1. Introduction
In the field of electrical drives, there is an increasing demand for highly integrated and compact driving solutions where performance is preserved or improved while costs and size are minimized. In order to pursue such features, DC motors tend to be replaced in most application fields by synchronous motors (SMs) in advanced drive systems, such as permanent magnet synchronous motors (PMSMs), synchronous reluctance motors (SRMs) as well as PM-assisted synchronous reluctance motors (PM-SRMs).
To drive these machines, position information is required. Position sensors are typically installed for operating SMs, such as resolvers or encoders, which lead to an increase in cost, space requirement, and system complexity. It is, therefore, desirable to provide techniques, which allow the operation of SMs without having to resort to the use of position sensors. To address this problem, a significant number of scientific contributions have been published over the past few decades. The proposed sensorless techniques rely mainly on the exploitation of two physical effects: induced back-EMF (electro motive force) and the presence of machine anisotropies.
The first approaches to sensorless driving of SMs were based on the exploitation of the back-EMF signal, whose voltage is proportional to the rotor speed. By measuring the phase voltages and currents, the angular position can be either obtained by applying model reference adaptive system techniques (MRAS) or observed by means of state observers, such as Luenberger observers, sliding mode observers, and Kalman Filters. The main disadvantage of back-EMF based sensorless techniques is their inapplicability at low speeds and/or standstill conditions. This limitation incited a new field of techniques that can perform over the whole speed range by exploiting the presence of machine anisotropies. In particular, the dependence of the phase inductances on the rotor position has been investigated.
The very first attempt was proposed by Schroedl in [
1,
2]. In his papers, he proposes the basic theory of a sensorless technique that he refers to as INFORM (INdirect Flux-detection by Online Reactance Measurement). As the name indicates, INFORM allows online measurement of the motor reactances by means of current measurements resulting from the injection of test pulses based on the utilization of a modified pulse width modulation (PWM) driving signal. It is important to remark that the majority of motors exhibit a dependence of the phase reactances on the rotor position because of the nonlinear effects including hysteresis of the stator’s soft magnetic material as well as reluctance variations and saturation effects.
Right after the work of Schroedl, a scientific contribution was presented by Lorenz [
3], who proposed a new way of modeling the dependence of the machine’s coil inductance on the rotor position under high-frequency excitation. In fact, in this work, the authors introduce the concept of leakage inductances by providing a simplified explanation of the physical behavior of motor phases under high-frequency excitation. Within the same work, the authors introduce a new approach to performing sensorless operations based on the injection of a rotating carrier. The currents induced by the carrier are modulated by the rotor position. Therefore, demodulation and state observation are necessary to extract the position information.
In [
4] a new injection technique based on an alternating carrier was proposed. Such injection is performed in the estimated rotor reference frame with the direct advantage of reducing the computational effort necessary for extracting the rotor information. In particular, a pulsating voltage vector is introduced along the q-axis of the estimated rotor reference frame. Also in this case, this technique requires an observer that is dependent on the motor parameters.
As injecting an alternating carrier has been proven to be generally more efficient than using a rotating carrier in terms of precision, applicability, versatility, and robustness, most of the scientific works following the work of [
5] have focused either on alternating carrier injection or on other arbitrary injection schemes [
6,
7,
8,
9].
By considering the scientific works mentioned above, it is therefore possible to distinguish the machine anisotropy based sensorless techniques between INFORM and high-frequency current injection (HFCI), the latter of which are based either on rotating, alternating or arbitrary carrier excitation. The most recent works in the field of sensorless operation aim at increasing the modeling precision necessary for performing sensorless operations, thus reducing the position estimation errors, and at the same time performing machine parameter identification, such as in the works [
10,
11]. New approaches combine sensorless operation with parameter identification to address the topic of the so-called self-commissioning [
12].
All of the above mentioned sensorless techniques have the usage of current signal information in common. Nevertheless, current sensors are typically characterized by low signal-to-noise ratio, low sensitivity, and limited bandwidth. Such limitations directly affect the performance of current measurement based sensorless techniques, especially in the case of low-power electromagnetic motors. In fact, the sensorless techniques presented up to this point have been primarily tested on middle to high power machines. Nevertheless, low-power SMs are more challenging in terms of quality of the sensory information given that the driving currents are smaller and with larger bandwidth, clearly representing a limitation for such techniques. The main issues related to low-power PMSMs reside in the necessary higher frequency voltage switching (due to the small values of the inductances) and to the limited bandwidth of current sensors which, in this case, need to operate at higher frequencies.
In the particular case of star-connected SMs with accessible star points, current measurements can be avoided for sensorless operation by measuring the voltage of the motor star point that can deliver the necessary information for the online determination of the motor inductances. A thorough investigation has already been conducted and published in [
13]. Nevertheless, a previous technique was first proposed in [
14] and it is based on measuring the voltage difference between the machine star-point and a virtual star-point. Such a technique has been then elaborated and proposed in the scientific community from different authors and under different names, such as VirtuHall, Direct Flux Control, and Direct Flux Observer. The first scientific works were those of Thiemann [
15] and Mantala [
16], who proposed approaches to excite the machine to get meaningful signals and techniques for extracting the position information. In [
17] an improved approach to the extraction of the position has been presented that reduces the presence of harmonics. To improve the quality of the measurements, a fast resettable integrator circuit (FRIC) was firstly proposed in [
18,
19].
The mentioned works concerning the usage of the machine star-point for sensorless operation have focused in particular on PMSMs with assumptions on the inductance matrix and, therefore, the nature of the measured signals. In this work, a new mathematical model of the star-point voltage is proposed to analyze the measured signals in relation to any kind of synchronous machine. The dynamic response of the machine star-point to the terminal voltage excitations is also presented. This paper is divided into three sections. In the first one, the mathematical description of the star-point voltage dynamic is presented. As it is necessary to measure the star-point, the effect of a measuring impedance is also taken into account. Furthermore, a method to extract information about the machine inductances, as well as the position information from the voltage difference between the machine star-point and a virtual star-point, is described. In the second section, two different methods for measuring the star-point voltage are presented: direct voltage measurement and fast resettable integrator circuit. Finally, in the third section, experimental results are presented and discussed to confirm the theoretical analysis discussed in the previous sections.
3. Measurement of the Voltage
As discussed in the previous section, measuring the
voltage in the two excitation states of the machine shown in
Figure 3 can retrieve the quantities
that contain information about the machine phase inductances. For this reason, a modified edge-aligned PWM is proposed as shown in
Figure 6, where the machine is driven in the excitation states 0 and I at the beginning of each PWM time period allowing measurements of the
voltage. In particular, the PWM time period starts at time
. One phase is then switched on at the time instant
and, finally, the driving excitation according to standard edge-aligned PWM starts at the time instant
. During these two states of excitation, measurements can be performed. It is important to remark that the introduction in the PWM pattern of these two excitation states reduces the maximum applicable voltage to the machine. For this reason, it is of interest to reduce the time of injection of these two states.
3.1. Direct Voltage Measurement
To measure
, a straightforward method is to measure the voltage
right before and after the switching between the machine excitations 0 and I. In this work, this measurement method is referred to as direct voltage measurement (DVM).
Figure 7 shows the simulated response of
,
, and
. As one can see, voltage oscillations are present, as described previously, due to the measuring impedance as well as to the parasitic capacitance. Measurements are performed at the generic time instants
and
, providing
and
. Ideally, it is preferable to choose
and
. Nevertheless, especially concerning the measurements performed at
, it is important to wait for the oscillations to decay to reduce measurement disturbances. Also, oscillations depend strictly on the machine parameters as well as on the impedance connected at the star-point, thus leading in some cases to a significant time for the oscillations to decay and, therefore, reducing the maximum applicable voltage.
3.2. Fast Resettable Integrator Circuit
Another method to measure
is the usage of a fast resettable integrator circuit (FRIC). This technique is based on measuring the integral of the
voltage. An analog integrator connected to the machine star-point and to the virtual star-point is activated when the machine state of excitation 0 is injected, thus integrating the voltage
during the time of the machine excitation. The integrator is then reset before the machine state of excitation I is provided. At the end of the application of this excitation state, the integrator is held in reset until the next PWM period.
Figure 8 shows the integration applied to the
voltage already presented in
Figure 7. As one can see, the oscillation affecting the integrated voltage decays much faster than in the case of DVM, thus allowing a measurement to be performed earlier and, consequently, to reduce the injection time of the excitation necessary to obtain the
quantities thus increasing the maximum applicable voltage. Let us define the quantities
and
as the measurements of the integral of
at the time instants
and
, respectively. Let us also define the time intervals
and
. To obtain the quantities of interest, one can use the following equations:
The obtained measurements only approximate to the real value of due to the presence of oscillations. Nevertheless, it has to be remarked that resembles closely the real value. In fact, during the state of excitation, 0 oscillations have usually already decayed at the beginning of a PWM time period. Concerning , one can observe that the obtained value is proportional to the reference value, thus introducing a small deviation from the measurements performed by means of DVM. Proposing a mathematical description of such deviation is particularly challenging, nevertheless it can be observed numerically that the proportionality factor between the FRIC measurements and the reference values do not change as long as , the oscillation frequency, and the damping factor do not change. Thus, it is possible to conclude that measurements obtained by means of the FRIC resemble closely the measurements obtained by DVM, while allowing a reduction of the needed time of the injection of the necessary excitation for measuring and, therefore, an increase of maximum applicable voltage. In both the discussed approaches, the measurement circuitry needs to be turned on the specific machine to obtain optimal measurements.
3.3. Measurement Electronics
Measuring
requires dedicated electronics. In
Figure 9, an electronic schematic is proposed that can either be used for DVM or for FRIC, which is based on a differential operational amplifier and its output is a differential voltage. For DVM operation, the impedances
Z are resistors. Also, the reset mechanism is not used. In particular, given
and
, this stage has a gain equal to
. Such gain needs to be adjusted to provide a reliable measurement without bringing the measurement stage into saturation. When operating as a FRIC, the impedances
and
are capacitors. In this case, the stage is tuned by setting
and by considering that the gain of the integrator stage is given by
, where
. In this case, the gain also needs to be adjusted to provide a measurement that does not drive the measuring stage into saturation. Moreover, the reset mechanism is used to mantain the integrator in reset when no measurement is performed. In this case, the feedback capacitors
are shortcircuited and the output is zero.
4. Experimental Validation
To evaluate the different performance between the DVM and the FRIC approaches, an experimental test-bench has been set up. A PMSM has been used as a test device whose electrical parameters are listed in
Table 1.
The PMSM has been coupled to a Baumer GBA2H 18 bit encoder and to a servomotor. An electronic board based on a 32-bit microcontroller, a three-phase MOSFET-based inverter, and dedicated electronics for implementing both the DVM and FRIC has been developed. The chosen microcontroller features 16-bit ADCs and a clock frequency of 400 MHz, which allows high timing precision in generating the required reset and sampling triggers of the FRIC circuitry. A dedicated USB based communication protocol is implemented to measure and record the obtained signals at high frequency.
Figure 10 and
Figure 11 show the experimental bench and the electronic board, respectively.
The electronic circuit implementing DVM is based on the schematic shown in
Figure 9 where
k
and
k
, allowing an amplification of the
voltage equal to 10. The FRIC electronics, instead, has been tuned by setting
and
are capacitors whose value is 470 pF. The choice of these parameters corresponds to an integration time constant equal to
ns. For both circuitries, a high-bandwidth differential operational amplifier has been chosen. The differential voltage
is scaled by means of voltage dividers and provided to the measurement circuit through a stage of voltage buffering. Both circuits operate in parallel to allow a comparison of performance between DVM and FRIC during the same experiment.
The three-phase inverter operates at a bus voltage of 24 V and is driven by means of the modified edge-aligned PWM pattern described earlier and shown in
Figure 6. In
Figure 12, the measured phase voltages
and
are shown. In this case, a duty cycle of 50% has been applied to all phases. To verify (
30), the
voltage has been measured during the transition of the machine from the excitation state 0 to the excitation state I, by switching the phase voltage
to the inverter bus voltage and leaving
and
connected to ground. In fact, as shown previously, the transfer functions in (
30) can be expressed as the series of an ideal transfer function representing the machine electrical behavior and a high-frequency transfer function modeling the presence of an impedance connected to the machine star-point, especially for the case of a parasitic capacitance in addition to a measuring circuit that, in this case, is given by the oscilloscope probe used for measuring
. A linear transfer function with 3 poles and 1 zero (as predicted by the mathematical derivation proposed earlier) has been identified by means of a nonlinear least-squares algorithm to approximate the star-point voltage response. This procedure has retrieved an adherence between the measured and the simulated responses of 93.84%, and results are shown in
Figure 13, where the voltages
,
, and the output of the simulated model are shown. It has to be remarked that the proposed mathematical model does not take into account the presence of eddy currents.
Measurements of the resulting
,
, and
voltages are shown in
Figure 14, where the FRIC output and the reset trigger are shown for completeness. The FRIC is enabled when the reset voltage is at a high level, i.e.,
V.
The chosen PWM frequency is 60 kHz, corresponding to a PWM time period of
s while the time delay for measurements is of 1
s. Thus, the maximum applicable driving voltage decreases by 6%. For this reason, it is generally preferable to keep the measurement time delay as small as possible to maximize the PMSM driving capability. The PMSM remains in the excitation state 0 from time
s to 0 s and in the excitation state I from 0 s to
s. In the case of DVM, measurements are acquired at times
s and
s. The FRIC circuitry, instead, is enabled for a time period of 300 ns during both excitation states, as shown in
Figure 14, and measurements are triggered at the same time instants used for DVM.
Experimental Results
Experimental investigations have been conducted under two scenarios. Firstly, the PMSM has been coupled to a servomotor that is used to impose a rotation of 1 revolution per minute (RPM) to the PMSM to measure
by means of DVM and FRIC in almost standstill conditions. The PMSM has been driven at zero current condition by driving all phases at
duty cycle.
Figure 15 shows the obtained results, where the
signals have been normalized.
The signal-to-noise ratio (SNR) has been evaluated per each measured signal. Given that is composed of non purely sinusoidal signals, the SNR has been evaluated by calculating the fundamental frequency and by considering all harmonics beyond the 5th one as noise. As one can see, the measured exhibits higher SNR when the FRIC approach is used. The reconstructed position is then compared to the position given by the encoder. In this case, the percentage error has been evaluated. In this case, FRIC has provided a maximum position error of while DVM provides a maximum position error of . One can also observe that the signals obtained by applying DVM or FRIC are similar but not equal as the FRIC method introduces a deviation from the reference value as discussed earlier.
Afterward, a comparison between DVM and FRIC has been conducted by driving the machine under no-load driving conditions in order to evaluate performances at higher speeds. Also, the rotor angle obtained by means of the FRIC approach has been used for driving the machine.
Figure 16,
Figure 17 and
Figure 18 show the measured
and reconstructed electrical positions when driving the PMSM with 1 V, 6 V and 12 V along the q-axis, respectively. In these cases, the PMSM under test rotates at respective speeds of 91.3 RPM, 614.5 RPM, and 1199.7 RPM. In all these measurements, the evaluated SNR is higher when the FRIC circuit is used, especially when the maximum voltage is applied. In this case, the measured
begins to distort, as visible in
Figure 18. More important is the electrical position error obtained by using the DVM and the FRIC approaches. In fact, in the first case, the position error ranges from
at 1 V to
at the maximum voltage. In the case of FRIC, instead, the position error ranges from
at 1 V to
at the maximum voltage.
5. Conclusions and Future Works
In this work, a new mathematical description of the star-point voltage dynamics has been proposed by considering also the presence of a measurement impedance and a parasitic capacitance. It has been observed that the transfer functions between the star-point voltage and the terminal voltages are proper second-order transfer functions whose static gains are given by the quantities that depend directly on the adjoint matrix of the machine inductance matrix . Differently from previous works, the proposed mathematical description does not consider a particular form of the inductance matrix with the only condition being the inductance matrix to be non-singular. Two different approaches have been proposed to measure the differential voltage between the star-point and the artificial star-point, namely DVM and FRIC. Conducted experiments have shown the capability of the FRIC to provide, in general, less noisy measurements than DVM and, also, a smaller position error. Nevertheless, it has to be remarked that nonlinear effects, such as the influence of the eddy currents and power-stage ringing, have been neglected. Therefore, future works will be conducted to improve the proposed mathematical model as well as the measurement circuitry. Concerning the measurement technique, the choice of the trigger time instants is made preliminarily on the device under test. A more rigorous approach in tuning the measurement circuits and time instants is to be researched. Moreover, it will be of interest to particularize the presented mathematical framework for some specific machine typologies, such as permanent magnet synchronous motors and synchronous reluctance machines. In fact, the dependency of the machine phase inductances on the rotor position may differ drastically, in particular due to the behavior of the mutual inductances that, as seen in this paper, contribute to the information extractable from the star-point. For this reason, a deeper investigation on the influence of the mutual inductances on the reconstructed electrical angle is currently under investigation.