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Abstract —This paper looks at the requirements and adequately scheduled maintenance, sensor reduction, fault
challenges of designing the Dual Three-Phase Permanent Magnet reconfiguration, and improved reliability [1], [2], [3], [4].
Brushless Machine (DTPPMBLM) for the driven The increasing interest has been a consequence of the
electromechanical servoactuator (EMA) for aerospace
advantages of permanent magnet brushless machine compared
applications. The main goals of the design are a high level of
actuator integration in order to minimize weight and volume, with the conventional dc motors. These advantages are mainly
fault tolerance, and high reliability. This paper addresses the the result of the elimination of the physical contact between
modeling problem associated with DTPPMBLM with uniform air the mechanical brushes and commutators. Among the
gaps that operate in a range where magnetic saturation may exist. numerous types of brushless machine, the permanent magnet
The mathematical model includes the effects of reluctance brushless machine (PMBLM) has emerged as the one with the
variations as well as magnetic saturation to guarantee proper
highest potential in high-performance applications [5], [6], [7],
modeling of the system. An experimental procedure is developed
and implemented in a laboratory environment to identify the [8]. For such high-performance applications, the mathematical
electromagnetic characteristics of the DTPPMBLM in the model of PMBLM must include the effects of reluctance
presence of magnetic saturation. It is demonstrated that the variations and, most importantly, the magnetic saturation
modeling problem associated with this class of the DTPPMBLM whose existence is inevitable when large torques are generated.
can be formulated in terms of mathematically modeling a set of This paper presents a method of constructing accurate
multidimensional surfaces corresponding to the electromagnetic DTPPMBLM models where both magnetic saturation and
torque function and the flux linkages associated with the machine
reluctance variation effects have been accounted for. It is
phase windings. The accuracy of the mathematical model
constructed by the developed method is checked against
demonstrated that an accurate description of the characteristics
experimental measurements. of DTPPMBLM may be obtained by modeling the torque
Index Terms—electromechanical servoactuator, Dual Three- function and the flux linkages associated with the stator phase
Phase Permanent Magnet Brushless Machine, mathematical windings. However, for the mathematical model to be
model computationally feasible in real-time motion control
applications, a method that is used to reduce the complexity of
I. INTRODUCTION the model without sacrificing its accuracy is presented. If the
mathematical model is excessively complex, one will have to
The advent of electromechanical actuation promises
resort to incorporating look-up tables in real-time motion
improved reliability, performance, controllability, and
control applications [9], [10]. To keep the complexity of the
efficiency as well as reduced maintenance in high-power mathematical model within feasible limits, through physical
applications that have historically been serviced by hydraulic reasoning, it is demonstrated that the modeling problem may
systems. Potential applications for electromechanical actuators be reduced to that of identifying a set of 2-D surfaces. Based
are control surface positioning in aircraft and sea vehicles, on this, a practical method for constructing accurate models of
thrust vector control in spacecraft, and a host of others. a DTPPMBLM is outlined and shown to be effectively
Electric machines have played a crucial role in the evolution implementable in a typical laboratory environment.
of the automotive industry. The EMA configuration in this The paper is organized as follows. In Section II, the
work consists of a permanent magnet brushless machine, fundamental electromechanical characteristics of the
reduction gear, and ballscrew. Often, multiple machine are DTPPMBLM are formulated in terms of a set of mathematical
employed for redundancy and a net reduction in the inertia to relationships. Section III sets forth some analytical results that
torque ratio. Such a reduction minimizes actuator impedance are used to demonstrate the importance of including the effect
and hence improves system efficiency. However, the use of of reluctance variations in the DTPPMBLM model. Section IV
multiple machine requires control to appropriately balance deals with the problems associated with the modeling of the
load across the machines. The appropriate load distribution can saturation nonlinearity for DTPPMBLM. Section V presents
be based upon machine health such that machine showing an experimental procedure used in identifying the
signs of impending failure may be operated at reduced power mathematical model of DTPPMBLM. The results
levels to improve their life expectancy. Other benefits may be corresponding to the set of experiments that have verified the
gained from a health monitoring system as well: more validity of the methods described in the earlier sections are
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978-1-4799-5162-8/14/$31.00 2014 IEEE
presented in Section VI. Finally, some concluding remarks are
)3 Gsy 3
made in Section VII. )2 Gsy 2
Gsy1
II. MATHEMATICAL RELATIONSHIPS OF THE DTPPMBLM
)1 Gsp1 Gsp 2
Gsp 2 Gsp1
A. Model of Magnetic equivalent circuit Gsp 3
Gsp 3
Gry
Gsy2 and Gsy3; stator teeth permeance Gsp1 ૠ Gsp2 and Gsp3;
Fig. 1. No-load Magnetic equivalent circuit of DRPMBLM
closed loop ĭ0ૠĭ1ૠĭ2 and ĭ3; the armature reaction MMF
of winding NI. )3 Gsy 3
The no load magnetic equivalent circuit of DRPMBLM is )2 Gsy 2
given in Fig. 1. The rating load magnetic equivalent circuit of Gsy1
DRPMBLM is given in Fig. 2. )1 Gsp1
Gsp1 Gsp 2
Gsp 2 Gsp 3
Gsp 3
NI
Gu Gm Gu
NI
Gr
Gr )0
Fr
Fr
Gry
Fig. 2. Rating load Magnetic equivalent circuit of DRPMBLM
ª 1 2 1 1 º
«G G G
G
0 0 » ª ) 0 º ª Fr º
« m r ry m
»« » « »
« 1 1 2 2 1 2 1 »« » « » (1)
« ( ) 0 » « )1 » « 0 »
« Gm Gm Gu Gsp1 Gsy1 Gsp1 Gsy1 »« » « »
« 2 1 2 2 1 1 2 1 »« » « »
« 0 ( ) ( ) » «) 2 » «0 »
« G sp1 G sy1 G sp1 G sp 2 G sy1 Gsy 2 G sp 2 G sy 2 »« » « »
« « » « »
« 2 1 2 2 1 1 »» « » « »
0 0 ( ) ) 0
«¬ Gsp 2 Gsy 2 Gsp 3 Gsp 2 Gsy 2 Gsy 3 »¼ 3 ¼ ¬ ¼ ¬
ª 1 2 1 1 º
«G G G
G
0 0 » ª ) 0 º ª Fr NI º
« m r ry m
»« » « »
« 1 1 2 2 1 2 1 »« » « » (2)
« ( ) 0 » « )1 » « 0 »
« G m G m Gu G sp1 G sy1 G sp1 G sy1 »« » « »
« 2 1 2 2 1 1 2 1 »« » « »
« 0 ( ) ( ) » «) 2 » « 0 »
« Gsp1 Gsy1 Gsp1 Gsp 2 Gsy1 Gsy 2 Gsp 2 Gsy 2 »« » « »
« 2 1 2 2 1 1 »« » « »
« 0 0 ( ) » « ) 3 » «¬ 0 »¼
¬ ¼
¬« Gsp 2 Gsy 2 Gsp 3 Gsp 2 Gsy 2 Gsy 3 ¼»
Newton's method requires Jacobian matrix calculation in which
B. Nonlinear solution
its elements are partial differential of G with respect to flux. In
Incorporating the permeances into the magnetic equivalent this case, since permeances are not explicit function of flux,
circuit model of DRPMBLM from Fig.1 and Fig.2, we can get obtaining analytical expressions for Jacobian matrix elements is
the magnetic circuit equation for the closed loops 0, 1, 2 and 3 not possible. Therefore, a Gauss-Siedel method with an
as follows (1) and (2): accelerating factor for faster convergence has been used to solve
The complete set of closed loop equations is a system which the problem.
can be represented as the matrix form below: The solution process has four steps: at the first step of the
[R][ĭ]=[F] (3) proposed analysis, assuming that the permeability of the core
where R is the matrix of magnetic resistance, ĭ is the vector is 1000 as an initial value. Inputting the MMF of winding (NI),
of branch fluxes, and F is the vector of magneto motive forces. the initial flux values ĭ0, ĭ1, ĭ2 and ĭ3 flowing in each closed
The resistance matrix is obtained by the same method as loop are obtained by solving Eq.(1) and (2). Then, the flux
permeance matrix for electric circuit which is mentioned above. density in each saturable stator and rotor yoke will be
Since the iron permeability is a function of flux density, calculated. By reference to B-u data of the core for the
elements of R are functions of flux; hence, the set of equations permeability of all saturable permeances are redefined and the
is non-linear. There are several methods for solving a set of non- permeance values of all saturable permeances are recalculated.
linear equations e.g. Newton's and Gauss-Siedel methods. In the third step, (1) and (2) is solved to yield a new flux
611
values ĭ0, ĭ1, ĭ2 and ĭ3. The new value will be compared to La § 8S · (10)
L15 L51 Lg cos ¨ 2 pT ¸
the old value in an infinite norm. If convergence is reached the 2 © 3 ¹
iterative process will be stopped and post processing L § 10S ·
L16 L61 a Lg cos ¨ 2 pT (11)
calculations for flux linkage will be performed, otherwise steps ¸
2 © 3 ¹
two and three will be repeated.
L
L23 L32 a Lg cos 2 pT 2S (12)
2
L § 8S · (13)
L24 L42 a Lg cos ¨ 2 pT ¸
2 © 3 ¹
L § 10S · (14)
L25 L52 a Lg cos ¨ 2 pT ¸
2 © 3 ¹
L
L26 L62 a Lg cos 2 pT (15)
2
Pr L § 10S · (16)
L34 L43 a Lg cos ¨ 2 pT ¸
2 © 3 ¹
L
L35 L53 a Lg cos 2 pT (17)
2
L § 2S · (18)
L36 L63 a Lg cos ¨ 2 pT ¸
Fig.3 Block diagram of the nonlinear solution procedure 2 © 3 ¹
L § 2S · (19)
C. The balance equations of the DTPPMBLM L45 L54 a Lg cos ¨ 2 pT ¸
2 © 3 ¹
The DTPPMBLM consists of a permanent magnet rotor, a
position sensor mounted on the rotor, and a means to provide L § 4S · (20)
L46 L64 a Lg cos ¨ 2 pT ¸
signals to the stator winding. In the absence of magnetic 2 © 3 ¹
saturation, the governing differential equations describing the L
L56 L65 a Lg cos 2 pT 2S (21)
dynamic behavior of DTPPMBLM may be written as: 2
d (4) La is the nominal (average) value of the winding inductance,
> U @ =R > I @ + ª < I , T º
dt ¬ ¼ Lg represents the amplitude of variation in the inductance due
Where T is the position variable. U and I are the phase to the nonuniformity of the air gap, and p is the number of
voltage input and current vectors, respectively. R is the permanent magnet pole pairs. The elements of the permanent
resistance matrix, and the flux linkage vector is defined by magnet flux linkage vector, Ȍm(ș), i.e., Ȝmk, k = 1,2,3,4,5,6
ª < I , T º ª L T º I ª < m T º (5) represent the flux linkages associated with the permanent
¬ ¼ ¬ ¼ ¬ ¼
magnet and phase k. For sinusoidally distributed stator
Where the inductance matrix L(ș) is a 6-by-6 symmetric windings, Ȝmk(ș) may be written as
matrix whose diagonal elements are the self inductances, and
§ 2 k 1 S · (22)
its off-diagonal elements are the mutual inductances of the Omk K e sin ¨ pT ¸ , k 1, 2,3, 4,5, 6
windings and are defined by © 3 ¹
§ 2 k 1 S · (6)
where Ke is the electromotive force, i.e the back EMF constant.
Lkk La Lg cos ¨ 2 pT ¸ , for k 1, 2,3, 4,5, 6 Equation (1) represents a system of differential equations
© 3 ¹ with time varying (periodic) coefficients. It is known [11], [12],
La § 2S · (7) [13] that for sinusoidally distributed windings, Floquet
L12 L21 Lg cos ¨ 2 pT ¸
2 © 3 ¹ transformation, which is frequently referred to as the Park's
L § 4S · (8) transformation, may be used to transform the above equations
L13 L31 a Lg cos ¨ 2 pT ¸ to system of differential equations with constant coefficients,
2 © 3 ¹
L represented in coordinate frame attached to the rotor. This
L14 L41 a Lg cos 2 pT 2S (9) orthogonal transformation can be expressed in matrix form as:
2
«
ªcos pT cos pT 2S
3
cos pT 4S
3
0 0 0 º
»
ªV q1 º
« »
«
2S
«sin pT sin pT 3 sin pT 3
4S 0 0 0
» ªV 1 º
»« » (23)
«V d 1 » « » «V 2 »
«V 01 » « 2 2 2 0 0 0 » «V »
2« 2 2 2 »« 3»
« »
«V q 2 »
« »
3« 0
«
0 0
cos pT cos pT 2S
3
cos pT 4S
3 » «V 4 »
»« »
«V d 2 » » «V 5 »
¬«V 02 ¼»
«
« 0 0 0
sin pT sin pT 2 S
3
sin pT 4S
3 » ¬«V 6 ¼»
« »
« 0 0 0 2 2 2 »
¬ 2 2 2 ¼
The subscripts 1, 2, 3, 4, 5, and 6 correspond to the stator fictitious windings attached to the rotor. The variables ı1, ı2,
windings, whereas the subscripts q, d, and 0 represent some ı3, ı4, ı5, ı6, ıq1, ıd1, ı01, ıq2, ıq2, and ı02, may represent
612
voltages, currents, or flux linkages. As a result, the v ª¬ v d 1 v q1 vd 2 v q 2 º¼
T
(35)
transformed set of equations describing the behavior of
T
DTPPMBLM in the rotating frame become i ª¬ i d 1 i q 1 i d 2 i q 2 º¼ (36)
dT d Oq1 (24)
vq1 Riq1 pOd 1 With current, the rotor position and mechanical rotor speed
dt dt
dO dT or the state variables, the state vector is
vd 1 Rid 1 d 1 pOq1 (25) T
(37)
dt dt x ª¬ i T : T º¼
dT d Oq 2 (26) With the voltage and load torque for the controlled variable,
vq 2 Riq 2 pOd 2 control of vectors is
dt dt
T
dO dT (27) v ª¬ v T T L º¼ (38)
vd 2 Rid 2 d 2 pOq 2
dt dt The state of the equation for the drive system can be expressed
Where Oq1 Lq1iq1 (28) as:
Od 1 Ld 1id 1 K e (29) di ½
L 1 ( R G T ) i L 1U
°
Oq 2 Lq 2iq 2 (30) dt
° (39)
d: 3 p T R T °
Od 2 Ld 2id 2 K e (31) i Gi : : L ¾
dt 2 J J J °
§3· dT
¨ ¸ La Lg Lq 2
And (32) °
Lq1 p: °
©2¹ dt ¿
§3· That is
Ld 1 ¨ ¸ La Lg Ld 2 (33)
©2¹ x Ax Bv (40)
The torque expression after the application of the Where
transformation becomes ª L 1 ( R G T ) O O º ª L 1 O º
« » ୈ « »
§ 3p ·
T iq1 , id 1 , iq 2 , id 2 ¨ ¸ Od 1iq1 Oq1id 1 Od 2iq 2 Oq 2id 2
(34) « 3 p iT G R: 1
A 0» B «O T »
© 2 ¹ « 2 J J » « J »
« » « T »
¬ OT p 0¼ ¬O 0 ¼
III. SIMULATION AND EXPERIMENTAL VERIFICATION Where L-1 is inductance inverse matrix, O is zero matrix, R
A. DRPMBLM geometrical model is resistance matrix, G is movement inductance matrix, p is the
number of pole pairs, Rȍ is rotation friction coefficient. From
The stator structure of DRPMBLM is distributed winding
the above state equation, for a given state variables u and TL,
structure and the back-EMF waveform is similar to sine wave,
and the initial value of state variables. In every discrete, the
it can get better low-speed torque characteristics and
interval by step in the same numerical solution, the dynamic
performance by using SVPWM drive. The specifications of
performances of the machine can be abtained.
DRPMBLM are listed in Tab. 2.
C. Verification by the results of the finite element analysis
Tab. 2 Major parameters of DRPMBLM 0.62
Outside diameter
phase self-inductance/ mH
613
150 20
100 15
Amperes
0 Phase EMF C1 Phase Current ic
0
-50
-5
-100
-10
-150
0 100 200 300 -15
electric degree
-20
Fig.5a Phase back electromotive force result from analysis 0 50 100 150 200 250 300 350
150 Electric Degree
Fig.7b Steady state winding current result from FEA
100 The model of the analysis and 2D-FEA simulation is shown
50
in Fig. 4, Fig. 5, Fig. 6 and Fig. 7.
Phase EMF A1
Phase EMF C1 Fig.4 show the waveforms of phase self-inductance from the
Volts
0 Phase EMF B1 analysis and FEA. It can be seen that the waveforms match
-50 each other closely, which validates the simulation.
Fig.5 and Fig.6 show the waveforms of back electromotive
-100 force from the analysis and FEA. It can be seen that the
-150 waveforms match each other closely, which validates the
0 100 200 300
electric degree simulation.
Fig.5b Phase back electromotive force result from FEA Fig.7 presents the waveforms of phase current at steady state
300 from the two simulations. The waveforms match closely too,
200 but the curves are not smooth when the load torque is 3.8N•m,
100 which may be due to the influence of the PWM control.
Volts
Phase EMF A1
0
Line EMF A1B1 IV. CONTROLLER REALISATION
-100 Line EMF A1C1
-200
A. Control strategy
-300 To achieve excellent performance for the DTPPMBLM in
0 100 200 300
electric degree dynamic operation, various kinds of control strategies such as
Fig. 6a Line back electromotive force result from analysis speed computation, execution of speed and current controller,
300 final switching logic generation and so on, needed to be
200
adopted. Therefore an outer-loop speed controller and an
inner-loop current controller are used when the DTPPMBLM
100
Phase EMF A1 operates in the motoring state.
Volts
614
B. Experimental hardware configuration up under rating and double load. Form the speed response
The block diagram and the hardware arrangement of an shown in Fig.9a and Fig. 10a, the machine reaches the steady
experimental DTPPMBLM drive system set-up are shown in state rapidly, the controller can track the speed command
Fig.8b, Fig.8c and Fig.8d, which consists of the following without presenting large overshoot and oscillation and with
units. very small steady-state error. The results show good speed
1) A desktop personal computer that runs Windows XP, which regulation and robustness against load variations for speed
is used to download the DSP and FPGA software and controller.
receive, transmit signal. Fig.11 shows the dual channel measured experimental
2) A 2×1.8 kW DTPPMBLM along with a dynamometer results of the rotor speed in the laboratory under different
machine is coupled with a transducer. operating conditions: start-up, steady state and sudden change
3) A fixed point DSP TMS320LF2812 that is used for of load. The experimental consists of the machine starting up
executing the control algorithm. from 0 to 0.15s with rating load TL=3.66N.m, and then an
4) A variable DC power (0~270Vdc) supply and dual Y three- additional double torque load TL=7.32N.m from 0.15 to 0.25s.
phase IGBT power converter, a drive circuit board used to In this operation process, the machine speed is accelerated
switch the IGBT on and off, and the voltage and current from 0 to 9400r/min at 0.045s, and then decreased to
sensors used to sense the voltage and phase current. 8100r/min at 0.165s. Finally, at 0.21s, the DTPPMBLM is
5) An interface circuit board that provides the interface returned to a steady state again and the rotor speed reaches
between the DSP and the measurement sensors. 8750 r/min.
10000
6) The phase commutation logic is implemented on a FPGA to
achieve near real-time performance. The commutation logic 9000
is transferred from the DSP to the FPGA using the digital 8000
I/O of the DSP. Hysteretic current control was implemented
7000
using analogue comparator circuits. Speed/(r/min)
6000
5000
4000
3000
2000
1000
0
0 10 20 30 40 50 60
Time/(ms)
Fig.9a speed waveforms at starting-up and TL=1.83N•m
Fig. 8b Structure of dual channel servo system
8000
Fig. 9a and Fig. 9b shows the measured speed and current
waveforms against time curve during the DTPPMBLM single 7000
Speed/(r/min)
615
4000
3000
2000
Speed/(r/min)
reference speed
1000 simulation speed
0
-1000
-2000
-3000
Fig.10b current waveforms at steady-state, 8750rpm and TL=3.66N•m -4000
10000 0 2 4 6 8
Time/(s)
9000 Fig. 12a Simulation DTPPMBLM step response
4000
8000
7000 3000
Speed/(r/min)
Speed/(r/min)
6000
reference speed
5000 1000
4000 0
3000 -1000
2000 -2000
1000 -3000
0 -4000
0 50 100 150 200 250 0 2 4 6 8
Time/(ms) Time/(s)
Fig.11 speed waveforms at steady-state, and sudden double load Fig. 12b Measured DTPPMBLM step response
-600
0 0.05 0.1 0.15 0.2 0.25 0.3
Time/(ms)
Fig. 12c Simulated DTPPMBLM frequency response
616
600 Critical Aerospace Application,” IEEE Trans. Ind. Electron., vol. 59, no.
reference speed
9, pp. 3532-3541, Sep 2012.
measured speed
400 [5] H. Asada and K. Youcef-Toumi, Direct Drive Robots: Theory and
Practice. Cambridge, MA: MIT Press, 1987.
200 [6] N. A. Demerdash, T. W. Nehl, and E. Maslowski, “Dynamic modeling of
Speed/(r/min)
VII. ACKNOWLEDGMENT
This work was supported by the Key Project of National
Natural Science Foundation of China (51177125).
VIII. REFERENCES
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617