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研究生： 賀業翔
Yeh-Hsiang Ho
論文名稱： 永磁同步馬達驅動系統之無位置感測控制與噪音降低研究
POSITION SENSORLESS CONTROL AND ACOUSTIC NOISE REDUCTION STUDY FOR PERMANENT MAGNET SYNCHRONOUS MOTOR DRIVE
指導教授： 廖聰明
Chang-Ming Liaw
口試委員:
學位類別： 碩士
Master
系所名稱： 電機資訊學院 - 電機工程學系
Department of Electrical Engineering
論文出版年： 2007
畢業學年度： 95
語文別： 英文
論文頁數： 151
中文關鍵詞： 永磁同步馬達 、無位置感測控制 、強健電流控制 、切換式整流器 、低頻切換 、隨機切換 、三階段激磁 、應電勢估測 、智慧型調控 、初始位置偵測 、單一方向啟動
外文關鍵詞： Permanent-magnet synchronous motor, position sensorless control, acoustic noise, robust current control, switch-mode rectifier, low-frequency switching, random switching, three-stage excitation, back-EMF estimation, intelligent tuning, initial rotor position estimation, unidirectional starting
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    • 摘 要
    本論文旨在從事永磁同步馬達(Permanent magnet synchronous motor, PMSM)驅動系統之無位置感測控制及噪音降低研究。首先建構一以數位信號處理器為主之PMSM驅動系統，應用一強健電流控制及應電勢估測機構可得緊密之線圈電流波形追控特性，而同時估得之應電勢可供從事弦波式同步馬達之無位置感測控制。接著研製升壓型切換式整流器(Switch-mode rectifier, SMR)，提供可調控之直流鏈電壓，增進馬達驅動系統之運轉性能。
    在降低低頻式SMR之振動及噪音研究方面，先由實驗中辨出主要電感之振動頻率。接著提出消除特定振動頻率及同時消除雙振動頻率之固定、交替及隨機之三階段激磁法。對於高頻SMR則採任意變化磁滯帶及任意變化切換頻率技巧之電流切換控制。各法均詳加介紹其原理及從事性能實測比較評定。
    最後在無位置感測控制方面，首先應用含有PMSM轉子絕對位置之估測應電勢從事施行弦波式同步馬達之無位置感測驅動控制之依據。以此方式所得之不理想直流無刷操控特性，再經所提智慧型調控予以改善，因而獲得良好之動態及穩態操控性能。此外，本論文也提出一初始位置偵測控制機構，並從事於無位置感測PMSM之單一方向啟動控制。
    關鍵詞：永磁同步馬達、無位置感測控制、強健電流控制、切換式整流器、低頻切換、隨機切換、三階段激磁、應電勢估測、智慧型調控、初始位置偵測、單一方向啟動。

    ABSTRACT
    This thesis is mainly concerned with the position sensorless control and the acoustic noise reduction studies for permanent-magnet synchronous motor (PMSM) drive. First, an experimental digital signal processor (DSP) based PMSM drive is established. A robust current control and back-EMF estimation scheme are proposed to yield close and robust current tracking performance. And the motor back electromagnetic force (EMF) can be observed and employed for performing the proposed sensorless control. Secondly, the suitable front-end switch-mode rectifiers (SMRs) are developed and utilized to establish boostable and well-regulated DC-link voltage for the followed PMSM inverter. In addition to the control and performance evaluation of the SMR-fed motor drive, the vibration and acoustic noise reductions for the SMR and the inverter-fed PMSM are also studied.
    In vibration and acoustic noise reductions of SMR, the important audible vibration modes of the inductor employed in the low-frequency (LF) SMR are first identified from measurements. Then the controls for eliminating one specific vibration mode and two vibration modes simultaneously via deterministic and stochastic three-stage excitation approaches are studied. As to the HF SMRs, a random switching frequency ramp-comparison current-controlled PWM (RC-CCPWM) scheme and a randomly band hysteresis CCPWM scheme are developed. Theoretical bases of all proposed control approaches are derived and their comparative performances are evaluated experimentally. On the other hand, the acoustic noise reduction for the PMSM drive via random PWM approach is also conducted.
    As to the sensorless control aspect, the motor back-EMF estimated using the proposed scheme, which contains the absolute rotor position information, is used to perform the position sensorless control of PMSM. The nonideal position estimation is then improved by an intelligent tuning scheme, wherein the estimated rotor position is tuned to yield minimum torque current component and thus better sensorless vector control performance. In addition, the motor can be automatically and quickly started under the preset torque current limit. Moreover, to achieve unidirectional starting under position sensorless control, a simple and practical initial rotor position estimation and starting scheme is further developed.
    Key words: Permanent-magnet synchronous motor, position sensorless control, acoustic noise, robust current control, switch-mode rectifier, low-frequency switching, random switching, three-stage excitation, back-EMF estimation, intelligent tuning, initial rotor position estimation, unidirectional starting.

    LIST OF CONTENTS ACKNOWLEDGEMENTS……………………………………………………….. I ABSTRACT……………………………………………………………………….. II LIST OF CONTENTS……………………………………………………………... III LIST OF FIGURES………………………………………………………………... VI LIST OF TABLES…………………………………………………………………. XII CHAPTER 1 INTRODUCTION…………………………………………... 1 CHAPTER 2 DSP-BASED PERMANENT MAGNET SYNCHRONOUS MOTOR DRIVE…………………………………………….. 7 2.1 Introduction………………………………………………….. 7 2.2 Structures of PMSMs………………………………………... 8 2.2.1 Rotor…………………………………………………... 8 2.2.2 Stator…………………………………………………... 10 2.3 Brushless DC Motor Operation of PMSM…………………... 11 2.4 Governing Equations of Sine-Wave PMSM………………… 11 2.5 Governing Equations of Square-Wave Type………………… 20 2.6 Estimation of Equivalent Circuit Parameters………………... 20 2.6.1 Back-EMF Constant…………………………………… 23 2.6.2 Winding Resistance and Inductance…………………... 23 2.7 DSP-Based PMSM Drive…………………………………… 29 2.7.1 Ratings of System Components……………………….. 29 2.7.2 Digital Control Practical Considerations…………… 32 2.7.3 DSP ADMC-401………………………………………. 34 2.7.4 Normalization of Digital Variable……………………... 35 2.8 Current-Controlled PWM Scheme…………………………... 35 2.8.1 System Configuration…………………………………. 35 2.8.2 Robust Current Control Scheme………………………. 37 2.8.3 Driving Performance…………………………………... 42 CHAPTER 3 FRONT-END SWITCH-MODE RECTIFIERS…………...... 51 3.1 Introduction………………………………………………….. 51 3.2 Classification of SMRs……………………………………… 51 3.3 LF AC-Switch Based SMR………………………………….. 54 3.3.1 Power Circuit………………………………………….. 54 3.3.2 Control Scheme……………........................................... 57 3.4 HF AC-Switch Based SMR…………………………………. 60 3.4.1 Upper Limit of KPi…………………………………….. 60 3.4.2 Simulated and Measured Results……………………… 63 3.5 Standard Boost-Type SMR………………………………….. 67 3.5.1 Power Circuit Components……………………………. 67 3.5.2 Design of Feedback Controller………………………... 70 3.5.3 Measured Results……………………………………… 70 CHAPTER 4 ACOUSTIC NOISE REDUCTION CONTROL OF FRONT-END SMRS………………………………………… 78 4.1 Introduction………………………………………………….. 78 4.2 Origins of Vibration and Acoustic Noise….………………… 78 4.3 Low-Frequency SMR with Auxiliary Narrow Pulse………... 80 4.3.1 Operation Priciple……………………………………... 80 4.3.2 Experimental results…………………………………… 84 4.4 Standard HF-SMR with Random Frequency RC-CCPWM Scheme…………………….………………………………… 91 4.4.1 High-Frequency SMR with RC-CCPWM Scheme……. 91 4.4.2 Experimental Results………………………………….. 96 4.5 High-Frequency SMR with Hyteresis CCPWM Scheme…… 99 4.5.1 Harmonic Spectral Analysis for Hysteresis CCPWM Scheme………………………………………………………. 99 4.5.2 Experimental Results………………………………….. 102 CHAPTER 5 POSITION SENSORLESS CONTROL FOR SINEWAVE PMSM……………………………………………………….. 108 5.1 Introduction………………………………………………….. 108 5.2 Comparative Survey of Existing Sensorless Control Methods 108 5.3 Starting and Initial Rotor Position Estimation…………… 116 5.3.1 Starting Methods………………………………………. 116 5.3.2 Rotor Initial Position Estimation……………………… 117 5.4 The Established Position Sensorless PMSM Drive and Problem Statements………………………………………….. 119 5.4.1 System Configuration…………………………………. 119 5.4.2 Methodology…………………………………………... 121 5.4.3 Speed Estimation Scheme……………………………... 122 5.4.4 The Proposed Robust Current Control and Back-EMF Estimation Scheme…………………………………………... 122 5.4.5 Error and Performance Analyses of the Proposed Back-EMF Estimation Scheme……………………………… 124 5.4.6 Experimental Performance Evaluation for the Developed Sensorless Controlled PMSM Drive….………... 127 CHAPTER 6 CONCLUSIONS…………………………………………….. 136 REFERENCES ……………………………………………………………….. 138 LIST OF FIGURES Fig. 2.1. Some rotor structures of PMSMs: (a) SPMSM; (b) inserted magnet type of IPMSM; (c) buried magnet type of IPMSM; (d) multi-layer magnet of IPMSM………………………………………………………. 9 Fig. 2.2. Outer-rotor and inner armature PMSM……………...…………………. 11 Fig. 2.3. Sine-wave type BDCM drive: (a) drive configuration; (b) winding currents; (c) winding current convention; (d) stator developed flux at time instant A; (e) stator developed flux at time instant B……………... 13 Fig. 2.4. An elementary PMSM: (a) configuration; (b) circuit connection………. 14 Fig. 2.5. The phasor diagram of a PMSM………………………………………... 18 Fig. 2.6. Idealized back-EMF and current waveforms of a square-wave PMSM... 21 Fig. 2.7. Simplified sine-wave PMSM models: (a) equivalent circuits; (b) per-phase armature winding model………………………....................... 22 Fig. 2.8. Parameter estimation for Y-connected motor with isolated neutral : (a) current excitation; (b) resulted flux distribution………………………... 24 Fig. 2.9. Parameters measurement for Y-connected motor with LCR meter: (a) equivalent circuit; (b) inductance; (c) resistance……………………….. 26 Fig. 2.10. Step-response estimation method for winding parameters: (a) circuit configuration; (b) measured current waveform………………………… 28 Fig. 2.11. The winding current response under different switching pattern………. 30 Fig. 2.12. Configuration of DSP-based PMSM drive……………………………... 31 Fig. 2.13. Some typical key issues of a PMSM drive……………………………... 32 Fig. 2.14. CCPWM scheme in: (a) abc-domain; (b) dq-domain…………………... 36 Fig. 2.15. The proposed current control scheme of a-phase winding: (a) control system configuration; (b) equivalent block diagram…………………… 38 Fig. 2.16. Measured phase-a winding currents and their commands by PI controller (RL = 21.6Ω) in abc-domain: (a) 500rpm; (b) 3000rpm……... 43 Fig. 2.17. Measured phase-a winding currents and their commands by the proposed robust controller with = 0.9 (RL = 21.6Ω) in abc-domain: (a) 500rpm; (b) 3000rpm……………………………………………….. 44 Fig. 2.18. Measured winding currents and commands due to a step speed command change (RL = 21.6Ω, = 2700rpm 3000rpm) in abc-domain: (a) PI controller ( = 0); (b) robust controller…………… 45 Fig. 2.19. Measured speed tracking and regulation responses in abc-domain by the PI controller and robust controller with different values of W: (a) RL = 21.6Ω, = 2700rpm→3000rpm; (b) =3000rpm, RL = 21.6Ω... 46 Fig. 2.20. Measured winding currents and their commands by PI controller (RL = 21.6Ω) in dq-domain: (a) 500rpm; (b) 3000rpm………………………... 47 Fig. 2.21. Measured winding currents and their commands due to a step speed command change (RL = 21.6Ω, = 2700rpm→3000rpm) in dq- domain:(a) PI controller (W= 0); (b) robust controller (W= 0.9)……...... 49 Fig. 2.22. Measured speed tracking and regulation responses in dq-domain by the PI controller and robust controller with different values of W: (a) RL = 21.6Ω, = 2700rpm→3000rpm; (b) =3000rpm, RL = 43.9Ω→21.6Ω………………………………………………………….. 50 Fig. 3.1. Seven typical SMR circuit topologies: (a) SMR-A; (b) SMR-B; (c) SMR-C; (d) SMR-D; (e) SMR-E; (f) SMR-S; (g) MSMR……………... 52 Fig. 3.2. AC-switch based SMRs: (a) circuit topology; (b) control block diagram and typical waveforms of a low-frequency switching control scheme…. 55 Fig. 3.3. The proposed voltage control scheme…………………………………... 58 Fig. 3.4. Measured DC output voltage Vd, voltage command and switching control signal vcont by the PI-controller with Gcv = 6.5+100/s: (a) due to step command change of 10V (270V→280V); (b) due to step load resistance change RL = 124Ω→115Ω…………………………………... 61 Fig. 3.5. Control block diagram of a ramp-comparison CCPWM high-frequency switching control scheme……………………………………………….. 62 Fig. 3.6. Simulated output voltage vd, input voltage vac, inductor current iL and its command of AC-switched based HF SMR with resistive load (RL = 78.5Ω)………………………………………………………………… 65 Fig. 3.7. Measured output voltage vd, input voltage vac, inductor current iL and its command of AC-switched based HF SMR with motor load (Vd = 300V, = 3000rpm, RL = 22Ω)……………………………………….. 66 Fig. 3.8. Circuit configuration of the standard SMR……………………………... 68 Fig. 3.9. Measured iL, its command (upper) and spectrum (lower) of iL of standard HF-SMR with resistive load (RL = 54.4Ω) at different switching frequencies: (a) fs = 30kHz; (b) fs = 20kHz; (c) fs = 10kHz; (d) fs = 5kHz…………………………………………………………….. 71 Fig. 3.10. Measured iL, its command (upper) and spectrum (lower) of iL of standard HF-SMR with motor load at different switching frequencies: (a) fs = 30kHz; (b) fs = 20kHz; (c) fs = 10kHz; (d) fs = 5kHz……………. 75 Fig. 4.1. Sources of noise and vibration in electromagnetic devices…………….. 79 Fig. 4.2. Key waveforms of three-stage excitation approach…………………….. 81 Fig. 4.3. Vibration reduction for LF-SMR: (a) proposed control scheme with two deterministically alternate narrow pulses for reducing two vibration modes; (b) PRBS generating circuit for randomly varying two different narrow pulses…………………………………………………. 83 Fig. 4.4. Measured results of LF-SMR (without narrow pulse) under PMSM load: (a) input voltage, current and switching signal; (b) inductor vibration; (c) spectrum of inductor vibration…………………………… 85 Fig. 4.5. Measured results of LF-SMR (without narrow pulse) under resistive load: (a) input voltage, current and switching signal; (b) inductor vibration; (c) spectrum of inductor vibration…………………………… 86 Fig. 4.6. Measured inductor vibration waveforms (upper) and spectra (lower) with narrow pulse under resistive load: (a) elimination of vibration mode l (2kHz); (b) elimination of vibration mode 2 (5.4kHz)…………. 88 Fig. 4.7. Measured inductor vibration waveforms (upper) and spectra (lower) of LF-SMR with narrow pulse under resistive load: (a) elimination of dual vibration modes using deterministic approach; (b) elimination of dual vibration modes using stochastic approach……………………………... 90 Fig. 4.8. Standard RC-CCPWM scheme…………………………………………. 93 Fig. 4.9. Acoustic noise reduction control for HF-SMR with RC-CCPWM: (a) random frequency triangular; (b) resulted current spectra……………… 94 Fig. 4.10. (a) Measured input voltage, inductor current and its command, inductor vibration waveform (middle) and spectrum (lower) of standard HF-SMR with standard robust RC-CCPWM (W=0.99, switching frequency = 5kHz) under resistive load ; (b) same as (a) with switching frequency = 3.5kHz~6.5kHz……………………………………………. 97 Fig. 4.11. (a) Measured input voltage, inductor current and its command, inductor vibration waveform (middle) and spectrum (lower) of standard HF-SMR with standard robust RC-CCPWM (W=0.99, switching frequency = 15kHz) under resistive load ; (b) same as (a) with switching frequency = 10kHz~20kHz………………………………….. 100 Fig. 4.12. Acoustic noise reduction control for HF-SMR with hysteresis CCPWM: (a) control scheme; (b) random signal modulated varying band; (c) current spectra corresponding to different bands; (d) resulted uniformly distributed current spectrum………………………………… 103 Fig. 4.13. (a) Measured input voltage, inductor current and its command, spectra of inductor current (middle) and inductor vibration (lower) of standard HF-SMR with robust hysteresis CCPWM (W=0.99, band = 2.5A) under resistive load; (b) same as (a) with band = 1.0A; (c) inductor vibration spectrum with band = 0.5A~1.5A……………………………………….. 105 Fig. 5.1. Typical configuration of a sensorless BDCM established using PMSM.. 110 Fig. 5.2. Classification of PMSM sensorless control methods…………………… 111 Fig. 5.3. Unconducted winding phase back-EMF measurement methods: (a) Equivalent circuit during the switches T2 and T3 being turned on; (b) the waveforms of terminal voltage va and neutral voltage vn…………… 114 Fig. 5.4. Conceptual diagram for illustrating the sensorless control based on third-order harmonic voltage: (a) air gap flux distribution of a BDCM; (b) ideal key waveforms………………………………………………… 115 Fig. 5.5. The proposed sensorless control scheme……………………………….. 120 Fig. 5.6. The proposed robust current controller and back-EMF estimation scheme…………………………………………………………………... 123 Fig. 5.7. Key waveforms of the proposed sensorless control scheme……………. 125 Fig. 5.8. Measured disturbance signals and Hall sensor signals Ha of a standard sine-wave BDCM drive at: (a) Vd = 250V, = 1500rpm, RL = 54.4Ω; (b) Vd = 250V, = 2500rpm, RL = 16.4Ω………………… 126 Fig. 5.9. The measured and the estimated speed with = 3.0A and 4.5A at (Vd = 250V, RL=54.4Ω, =1000rpm)……………………………………….. 128 Fig. 5.10. The measured and before and after making the commutation phase angle tuning at (Vd = 250V, = 1500rpm, RL = 54.4Ω)…………………………………………………………………... 130 Fig. 5.11. The measured during making the commutation phase angle tuning at (Vd = 250V, = 1500rpm, RL = 54.4Ω )…………………………… 131 Fig. 5.12. Measured speeds due to a step speed command change (1500rpm to 1700rpm) at (Vd = 250V, = 1500rpm RL = 54.4Ω ) of the developed sensorless PMSM drive before and after commutation phase angle tunings…………………………………………………………………... 132 Fig. 5.13. The measured speeds of the developed sensorless PMSM drive at (Vd = 250V, RL = 54.4Ω, = 3.0A): (a) = 0 to 100rpm; (b) = 0 to 50rpm…………………………………………………………………… 133 Fig. 5.14. Ramp speed command responses: (a) ramp speed command generator; (b) measured speeds of the developed sensorless PMSM drive under ramp speed commands with different ramping rates at (Vd = 250V, RL = 54.4Ω, = 3.0A, = 1200rpm); (c) measured current commands corresponding to (b)…………………………………………………. 134 LIST OF TABLES Table 3.1 Measured inductances and ESR (Rs) of different inductor cores at some frequencies………………………………………………………. 56 Table 3.2 The values of corresponding to different values of switching frequencies and inductors……………………………………………… 64 Table 3.3 Measured results of standard HF-SMR with resistive load (RL = 54.4Ω) at different switching frequencies……………………………... 73 Table 3.4 Measured results of standard HF-SMR with motor load at different switching frequency…………………………………………………… 77

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    D. Performance Improvement Control
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    E. Front-End Switching Mode Rectifiers
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    F. Random Switching, Vibration and Acoustic Noise Reduction
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    G. Position Sensorless Control
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    H. Initial rotor position detection and starting method
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    I. DSP-Based Digital Control and Digital Signal Processor
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