Evaluation of Sensor Solutions & Motor Speed Control Methods for BLDCM /PMSM in Aerospace ...

183 Pages·2017·14.31 MB·English

Evaluation of Sensor Solutions & Motor
Speed Control Methods for BLDCM
/PMSM in Aerospace Applications
Mattias Johansson
Space Engineering, masters level
2017
Luleå University of Technology
Department of Computer Science, Electrical and Space Engineering
Lule˚a University of Technology
Master Thesis
Space Engineering, Specialization Spacecraft & Instrumentation
Evaluation of Sensor Solutions & Motor
Speed Control Methods for
BLDCM/PMSM in Aerospace
Applications
Author:
Mattias Johansson
January 14, 2017
Abstract
The goal of this thesis was to evaluate sensors and motor speed control methods for PMSM/BLDC
motors in Aerospace applications. The sensors and methods were evaluated by considering accuracy,
robustness,cost,developmentgainandparametersensitivity. Thesensorsandmethodschosentosimu-
lateweredigitalHallsensorsandsensorlesscontrolofBLDCmotors. UsingMatlabSimulink/Simscape
somemotorspeedcontrolmethodsandmotorspeedestimationmethodsweresimulatedusingtheHall
sensors and sensorless control as a basis. It was found that the sensorless control methods for BLDC
motors couldn’t estimate the speed accurately during dynamic loads and that the most robust and
accuratesolutionbasedonthesimulationswasusingthedigitalHallsensorsforbothspeedestimation
and commutation and this was tested on a hardware setup.
Acknowledgements
I would like to thank my supervisor Ingemar Th¨orn for all the help and support he has given me,
especially for always taking the time to listen when I had questions and thoughts. I would also like to
thank Jonas Dahlqvist for always having a door open and making sure that I integrated successfully
into my new environment. Damiano Varagnolo for giving me the tools to succeed after the university,
his expertise and passion for teaching control theory has greatly helped me taking on this challenge.
Lastbutnotleast,IwouldliketothankmybeautifulJennywhoalwayslistenedtomyendlesstalking
about Kalman filters and Hall sensors, thank you for your love and support.
Acronyms
ADC Analog to Digital Converter
BLDCM BrushLess Direct Current Motor
BW BandWidth
CCS Code Composer Studio
COG Center Of Gravity
DAC Digital to Analog Converter
EKF Extended Kalman Filter
FLC Fuzzy Logic Control
FOC Field Oriented Control
GPIO General Purpose Input Output
IDE Integrated Development Environment
KVL Kirchhoff’s Voltage Law
LED Light Emitting Diode
MCU Micro Controller Unit
MRAC Model Reference based Adaptive Controller
ODE Ordinary Differential Equation
PFC Power Factor Correction
PI Proportional Integral
PID Proportional Integral Derivative
PM Permanent Magnet
PMSM Permanent Magnet Synchronous Motor
RDC Resolver to Digital Converter
RK Runge Kutta
RPM Revolutions Per Minute
SPI Serial Peripheral Interface
SPWM Sinusoidal Pulse Width Modulation
SS Steady State
SVPWM Space Vector Pulse Width Modulation
THD Total Harmonic Distortion
UKF Unscented Kalman Filter
USB Universal Serial Bus
Contents
1 Introduction 1
1.1 Objectives & Goals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Thesis Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
I Theory 4
2 Sensors 5
2.1 Hall effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.1 Analog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.2 Digital . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.3 Magnetic considerations . . . . . . . . . . . . . . . . . . . . . . 9
2.1.4 Placement on Motor . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.1 Resolver to Digital Converter . . . . . . . . . . . . . . . . . . . 15
2.3 Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.1 Incremental vs Absolute . . . . . . . . . . . . . . . . . . . . . . 16
2.3.2 Optical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3.3 Capacitive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 Chosen Sensors to Evaluate . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Sensorless Control 20
4 Brushless Electric Motor 21
4.1 Motor Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Saliency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3 Mutual Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.4 Electrical Degrees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.5 Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.6 Torque Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.7 Back Electromotive Force . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.8 Motor Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.9 BLDCM vs PMSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.9.1 Back EMF Shape . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.9.2 Electromagnetic Torque . . . . . . . . . . . . . . . . . . . . . . 30
4.10 Motor reference frame . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.10.1 a-b-c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.10.2 α-β . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.10.3 d-q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.11 Dynamic Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.11.1 Transfer Function . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.11.2 State Space Model . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.11.3 Flux Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.11.4 Discretization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5 Commutation 43
5.1 Inverter Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 Trapezoidal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.3 Sinusoidal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.4 Space Vector Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6 Speed Control Methods 47
6.1 Ziegler-Nichols Tuning Process . . . . . . . . . . . . . . . . . . . . . . . 49
6.2 PI Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.3 Hybrid Fuzzy PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.4 Adaptive Fuzzy PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.5 Field Oriented Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7 Speed Estimation 61
7.1 Hall sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.2 Linear Extrapolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.3 Modified Fourth Order Runge-Kutta Extrapolation . . . . . . . . . . . 63
7.4 Back-EMF Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.5 Back-EMF Observer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.6 Kalman Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.7 Extended Kalman Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.8 Unscented Kalman Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.9 Luenberger Observer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.10 MRAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8 Initial Position & Start-up Methods 75
8.1 Open Loop Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.2 Inductance Comparison Method . . . . . . . . . . . . . . . . . . . . . . 75
8.3 Extended Inductance Comparison Method . . . . . . . . . . . . . . . . 78
II Simulations 80
9 Chosen Methods to Simulate 81
10 Simulation Model 84
11 Evaluation Strategy 86
12 Control Methods Simulation Results 92
12.1 Ziegler-Nichols Tuning Method . . . . . . . . . . . . . . . . . . . . . . 92
12.2 PI Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
12.3 Hybrid Fuzzy PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
12.4 Adaptive Fuzzy PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
13 Speed Estimation Simulation Results 99
13.1 Hall sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
13.2 Back-EMF Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
13.3 Linear Extrapolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
13.4 Modified Fourth Order Runge-Kutta Extrapolation . . . . . . . . . . . 106
13.5 Kalman Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
13.6 Unscented Kalman Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 117
13.7 MRAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
14 Comparison & Evaluation of Simulation Results 122
14.1 Control Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
14.2 Speed Estimation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
14.3 Extended Simulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
III Verification by Test 128
15 Chosen Methods to Verify & Verification Strategy 129
16 Hardware Setup 130
16.1 Test Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
16.1.1 BLWS235D-160V-3000 . . . . . . . . . . . . . . . . . . . . . . . 131
16.1.2 HDD 09N-Ma-A-A-A-AAA . . . . . . . . . . . . . . . . . . . . 132
16.2 TI High Voltage Motor Developers Kit . . . . . . . . . . . . . . . . . . 133
16.3 F28035 Piccolo controlCARD . . . . . . . . . . . . . . . . . . . . . . . 133
16.4 C2000 Resolver to Digital Kit . . . . . . . . . . . . . . . . . . . . . . . 134
16.5 Mechanical Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
17 Software Setup 135
18 Test Results 136
IV Final Discussions & Conclusions 137
19 Discussion & Future work 138
20 Conclusion 143
Appendix A: MATLAB Code 148
Appendix B: Simulink Models 165