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Comparative performance analysis of field-

oriented control and direct torque control for a


fractional-slot concentrated winding interior
permanent magnet synchronous machine
N. Q. Dai, Rukmi Dutta, and M. F. Rahman

Φ
Abstract -- This paper presents performance analysis of a difficulty in winding automation, long end-winding in the
fractional-slot, concentrated, non-overlapping winding Interior stator and higher copper losses compared to concentrated
Permanent Magnet (IPM) Synchronous Machines under winding. However, CW generates non-sinusoidal MMF
two commonly used control strategies: rotor field which contains harmonics and sub-harmonics that do not
oriented control (RFOC); and Direct Torque Control (DTC).
Application of concentrated winding to IPM machine is gaining rotate at synchronous speed. These additional harmonics are
attention from research community because of its advantages the main cause of increased frequency related losses. Low
such as high-power density, high efficiency, short end-turns, winding factor and higher torque ripples are also commonly
wider flux-weakening capability, fault tolerance, robust rotor, cited short-comings of the CW. Recent studies [4-7] showed
and presence of additional reluctance torque component. The that a winding factor close to unity and low cogging torque
major disadvantage of concentrated winding is non-sinusoidal can be achieved in the CW machine if an appropriate
magnetomotive force (MMF. However, using appropriate
combination of slots and poles, sinusoidal EMF and low cogging combination of slots and poles are chosen.
torque can be achieved despite presence of MMF harmonics. A Recently, El-Refaie,T. M Jahns [4] showed that
14-pole/ 18-slot, double layer concentrated winding IPM sinusoidal EMF and wide flux-weakening can be achieved in
machine had been designed and constructed at the University the surface-mounted permanent magnet machines by using
of New South Wales. Above mentioned two control schemes fractional slot concentrated winding. This has opened the
were applied to this constructed prototype machine. The path to apply CW to IPM machine as well. However, in the
performances of the two control schemes are compared in
terms of torque and current ripple, transient responses for the CW stator, the mutual inductance between two phases is
step variations of speed and load under maximum torque per relatively low. Consequently, the saliency ratio of the CW
ampere and field weakening regions. Both RFOC and DTC are IPMSM is lower than a DW IPMSM [8]. Despite of low
based on the dq model of the machine which assumes sinusoidal saliency ratio, the application of CW in IPMSM can extend
variation of MMF. The experimental result of the concentrated the flux-weakening range [9, 10]. A prototype 14-pole, 18-
winding IPM machine indicates that the conventional dq model slot, double layer CW-IPMSM machine was designed and
starts to deteriorate in the field-weakening region resulting in a
steady-state error between estimated flux and measured flux. constructed at the University of New South Wales [8]. The
This paper attempts to investigate the sources of this error and detailed design optimization of this prototype machine was
causes of deterioration of the dq model. This work is a published elsewhere and will not be discussed here [9-12].
preliminary investigation for the possible improvement in the This prototype machine has achieved higher torque density
control schemes of the concentrated winding IPM machine. and wider constant power speed range compared to a DW
IPMSM of similar size. The rotor of the machine consists of
Index Terms-- Direct torque and flux control, fractional-slot
fourteen V-shaped buried magnet poles. Fig.1 shows rotor
concentrated non-overlapping winding, interior permanent
magnet synchronous machine, maximum torque per ampere, and stator of the prototype CW-IPMSM machine.
flux weakening.

I. INTRODUCTION

T HE interior permanent magnet synchronous machine


(IPMSM) has been a popular choice for many high
performance applications due to its high power and
torque density and efficiency. Compared to the surface-
mounted permanent magnet machines, the IPMSMs have
higher mechanical durability due to buried magnet.
Furthermore, the IPMSMs also have higher demagnetization
withstanding capability and additional reluctance torque
resulted from rotor saliency [1-3].
In the conventional ac machines, distributed winding
(DW) which result in sinusoidal back EMF waveforms are Fig. 1. Rotor and stator
desired for achieving high efficiency and low torque ripple In the literature there are number of papers which have
[4]. However there are several disadvantages such as discussed various design issues of CW-IPM machine [4, 9,
10, 13-16]. However, there is hardly any paper which has
discussed control of the CW PM machine. This paper is an
The authors are with the School of Electrical Engineering and
Telecommunications, University of New South Wales, NSW 2033, attempt to fill this gap. The paper will concentrate mainly on
Australia (e-mail: dai.nguyen@unsw.edu.au). two commonly used control schemes: rotor field oriented

978-1-4673-0142-8/12/$26.00 ©2012 IEEE 879


control (RFOC) and direct torque control (DTC). Both ω rotor anglular velocity in electrical rad/s.
RFOC and DTC are based on the dq-model of the machine. The three-phase voltages, currents and flux linkages are
Section II describes the dq-model of the IPMSM. transformed into d-q coordinate by using the well-known
The RFOC or current vector control is a high Park’s transformation:
performance control scheme. Several trajectory control ⎡ 2π 2π ⎤ a
cos θ cos(θ − ) cos(θ + ) ⎡ ⎤
techniques can be derived based on the d-q model of ⎡d ⎤ 2 ⎢ 3 3 ⎥⎢ ⎥
IPMSM, including maximum torque per ampere (MTPA), ⎢q ⎥ = 3 ⎢ ⎥ ⎢ b ⎥ (3)
maximum torque per voltage (MTPV), field weakening ⎣ ⎦ ⎢ − sin θ − sin(θ − 2π ) − sin(θ + 2π ) ⎥ ⎢ ⎥
c
(FW) and loss minimization. In RFOC scheme, the
⎢⎣ 3 3 ⎥⎦ ⎣ ⎦
controllers are based on the dq model of the machine. Hence, where θ is the rotor position in electrical radian.
the variation of the machine parameter affects the The torque expression for a permanent magnet machine
performances of the controllers. However, there are many in the d-q coordinate is
novel control strategies which can compensate the parameter 3
T = p ⎡⎣ λ pm iq + ( Ld − Lq )id iq ⎤⎦ (4)
variation and enhance the performance of the basic RFOC 2
[17-20]. The major drawback of RFOC is the requirement of where p is number of pole pairs.
rotor position feedback, although sensorless version is also
being developed in the recent years [19, 20]. The basic B. Trajectory control in rotor reference frame
RFOC i.e. without compensating for any parameter variation Based on maximum torque per ampere, a relation
was applied to the prototype CW-IPM machine. The results between id and iq are derived in [24] and given as,
were presented in section III. λ pm λ pm
2

The DTC scheme is relatively new control method for the id = − + iq2 (5)
IPMSM. In DTC, the torque is controlled directly by 2( Lq − Ld ) 4( Lq − Ld ) 2
controlling the amplitude and the rotation angle of the stator Considering the constraints of voltage, the flux linkage is
flux linkage vector. It is executed in the stationary reference related to the terminal voltage as follows
frame and therefore, the continuous information of rotor 2
positions is not required. The performance of the DTC is not ⎛V ⎞
λ + λ = ( Ld id + λ pm ) + ( Lq iq ) ≤ ⎜ om ⎟
2
d
2
q
2 2
(6)
dependent on the machine parameters except for the stator ⎝ ω ⎠
resistance. In the DTC, the torque and stator flux linkages where Vom = Vmax − RI am is the maximum voltage of the
are calculated from the measured current and DC-link or machine.
stator voltages. Since the rotor position feedback is not a The stator current is limited by the rated current of the
requirement, DTC is inherently sensor less. However, there machine and current limit is given as,
were some difficulties to employ DTC at very low or zero
speed. These difficulties have been overcome recently for I a = id2 + iq2 ≤ I am (7)
DW-IPMSM [21-23]. The basic DTC was applied to the where I am is the maximum current of the machine.
prototype CW-IPMSM and results were presented also in
section III. In id − iq plane, the current limit produces a circle and
The section IV discusses some of the issues encountered voltage limits produces ellipse. The ellipse shrinks as speed
while implementing the RFOC and DTC to IPMSM with increases. The equation (5) produces a trajectory in the
CW. id − iq plane under maximum torque per ampere operation.
The operating point of the machine is at the intersection of
II. MATHEMATICAL MODEL OF AN IPMSM the MTPA trajectory and current limit circle under full load
condition at base speed. Above this speed, due to the voltage
A. Mathematical model of the IPMSM in rotor reference
constraint, the machine must operate with flux-weakening
frame
condition. Under the flux-weakening, the operating point
In the d-q coordinate that rotate synchronously with rotor, moves from the MTPA trajectory along the current limit
the flux linkage and voltage equations of the IPMSM are boundary toward the intersection of the voltage limit ellipse
expressed as follow of the operating speed and current limit circle. The Fig.2
⎡λd ⎤ ⎡ Ld 0 ⎤ ⎡id ⎤ ⎡λ pm ⎤ shows the current limit, voltage limit, MTPA trajectory and
⎢ λ ⎥ = ⎢ 0 L ⎥ ⎢i ⎥ + ⎢ ⎥ (1) movement of the operating point during flux weakening
⎣ q⎦ ⎣ q⎦⎣ q⎦ ⎣ 0 ⎦
(FW) for a typical IPMSM.
⎡vd ⎤ ⎡id ⎤ d ⎡ Ld 0 ⎤ ⎡id ⎤ ⎡ 0 −ω Lq ⎤ ⎡id ⎤
⎢ v ⎥ = Rs ⎢ i ⎥ + ⎢ 0 +
Lq ⎥⎦ ⎢⎣ iq ⎥⎦ ⎢⎣ω Lq 0 ⎥⎦ ⎢⎣iq ⎥⎦
⎣ q⎦ ⎣ q ⎦ dt ⎣
⎡ 0 ⎤
+⎢ ⎥ (2)
⎣ωλ pm ⎦
where,
Rs stator resistance
Ld , Lq d- and q- axis inductances
λ pm Fig. 2. Current Trajectories in id − iq plane
permanent magnet flux linkage
id , iq d- and q- axis currents
vd , vq d- and q- axis voltages

880
C. Mathematical model of an IPMSM in the stator Fig.3 shows these trajectories in T − λs plane for an
reference frame IPMSM.
The coordinate αβ is fixed to the stator in the stationary
reference frame. The three-phase quantities can be
transformed to αβ co-ordinate by using (3), but in this case
θ is the angle between a-phase axis and α-axis which is zero.
The flux linkage of an IPMSM can be expressed in the
stationary reference frame as,
⎧λα = (vα − Rs iα )dt
⎪ ∫ (8)

⎪⎩λβ = ∫ (vβ − Rs iβ )dt

λs = λα2 + λβ2 (9) Fig. 3. Current Trajectories in T − λs plane


where λα , λβ : stator flux linkage. E. Determination of trajectories at different speeds for
both RFOC and DTC
The electromagnetic torque can be estimated as In order to achieve high efficiency, the proper trajectory
3 should be selected depending on the operating speed of the
T = p(λα iβ − λβ iα ) (10)
2 machine. The MTPA control is selected below the base
In a discrete control system, the flux linkage and torque speed, whereas flux weakening is adopted for the operation
equation then become above cross-over speed. The crossover speed can be defined
⎧⎪λα (k ) = λα k −1 + (vα k −1 − Rs iα )Ts as the minimum speed for voltage-limit, maximum output
⎨ (11) power operation. Between base speed and crossover speed,
⎪⎩λβ (k ) = λβ k −1 + (vβ k −1 − Rs iβ )Ts the torque determines control modes. The Fig.4 shows the
flow chart of selection of control modes for both RFOC and
3
T (k ) = p {λα (k )iβ (k ) − λβ (k )iα (k )} (12) DTC.
2
D. Trajectory control for DTC ωref < ωb

In the FOC, the flux and torque regulation is done via the
d- and q-axes currents respectively. However in the DTC,
the flux and torque are directly controlled by suitable and
optimal selection of the voltage vectors. Unlike RFOC, the
equivalent trajectory for DTC is determined in the T − λs ωref > ωcr

plane.
1) MTPA trajectory in the T − λs plane
The MTPA condition can be achieved by seeking the λs1 > λs 2
maximum output torque for particular current amplitude.
(λ + Ld id ) + ( Lq iq ) 2 ≤ Vom
2
ω
The MTPA trajectory in the T − λ plane is given by, pm

⎧ ⎡ L2d ⎤
⎪λs = λ pm
2
+ ⎢ 2 Ld − ( ) ⎥ λ pm id + ( L2d + L2q )id2
⎪⎪ ⎣⎢ Lq − Ld ⎦⎥
⎨ (13)
⎪ 3 λ pm
⎪ T = p ⎡⎣λ pm + ( Lq − Ld )id ⎤⎦ id −
2
id
⎪⎩ 2 Lq − Ld

2) Voltage and current limit trajectory in the T − λ s


Fig. 4. Determination of the reference stator flux linkage
plane
The constrains of voltage and current given in (6) and (7) III. EXPERIMENTAL RESULT
can be replaced in the T − λs plane as, This section discussed the experimental result obtained
ωre λs = ωbλsr = ωc λ pm < Vo m (14) from the prototype CW IPMSM machine with DTC and
RFOC.

⎪ λs = ( λ pm + Ld id ) + ( Lq iq )
2 2
DTC scheme was implemented first and steady-state and
⎨ (15) dynamic performances of the prototype CW- IPMSM were
⎪T = 3 p ⎡λ pm iq + ( Ld − Lq )id iq ⎤ examined under MTPA and flux-weakening. Later, RFOC
⎩ 2 ⎣ ⎦
was applied to the machine under similar condition as DTC.
where ωre , ωb , and ωcr are rotor, base and crossover The performances of the DTC and RFOC for the prototype
CW-IPMSM were compared. Table I shows some of the key
Vom
speeds respectively, with ωcr = parameters of the prototype machine.
λ pm

881
TABLE I estimated speed and actual speed is less than 4 rpm.
PARAMETERS OF IPMSM WITH CW USED IN THIS PAPER
460

Number of pole pairs p 7 455


reference
(black)
measured
(blue)
estimated
(red)

speed(rpm)
Stator resistance Rs 9.6 Ω 450

Magnet flux linkage λ pm 0.4 Wb 445

d-axis inductance Ld 0.0864 H


440
0 0.5 1 1.5 2 2.5
time (sec)
3 3.5 4 4.5

13

q-axis induction Lq 0.0975 H reference


(red)
estimated
(blue)
12.5

Vmax

torque(N.m)
Phase voltage 170 V 12

Maximum phase current I am 2.8 A 11.5

Base speed ωb 450 rpm 11


0 0.5 1 1.5 2 2.5
time (sec)
3 3.5 4 4.5

0.475

Rated torque Tb 12 Nm reference


(red)
estimated
(blue)

Friction coefficient D 0.0004 Nm/rad/s

flux(Wb)
0.47

2
Rotor inertia J 0.00087 kgm
0.465

A. System Configuration
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
time (sec)

5
The block diagram of DTC and RFOC are shown in Fig.5
and Fig.6 respectively. The control algorithms were speedsrror (rpm)

implemented using DS1104 controller board. The 3- phase, 0

50A, 600V Mitsubishi intelligent power modules with IGBT


switches were used in the voltage source inverter. A rotary
encoder is used for speed and rotor position feedback. -5
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

VDC time (sec)

ωref T* Vq* Fig. 7. Speed, torque, flux linkage and speed error of the DTC drive under
dq − αβ steady-state.
ωest λs* Vd*
2) Dynamic Performance
λs The Fig.8 shows speed, torque, flux and speed-error
between estimated speed and measured speed under transient
condition when the machine is accelerated from 200 to 700
dθ λ λ = ∫ (v − Rsi)dt abc − αβ rpm and then decelerated back to 200rpm. The figure shows
dt
θ = arctan( β )
λα 3
T = p(λα iβ − λβ iα )
that the speed settling time is only for 0.2 sec which is an
2 indication of the satisfactory dynamic performance under
Fig. 5. The block diagram of DTC for an IPMSM with CW DTC in the prototype CW IPMSM.
VDC
The Fig.9 shows the locus of the measured flux linkage.
ωref iq* Vq*
dq − abc
The change in flux linkage due to flux-weakening (FW) can
iq
ωr
id* Vd* also be seen in the figure. The machine runs under flux-
id
weakening mode at 700 rpm with full load. The result
vdo = −ω Ld id indicates the smooth response can be obtained when the
vqo = ω (λ pm + Ld id ) operation modes switched between MTPA and FW.
⎡ 2π 2π ⎤
cos θ m cos(θ m − ) cos(θm + ) ⎥ ⎡ia ⎤
Howevere, during the flux-weakening it has been noticed
2⎢
⎡id ⎤
⎢i ⎥ =
⎣ q⎦

3⎢
3

3 ⎢ ⎥
⎥ ib
2π ⎢ ⎥
− sin θ m − sin(θ m − ) − sin(θm + ) ⎥ ⎣⎢ic ⎦⎥
that estimated flux starts to deviate from the actual flux of
⎢⎣ 3 3 ⎥⎦
the machine. It indicates changing behavior of the dq model
dθ θr in the flux-weakening region. Fig. 17 shows this deviation
dt which will be discussed further in the section IV.
Fig.10 shows the experimental torque and flux trajectory
Fig. 6. The block diagram of RFOC for an IPMSM with CW
of the DTC drive on the T − λs plane under MTPA for the
B. Direct torque and flux control prototype IPMSM with CW.
The base speed of the prototype machine is 450 rpm. At The dynamic response of the drive to a load step change
full load, flux-weakening starts above this speed. is illustrated in Fig.11. The machine initially was run at 450
1) Steady state performance at 450rpm with full load rpm under no-load condition, then the full load of 12 Nm
The Fig.7 shows speed, torque, flux and speed-error was applied to the shaft of the motor at t = 0.95 s. At t = 2.55
between estimated speed and measured speed under steady- s, the load torque was abruptly removed and the machine
state condition with full load. came back to the no-load condition. Again the settling time
It can be seen from the figure that the torque and flux is 0.1s, showing a satisfactory dynamics performance.
linkage have very small ripples of approximately 0.4 Nm
and 0.003 Wb respectively. The speed error between

882
600
800 measured measured
(blue) 550 (blue)

600 500
speed (rpm)

speed (rpm)
450
400
reference
estimated 400 estimated
(black)
(red) (red)
200 reference
(black) 350

0 300
0 0.5 1 1.5 2 2.5 3 3.5 4 0 1 2 3 4 5 6
time (sec) time (sec)

15 15
estimated estimated
10 (blue) (blue)
10

torque (N.m)
5
torque (N.m)

reference
(red)
5
0
reference
-5 0
(red)
-10
-5
0 1 2 3 4 5 6
-15 time (sec)
0 0.5 1 1.5 2 2.5 3 3.5 4
time (sec)
0.48
estimated
0.48 0.46 (blue)
reference
0.46 (red) reference

flux (Wb)
0.44 (red)
flux (Wb)

0.44 estimated
(blue) 0.42

0.42
0.4
0.4
0.38
0 1 2 3 4 5 6
0.38 time (sec)
0 0.5 1 1.5 2 2.5 3 3.5 4
time (sec) 100
150
50
speed error (rpm)

100
speed error (rpm)

50 0

0
-50
-50

-100 -100
0 1 2 3 4 5 6
time (sec)
-150
0 0.5 1 1.5 2 2.5 3 3.5 4
time (sec)
Fig. 11. Speed, torque, flux linkage response and speed error at 450 rpm
Fig. 8. Speed, torque, flux linkage and speed error of the DTC drive for with load disturbances
speed change of 200 rpm to 700 rpm
C. Rotor field oriented control(RFOC)
RFOC scheme was experimentally implemented under
the similar conditions as the DTC.
MTPA
1) Steady state performance
The Fig.12 illustrates the steady state response of RFOC
drive at 450 rpm under full-load condition.
FW
460

reference measured
455 (red) (blue)
speed (rpm)

450

445

440
0 1 2 3 4 5
time (sec)

15

Fig. 9. Locus of flux λs in constant torque ( MTPA) and FW regions 14


torque(N.m)

13

12

11

10

9
0 1 2 3 4 5
time (sec)

Calculated 3

Measured
flux 2

flux
current i (A)

1
a

-1

-2

-3
1 1.01 1.02 1.03 1.04 1.05 1.06 1.07
time (sec)

Fig. 12. Speed, torque, stator current at 450 rpm under full-load with
Fig. 10. Torque and Flux trajectory of the DTC drive on the T − λ plane RFOC

883
The rotor speed, torque and stator current are shown. For
480
the RFOC, the speed ripple and torque ripple are
reference
approximately 4 rpm and 2 Nm respectively. The speed 460 (red)

ripple of RFOC is the same as DTC, however the torque

speed (rpm)
ripple are significantly higher than that of the DTC. It is 440

possibly due to the parameter variation which was not measured


compensated in this RFOC. Further investigation will be 420 (blue)

carried out in future to improve the steady-state performance


400
of RFOC. 0.5 1 1.5
time (sec)
2 2.5

800 12

700 reference 10
(red)
600 8

torque 9N.m)
speed (rpm)

6
500
estimated
4
400 (blue)
2
300
0
200
-2
0.5 1 1.5 2 2.5
100 time (sec)
0 1 2 3 4 5
time (sec)

Fig. 13. Speed response of the RFOC drive for speed change of 200 rpm to Fig. 15. Speed and torque response at 450 rpm with load disturbances
700 rpm
Fig.13 shows the speed response for the step speed IV. DISCUSSION
change from 200 rpm to 700 rpm. Fig.14 shows the id − iq The DTC and RFOC schemes are based on the dq model
current response of the RFOC drive for a load step change. of the machine which assumes sinusoidal MMF. However,
In the RFOC, the maximum id − iq current ripples are the fractional-slot, concentrated, non-overlapping winding
approximately 1 and 0.3 ampere respectively, resulting in the produces MMF which is rich in harmonics and sub-
high torque ripple. The likely cause of these offset is the harmonics. Hence, the conventional dq model of the IPM
inaccurate dq-model of the CW IPMSM. machine with DW is not accurate for the IPM machine with
CW. The inaccuracy increases under flux-weakening
1 condition. It is well known that harmonics in the flux-
measured (blue) linkage increases under flux-weakening condition for the
d-axis current id (Ampere)

0.5 IPMSM with DW. Same is also true for the IPMSM with
CW because of which dq model of the machine deteriorates
0 further under flux-weakening. Although the DTC and RFOC
were applied successfully to the prototype IPMSM with CW,
-0.5 a noticeable steady-state error was observed between the
reference (red) measured and estimated flux-linkage of the machine,
-1 especially in the flux-weakening region.
0 2 4 6 8 10
time (sec) The Fig.17 illustrates the measured and calculated flux
5 linkage from the dq-model of the prototype machine under
4 flux-weakening. The calculated flux linkage from the dq-
q-axis current iq (Ampere)

3 model is less than that of the flux linkage from the


measured (blue)
2 experiment at the starting of the field weakening region.
1 However, the difference between those two flux linkages
0 reference (red) becomes smaller as the speed increases. Further
-1 investigation is necessary to understand the causes of these
-2 differences so that it could be minimized or eliminated
-3
0 2 4 6 8 10
completely. One of the possible solutions is modification of
time (sec) the conventional d-q model to reflect the condition of the
Fig. 14.id − iq current responses of the RFOC drive for load disturbances concentrated winding precisely.
The Fig.15 illustrates the speed and torque response under
similar load disturbances as the DTC at based speed under
RFOC scheme. From the figure, it can be observed that the
speed dropped 30 rpm when the step load was applied to the
shaft of the motor. The speed and torque regulation time are
0.8 and 0.2 sec respectively, which are higher compared to
the DTC scheme shown in Fig.11.

Fig. 17. Comparison flux linkage from experimental result and dq model

884
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