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Abstract—This paper proposes a general approach to designing It is common that sensorless drives utilize the open-loop con-
a stability control for open-loop operation that can be used for trol for zero and low speeds and the closed-loop field-orientated
either induction motor, permanent magnet synchronous motor, or control based on a back-electromotive force (EMF) position es-
any other motor drives. A speed or frequency set point is adjusted
by a frequency compensation value to provide the stability control timator for higher speeds. In this case, the transition from a
to mitigate hunting or motor stoppage. The proposed method can high-speed closed-loop control to a low-speed open-loop con-
be utilized in either conventional motor drives or motor drives with trol is challenging. A permanent magnet (PM) motor could even
an output filter and a transformer used for oil pump applications. lose synchronization or stop due to hunting under the open-loop
Index Terms—Electric submersible pump (ESP), induction mo- control without any stability control.
tor, motor control, oil pump application, permanent magnet syn-
chronous motor (PMSM), position sensorless, stability control. A. Conventional V/f Open-Loop Control
Typical open-loop sensorless systems employ a voltage–
I. INTRODUCTION frequency (V/f, alternatively known as volts per hertz, V/Hz)
controller providing a voltage set point according to a desired
ENSORLESS motor drives are used in a variety of appli-
S cations, particularly where providing position and/or speed
sensors directly at a motor is difficult or impractical. In particu-
motor speed or frequency. A simple open-loop V/f control is the
most commonly used sensorless control for induction motors
for applications such as fans, blowers, and pumps, where high
lar, sensorless control for permanent magnet synchronous mo-
dynamic performance is not a demand.
tors (PMSMs) has led to much research due to attractive features
It is known that motors by V/f control can be stabilized by the
such as high power density and high efficiency. For example, in
frequency feedback control [1]–[8], and/or voltage amplitude
electric submersible pumps (ESPs) for oil pump applications,
adjustment [6], [8], [12]. Existing stability controls are mostly
there has been an emerging trend of using PMSMs. For those
designed for V/f drives that utilize the calculated/measured
ESP drives, the installation of a position sensor attached to the
power [1], [2], [4], [5] or sensed dc-link current [3], [5]–[8],
motor shaft is not practical.
or sensed motor phase currents [11], as input to the stability
Generally speaking, PMSMs are not available with damper
control. For example, using sensed dc-link current for the sta-
windings in the rotor. Without damper windings, the synchro-
bility control can be undesirable due to noisy dc-link current
nization of motion of the rotor with the stator applied frequency
signals and requiring additional hardware (dc-link current sen-
under the open-loop control is not guaranteed [3]. This causes
sor) to the existing motor drive products.
instability problems in those PMSMs under the open-loop con-
However, most of the papers present a specific stability con-
trol. For example, motor velocity could oscillate about the set
trol method, mostly designed for V/f motor drives. Few papers
point after load perturbations.
cover a generic frequency stability strategy that can be used for
either a V/f control or a current-regulated open-loop velocity
control.
Manuscript received October 3, 2016; revised December 13, 2016; accepted
December 18, 2016. Date of publication January 30, 2017; date of current
version May 18, 2017. Paper 2016-IACC-1088.R1, presented at the 2015 B. Current-Regulated Open-Loop Control for Drives With an
IEEE Industry Applications Society Annual Meeting, Addison, TX, USA, Output Filter and a Transformer
Oct. 18–22, and approved for publication in the IEEE TRANSACTIONS ON IN-
DUSTRY APPLICATIONS by the Industrial Automation and Control Committee of Motor drives with an output filter and a transformer are com-
the IEEE Industry Applications Society.
J. Liu, T. A. Nondahl, and P. B. Schmidt are with Rockwell Automa- monly used for applications like ESP for oil pumps. A typical
tion, Milwaukee, WI 53204 USA (e-mail: jliu2@ra.rockwell.com; tanondahl@ configuration is shown in Fig. 1, which has the following:
ra.rockwell.com; pbschmidt@ra.rockwell.com). 1) a medium-voltage (MV) induction or PMSM motor with
S. Royak is with Rockwell Automation, Cleveland, OH 44124 USA (e-mail:
sroyak@ra.rockwell.com). no position sensor;
T. M. Rowan is with Rockwell Automation, Mequon, WI 53092 USA (e-mail: 2) a long cable, which is typically 1000 m or more;
tmrowan@ra.rockwell.com). 3) an output transformer to increase the low-voltage drive
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org. output voltage to the levels of MV to allow for cable
Digital Object Identifier 10.1109/TIA.2017.2661249 voltage drop plus motor requirement;
0093-9994 © 2017 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See http://www.ieee.org/publications standards/publications/rights/index.html for more information.
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2518 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 53, NO. 3, MAY/JUNE 2017
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LIU et al.: GENERALIZED STABILITY CONTROL FOR OPEN-LOOP OPERATION OF MOTOR DRIVES 2519
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2520 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 53, NO. 3, MAY/JUNE 2017
Fig. 9. Stability control for a motor drive with an output Sinewave filter, a transformer, and a long cable. The calculated torque (p.u.) is used as the stability
signal.
Another possible implementation provides an estimated PF frame to a stationary “αβ” reference frame. An estimated (p.u.)
or PF angle computed according to real and imaginary power torque value is calculated based on iα and iβ and also based on
values P and Q, as shown in Fig. 6. the voltage command vα∗ and vβ∗ . The estimated torque is then
Yet another example is shown in Fig. 7, in which the stability used as the stability control signal to compute the frequency
signal generator provides a per-unit power estimate value, upon compensation value. Moreover, an HPF is utilized to remove
which the frequency compensation is calculated. Other possible undesirable dc offsets. A gain is used to amplify the filtered sig-
examples include computation of an estimated value as an error nal, and a limiter is included to limit the range of the frequency
between the open-loop angle and an estimated rotor position. compensation signal.
A conventional V/f motor drive system using the calculated In [13] and [14], an open-loop current-regulated control is
torque as the stability signal is shown in Fig. 8. The illustrated designed for a motor drive with the transformer and an output
stability signal generator includes a stationary reference frame sine wave filter that are commonly utilized for ESP drives. Fig. 9
converter for conversion of the current feedback signals and shows a current-regulated open-loop velocity system for drives
the voltage command signals or values from the abc reference with an output sine wave filter and a transformer using a stability
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LIU et al.: GENERALIZED STABILITY CONTROL FOR OPEN-LOOP OPERATION OF MOTOR DRIVES 2521
Fig. 11. Simulation result of V/f open-loop control with a 6.6-kV CHB drive
and an induction motor running at 0.2-p.u. speed, no load, stability control
was disabled first and then enabled at 2.5 s. (Top) Motor phase currents (p.u.).
(Middle) Motor reference and feedback speed (p.u.). (Bottom) Load torque and
electromagnetic torque (p.u.). Time scale is 1 s/div.
TABLE I
15-KW PM MACHINE PARAMETERS
Fig. 10. 6.6-kV CHB motor drive used in simulation.
Parameter (unit) Value
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2522 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 53, NO. 3, MAY/JUNE 2017
Fig. 12. Experimental setup: conventional motor drive with V/f open-loop
control. Fig. 15. Experimental result of V/f control with a PM motor running at
300 r/min, no load, stability control was disabled first and then enabled.
Ch1: speed (encoder), 100 r/min/div; Ch2: Iq , 2A/div; Ch3: calculated torque,
0.1 unit/div. Time scale is 1 s/div.
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LIU et al.: GENERALIZED STABILITY CONTROL FOR OPEN-LOOP OPERATION OF MOTOR DRIVES 2523
Fig. 19. Experimental result with the stability control. The motor is operating
Fig. 17. Experimental result of the current-regulated open-loop velocity con- at 150 r/min subjected to a step load change from 0.273 to 0.964 p.u. Ch1:
trol of a PM drive with an output filter and a transformer. The motor is operating Encoder speed (100 r/min/div); Ch2: Torque_pu (0.5 unit/div); Ch3: Reference
at 190 r/min at no-load condition with current reference at 0.3 p.u. Stability speed (100 r/min/div); and Ch4: Motor current Iu (20 A/div). Time scale is
control was disabled first and then enabled. Ch1: encoder speed (50 r/min/div); 500 ms/div.
Ch3: calculated torque p.u. (0.05 unit/div); Ch4: motor current Iu (20 A/div).
Time scale is 500 ms/div.
Fig. 18. Experimental result without any stability control. The motor is oper-
ating at 150 r/min subjected to a step load change from 0.273 to 0.964 p.u. Ch1:
Encoder speed (100 r/min/div); Ch2: Torque_pu (0.5 unit/div); Ch3: Reference Fig. 20. Experimental result without any stability control at no load. It
speed (100 r/min/div); and Ch4: Motor current Iu (20 A/div). Time scale is shows sensorless operation during transition from a closed-loop EMF observer
500 ms/div. to a current-regulated open-loop velocity control. Ch1: encoder speed (100
r/min/div); Ch2: torque p.u. (0.5 unit/div); Ch3: reference speed (100 r/min/div);
and Ch4: motor current Iu (20 A/div). Time scale is 500 ms/div.
Fig. 17 shows the experimental result of the current-regulated
open-loop velocity control of a PM drive with an output filter
and a transformer. The estimated p.u. torque (shown in Fig. 9) As aforementioned, sensorless drives could also utilize an
is utilized as the stability signal. The PM motor is operating at open-loop control for zero and low speeds and a closed-loop
190 r/min with the current reference at 0.3 p.u. with only the field-oriented control based on an EMF position estimator for
inertia load of the dyne. To demonstrate the effectiveness of the higher speeds. Without any stability control, a PM motor could
proposed stability control, the stability control was disabled first even lose synchronization or stop due to hunting without any
and then enabled. Obviously, the motor velocity oscillation is stability control during the transition from a closed-loop control
effectively reduced by the stability control. to an open-loop control.
In Fig. 18, the PM motor without any stability control is Fig. 20 shows the drive system (shown in Fig. 9) during a tran-
operating at 150 r/min and subjected to a step load change sition from a closed-loop EMF observer to a current-regulated
from 0.273 to 0.964 p.u. Without any stability control, unde- open-loop velocity control without any stability control.
sirable hunting occurs when there is a step change of the load. Fig. 21 shows the system during transition from a closed-loop
Fig. 19 shows the PM motor subjected to the step load change EMF observer to an open-loop control with the stability control
from 0.273 to 0.964 p.u. with the stability control. Clearly, to compare with the results shown in Fig. 20. It is shown that the
the velocity oscillation on the motor shaft is effectively re- undesirable hunting under the open-loop control has been effec-
duced/eliminated by the proposed stability control. tively suppressed by utilizing the proposed stability scheme.
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2524 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 53, NO. 3, MAY/JUNE 2017
VI. CONCLUSION
Jingbo Liu (S’99–M’06–SM’10) received the
This paper focused on a generalized stability control scheme B.Eng. and M.Eng. degrees from the Huazhong Uni-
versity of Science and Technology, Wuhan, China,
for position sensorless open-loop operation that can be used for in 1997 and 2000, respectively, and the Ph.D. degree
conventional motor drives or motor drives with an output filter from Ohio State University, Columbus, OH, USA, in
and a transformer. A speed or frequency set point was adjusted 2005, all in electrical engineering.
She joined Advanced Technology Milwaukee
by a frequency compensation value to provide a signal that was Labs, Rockwell Automation, Milwaukee, WI, USA,
then used in controlling the drive to mitigate hunting or motor in 2005. She holds six U.S. patents. Her research
stoppage. Typical options for a stability command generator interests include power converters and control of ac
motor drives.
include calculation of a compensation signal proportional to
torque, torque current, power, PF, torque angle, PF angle, etc.
Simulation results with a 6.6-kV CHB induction motor drive Thomas A. Nondahl (S’73–M’77–SM’96–F’02) re-
have been shown. Experimental results with a 15-kW drive, ceived the B.S., M.S., and Ph.D. degrees in electri-
cal engineering from the University of Wisconsin–
which uses the proposed stability control scheme, have been Madison, WI, USA.
presented in this paper. Simulation and experimental results After graduation, he joined GE’s Corporate
have validated the effectiveness of the proposed stability control Research and Development Center, Schenectady,
NY, USA, and spent four years analyzing and de-
strategy. signing electrical machines. In 1981, he joined
Allen-Bradley’s Corporate Technology Development
Group, Milwaukee, WI, as a Researcher. During the
REFERENCES next six years, he developed technology used in four
[1] R. S. Colby and D. W. Novotny, “An efficiency-optimizing permanent- ac and dc drive products. In 1987, he transferred to the Drives Product Group
magnet synchronous motor drive,” IEEE Trans. Ind. Appl., vol. 24, no. 3, and continued work on motor drives, electrical machines, and digital communi-
pp. 462–469, May/Jun. 1988. cations. In 1996, he joined Advanced Technology Milwaukee Labs, Rockwell
[2] Y. Nakamura, T. Kudo, F. Ishibashi, and S. Hibino, “High-efficiency drive Automation, Milwaukee, as a Research Manager. He holds 35 U.S. patents.
due to power factor control of a permanent magnet synchronous motor,” From 1996 until retirement in 2016, he conducted research projects in areas
IEEE Trans. Power Electron., vol. 10, no. 2, pp. 247–253, Mar. 1995. such as permanent magnet motor control, real-time digital communication, in-
[3] P. D. C. Perera, F. Blaabjerg, J. K. Pedersen, and P. Thøgersen, “An verters for induction motors, and control of ac servo drives.
efficiency-optimizing permanent-magnet synchronous motor drive,” IEEE Dr. Nondahl joined the IEEE Industry Applications Society in 1981. He
Trans. Ind. Appl., vol. 39, no. 3, pp. 783–791, May/Jun. 2003. has served multiple roles within the society including the Electric Machines
[4] M. Matsushita, H. Kameyama, Y. Ikeboh, and S. Morimoto, “Stabilization Committee Chair, the Society Treasurer, the Annual Meeting Chair, the Society
control of sensorless sinusoidal wave drive for control of power factor of President, and the Editor-in-Chief of the IEEE TRANSACTIONS ON INDUSTRY
PM motor,” in Proc. IEEE Int. Conf. Elect. Mach. Syst., Nov. 2009, pp. 1–5. APPLICATIONS. He received the Rockwell Engineer of the Year Award in 1988.
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LIU et al.: GENERALIZED STABILITY CONTROL FOR OPEN-LOOP OPERATION OF MOTOR DRIVES 2525
Peter B. Schmidt (M’79) received the B.S. and Timothy M. Rowan (M’87) was born in
M.S. degrees in physics from John Carroll Univer- Milwaukee, WI, USA, in 1958. He received the B.S.
sity, Cleveland, OH, USA, in 1977 and 1979, re- degree from Marquette University, Milwaukee, in
spectively; the M.S. degree in electrical engineer- 1980, and the M.S and Ph.D. degrees in electrical
ing and computer science from Marquette University, engineering from the University of Wisconsin, Madi-
Milwaukee, WI, USA, in 1984; and the Ph.D. degree son, WI, in 1982 and 1985, respectively, all in elec-
in electrical engineering from the University of Wis- trical engineering.
consin, Madison, WI, in 1991. He is currently a Senior Principal Engineer with
He started working for the Allen-Bradley Com- Rockwell Automation, Milwaukee, where he works
pany (A-B) in Corporate Research and Design, Mil- on the development of low-voltage standard drive
waukee, in 1979. The majority of his research projects products.
were centered on research and development in factory automation, specifically
in the areas of robotics and computer vision. When A-B was purchased by
Rockwell Automation, Milwaukee, he stayed with the company as the corpo-
rate research and development function was transformed into the Advanced
Technology Laboratory. He continues to work in the areas of motion control,
process control, and tuning. His major fields of study included automatic control
systems and energy/power systems.
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