

22 August 2013

Inverter/controller

PMSM Torque Sensor

Shaft

Dynamometer

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Experimental Setup with Engine

22 August 2013

Diesel Engine PMSM Generator Torque Sensor

Inverter/controller

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Experimental Characterization

22 August 2013

• Data collection:

• The current space vector is swept in the region of interest.

• Flux calculation from measured data:

d axis

q axis

pm

sV current vectorvoltage vector

qi

qv

dv di

sI

,q q s

d d q

e

v i Ri i

, d s d

q d q

e

i R vi i

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Characterization Results

• PMSM specifications:

• Test Setup:

Parameters Motor Generator Rated power 125 kW 125 kW

Rated speed 1500 RPM 1900 RPM

Max speed 5000 RPM 3000 RPM

Line voltage

Max current

No. poles 4 8

22 August 2013

Top-Level Control

Computer with

LabView User Interface

Inverter with

DSP & CAN Link

interface

(Low-Level Controller)

125 kW

PMSMDyno

Load

DC Power

Source

,

, ,a b c

Control Room

Physical Barrier Experimental Room

CAN optical link

abci

encoder

* T and monitoringdcV

abcv

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Generator, Experimental Results

22 August 2013

-200 -150 -100 -50 0

-0.1

0

0.1

0.2

0.3

id

d(i

d,i

q)

125 kW PM Genertator, d-axis flux linkage

-200 -150 -100 -50 0

0.5

1

1.5

2

x 10-3 125 kW PM Genertator, d-axis Inductance

Ld(i

d,i

q)

id

Saturation due to iq


50 100 150 200

0.1

0.2

0.3

0.4

0.5

iq

q(i d,i q)

125 kW PM Genertator, q-axis flux linkage

0 50 100 150 200

3

4

5

6

7

8

x 10-3 125 kW PM Genertator, q-axis Inductance

L q(i d,i q)

iq

Saturation due to id


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Motor, Experimental Results

22 August 2013

-200 -150 -100 -50 0

0

0.2

0.4

0.6

0.8

id

d(i

d,i

q)

125 kW PM Motor, d-axis flux linkage

pm

-200 -150 -100 -50 0

4

5

6

x 10-3 125 kW PM Genertator, d-axis Inductance

Ld(i

d,i

q)

id



50 100 150 200

0.2

0.4

0.6

0.8

1

1.2

iq

q(i d,i q)

125 kW PM Motor, q-axis flux linkage

0 50 100 150 200

0.01

0.015

0.02

0.025

125 kW PM Motor, q-axis Inductance

L q(i d,i q)

iq



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FEA parametric results

22 August 2013

0

0.001

0.002

0.003

0.004

0.005

0.006

0.007

0 100 200 300

Indu

ctan

ce (

H)

Current(A)

Generator Inductances

Ld Lq

0

0.005

0.01

0.015

0.02

0.025

0 100 200 300

Indu

ctan

ce (

H)

Current (A)

Motor Inductances

Ld

Lq

• Determined using a FEA magnetostatic simulation.

• This type of simulation was used, since it is considerably less time consuming than a full transient-magnetic simulation.

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Proposed Linear approximation

• d-axis inductance approximation:

22 August 2013

-200 -150 -100 -50

2.5

3

3.5

4

4.5

5

x 10-3

Ld

id

Ld including cross-saturation

sec1&1( , ) ( ) ( )d d q d d d qL i i L i i

-220 -200 -180 -160 -140 -120 -100 -80 -60 -40 -20

2.5

3

3.5

4

4.5

5

x 10-3

Inducta

nce(H

)

D axis Current (A)

Ld including Saturation and Cross-Saturation

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• q-axis inductance approximation:

22 August 2013

0 50 100 150 200 2500.005

0.01

0.015

0.02

0.025

0.03

Lq

iq

Lq, including cross-saturation

qL

qi

Sector 4Sector 3

Sector 2Sector 1

45

3_ upper

3_ lower

2 _ lower

2 _ upper

1_ upper

1_ lowerCross-saturation

Cross-saturation

Cross-saturation

4x3x2x

Using 4 linear sectors it is possible to represent the true Lq(id,iq).

Sector 1 and 2: Linear function with shift dependent on id.

Sector 3: Linear function, where slope changes as a function of id.

Sector 4: One linear function.

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UNCLASSIFIED


22 August 2013

3_ 3_ 4 3_

_ 4 3 4 3

( )( )

lower upper upper

d d

d rated

m i ii x x x x

3_ 3_sec.3

3_( )upper lower

d d d upper

rated

i ii

sec.3

3( , ) ( ) ( ) ( )sec.3

q d q d q d dL i i m i i x i

• Q-axis inductance approximation sector 3:

The proposed method to estimate the q-axis inductance, closely follows the experimentally determined inductance.

20 40 60 80 100 120

0.01

0.015

0.02

0.025

0.03

Q a

xis

inducta

nce (

H)

Q axis Current

Lq including Saturation and Cross-Saturation

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Controller Evaluation

• The performance degradation due to the exclusion of the

saturation effects is evaluated using a motor controller.

• Controllers based on different parametric information

were developed and evaluated in the most accurate

model.

22 August 2013

Motor Model

Based on Experimental Data

Torque,

Losses

Torque

requestMotor Controller

Based on:

1. Detailed Parameters

2. Parameters w/o

cross saturation

3. Proposed Method

4. FEA based

parameters

Speed

0 50 100 150 200

0.20.40.6

0.81

1.2

1.4

iq

q(i

d,i

q)

-200 -150 -100 -50 0

0

0.5

1

id

d(i

d,i

q)

125 kW PM Motor, d-axis flux linkage

pm

* *,d qi i

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Results, Power Losses

22 August 2013

200 250 300 350 400 450 500

500

1000

1500

Tcom

Pow

er

Copper

Losses

Losses as a function of loading

P

loss w cross-sat (LUT)

Ploss

w/o cross-sat (LUT)

Ploss

w proposed

Ploss

w FEA

200 220 240 260 280 300

400

600

800

1000

1200

Tcom

Pow

er

Copper

Losses


P


Ploss

w/o cross-sat (LUT)

Ploss

w proposed

Ploss

w FEA

200 250 300 350 400 450 500 550

1000

2000

3000

4000

Tcom

Pow

er

Copper

Losses


P


Ploss

w/o cross-sat (LUT)

Ploss

w proposed

Ploss

w FEA

200 210 220 230 240 250 260 270 280 290

1500

2000

2500

3000

Tcom

Pow

er

Copper

Losses


P


Ploss

w/o cross-sat (LUT)

Ploss

w proposed

Ploss

w FEA

Generator power losses at rated speed

Generator power losses at 3000 RPM

Motor power losses at rated speed

Motor power losses at 3000 RPM

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Results, Torque Performance

22 August 2013

Generator Torque performance,

200 250 300180

200

220

240

260

280

300

320

Tcom

Toutp

ut

Generator Torque Performance

Tout

w cross-sat (LUT)

Tout

w/o cross-sat

Tout

w proposed

Tout

w FEA

200 300 400 500150

200

250

300

350

400

450

500

Tcom

Toutp

ut

Generator Torque Performance

200 400 600150

200

250

300

350

400

450

500

550

600

650

Tcom

Toutp

ut

Motor Torque Performance

200 250 300160

180

200

220

240

260

280

300

320

Tcom

Toutp

ut

Motor Torque Performance

T

out w cross-sat (LUT)

Tout

w/o cross-sat

Tout

w proposed

Tout

w FEA

At rated speed, At 3000 RPM Motor Torque performance,

At rated speed, At 3000 RPM

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Voltage Performance

22 August 2013

200 250 300 350 400 450 500 550 600300

320

340

360

380

Tcom

Vm

ag

Voltage Commands, with a 340V Limit

V

mag w cross-sat (LUT)

Vmag

w/o cross-sat

Vmag

w proposed

Vmag

w FEA

Motor Voltage Commands at rated Speed

• Voltage commands are vital for proper operation of the

motor drive.

• Inverters have a voltage limit and field weakening

performance depends on the voltage command.

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Current Performance

22 August 2013

• Motor controller, dq-axis currents commands, as a

function of torque command at rated speed.

200 250 300 350 400 450 500 550 600-200

-150

-100

-50

0

Tcom

i d c

om

mands

d-axis current commands variations, rated speed

id w cross-sat (LUT)

id w/o cross-sat

id w proposed

id w FEA

200 250 300 350 400 450 500 550 60040

60

80

100

Tcom

i q c

om

mands

q-axis current commands variations, rated speed

iq w cross-sat (LUT)

iq w/o cross-sat

iq w proposed

iq w FEA

UNCLASSIFIED

UNCLASSIFIED

Conclusions

• Including the saturation effects of a PMSM improves the torque performance of a motor drive system.

• Higher torque performance aids in reducing the motor losses. Hence, better efficiency is achieved.

• Increments in the torque performance increases the efficiency of the overall system.

• The piecewise linear approximation accurately describes the non-ideal behavior of a PMSM.

• This approach demonstrated a reduction in copper loss of up to 900W (efficiency gain of 1.36%) for a 125kW machine.

• This method is realizable in the majority of motor control DSPs due to its computational efficiency with no additional cost.

22 August 2013

high performance controllers based on real …experimental characterization 22 august 2013 • data...

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