Compact Realisation of PWM-VSl Current Controller for PMSM Drive

Application using low cost standard microcontroller

Lars Norum, Wala'emar Sulkowski, h s Arne Aga

Department of Electrical Engineering and Computer Science

The Norwegian Institute of Technology, N-7034 Trondheim. Norway
Phone: + 47 7 594241 Tekfax: 4 7 7 59 42 79

Abs;ract:
This paper presents a completely digital realisation of PWM-
VSI current controller for PUSU drive application. l%c
current controll algorithm, including &coupling and
compensationfor mrrschinc parameters variation, is presented.
Thc controller is implemented in a single-board control
computer which is based on a new 16 bit microcontroller.
Experimental results are included

Introduction
The high efficiency, combined with compact design,
make permanent magnet excited AC motors auractive in high
performance electric drives. In tool machine servo and mobile
applications, the torque requirement is usually high for low
speeds, but allowing for decreased toque at higher speeds, i.e. Gw&&mmh
requirements which typically are met by field weakening in 'Ihe d-q transformed PMSM model in per unit values
traditional motor drives. As explained in [1,2,9], the salient with basic assumption that reference frame d-axe is fmed with
pole permanent magnet synchronous motor (PMSM) is an rotor permanent magnet flux Ymcan be described as a set of
alternative for drives where toque characteristic with flux
weakening isqmted. nonlinear differential equations with current and temperahue
dependent parameters [6.7].
Digital current controller and voltage modulation can
only give high bandwith cutrent control when the execution
time is short.In neported digital current controllers, either fast
signal processors with additional hardware devices or ASKS
[8] have been used to obtain satisfactory calculation speed.
These solutions give additional complexity in controller
hardware and quite a bit of software challenges. However, the
perfomance of sin& chip microcontrollersimproves rapidly.
'Ihispaper p-ts a PMSM drive with a fully digital regulator (3)
implemented in a microcontroller with on-chip peripherals
without additional processing circuits. (4)
To use the onchip embedded microcontroller peripherals
to realize the PWM output it was necessary to use a simple
and' fast modulation algorithm, suitable for digital
implementation. For accurate dynamic current control the
coomller structure should take into account existing PMSM
nonlinear properties i.e. currant dependent reactances.
The piesented control algorithm have been tested on an
experimental 2.8 kW PMSM drive. The applied control strategy where: ud. uq, b.iq. Yd, Yq are the complex space-vector
is presented, but the paper mostly focuses on the realization of d-q components for voltage.cum?nt and flux
the digital controller and the performance obtained. The drive respectively; q and % are d-q axis synchronous
is schematically drawn in figure 1. reactances.

0-7803-0695-3192$3.00 '1992 IEEE

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 + e
tII
Fig.2. The structure of PMSM mathematical model.
The Emf of rotation in electrical part and torque equation
in mechanical part are sources of nonlinearity. The core
nonlinear property (saturation) affects in form of Xd and x4
changing with stator current. Assuming that current control
strategy keeps id current component on zero level the
influence of the xd parameter variations can be neglected. The
dynamic changes of IYmI affects as disturbance on id as Emf
of transformationrepresented as dLy, derivative block.
Due to requirement for good dynamic and static
performance in different operation regimes (as acceleration,
breaking, field weakening) the current controller needs to
guarantee d-q stator current components decoupled control.
This implies controller structure inherently based on
machines mathematical model shown in fig.2. To keep stator
current components separated the nonlinear regulators with
decoupling compensation terms were applied.
As a result of controller fixed constant reactances
values Xbef and Xqref, the cross disturbances and steady state
errors occurs. Figure 8a shows family of the +
current
responces to the +ref step changes.
The current regulators amplification factor Kq
calculated for the constant reactances values[6,7] is inadequate
for the whole used currents range. The proposed decoupling
is based on knowlege of & stator current dependent machine
parameters. To make fast responce and avoid overshooting the
amplification of current regulator Kq , reactances Xdref and
xqRf were stored as $ stator current dependent nonlinear
functions values in look-up tables.
Calculated stator voltage vector d-q components Vdref and
Vqref and rotor position 8 were used as a input values for
PWM voltage vector averaging method algorithm [ 16,171.
68 1
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r5IUf
\\
Fig 3. The algorithmfor current controllerfor salient-pole PMSM
-
COMPACT REALISATION
An experimental PMSM drive with a commercial 2.8kW
salient pole motor and fully digital current controller has been
built. The motor data listed in the appendix is given by the
manufacturer [18]. The motor is supplied from a three phase
inverter with IGBTswitches.
The current controller algorithm is implemented in a
Siemens SAB80C166 [20] microcontroller. The
microcontroller is sited to a evaluation board from ertec Gmbh
[21] supporting RAM, ROM, addressing logic and clocking
crystal. It is a high performance single-chip microcontroller
with ten 10 bit A/D converter channels, sixteen capture and
compare channels based on two 16-bit time bases. The
capturdcompare units have a resolution of 400ns. There is a
god priority scheme for the interrupt system, with 40Ons
interrupt response. Interrupts for data transfer can be serviced
by cycle stealing direct memory access by the pheriperal event
controller (PEC). The 32kB RAM and 32kB ROM give suffi-
cient space for the programs, look-up tables and also for
logging of control variables and measurements. User
communication and presentation of monitored data is
performed on a PC connected through the RS232 port. Figure
4 gives an overview of the measurement and calculation hard-
ware. For simplicity, only functions which are necessary for
this drive are shown.
A resolver on the shaft provides rotor position. Resolver
to digital (WD)conversion is performed by an AD2S80KD
[22]. The maximum speed limits the resolution of position to
12 bit.
 Fig .4 . Logic bloc diagram. overall drive system
Additional sample and hold ( S / H ) circuits ensured
simultaneous sampling of the measured currents. The currents
were measured with LEM transfoshunts in two phases only,
since no zero sequence currents are present. The switching
ripple in the currents made it necessary to filter the
measurements to avoid aliasing. Time delays in the current
control loop may cause error in torque control at higher
speeds, thus the phase shift caused by the filter should be mini-
mized. A low pass filter with lkHz bandwith reduced the
switching ripple to less than 1% of the rated current, which
was considered as acceptable.
For practical reasons, the a l l drive control circuits have
been located on three standard Europe cards. However, the
necessary circuits cover an area smaller then size of a double
Europe card.
Figure 5: Block diagram of the controller hardware.
A high performance high bandwith current controller for
this drive requires a sampling rate of about 5-2OkHz. With the
Siemens SPB8OC166 microcontroller a sampling rate of
lokHz was accomplishedBven if the SAB8Oc166 is a fast
device efficient programs had to be made to accomplish this
sampling thquency. The code for the current control loop, and
for communication with terminal PC is written in the ASM166
assembler language.
682
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The functions in the microcontroller block in fig.4 are
implemented as two tasks in the sofhvare. One containing the
current controller, logging of measured values and generation
of current references. The other task takes care of
communication with the PC.
The current loop routine is driven by a software interrupt
starting every 1OOp. In this interrupt AID conversions of the
two current measurements are initiated, speed is calculated
and filtered from measured position values.
When the A/D conversions are finished an interrupt
service rutines containing the main code for the current loop
starts. The cuttent measurement are first transformed to dq-
frame. Nonlinear values for decoupling and controller
parameters are looked up according to the state of the
refemce currents. Then the algorithms for the axis current
controllers are executed. Calculations of decoupling terms and
Emf compensation for the controller outputs gives the dq-
frame voltages to be applied to the motor. The dq-frame
voltages are transformed to 3 phase voltage values that are
used to calculate switching time points for the voltage PWM
modulator.
Fig.6. Timing relations in the current loop.
 41.4 b)

12-
1.I
1
12 ~ -I ~ -
1-

4% i i i i io
N
i2 i4 i6 ia A
Fig.7. Responses in q-axis current to diflerent changes in q-axis current reference iqreffor a) constant
controller parameters b) iq dependent controller parameters

At the end of the current loop routine the time instant for
the next software interrupt is loaded. Logging of measured and
calculated values can also be performed. Finaly currents
references are generated.
The method for currents reference generation can be
chosen from terminal PC. The references can be read from a
tables or calculated by the speed controller. The speed
controller reference is generated in about the same fashion as
the current conmller references.

EXPERIMENTAL RESULTS

The speed and current controller implemented in by the

Simens microcontroller SAB8OC166 was tested on 2.8kW
PMSM drive (see motor data [18]) with IGBT voltage source
inverter. The sampling time for speed and current control was
loop.
The performance of the current controller can be
described in classical way by the response to a reference step
change. The rise time and the overshoot of the current
response are trade offs when tuning the drive parameters.
Fig.7b. shows the iq stator current response family to reference
step change for proposed iq dependent nonlinear parameter
tuned current controller. This allows for no overshoot
operation and c m n t rising time less then lms. Stator currents
were measured by LEM elements transformed and stored at
microcontroller memory by part of control algorithm. Logged
data was analysed and presented by using Matlab routines in
host PC.The more detailed test is shown in figure 8. where the
current controller response for one per unit step change is
shown. The proper &coupling and Emf compensation is
proved by the no transients behaviour in d-axis and zero steady
state exror in both d and q axis current regulators outputs. Fig.8. The current controller responsefor iqrefone per unit step change
The current loop dynamic performance, to sinusoidal a) iq current resppnse b) idcurrent response c) output of id current
+
perturbations of c m n t reference, is shown in figure 9 as a regulator d) output of iq current regulator.
amplitude and phase diagram.

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 loo c [l]
iiw
-120
-100
-140
102
Fig.9.. Thc dynamicallyperjorm~ccof the iq cyrrQIl controller
The dynamically performance of the whole drive with
speed and current control at no load condition is shown on fig
10. By applying a constant reference signal with a small
sinusoidal component added, the mechanical speed bandwith
was measad. The mult shows god performance up to
lOOHz with the filter in speed measucement limiting the
bandwith.
: $Fig.10. The dyMmic.CdlypCrfonC oflhe whole drive with speed and
lb
current control at no load conditwn
CONCLUSION
The realisation of a high performance fully digital
PMSM drive requks a current controller with &coupling and
compensations for nonlinearities. By using a low cost
microcontroller this can be realized in a compact form. Fast
execution time, and though high speed and current bandwith.
can be achived by effecient programing. With this solution,
10- m,.mg frequency for the current control loop was
obtained. The current rise time to nominal value, without
overshoot in the quadrature axis, and speed bandwith up to
lOOHz was obtained.
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Motor data

M.nuf.cturer Model
Industrial Drlves [*+I B-206.c
Ratedcumnt (m) Irated 10 A
Rated voltage (rms, 1-1) hl?d 250 v
Ratedmue TPIICA 6.83Nm
Wspced %ted 4900rpm
D m t axis inductance 4 5.33 mH
Quadratlirepxlripdll- Lq 13.W
Back cqf(rms 1-1) KE 31.1Vkrpm
Moment of inertia I 2.512 .IO4 knm2

685

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