L2-60152 - Advanced methods for parameter identification and vector control of permanent magnet synchronous machines

Within the Applied Project the application of advanced parameter identification and control methods for permanent magnet synchronous machines (PMSMs) to industrial development, production and end-products is addressed. The project will be performed in close collaboration with MAHLE Electric drives Slovenia d.o.o., a leading international development partner and supplier of the automotive industry that is proactively addressing the challenges of sustainable e-mobility by the development of innovative, energy and material efficient, cost-effective electric drives and powertrains. The company develops, manufactures and markets starters, alternators, various auxiliaries and traction electric drives and other mechatronic systems. The majority of MAHLE drives (auxiliaries and traction) are PMSM-based due to exceptional characteristics such as high power-density, good dynamic performance, high efficiency, and wide speed operation range within the variable-speed drives (VSDs).

The presented MAHLE products could leverage the many benefits of advanced FOC within VSDs, where implementation of advanced FOC methods is not only essential for the final product, but also for product development, testing and production. Implementation of FOC poses intricate challenges that need to be addressed to achieve optimal performance and reliability. The three main challenges linked to industrial implementation are parameter identification, sensor-less operation and computational complexity. These challenges will be addressed within the project.

The PMSM drives of MAHLE integrate a highly diverse and nonlinear group of PMSMs that operate in changing and challenging operating conditions, therefore implementation of advanced methods for parameter identification and FOC is essential. Challenges in implementing advanced parameter identification and advanced FOC can be overcome by using appropriate hardware and software solutions and by applying advanced control algorithms and techniques. These challenges are extensively researched and addressed in the scientific community. To overcome the Technology Readiness Level (TRL) gap and push innovative low TRL concepts into application, an iterative systematic model-based design (MBD) approach within a long-term reinforcement collaboration between UM FERI and MAHLE is applied. The proposed MBD workflow includes systematic development and validation by leveraging block programing in Simulink with Automated Code Generation (ACG), as well as Processor-in-the-Loop (PiL) and Hardware-in-the-Loop (HiL) validation before experimental testing and validation. In this extended rapid control prototyping (ERCP) workflow, problems will be identified and redesigned early in the project. The ERCP workflow will be applied in two stages for an additional layer of verification and validation. First on powerful dedicated ERCP hardware that is available within UM FERI research group and second on two versions of industrial hardware. In the MBD contemporary artificial intelligence (AI) techniques will be applied to reduce required computational burden and make the implementation of advanced methods on industrial hardware feasible. The proposed workflow will enable implementation of advanced parameter identification and FOC on industrial hardware. A unified MBD workflow with ACG will, furthermore, enable straightforward modification, adaptation, and improvement of the implemented code for individual future applications.

The MAIN OBJECTIVE of the Applied Project is to develop a unified approach for advanced parameter identification of MAHLE PMSMs and implement advanced FOC that will enable field-weakening and deep field-weakening operation, automated commissioning, on-line parameter estimation with self-tuning, as well as sensor-based or sensor-less control. The goal is to leverage the MBD workflow and utilize ACG, and to validate the proposed concepts at TRL 7.

UM FERI