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AbstractTo develop a high-performance and reliable permanent performances. It has been extensively investigated in the
magnet synchronous machine (PMSM) drive for electric vehicle literature. In [11], extended Kalman filter is employed to
(EV) applications, accurate knowledge of the PMSM parameters estimate the rotor flux in which the winding resistance and
is of significance. This paper investigates online estimation of inductances are assumed to be known. In [12], the recursive
PMSM parameters and VSI nonlinearity using current injection
least square (RLS) algorithm is applied to estimate the dq-axis
method in which magnetic saturation is also considered. Firstly, a
novel DC component based current injection model considering inductances while the winding resistance and rotor flux are set
VSI nonlinearity is proposed, which employs the DC components to their nominal values. It is rank-deficient to estimate more
of dq-axis currents and voltages for PMSM parameter and VSI than two parameters by using the steady-state machine
distorted voltage estimation. This method can eliminate the equations [13], [14]. Therefore, many papers estimate some
influence of rotor position error on VSI nonlinearity estimation. parameters while fix the rest to their nominal values. However,
Secondly, a simplified linear equation is employed to model the the PMSM parameters are varying nonlinearly, so it will
cross- and self-saturation of the dq-axis inductances during introduce great estimation errors to fix some parameters during
current injection, which can facilitate the estimation of the on-line parameter estimations.
inductance variations induced by magnetic saturation. Thirdly, a
In order to solve the rank-deficient problem, many
novel current compensation strategy is proposed to minimize the
torque ripples caused by current injection, which contributes to researchers have investigated to inject pulsating signals such as
making our approach applicable to both surface and interior currents and position-offsets into the machine to obtain
PMSMs. Therefore, the proposed on-line parameter estimation additional steady-state machine equations for on-line parameter
approach can estimate the winding resistance, rotor flux, VSI estimation [15]-[17]. In particular, current injection methods
distorted voltage, and the varying dq-axis inductances under have aroused considerable interests, because it is capable of
different operating conditions. The proposed approach is estimating the winding resistance, dq-axis inductances as well
experimentally validated on a down-scaled laboratory interior as rotor flux. In [13], the current injection method is proposed
PMSM prototyped for direct-drive EV powertrain. to estimate the winding resistance and rotor flux of a surface
Index Terms PMSM, Online parameter estimation, VSI
PMSM without the influence of magnetic saturation. However,
nonlinearity, Magnetic saturation, Current injection.
they are unable to estimate the varying dq-axis inductances due
to magnetic saturation. Moreover, their method is limited to
I. INTRODUCTION
id=0 control and can cause high torque variations during current
Precise estimation of PMSM parameters is critical to achieve injection, which will degrade the drive system performance.
high-performance and reliable PMSM drives, which have high During parameter estimation, the reference voltages from the
demand in the electric vehicle (EV) traction applications due to PI controller are often used as the voltage measurements [18].
their strict requirements in terms of high efficiency, compact However, the reference voltage is not equal to the actual
design, light weight and fast dynamic response, and the harsh voltage due to the VSI nonlinearity [19]-[21]. Therefore,
operating environment in a vehicle [1]-[5]. For PMSMs based neglecting the VSI nonlinearity will certainly affect the
direct-drive EV application, high current is required to deliver performance of on-line parameter estimation. In [22], [23], the
the propulsion torque, so the issues related to temperature and mathematical model of VSI nonlinearity is proposed and used
magnetic saturation are critical. The rise of temperature will for VSI nonlinearity compensation. This VSI model has been
induce the winding resistance to increase and rotor flux linkage employed in [9] and [24] for parameter estimation, in which the
to decrease, and the magnetic saturation will cause the dq-axis VSI distorted voltage is calculated from the parameters of the
inductances to vary [6]-[10]. In other words, different power electronic devices. However, the parameters of the
operations in direct-drive EV applications will result in power electronic devices are not always available and they
different PMSM parameters. Therefore, the knowledge of change at different operating conditions. In order to deal with
accurate PMSMs parameters is important in facilitating the this problem, reference [18] proposes to estimate the VSI
design and development of high-performance drive and control distorted voltage by combining the VSI model with the PMSM
algorithms for direct-drive EV applications. machine equations. The VSI distorted voltages are sixth order
On-line parameter estimation is capable of adaptively harmonics, therefore, [18] uses the high frequency components
updating PMSM parameters for different operating conditions, for distorted voltage estimation. However, the high-frequency
which can effectively improve the machine and drive components contain not only the sixth-harmonic but also other
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Transactions on Transportation Electrification
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*
dq-axis voltages and currents. Here, udq and idq are equal to
the average measurements of voltages and currents, so they can
be obtained from (7). In particular, this paper uses the average
measurements in each electrical cycle for parameter estimation,
so in (7), N=t /Ts, where t is the time of one electrical cycle
and Ts is the sampling time.
N N
udq k , idq
idq k
1 1
udq
* *
(7)
N k 1 N k 1
Substituting (7) into (6) yields the DC component based
estimation model (8) and (9), where and
are the DC
components of the distorted coefficients.
Fig. 2. dq-axis equivalent circuit model including VSI nonlinearity.
udi* Ridi i Lqi iqi DdiVdead
u R rcd idi i Lqi iqi DdiVdead U sin i
*
di (8)
(5) uqi* Riqi i Ldi idi i M DqiVdead , i 1,..., K
u R rcd iqi i Ldi idi i M DqiVdead U cos i
*
qi
1 N
In real applications, the resistance term rcd is regarded as a part Ddi 2 sin k int 3 k +i 6
of winding resistance and this is the reason why the estimated N
k 1 3
winding resistance is normally larger than the actual one. (9)
1 N
Moreover, the term Vdead is much larger than U [14] and thus the Dqi 2 cos k int 3 k +i
last distorted terms containing U are neglected in this paper. N k 1 6 3
With these in mind, (5) can be simplified as (6). It can be seen from (9) that and are only functions of
udi* Ridi i Lqi iqi DdiVdead the angle of current vector, i , and are independent of rotor
(6) position, and they are constant at steady state. Thus, the
uqi* Riqi i Ldi idi i M DqiVdead , i 1,..., K and can be computed in advance for
coefficients
From (6), the VSI nonlinearity introduces the distorted voltage parameter estimation. Fig. 4 presents the at different
and
terms DdVdead and DqVdead into the steady-state equations. It increases
steady states. It can be seen that the magnitude of
should be noted that when a small amount of current is injected
with the increase of , while the magnitude of decreases
into the machine, the variation of the distorted voltage Vdead is
not significant. So it is assumed to be constant in this paper to with the increase of . Moreover, when is small, is almost
simplify the parameter estimation. The Dd and Dq waveforms at constant and the relation between and can be modeled
=0 degree are shown in Fig. 3. It can be seen that they have with a linear equation.
sixth-order harmonics and Dq is larger than Dd. Therefore,
ignoring VSI nonlinearity has a great impact on the inductance
estimation.
At the steady state, i is fixed, so DdVdead and DqVdead are
functions of rotor position. Therefore, the estimation of Vdead
will be affected by rotor position error. In what follows, the DC
components of the measurements are employed for parameter
estimation, which can efficiently eliminate the influence of
rotor position error on the parameter estimation.
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Since the current injection can be completed in a very short Use (9) to compute the coefficient
period of time and the current control loop is much faster than Ddi , Dqi , i 1, 2,3
the mechanical system response, this paper assumes that the
load torque is constant during current injection. Let Tei be the Use (12) and (18) to estimate
electromagnetic torque at the ith steady state, i=1,, K, then the R, V dead
constant load torque leads to (10). With some mathematical
substitution, (11) can be obtained from (8). Substituting (10) Use (13), (15) and (18) to estimate
into (11) yields the result (12). It can be seen that R and Vdead M , Ldi , Lqi , i 1, 2,3
can be estimated from (12) with some estimation algorithm for
K=3. In what follows, the RLS algorithm will be employed for End
parameter estimation. More importantly, the estimation of R
Fig. 5. The flowchart of the recursive least square based parameter estimation.
and Vdead is not influenced by the magnetic saturation.
Tei =Tej , 1 i , j K (10) where i=1,, K. It can be seen that the rotor flux and the
dq-axis inductance can be estimated from (16) because the rank
udi* idi +uqi* iqi R idi2 +iqi2 iTei Dqi iqi Ddi idi Vdead (11) of (16) is equal to the number of parameters to be estimated.
j u i +u i u i +u i =
*
di di
*
qi qi i
*
dj dj
*
qj qj
Remark 2: When one of the injected current is zero, for
example, id2=0, (16) can be rewritten as
Vdead D i D i D i D i (12) D V
uq*2 Ri (17)
j qi qi di di i qj qj dj dj q2 q 2 dead 2 M
R i + i i + i , 1 i, j K
2 2 2 2 Thus, the rotor flux can be directly estimated from (17) without
j di qi i dj qj
the influence the magnetic saturation.
Without loss of generality, let and be the winding C. RLS based Parameter Estimation Method
resistance and VSI distorted voltage estimated from (12).
Substituting them into (12) yields (13) and (14) This paper employs the recursive least square (RLS)
algorithm for online parameter estimation because it is simple
D V
Ri
udi* di di dead i Lqi iqi (13) and robust. Given the model (18) where yk and kT are known
D V model parameters while x is the model parameters to be
uqi* Riqi qi dead i Ldi idi i M (14) estimated, the RLS algorithm for estimating x is listed in (19).
where i=1,, K. It can be seen that the q-axis inductances at yk Tk x (18)
different current magnitudes can be estimated by using (13),
even though there is magnetic saturation. However, it is unable xk 1 xk Gk 1 y k 1 Tk 1 xk
to estimate the rotor flux and d-axis inductance from (14), 1
because the number of parameters to be estimated is (K+1) but Gk 1 Pk k 1 1 Tk 1 Pk k 1 (19)
the rank of (14) is K.
Pk 1 Pk Gk 1Tk 1 Pk
Since the magnitude of the injected current is small, the
linear equation (15) is used to model the cross- and self- The RLS based parameter estimation can be implemented with
saturation of dq-axis inductances during current injection. (12)~(19). For instance, based on (13) the RLS based q-axis
Ld Ld 0 d id q iq inductance estimated can be implemented with (19) where
(15) x Lqi , i iqi ,
Lq Lq 0 q iq d id (20)
D V
y udi* Ri
where q and d are the d-axis cross- and self-saturation di di dead
constants, respectively; d and q are the q-axis cross- and The estimation of other parameters can be obtained similarly.
self-saturation constants, respectively, and Ld0 and Lq0 are the The flowchart of the proposed RLS based online parameter
d-axis and q-axis unsaturated inductances, respectively. In real estimation is illustrated in Fig. 5. It should be emphasized that
implementation, the magnitude of injected current is small, so the proposed algorithm is computation-efficient because its
the cross-saturation effect is much smaller than self-saturation computation complexity is proportional to the number of
effect [26]-[29], so the cross-saturation constants d and q are measurements used for parameter estimation. Assume that N
assumed to be zero to simplify the estimation. Substituting (15) measurements are used, then the computation complexity is
into (14), (16) is obtained. O(N). Specifically, the proposed algorithm involves iteratively
D V ( L i i 2 )
udi Ri
* executing (19), and the number of iterations is equal to N. For R
di di dead i q 0 qi q qi
(16) and Vdead estimation, k, Pk and Gk are 22 dimensional matrix,
* D V
uqi Ri qi
qi dead i Ld 0 idi d idi M
2
so each iteration involves computing a 22 dimensional matrix
inversion and some matrix multiplications, which does not
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iq
Lq Ld iq1id (22)
The proposed approach is tested on a laboratory interior PMSM
drive system that is designed for direct-drive EV applications as
Ld Lq idi M shown in Fig. 7. It is controlled by FPGA-based real-time
simulator (RT-Lab) and fed by an IGBT module. The drive
In the experiment, two d-axis currents are injected into the
system consists of a test motor and a dyno machine that can be
interior PMSM drive system for parameter estimation. Thus,
independently controlled to produce the desired torque. The
the q-axis current in (22) is compensated to minimize the torque
torque transducer can measure the output torque of the test
ripple caused by current injection. It should be emphasized that
motor, and the thermal detector can monitor the temperature of
the nominal values of the dq-axis inductances and rotor flux can
the winding resistance. The detailed parameters of the test
be used to compute the compensated q-axis current in (22),
motor are listed in Tables I.
because the PI controller is able to automatically modify the
control errors. TABLE I: THE DESIGN PARAMETERS OF THE TESTED INTERIOR PMSM
In order to evaluate the proposed current compensation Rated current 15 A
method, the test motor is operated under two different loading Rated speed 575 rpm
conditions, namely, 10 Nm and 20 Nm. The dq-axis currents
Rated voltage 275 V
and the electromagnetic torque without current compensation
Winding resistance (at T=22) 1
are given in Fig.6 (a) and (c). It can be seen that the torque
Winding resistance (at T=120) 1.5
ripples are caused by the injected d-axis current, and the torque
ripples are increasing with the increase of loading conditions. Magnet flux (at T=22) 0.67 Wb
Therefore, it will influence the drive performance without any Magnet flux (at T=120) 0.63Wb
compensation strategy. The dq-axis currents and the output Number of pole pairs 4
torque with the proposed compensation strategy are shown in
Fig. 6 (b) and (d). It can be seen that the torque ripples caused
by the injected d-axis current have been efficiently reduced.
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Fig. 9. VSI distorted voltage estimation results obtained from the proposed
on-line estimation approach at motor speeds of 50 rpm and 200 rpm.
experiment, investigations with and without considering VSI
nonlinearity are performed to highlight that the estimation
performance can be improved by considering VSI nonlinearity.
Here, without considering VSI nonlinearity means that the
VSI distorted voltage Vdead is set to be zero during estimation.
Fig. 7. Experimental setups for parameter estimation. (a) Inverter and control Figures 8(a) and (b) present the estimation of winding
circuits. (b) Temperature measurement. (c) Dyno and test motors. resistance at 50 rpm and 200 rpm, respectively. It can be seen
that without considering VSI nonlinearity, the estimated
winding resistance is 1.21 at 50 rpm and 1.25 at 200 rpm;
while considering VSI nonlinearity, the estimated resistance is
1.01 at 50 rpm and 1.198 at 200 rpm. Without considering
VSI nonlinearity, the estimation errors are 0.21 at 50 rpm and
0.15 at 200 rpm, while considering that, the estimation errors
are 0.01 at 50 rpm and 0.098 at 200 rpm. Obviously, the
estimated winding resistance is much more accurate with
respect to the nominal value by considering VSI nonlinearity.
The resistance estimation method proposed in [10] is compared
with our approach. The compared method uses the
instantaneous measurements and RLS algorithm for
parameter estimation. As shown in Fig.8, for the compared
method, the estimated resistance is 0.9 at 50 rpm and 1.217
at 200 rpm, so the estimation errors are 0.1 at 50 rpm and
0.117 at 200 rpm. Obviously, the proposed approach can
improve the estimation performance by using the DC
components of the measurements.
Fig. 8. Resistance estimation results by using the proposed and compared
estimation approaches. (a) At speed of 50 rpm. (b) At speed of 200 rpm.
The resistance is estimated from (12), so the estimation error is
mainly caused by VSI nonlinearity apart from the measurement
During the experiment, the proposed approach is validated on
noises. The estimation error due to VSI nonlinearity is given in
the test motor operating at 50 rpm and 200 rpm, and the loading
(23). The current injection can be finished in a very short period
dyno machine is controlled to produce a load torque of 20 Nm
of time, so the rotor speed can be assumed to be constant during
for the test motor. The vector control shown in Fig. 1 is
current injection, and then (23) can be simplified as (24).
employed for motor control and parameter estimation.
Following the implementation flowchart, when the PMSM j Dqi iqi Ddi idi -i Dqj iqj Ddj idj
R Vdead (23)
drive system reaches its steady state, the first steady-state
measurements are collected, and then two different d-axis
2
2 2
j idi + iqi -i idj + iqj
2
currents (id1=-1 A and id2=-2 A) are orderly injected into the
R
D i Ddi idi
qi qi -D i D i V
qj qj dj dj
(24)
drive system and the corresponding steady-state measurements
are collected accordingly. The proposed approach is performed i2
di +i 2
qi - i +i
2
dj
2
qj
dead
following the flowchart in Fig. 5 and the results are as follows. As suggested from (24), the estimation error is proportional to
the VSI distorted voltage and it is independent of the rotor
A. Winding Resistance Estimation speed. The estimated VSI distorted voltage at 50 and 200 rpm
The value of the winding resistance tested at room temperature are shown in Fig. 9. It can be seen that Vdead converges to about
is 1 and it will increase to about 1.5 when the winding 0.36 V. Thus, for id0=0 and id1=1 A, the estimation error is 0.25
temperature rises to 120 . The 50 rpm experiment is approximately 25% of the nominal value. The experimental
performed at room temperature, so the nominal winding result shows that the estimation error due to VSI nonlinearity is
resistance is 1 , while the 200 rpm experiment is performed at about 0.2 at 50 rpm, which agrees with the theoretical results.
Thus, the winding resistance estimation performance is
the temperature of 40, so the nominal winding resistance is improved by considering the VSI nonlinearity. Moreover, the
about 1.1 according to the linear thermal model. In the estimated winding resistance is increasing with the rising of
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Transactions on Transportation Electrification
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Transactions on Transportation Electrification
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