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The thesis deals with the design of a permanent magnet synchronous machine controller that isimplemented on an embedded platform to replace the off-the-shelf controller currently being used in theelectric race car of the KTH Formula Student team. Software implementation of the control algorithmwas tested in laboratory environment on the hardware prototype of a 2-level three-phase voltage sourceinverter.Field oriented control and finite control set model predictive control algorithms were implemented insimulation environment. The latter performed better in terms of reducing switching activity and torqueripple, but needs vastly more computational resources due to its nature of being an online optimizationproblem. Trade-off curve of phase current harmonic distortion and switching activity showed that themodel prediction control algorithm performs better in the low frequency range (1-20 kHz). Obtainedsimulation results were used for power electronics component selection.Field oriented control was implemented on a TMS320F28335 DSP. SPI communication was employedto configure gate driver circuits and perform error handling. The DSP program follows interrupt basedorganization and the main control loop runs on the variable frequency of the pulse width modulation.Low voltage test results on three-phase inductive-resistive load showed that the controller outputssinusoidal current. Efficiency measurement, high voltage and motor testing were hindered by interferencefrom the Silicon-Carbide MOSFETs that prohibited correct operation of hardware. / Den här uppsatsen handlar om designen och implementeringen av en motorstyrning för en permanen- magnetiserad synkronmotor, med syfte att ersätta standardmotorstyrningsenheten i KTH Formula Students tävlingsbil. Implementationen av styralgoritmen testades experimentellt tillsammans med en prototyptillverkad frekvensomriktare i labbmiljö. Regleralgoritmer för field oriented control och finite control set model predictive control implementerades och testades i simuleringsmiljö. Den senare algoritmen visade sig prestera bättre i form av lägre vridmomentsoscillationer trots lägre switch-frekvens men den kräver samtidigt mer beräkningskraft. Övertonsinnehållet (THD) i fasströmmarna som funktion av switchfrekvensen undersöktes för de båda regleralgoritmerna, algoritmen för model predictive control gav lägre THD vid lägre frekvenser (1-20 kHz). Simuleringsresultaten användes för att motivera valet av komponenter till frekvensomriktaren. Regleralgoritmen för field oriented control implementerades och testades experimentellt med hjälp av ett utvecklingskort (TMS320F28335) från Texas Instruments. SPI-kommunikation användes för att konfigurera drivkretsana samt för att utläsa felkoder. Experimentalla tester som utfördes på låg spänningsnivå visade att strömmen till lasten var sinusformad. Mätning av verkningsgrad och provning tillsammans med motorn på en högre spänningsnivå gick inte att geno av att de snabba switchförloppen i kiselkarbidtransistorerna störde ut motorstyrningen.

There are several benets of electrohydraulic power steering systems, as compared to hydraulicpower steering systems where the pump is driven directly by the engine of the vehicle. Someof these benets are increased eciency and improved steering performance. The purpose ofthis project is to create a simulation model of the electrohydraulic power steering system inSimulink, excluding the hydraulic circuit. The model should thus consist of the electric motor,the drive electronics, the control system, the hydraulic pump as well as the communication andinterface to the master simulation system in which the model will be used.As a start a mathematical model of the motor is derived. Then the motor controller includingtwo current controllers and a speed controller is developed. The switching signals for the threephase bridge that drives the motor are calculated using space vector modulation. The motordrives a hydraulic pump, which is modeled using data sheet eciency curves. Finally a thermalmodel of the drive is developed. To fulll real time requirements, a lumped parameter approachis chosen. The nal model is exported as a Functional Mock-up Unit, which is a black-boxencapsulation of the complete simulation model.The simulation model is compared to measurement data to conrm its validity. Thesecomparisons shows that the dynamic response of the motor and its controller are close to themeasured values and that the thermal model adequately corresponds to the thermal tests. Thehydraulic pump model varied from measurements more than the other sub-modules. It was,however, seen as acceptable. Overall the system response was satisfactory, but naturally a lotof future improvements and new features could be made to improve the model. / Det finns flera fördelar med elektrohydraulisk servostyrning, där hydraulpumpen drivs av en el-motor, jämfört med hydraulisk servostyrning, där pumpen drivs direkt av fordonets förbränningsmotor. Några av dessa fördelar är ökad effektivitet och förbättrad styrprestanda. Syftet med detta projekt är att skapa en Simulink-modell av ett elektrohydraulisk system för servostyrning, exklusive hydraulkretsen. Modellen ska alltså bestå av delmodeller för elmotorn, drivelektroniken, styrsystemet, hydraulpumpen samt kommunikation med den övergripande simuleringsplattformen.Inledningsvis beskrivs en matematisk modell av elmotorn och efter det utvecklas motorstyrningen, bestående av två strömregulatorer samt en hastighetsregulator. Spänningen från strömregulatorerna uppnås genom space vector-modulation, som beräknar de pulskvoter som krävs för att uppnå denna spänning. Elmotorn driver en pump. Denna pump modelleras med hjälp av data från pumpens datablad. Slutligen modelleras drivelektronikens termiska egenskaper med ett termiskt nätverk. Den slutliga modellen omsluts av en Functional Mock-up Unit somintegreras i den övergripande simuleringsplattformen.

This dissertation is concerned with the design of permanent magnet synchronous motors (PMSM) to operate at super-high speed with high efficiency. The designed and fabricated PMSM was successfully tested to run upto 210,000 rpm The designed PMSM has 2000 W shaft output power at 200,000 rpm and at the cryogenic temperature of 77 K. The test results showed the motor to have an efficiency reaching above 92%. This achieved efficiency indicated a significant improvement compared to commercial motors with similar ratings. This dissertation first discusses the basic concept of electrical machines. After that, the modeling of PMSM for dynamic simulation is provided. Particular design strategies have to be adopted for super-high speed applications since motor losses assume a key role in the motor drive performance limit. The considerations of the PMSM structure for cryogenic applications are also discussed. It is shown that slotless structure with multi-strand Litz-wire is favorable for super-high speeds and cryogenic applications. The design, simulation, and test of a single-sided axial flux pancake PMSM is presented. The advantages and disadvantages of this kind of structure are discussed, and further improvements are suggested and some have been verified by experiments. The methodologies of designing super high-speed motors are provided in details. Based on these methodologies, a super high-speed radial-flux PMSM was designed and fabricated. The designed PMSM meets our expectation and the tested results agree with the design specifications. 2-D and 3-D modeling of the complicated PMSM structure for the electromagnetic numerical simulations of motor performance and parameters such as phase inductors, core losses, rotor eddy current loss, torque, and induced electromotive force (back-EMF) are also presented in detail in this dissertation. Some mechanical issues such as thermal analysis, bearing pre-load, rotor stress analysis, and rotor dynamics analysis are also discussed. Different control schemes are presented and suitable control schemes for super high- speed PMSM are also discussed in detail.

The original idea of the thesis was realized to control the electric drive of the rotor with a special feature. Without using a complex mechanism, the angle of each blade of the rotor can be controlled individually. The blades are fixed independently to a permanent magnet and the housing encompassing the rotor contains coils. By powering the coils, the whole rotor turns into a permanent magnet motor and by using a control algorithm, each blade can be separately driven. In the first chapter, the introduction to the main idea of the research project is described along with working principle of rotor blade. The basic concept of blade angle is introduced. The second chapter is the state of Technique. In this chapter, the working principle and basics of permanent magnet synchronous machine and brushless motor with mathematical model is described. Also, space vector pulse width modulation and double acting piezoelectric actuator model for helicopter rotor are explained. The third chapter is the overall description of the initial status of the research project. This part includes the basic principle of the control system, sensorless field-oriented control of Permanent Magnet Synchronous Machine (PMSM). Also, the motor parameters calculated from the python script of motor design are listed in tabular form. The fourth chapter focuses on control strategy implementation. First of all, the criteria for selecting the microcontroller are described. After that, the structure of the program with a flow chart was explained. Also, a short description is mentioned of how space vector pulse width modulation is applied. The main function of the position and speed controller with block diagram is explained. Moreover, back-EMF based observer and EKF-based observer are described. In the fourth chapter, the initial problem of the research project is discussed. To overcome this problem, a set of experiments is carried out. In the last chapter, the result of the experiment with proper explanation is summarized. Further on the future work to solve the problem is listed.

The tendency of recent years towards electrification of aircraft components and subsys-tems has opened the door for a wider usability of electro-mechanical actuators (EMAs) inthat context. EMAs are already in use in aircraft industries but mainly in civil aviation forsecondary control systems and non-critical applications. Therefore it is evident that thereexists a need for further research in the sector of utilization of EMAs for other areas withinthe aircraft manufacturing industry before they can be effectively applied. In this thesisan analysis of the power and thermal behaviour of EMAs has been done to evaluate theirapplicability in primary control systems for fighter aircrafts as compared to conventionallyused hydraulic systems. Furthermore, a method for scaling of such actuators in an initialdesign stage where few parameters are known has been developed and validated. One ofthe most substantial drawbacks against choosing EMAs for these purposes is the disadvan-tageous thermal transfer capability of electrical machines in high power applications. Aninvestigation has therefore also been made on calculation of power losses of electrical mo-tors and inverters. The results have been compared against a servo hydraulic actuator. Ascalable simulation model derived from motor data statistics has been developed in orderto simulate power losses and the thermal behaviour of these actuators. The model takesvery few parameters as input as an aircraft designer working in the preliminary stages ofthe design process often have limited knowledge of the final product, but at the same timeneed a fairly accurate view of how the actuators ought to be scaled with regard to weight,power and thermal transfer. The model shows promising results when verified against anactual electro-mechanical actuator on Iron Bird test rig. Finally, this work aims to furtherthe development of an Iron Bird situated on Linköping University, through an integrationbetween three thesis projects where the final product shall be an Hardware In The Loop(HWIL) simulation with several actuators involved.

Enhancing the dependability and power density of a SPMSMs is crucial for its extensive utilization in the automotive and aerospace sectors. One major concern regarding these machines is the significant thermo-mechanical loads experienced by the overall rotating assembly due to high rotational speeds and a wide operational temperature range from $50^\circ C$ to $150^\circ C$. This poses a considerable challenge in maintaining structural integrity among the components. Redesigning components to reduce assembly complexity and weight necessitates careful consideration of boundary conditions and contact modeling to prevent catastrophic failures like magnet fly-by conditions. To reduce model complexity, a simplified approach involves integrating the hub and shaft; both machined from AISI 4340. Additionally, the application of a carbon fiber sleeve is investigated through 3-dimensional composite modeling to enhance structural integrity. The primary objective of this thesis is to scientifically justify the design and validation of an integrated rotor hub and shaft using efficient FEM and integration strategies, with the aim of maximizing the durability of a $150kW$ radial flux SPMSMs spinning at $20,000 rpm$. The integrated topology optimization is evaluated using a multiphysics platform alongside studies on motor assembly eigenfrequency. By employing the integrated approach and utilizing AISI 4340 for both the shaft and rotor hub, a weight reduction of $1.84kg$ is achieved, eliminating the need for standard components such as balancing end clamp plates, locknuts, and washers. Furthermore, introducing a carbon fiber sleeve enhances structural integrity, thereby reducing adhesive stress. The design and optimization of the rotating components ensure that the maximum von Mises stress is $50\%$ lower than the material's yield strength. Reduced masses lead to lower centrifugal forces, thereby diminishing radial stress and promoting component and assembly stiffness. / Thesis / Master of Applied Science (MASc) / This thesis aims to increase the reliability and power density of a surface-mounted permanent magnet synchronous machine (SPMSMs), a commonly used traction motor in the automotive and aerospace industries. One of these machines' main challenges is designing their components to withstand the high mechanical loads caused by their fast rotational speeds. The studies performed in this thesis use a computer modeling technique called Finite Element Modeling (FEM) to strategize and design an integrated rotor hub/shaft by maximizing the durability of a 150kW radial flux SPMSMs rotating at 20,000 rpm. Upon evaluating the integrated design using a variety of physics-based simulations, the design was found to save 1.84kg in weight, reducing centrifugal forces and improving the overall stiffness of the motor assembly. This research could lead to more efficient and durable electric SPMSMs for various applications.

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