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Sensorless control of high-speed IPMSM based on rotor-flux and fictitious-flux estimation

The paper proposes a new algorithm and implementation of a motion sensorless control system for permanent magnet synchronous drive for high-speed and high-power applications. The experiments were carried out on a 112 kW IPMSM with rated speed of 48,000 r/min in a very wide speed range — from standstill up to the rated speed. The observer is based on the rotor flux components expressed in the hypothetical-estimated reference frame which is rotating with the estimated speed. The rotor flux is calculated from the stator flux linkage and the fictitious/active flux with the so-called by the authors the “rotor flux components' observer in the hypothetical rotor reference frame, based on the fictitious flux in the rotor reference frame”. This proposed observer can be applied even if the stator d-q inductances are very low (Ld=45.32 μH − Lq=63.45 μH). In this application the high-speed permanent magnet motor is a salient one, so the full observer can be applied to all synchronous motor drives (surface permanent magnet motor-SPMSM, dc. excitation-SM or transverse-flux motor-TFM). The observer is developed using the Lyapunov design, resulting a system with a full observer for the motor states. The observer assures stability even for very low speed. An experimental system was built based on PWM rectifier and PWM inverter to assure the regenerative braking, taking into account the rated/starting current being relatively high-hundreds of amps. Experimental results are presented to verify the principles and to demonstrate the effectiveness of the proposed sensorless control algorithm. The IPMSM motor is vector controlled by a floating-point TMS320C6713-Digital Signal Processor. The test results prove very good dynamic performances in all ranges and very low errors in position estimation and no errors in speed estimation in the steady-state operation and full load condition.