A new ECE model is proposed to reflect the tolerance of manufacturing and material, etc. The proposed new ECE model is developed by combining the ECE model derived from ANSYS in the motor design (original ECE model) and calibration of flux linkage and inductor parameters from real motor test. The calibration of flux linkage and inductor parameters are carried out based upon back EMF coefficient calibration under no load condition and MTPA test with current excitation under zero, 45 degrees and 90 degrees. The former one is used to correct the flux without excitation current to the motor. The later one is used to consider the self- and mutual- cross-coupling inductances and saturation effect. The proposed method provides accurate results while not requiring intensive tests. The proposed new ECE model can be applied to motor drives control. A 60kW IPM motor with maximum speed of 13000 rpm is designed for verification. The results for the proposed new ECE model, original ECE model and real motor are presented. And the error for the original ECE model and real motor is reduce from 10% to 1% for using the proposed new ECE model. The improvement becomes more relevant under high speed application with field weakening control by considering the tolerance of manufacturing and material etc.

The proposed concept in this paper was composed of the prototype verification technologies from different fields, included numerical model, embedded software, and virtually physical test for the interior permanent magnet synchronous motor (IPMSM) drive systems. The proposed developmental framework is comprised of model-in-the-loop (MIL), software-in-the-loop (SIL), and hardware-in-the-loop (HIL) and achieves rapid prototype verification through the collaboration and coordination between each other. The MIL is based upon the IPMSM model, including motor parameters variable by magnet saturation and cross-coupling effects, under different operating conditions. As part of motor control software development, the SIL uses motor control modules that take non-linear motor parameters into account. The proposed speed-up modeling to HIL is based on the code generator function, which is popularly used for software development, which allows the hardware model in MIL to be quickly converted into program code and then performed in HIL. Similarly, the motor control modules from SIL can be converted into source code and implanted into the DSP based control board. Finally, the HIL platform will test with the DSP based control board to achieve rapid verification of motor control technology and improve the development cycle of motor drives. The proposed framework is validated by comparison with a 2 kW IPMSM system in which the motor control methods are implemented in DSP based inverter-fed drives. The experimental results present the deviation between the proposed rapid development framework and the actual IPMSM drives, the lower deviation up to 1.16 % under rated speed with half load condition. The results show the time-saving and cost reduction of the process for motor control technology development.

The purpose of this paper is to propose an efficiency improvement method for motor drives with DC-link voltage optimization control. A four-switch buck-boost DC/DC converter is used for DC-link voltage regulation in front of the inverter to provide regulated voltage. The advantages of bidirectional buck-boost converter include providing wider voltage regulation range and energy recovery capability. The proposed method is developed based upon the minimization of Total Harmonic Distortion of motor current and tuning the DC-link voltage on-line adaptively. Neither motor parameter nor look-up table is required.Experimental results for permanent-magnet synchronous motor drives are presented to validate the effectiveness of the proposed method. The overall efficiency improvement of motor drives with buck-boost converter can go up to 23.55% under low speed as compared with that without DC-link voltage regulation and buck-boost converter for the proposed DC-link voltage optimization method.

The main theme of this paper is to propose an online parameter identification and self-commissioning of current controller for servo motor drives as time delay is taken into consideration. The advantages of considering time delay include increase of current controller bandwidth and easy to achieve delay compensation. The electrical parameters and time delay required for self-commissioning of current controller are identified on-line through injecting signal and real-time Fast Fourier Transform (FFT) under standstill. The current controller gains are determined based upon the magnitude optimal method as the delay is considered while retaining the maximum phase margin. The experimental results will be shown, which are derived from DSP-controlled PMSM servo drives. With the proposed parameter identification method, in which time delay identification is included, the measured bandwidth of current loop is improved as compared with that without such consideration. These results confirm the effectiveness and claims of the proposed method.