This thesis deals with the modelling, simulation and control of Permanent Magnet Synchronous Machines (PMSM) used specially in electric and hybrid vehicles. With the availability of fast semiconductor switches and high speed processors, Vector controlled drives are gaining popularity. One disadvantage of this type of control however, is the need for high cost, high resolution sensors (encoders) for determining the rotor position. Position sensorless schemes have evolved over a decade and this thesis addresses this issue. Two schemes have been proposed for the elimination of encoders in vector controlled drives. One is a semi-sensored scheme wherein a combination of low cost hall sensors and a digital position estimator gives the position information. In the second scheme, a reduced order observer called Luenbuerger observer has been used to estimate speed and rotor angle. The problem of finding rotor angle at standstill has also been dealt with. This thesis also discusses the difference in simulating a BLDC (Brushless DC) and PMSM machine. An experimental set-up consisting of MOSFET inverter and TMS320LF2407 DSP based digital controller was developed in the laboratory to implement the control algorithms. Two PMSM machines were procured from a two-wheeler manufacturer to set up the rig. Simulations were done in MATLAB/ Simulink (Off-line) and Xilinx XC3S400 (in real-time) to verify the concepts. Simulation and experimental results are finally compared.

This thesis is focused on problematics of control of brushless DC motor in the sensor and also in the sensorless mode. Also it interprets possibilities of BLDC motor control with one faulty sensor and derivation and simulation of mathematical model. First part mentions options of rotor position sensing as well as existing methods of sensorless BLDC motor control. Second part describes control algorithms of sensor and sensorless motor control realised on device dSPACE and also realisation of faulty sensor control algorithm. Third part deals with derivation of mathematical model, its realisation using Matlab Simulink software and identification of its parameters. Last part concludes results and compares control methods used on the real system.

Algorithms of sensorless control of surface permanent magnet synchronous motors are discussed in the dissertation thesis. A method for position and speed estimation in high-speed region based on model reference adaptive system is described. Furthermore, classical approach using Kalman filtering was verified. Kalman filter expected the rotor speed to be constant as a modification of model using variable speed approach. These algorithms are not able to work at low speed region, thus a new method was proposed. This method is designed on extended Kalman filtering and uses the model which describes the stator inductance changes in - coordinates. At motor start, knowledge of initial rotor setup is required. The algorithm for initial rotor angle using high frequencies injected into the motor was proposed.

De nos jours, les véhicules électriques et hybrides ont suscité un très grand intérêt en raison de préoccupations environnementales et énergétiques. Dans ces véhicules, les machines électriques utilisées sont des machines conventionnelles asynchrones et synchrones à aimants permanents. La machine à réluctance variable est une technologie candidate potentielle pour les chaînes de traction électriques et hybrides. Cette machine conçue sans aimants et redondante peut réunir la robustesse et le faible coût de la machine asynchrone aux bonnes performances de la machine synchrone à aimants permanents. Dans ce contexte, le premier objectif de cette thèse est de proposer des stratégies de commandes robustes de la machine à réluctance variable par la prise en compte des contraintes des chaînes de traction électriques en vue de réaliser une étude comparative des performances. Dans cette étude, les commandes proposées sont les commandes classiques de type PI, les commandes par mode glissant et les commandes par mode glissant d'ordre supérieur. Le deuxième objectif consiste à développer des observateurs d'état pour la commande sans capteur de position mécanique de la machine à réluctance variable. Des observateurs robustes basés sur la théorie du filtre de Kalman étendu et les modes glissants sont synthétisés pour atteindre cet objectif. Enfin, le troisième objectif est de faire une analyse des défauts électriques de type circuit ouvert de l'étage électronique de puissance par l'approche signal afin de développer une méthodologie de détection et de localisation automatique de ces défauts. / Nowadays, electric and hybrid vehicles are gaining increased attention due to environmental and energy concerns. In these vehicles, the electrical machines used are the conventional machines, namely induction and permanent magnet synchronous machines. The switched reluctance machine is a potential candidate technology for electric and hybrid drivetrains. This machine designed without magnets and redundant windings, can combine the robustness and low cost of induction machines to the good performance of permanent magnet synchronous machines. In this context, the first objective of this thesis is to propose robust control strategies of the switched reluctance machine, taking into account the constraints of electric vehicles in order to make a comparative performance study. In this study, PI control, sliding mode control and higher order sliding mode control are proposed. The second objective is to develop state observers for sensorless control. Robust observers based on extended Kalman filter theory and sliding modes are synthesized to achieve this goal. Finally, the third objective is to make an analysis of electrical open-circuit faults of the electronic power stage using the signal approach in order to develop a methodology of automatic fault isolation.

Hybrid electric vehicle (HEV) concept has, combining conventional internal combustion engines and electric drives, gained more and more interest due to its environmental friendly features. A PMSynRel based electric drive is considered as a good option due to its high torque density and high efficiency. To reduce the overall cost of HEVs, the position resolvers can be replaced by Hall-sensors or using sensorless control. However, the dynamics of such electric drives may be degraded. The main objective of this MSc project is to develop torque dynamics of such electric drives when operating with/without a position sensor. The developed torque dynamic can be used to analyze the limits of hall senor/sensorless strategy when, e.g. anti-oscillation control isrequired. The torque dynamic is presented as a matrix based transfer function extracted from the speed responses and torque responses using Identification Tool Box in Matlab. Firstly, the transfer function was derived by means of simulations in both time and frequency domains. Secondly, similar procedures were applied to extract the transfer functions based on the experimental results.

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Hybrid stepper motors are a common type of electric motor used throughout industry thanks to its low-cost, high torque at low speed and open loop positioning capabilities. However, a closed loop control is often required for industrial applications with high precision requirements. The closed loop control can also be used to lower the power consumption of the motor and ensure that stalls are avoided. It is quite common to utilise a large and costly position encoder or resolver to feedback the position signal to the control logic. This thesis has explored the possibility of using a low-cost position sensor based on Hall elements. Additionally, a sensorless estimation algorithm, using only stator winding measurements, has been investigated both as a competitive alternative and as a possible complement to the position sensor. The thesis work summarises and discusses previous research attempts to adequately measure or estimate and control the hybrid stepper motors position and load angle without using a typical encoder or resolver. Qualitative results have been produced through simulations prior to implementation and experimental testing. The readings from the position sensor is subject to noise, owing to its resolution and construction. The position signal has been successfully filtered, improving its accuracy from 0.56° to 0.25°. The output from the sensorless estimation algorithm is subject to non-linear errors caused by errors in phase voltage measurements and processing of velocity changes. However, the dynamics are reliable at constant speeds and could be used for position control.

Thesis (PhD)--Stellenbosch University, 2014. / ENGLISH ABSTRACT: The position sensorless controllability of the reluctance synchronous machine (RSM) is investigated in this thesis with the focus on industry applications where variable and dynamic torque is required from startup up to rated speed. Two low speed as well as one medium to high speed position sensorless control (PSC) method for RSMs are investigated. These methods are extended to operate in the entire rated speed region with a hybrid PSC structure that makes use of phase locked-loop synchronisation and a hysteresis changeover method. It is shown in this thesis that PSC of the lateral rib rotor RSM is not possible from zero up to ± 0.2 p.u current. It is shown through finite element (FE) simulations that PSC of the ideal rotor RSM however, is possible at zero reference current. A novel construction method is used to build two ideal rotor RSMs. Measured flux linkage curve results of the ideal rotor RSMs correlate well with simulation results and it is shown that the electrical angle of the machine can be tracked successfully at zero reference current. The FE simulation package is used to compare the saliency of the RSM on a per-unit scale to three types of field intensified permanent magnet (FI-PM) synchronous machines and a field weakening interior permanent magnet synchronous machine. It is shown that the saliency of the RSM is larger than that of the investigated PM machines from zero up to rated load. It is thus concluded that the RSM is well suited to saliency-based PSC (SB-PSC) methods, which are used to control synchronous machines at startup and low speeds. The hybrid PSC methods developed in this thesis, are tested and evaluated on three proposed industry applications. The first is a reluctance synchronous wind generator with an inverter output LC filter. The LC filter allows long cables to be used and reduces the voltage stress on the stator windings of the machine. The combination of the LC filter and hybrid PSC method allows the power electronics and controller to be stationed in the base of the turbine tower. A new stator quantity estimation method is derived to omit the need of current and voltage sensors on the machine side of the LC filter. Good maximum power point tracking laboratory results are shown with the high frequency injection-assisted hybrid PSC method. The second application investigated is a position sensorless controlled variable gear electric vehicle (EV) RSM drive. Simulation and measured results show good torque capabilities of the position sensorless controlled EV RSM. It is shown through simulation results that the fundamental current harmonic is dominant in the demodulation scheme of the high frequency injection position sensorless control (HFIPSC) method due to the high current rating of the proposed RSM. The HFI-PSC method is extended to reduce the effect of the fundamental current harmonic in the demodulation scheme without adding any additional filters. The final investigated application is a novel mine scraper winch, which uses two position sensorless controlled RSMs to retrieve ore from the blast site underground. The new design improves on the safety, efficiency and durability of the current scraper winch design. Measured results show that the position sensorless controlled winch RSM is able to deliver rated startup torque with both investigated SB-PSC methods. Finally an automation method is implemented and tested to limited the applied force on the scraper and automatically free itself when stuck. / AFRIKAANSE OPSOMMING: Die posisie sensorlose beheer eienskappe van die reluktansie sinchroonmasjien (RSM) word in hierdie tesis ondersoek met die fokus op industriële toepassings waar varierende dinamiese draaimoment vereis word vanaf stilstand tot by ken spoed. Twee lae spoed- en een ho¨e spoed posisie sensorlose beheer (PSB) metodes vir RSMe is ondersoek. Hierdie metodes is uitgebrei om twee hibriede PSB metodes to skep wat die RSM van stilstand tot by kenspoed posisie sensorloos kan beheer. Die ontwikkelde hibriede metodes maak gebruik van ’n histerese oorskakelings skema en fase geslote lus sinchronisasie Daar word in hierdie tesis bevestig dat die laterale rib RSM nie beheer kan word met die geondersoekte PSB metodes by nul stroom nie. Eindige element simulasie resultate wys egter daarop dat die ideale rotor RSM wel beheer kan word met die geondersoekte metodes by nul stroom. ’n Nuwe konstruksie metode is voorgestel om twee ideale rotor RSMe to bou. Gemete vloed omsluiting kurwes resultate korreleer baie goed met dié van die eindige element simulasies. Gemete resultate wys ook daarop dat PSB van die nuwe masjiene moontlik is by nul stroom. ’n Eindige element pakket is gebruik om die speek-koëffissiënt van die RSM te vergelyk met drie tipes veld-versterkte permanent magneet masjiene, asook een veld verswakte permanent magneet versinkte masjien. Die simulasie resultate wys dat die RSM se speek-koëffissiënt hoër is as die van die geondersoekte permanent magneet masjiene. Die RSM is dus geskik vir speek-koëffissiënt georienteerde PSB metodes, wat hoofsaaklik by stilstand en lae spoed gebruik word. Die ontwikkelde hibried PSB metodes is getoets en geëvalueer met drie voorgestelde industriële toepassings. Die eerste is ’n reluktansie sinchroon wind generator met ’n omsetter uittree laagdeurlaat filter. Die laagdeurlaat filter laat toe dat langer kabels vanaf die omsetter na die generator gebruik kan word. Die kombinasie van die laagdeurlaat filter en die PSB metodes laat toe dat die drywingselektronika en die beheerders in die toring basis geplaas kan word. Dit kan die gewig van die nasel verminder. Goeie maksimum drywingspunt volging laboratorium resultate word getoon met die hoë frekwensie ondersteunde hibried PSB metode. Die tweede geondersoekte toepassing is ’n posisie sensorlose beheerde, varierende ratkas elektriese voertuig RSM. Goeie simulasie en gemete draaimoment resultate van die RSM word getoon. Simulasie resultate toon dat die fundamentele q-as stroom harmoniek dominant is in die demodulasie skema van die hoë frekwensie PSB metode, as gevolg van die hoë ken stroom van die motor. Die hoë frekwensie PSB metode is uitgebrei om die fundamentele stroom harmoniek te onderdruk in die demodulasie skema sonder om enige filters by te voeg. Die finale toepassing is ’n nuwe myn windas wat van twee posisie sensorlose beheerde RSMe gebruik maak om klippe ondergronds te verplaas vanaf die ontploffings area. Die voorgestelde ontwerp verbeter die huidige ontwerp ten opsigte van die veiligheid, energie effektiwiteit en robuustheid. Gemete resultate wys dat ken draaimoment moontlik is met altwee speek-koëffissiënt metodes. ’n Automasie metode, wat die maksimum draaimoment op die windas beperk en automaties homself bevry indien hy vasval, is voorgestel en geëvalueer.

L’objectif de cette thèse est de proposer des stratégies de diagnostic dans le cas d'une commande en vitesse sans capteur mécanique (vitesse/position) d’une machine asynchrone triphasée en présence de défaut d'ouverture des transistors IGBT (Insulated Gate Bipolar Transistor) de l’onduleur. Une étude de l’impact de ces défauts sur les performances de ces structures sans capteur mécanique en termes de stabilité et de robustesse des observateurs en mode dégradé est présentée. Un observateur par mode glissant (Sliding Mode Observer) à base de modèle est développé et validé expérimentalement en vue de la commande sans capteur mécanique de la machine asynchrone triphasée. Les signaux issus de l’observateur (approche modèle) sont utilisés conjointement avec ceux mesurés (approche signale) pour former une approche hybride de diagnostic de défauts des transistors IGBT de l’onduleur. Un observateur par mode glissant d’ordre 2 à base d’un algorithme Super-Twisting est ensuite développé en vue d’améliorer la stabilité et d’assurer la continuité de fonctionnement du système en présence d'un défaut afin de pouvoir appliquer une stratégie de commande tolérante aux défauts dans les meilleures délais et conditions de fonctionnement. / The main goal of this thesis is to propose diagnostic strategies in the case of a sensorless speed control of a three-phase induction motor under an opened-switch or opened-phase fault. A qualitative analysis of the performances, in terms of stability and robustness, of sensorless control applied to the electrical drive in pre-fault and post-fault operation modes is presented. A model-based sliding mode observer is developed and experimentally validated for sensorless speed control of three-phase induction motor. The signals issued from the observer (model approach) as well as the measured ones (signal approach) are simultaneously used to form a hybrid approach for inverter open-switch fault detection and identification. A second-order sliding mode observer based on Super-Twisting algorithm (STA) is also developed to improve the stability and to ensure the continuity of operation of the electrical drive especially during transient states induced by the fault, permitting thus to apply the reconfiguration step without losing the control