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Fig. 1. Construction of a SAG mill with the stator and the rotor
separately mounted.
I. I NTRODUCTION
HE production of cement requires machinery for crushing the cement clinker produced by a rotary kiln and
to subsequently grind it to powder. The same procedure is
followed in copper mining [1]. Crushed copper ore is ground
to powder, from which the copper content is extracted in a
chemical process.
The production of fine powder is efficiently done in semiautonomous grinding (SAG) mills. Fig. 1 shows the construction
of a SAG mill [2]. It consists of a rotating hollow cylinder of
about 12 m in diameter. Two sets of bearings in ring-shaped
structures support the cylinder to let it rotate. State-of-the-art
gearless drives have about 76 salient poles attached around
the mill cylinder. They form the rotor of a separately excited
Manuscript received May 22, 2014; revised July 22, 2014, August 29,
2014, and October 19, 2014; accepted November 7, 2014. Date of
publication December 9, 2014; date of current version May 8, 2015.
J. Holtz is with Wuppertal University, 42119 Wuppertal, Germany
(e-mail: j.holtz@ieee.org).
G. da Cunha, N. Petry, and P. J. Torri are with WEG Automaao,
89256-900 Jaragu do Sul, Brazil.
Color versions of one or more of the figures in this paper are available
online at http://ieeexplore.ieee.org.
Digital Object Identifier 10.1109/TIE.2014.2378732
Fig. 2.
0278-0046 2014 IEEE. Translations and content mining are permitted for academic research only. Personal use is also permitted, but republication/
redistribution requires IEEE permission. See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
HOLTZ et al.: CONTROL OF SALIENT-POLE SYNCHRONOUS MACHINES USING SYNCHRONOUS OPTIMAL PWM
3373
Fig. 3.
Brazil.
Fig. 4.
3374
Fig. 5.
(3)
q (s) = Lq
L2qQ s
R Q + LQ s
mmm
(4)
(5a)
(6a)
(6b)
Equations (5) and (6) serve for computing the harmonic currents generated by the three-level inverter voltage waveforms.
III. S YNCHRONOUS O PTIMAL PWM
d = Ld id + Lf d if + LDd id
A. Modulation Index
q = Lq iq + LQq iQ
D = LD iD + LdD id + Lf D if
Q = LQ iQ + LqQ iq
f = Lf if + Ldf id + LDf iD .
d (s)
Lf LD L2f D Ld L2dD Lf L2f d LD +2Lf d LdD Lf D
s2
=
2
2
Lf Ld Lf D s +(Rf LD +RD Lf )s+Rf RD
(Rf LD +RD Lf )Ld L2f D RD L2dD Rf s+Ld Rf RD
+
Lf Ld L2f D s2 +(Rf LD +RD Lf )s+Rf RD
(2)
4ud
(8)
is the fundamental voltage at the six-step operation of the inverter. The modulation index ranges within 0 m 1, where
the unity value corresponds to the six-step mode.
HOLTZ et al.: CONTROL OF SALIENT-POLE SYNCHRONOUS MACHINES USING SYNCHRONOUS OPTIMAL PWM
3375
B. Current Harmonics
The machine currents are composed of a fundamental current
component i1 and the harmonic currents ih generated by the
inverter switching. Harmonic currents substantially contribute
to the machine losses. Minimizing the RMS harmonic current
is therefore an objective of synchronous optimal PWM [15].
The RMS harmonic current, i.e.,
1
[i(t) i1 (t)]2 dt
(9)
Ih rms =
T
(T )
does not only depend on the respective pulse pattern but also
on the internal impedance of the machine. This influence is
eliminated when the distortion factor is used as a figure of
merit. The distortion factor is derived from the normalized RMS
harmonic content, i.e.,
2
Uk
l
1
Ih rms
1
2
=
Ik =
(10)
I1
I1
U1
k1 l
k=2
k=2
1h rms
Ih rms six-step
(11)
fs
f1
(12)
0 1 t /2
ua (1 t) = ua (1 t ),
0 1 t .
(13a)
(13b)
(14)
for every steady-state operating point N, m defines the respective sets of N switching angles ai per fundamental period
T1 = 2/1 . The optimal sets are precalculated offline and
stored in a memory table of the controlling microprocessor. The
switching angles are retrieved during the operation in real time
and used for inverter control.
A pulse pattern is now considered the superposition of alternating positive and negative voltage steps at the respective
switching angles i . The waveform of phase a is examined in
the following. Waveforms ub and uc , as shown in Fig. 6 for
N = 5, are identical except for their respective phase displacements. The fundamental voltage component of the pattern is
ua1 (i ) =
N
4ud
(1)i+1 cos(ai ).
i=1
(15)
(1)i+1 cos(ai )
(16)
i=1
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4ud
1
n=1 6n 1
1
4ud
i+1
(1)
cos(6n 1)i
udk =
n=1 (6n 1)
i=1
(17)
i=1
uqk
n 1, . . . , .
(18)
(20a)
(1) 2 (31) cos ((6n 1)1 t)
1
4ud
=
(1)i+1 cos(6n 1)i
n=1 (6n 1)
i=1
1
(20b)
Pulse pattern optimization is done offline assuming steadystate conditions. The harmonic currents are represented by discrete spectra ik , k = 1 6n, n 1, . . . , . They are computed
by replacing Laplace operator s jk1 in (3) and (5). The
harmonic components of the machine current are then with
good approximation obtained by solving (5) for the respective
currents as follows:
idk =
uqk jk udk
1 d (k 2 + 1)
(21a)
iqk =
udk j k uqk
.
1 q (k 2 + 1)
(21b)
(22)
uh
(1 t) =
4ud
1
n=1 6n 1
i=1
exp (1)
j6nw1
(23)
E. Optimization Procedure
(19)
fs max
fs max
m
.
N +1
N
(24)
HOLTZ et al.: CONTROL OF SALIENT-POLE SYNCHRONOUS MACHINES USING SYNCHRONOUS OPTIMAL PWM
Fig. 7.
3377
6) The resulting function i (m) will show various discontinuities. These will cause undesired transients during
the operation of the drive. They are eliminated by a
postoptimization procedure.
3378
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http://www.cleantechfinland.com/content/
outotec-presents-worlds-largest-sag-mill
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HOLTZ et al.: CONTROL OF SALIENT-POLE SYNCHRONOUS MACHINES USING SYNCHRONOUS OPTIMAL PWM
3379
Paulo Jos Torri received the Diploma in electrical engineering from the Federal University
of Santa Maria, Santa Maria, Brazil, in 1984
and the M.Sc. degree in electrical engineering
from the Federal University of Santa Catarina,
Florianopolis, Brazil, in 1986.
In 1987, he joined WEG Automaao, Jaragu
do Sul, Brazil, where he worked on the research and development (R&D) of products for
power electronics systems, drives, and electric
machines. He is currently the Manager of the
R&D Department, WEG Automaao, where he is responsible for the
development of products in the field of low-voltage and medium-voltage
power converters, high power, and renewables.