FOC Using Self Commissioning Scheme

Journal of China Institute of Technology V.40-2009.
06

305
Sensorless Vector-Controlled Induction Motor Drive with a
Self-Commissioning Scheme Using One Current Sensor
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Cheng-Hung Tsai
F
Department of Electrical Engineering,
China Institute of Technology
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Abstract
A sensorless vector control based on self-commissioning scheme is presented by
using only one current sensor without speed and voltage sensors. Using inverters allows
easy control of induction motors at variable speeds. This feature, along with small size
and low cost has resulted in these inverters being used in realizing sensorless vector
control. When adopting the sensorless vector control method, many electrical
parameters of the induction motor are needed. From this, the design of a simple control
hardware is derived by comprising of a DSP chip for the proposed scheme which using
only one current sensor. The self-commissioning scheme permits the setting of the
parameters for good dynamic performance of the induction motor. Simulations and
various oscillograms demonstrate the behavior of the sensorless vector controller
operating a pulse width modulation inverter.
Keywords: sensorless control, self-commissioning, induction motor, current sensor
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1. Introduction
Pulse width modulation (PWM) inverter-fed induction motor drives are widely
used for the operation of all kinds of industrial production and automation processes.
The conventional method of vector control has been slip-frequency control. This
method reduces the structural features of squirrel-cage induction motors and restricts the
application because it requires a speed sensor. Lately, the speed-sensorless controls
[1] [6] for field-oriented control techniques have been proposed to avoid the use of a
speed sensor. However, the parameters of the induction motor must be known. Thus, the
self-commissioning is necessary for inverters.
This paper presents a vector control scheme with speed- and voltage-sensorless
drive of induction motors for general-purpose drive applications. The sensorless vector
control scheme is based on the voltage equation of an induction motor. However, the
accuracy of the voltage model depends on a precise alignment of the respective values
of stator resistance and leakage inductance of the model with those of the machine.
Thus, the system itself needs to determine the electrical parameters of the machine
during commissioning and sets the control parameters accordingly. Then the control
parameters are used by the sensorless vector control scheme.
It is known that the rotor speed is determined by the difference between the
synchronous angular frequency and the estimated slip angular frequency which is
estimated from the detected dc link current and the stator-flux reference. However, in
conventional sensorless algorithm published at low speed range with some problems in
the low-speed drive characteristics. Therefore, the PWM strategy is needed to reduce
the error between the reference and the actual voltages in order to obtain the stable
low-speed rotation, because the low-voltage control accuracy plays an important role as
the speed decreases. Owing to the factors of the voltage inaccuracy include the
quantization error in the digital controller, the forward voltage drop of switching devices,
and the dead time of the inverter and so on, the compensation algorithm [6] is adopted
here for low-speed range of the sensorless vector control.
Journal of China Institute of Technology V.40-2009.06

307
2. Parameter identification
A good dynamic performances in sensorless vector control scheme is desirable.
Thus, many parameters are necessary to be obtained accurately. A number of schemes
[7]-[9] are proposed for parameter identification in the recent literatures. It is seen that
the parameter estimation methods proposed by [7] is too complex such that it is not easy
to implement on a single chip and references [8] and [9] need speed sensor and extra
hardware. From the point of view, we bring up an improved idea that can be easily
implemented on a microprocessor without extra hardware and speed sensor by using
only one current sensor in the dc link. For achievement of sensorless vector control
scheme, some parameters are needed to be decided:
1) stator resistance
s
R .
2) rotor resistance
r
R , stator leakage inductance
ls
L and rotor leakage
inductance
lr
L .
3) stator inductance
s
L , rotor inductance
r
L and mutual inductance
m
L .
4) inertial moment J .
The identification process for each parameter is shown in Fig. 1 and each
measuring step is introduced in the following.
2.1 Measurement of stator resistance
It is known that the stator resistance can be determined by a test at dc level, where
the applied voltage-to-current ratio is measured as shown in Fig. 2. The applied voltage
is calculated by multiplying the modulation index of the pulse modulator with the dc
link voltage. However, due to the quantization error of microprocessor, dead time effect
and switching devices voltage drop, the actual value of the voltage is less than its
calculated value. The error due to these effects can be improved by software design [6].
Thus, the stator resistance will be defined by the following equation:
R
V
I
s
AB
a
=
05 .
. (1)
2.2 Measurements of leakage inductance and rotor resistance
Fig. 3 shows the principle of the measurement method for
r
R ,
ls
L and
lr
L .
When the motor does not rotate, the slip S is 1 and the secondary circuit is changed to
a series circuit of
lr
L and
r
R . If the primary frequency is more than the standard
frequency, impedance of mutual inductance
m
L will be much more than that of the
308
secondary circuit. Then the equivalent circuit is changed to Fig. 3(b). When a single
phase ac voltage is added (as shown in Fig. 4), the voltage and current vector diagram is
as shown in Fig. 3(c). In view of it, the direction of vector
*
1
V is along the q axis.
The q axis component and the d axis component of primary current vector
a
I are
the active power current
q
I and the reactive power current
d
I , respectively. The
power-factor angle is and the rotating angle from the fixed axis of
*
1
V is . From
the method of single phase ac test shown in Fig. 4, the A phase voltage command
*
a
V
is calculated from the primary angle command and primary voltage vector
*
1
V . The
instantaneous current
a
i of A phase is given as
) sin( 2 =
a a
I i . (2)
Let

0
sin 2
1
d i I
a q
, (3)

0
) cos ( 2
1
d i I
a d
. (4)
Thus, the following results can be obtained from above equations,
0
sin ) sin( 2
2
d I I
a q

= I
a
cos . (5)
and
. sin
cos ) sin( 2
2
0

a
a d
I
d I I
=
=

(6)
Then, the active power and relative power will be described as:
q a a
I V d i V I V P
*
1
0
*
1
*
1
sin 2
1
cos = = =

. (7)
and
d a a
I V d i V I V Q
*
1
0
*
1
*
1
cos 2
1
sin = = =

. (8)
Therefore, ) (
r s
R R + can be calculated as

309
a
d q
q
r s
I
V
I I
I V
R R
cos 2
) ( 5 . 0
*
1
2 2
*
1
=
+

= + . (9)

From the relationship of reactive power, ) (
lr ls
L L + is determined as

=
+

= +
a
d q
d
lr ls
I
V
I I
I V
L L
sin 2
) ( 5 . 0
*
1
2 2
*
1
. (10)
2.3 Measurement of self inductance
It is known that the single phase equivalent circuits of induction motor can be
expressed by the T model and L model. The relationship between these two models is
shown in Fig. 5. In L model, the primary voltage vector command
*
1
V with primary
angular frequency command can be described as

m a s
E I L j R V + + = ) (
*
1

m
r
m
a s
I
L
L
j I L j R
2
) (

+ + = (11)
From equation (11), the induced voltage
m
E is obtained and equation (13) is derived
from Fig. 6.
m
r
m
m
I
L
L
E
2
= (12)
) sin cos ( sin cos
2

q d
r
m
I I
L
L
H F = + (13)
Dividing both sides by cos and substituting tan
sin
cos
= =
H
F
, it yields
) sin cos (
sin cos
2

q d r
m
I I
H F
L
L
+
=
) (
2 2
H I F I
H F
q d

+
=
. (14)
310
From the definition of total leakage coefficient = 1
2
L
L L
m
s r
,
L
L
L
L
s
m
r
s
= +
2
, (15)
L
L
L L
L L
L
L
L L L
s
m
s r
s ls
m
r
lr ls lr
= = + + ( ) 1
2
. (16)
Therefore, the self inductance
s
L can be obtained
) (
) (
2 2
lr ls
q d
s
L L
H I F I
H F
L + +
+
=
(17)
2.4 Measurement of inertia
For the purpose of measuring the inertia J of the induction motor, a technique
will now be described in which a sequence of square wave torque current command
q
I
and a constant command
d
I are applied to the drive as shown in Fig. 7. In view of it,
two command currents are applied to the inner current loop. Because the decoupling
control of the drive, the induction motor will behave like a dc motor. Then, the motor
will accelerate from
1
to
2
and decelerate from
2
to
1
as shown in Fig. 8.
Inertia J can be calculated from the estimated speed and estimated electromagnetic
torque
1
e
T ,
2
e
T by using the following equation.
dt
d
dt
d
T T
J
e e
2 1
2 1

= (18)
It is seen that the average value of inertia J from Fig. 8 is calculated in order to
have a better result. It is noted that inertia J can be measured exactly even for a motor
with load, although the influence of load torque is now cancelled.
2.5 Simulation and measurement results
In order to test the accuracy of the proposed self-commissioning scheme, the

311
computer simulation, self-commissioning results and manual measurement results are
listed in Table I. The computer simulation is derived by Matlab/Simulink software. By
comparing the manual method and simulation results, the proposed method is obviously
accurate. However, due to the dead time effect, quantization error and switching device
on-loss, the self-commissioning results without compensation have some inaccuracy as
given in the fourth column of Table I. After compensating these factors with method of
[6], the accurate results shown in the last column can be obtained and these values will
be used for sensorless vector control. Since these measurements can be done
automatically, any induction motor will be easily driven using sensorless vector control
even if the motor is set with a load.
3. Stator-flux-oriented sensorless principle and line current estimation
After the parameters are identified accurately, they are adopted by a sensorless
vector control system. A block diagram of the proposed system is shown in Fig. 9. It
contains a flux loop, a current loop and an outer speed loop. Firstly, the speed regulator
generates the torque reference for the torque loop and the output of the torque regulator
defines the q -axis voltage command while the flux loop generates the d -axis voltage
command. Next, the d - axis and q -axis voltage commands are then fed to the
estimator and the space vector PWM.
In this system, the stator flux
s
and
s
are estimated from the integration of
phase voltages command minus the voltage drop in the stator resistance in the stationary
(stationary dq ) reference frame [3]:
dt i R V
s s s s

= ) (
*

, (19)
dt i R V
s s s s

= ) (
*

, (20)
2 2

s s s
+ = , (21)
s
s
cos = , (22)
312
s
s
sin = , (23)
where
*
s
V
and
*
s
V
are stator voltage commands expressed in a stationary

frame,
is the estimated stator flux angle with respect to the -axis of the stationary
reference frame.
The electromagnetic torque can be expressed in terms of the stator flux and the
stator current as below:
)

(
4
3
s s s s e
i i
P
T

= , (24)
where, P = Number of poles of the machine.
The PI controller is used here to regulate the magnitude of the stator flux so as to
achieve zero steady state error. In order to improve the transient performance of the flux
regulator, a decoupling compensator is added to compensate the coupling between the
torque producing current and the flux. The decoupling compensator is represented by
the following equations:
) (
) (
ds s ds r
qs r s s
sl
i L
i p L L

+
= (25)
) 1 (
p
i
i
r
qs r sl
dq

+
= (26)
where
sl
is the estimated slip frequency;
dq
i is the output of the decoupling compensator;
r
is the rotor time constant;
dt
d
p = is the differential operator.
Notice that the stator flux angle
can be expressed as
s
s
tan
1
= . (27)
The synchronous frequency can then be related to
s
and
s
as follows:

313
2 2
1

)]
( [tan
s s
s s s s
s
s
e
dt
d
dt
d

= = =

& &
. (28)
By using equations (25) and (28), the rotor speed can be derived
$ $ $

r e sl
=
. (29)
The relationship of
dc
i , the dc link current, to the motor line current for all eight
inverter switching states is given in Fig 10. The inverter switch configuration and
possible directions of current flow for state (1,0,0) are also illustrated. When space
vector PWM is used, each cycle includes inverter operation at two adjacent active states.
Thus, two line currents flow in the dc link in each cycle [4]. Apart from a short period
of regeneration at the start of each cycle due to the simultaneous switching of all three
inverter poles, the dc link current begins and ends each cycle at zero. Sampling
dc
i at
state 1 and state 2 yields samples of
a
i and
c
i respectively. Then the stator current
in the frame can be determined from two phase currents as follows:
as s
i i =
) 2 (
3
1
as bs s
i i i + =
(30)
or
as s
i i =
) 2 (
3
1
as cs s
i i i + =
(31)
or ) (
cs bs s
i i i + =
) (
3
1
cs bs s
i i i =
(32)
To avoid acquiring
dc
i during a switching transient, the samples are taken
towards the end of the active state times. These sampling times as well as the acquired
line currents for state 1 and state 2 are given in Fig. 11, where the offset time
T , is
made as small as the acquisition and conversion process permit.
4. Simulation and experimental results
The experimental setup includes a complete motor drive consisting of a
three-phase PWM inverter with a switching frequency of 3.3 khz and a 3-hp induction
motor. The proposed control scheme, including the parameter identification, sensorless
vector control, and the space vector PWM, is performed by a microprocessor Intel
80196mc. The first stage of the program is to identify the machine parameters that are
used for sensorless vector control. Next, the adopted speed and flux controllers are
314
roughly set and the extra hardware used here only the current sensor circuit. It is noted
that the whole control scheme is implemented by the microprocessor.
The simulation and experimental results are shown in figures 12-13. First, a speed
reference alternating between 900 rpm is applied to the system and the response of the
controller is shown in Fig. 12. It can be seen that the proposed control scheme give
excellent speed regulation with an acceptable ripple content. Clearly, there is no obvious
performance degradation by adopting the single sensor approach outlined in the paper.
Fig. 13 shows the speed reference is 36 rpm and with no load. It proves that the
actual current without obvious error compared to the simulation result. It also shows
that the estimated speed is close to the measured speed. It is noted from Fig. 12 that
torque current ripple increases as speed approaches zero. This is because of the error
effect appears in flux estimation. Since the voltage reference is used in flux estimation,
error due to dwell time becomes significant at low speed (and low voltage). At the same
time, the error will be happened in stator resistance. All these factors cause some
degradation torque estimation and speed estimation.
5. Conclusion
A fully digital sensorless self-commissioning scheme based on space vector PWM
is proposed to control induction motor under speed and voltage sensorless field-oriented
system. The issues governing the generation of robust and reliable estimates of phase
currents have been addressed in detail. The scheme has been verified by experimental
results implementing PWM inverter and motor systems. It is worth to noted that the
controller is implemented completely in software on a Intel 80196mc system with only
one current sensor in the dc link. The main results obtained in this paper are
summarized as follows:
1) The parameter of the induction machine can be measured accurately.
2) The technique uses only dc link current measurement to generate estimates of
phase current, flux, torque and rotor speed.
3) The experimental characteristics of the proposed algorithm show that the
satisfactory dynamic response can be also obtained at low-speed range.
As a result, the author believe that the proposed sensorless vector control with
self-commissioning scheme using single sensor will cultivate the possibility of low cost,
high performance sensorless vector control of induction motor.

315
References
1. Lopez, J. C., Romeral, L. Arias, A., and Aldabas, E. (2006) Novel fuzzy adaptive
sensorless induction motor drive. IEEE Transaction on Industrial Electronics,
53(4), 1170-1178.
2. Bojoi, R., Guglielmi, P., and Pellegrino, G.-M., (2008) Sensoreless direct
field-oriented control of three-phase induction motor drives for low-cost
applications. IEEE Transaction on Industrial Electronics, 44(2), 475-481.
3. Montanari, M., Peresada, S. M., Rossi, C., and Tilli, A., (2007) Speed sensorless
control of induction motors based on a reduced-order adaptive observer. IEEE
Transactions on Control Systems Technology, 15(6), 1049-1064.
4. Salomaki, J., Hinkkanen, M., and Luomi, J., (2006) Sensorless control of
induction motor drives equipped with inverter output filter. IEEE Transaction on
Industrial Electronics, 53(4), 1188-1197.
5. Lascu, C., Boldea, I., and Blaabjerg, F., (2000) A modified direct torque control for
induction motor sensorless drive. IEEE Transactions on Industry Applications,
36(1), 122-130.
6. Lee, J. S., Takeshita, T., and Matsui, N., (1997) Stator-flux-oriented sensorless
induction motor drive for optimum low-speed performance. IEEE Transactions on
Industrial Applications, 33(5), 1170-1176.
7. Chai, H., and Acarnley, P. P., (1992) Induction Motor Parameter Estimation
Algorithm Using Spectral Analysis. IEE Proceedings B, 139(3), 165-174.
8. Krishnan, R., and Doran, F. C., (1987) A method of sensing line voltages for
parameter adaption of inverter-fed induction motor servo drives. IEEE
Transactions on Industrial Applications, 23(4), 617-622.
9. Summer, M., and Aher, G. M., (1993) Auto-commissioning for voltage-referenced
voltage-fed vector-controlled induction motor drives. IEE Proceedings B, 140(3),
187-200.
316

Figure 1 Sequence of measurements for machine parameters.

Figure2 Measuring method of stator resistance.

DC test for . s
R
Single phase AC test for .
lr ls r
L L R , ,
Three phase AC test for .
m r s
L L L , ,
Inner current loop test for
measuring inertial moment
J

317
Single phase test
L
ls
R
s
L
lr
L
m
R
S
r
L
ls
R
s
L
lr
R
r
S
R
S
R
r
r
= 1,
L L R
m lr r
>> +
~
V
1
*
~
V
1
*
lr ls
L L L +
(a)

q-axis
d-axis
V
1
*
I
a
I
b
I
c
I
q
I
d
stator-axis

(b) (c)
Figure 3 Principle for resistance and leakage inductance measurement.

Figure 4 Single-phase ac test.

Dead time and
forward voltage
drop compensation
Gate signal
+ A
+ B
+ C
direction a
i
+
0
*
=
b
V
0
*
=
c
V
=
*
a
V
*
1
V
sin 2
*
1
V
dt

*

318
s
R
ls
L
lr
L
1
I
0
I
m
L
2
I
S
R
r
s
R

L
1
I
m
I
+
m
E
m
L
2
I
S
R
r
T model L model

r
m
m
L
L
L
2

= L L
L
L
L
ls
m
r
lr
= +
2
) (
r
m
r r
L
L
R R =
a
I I =
1

Figure 5 Single-phase equivalent circuit of the induction motor.

q-axis
d-axis
V1
*
I
a
I
q
I
d
stator-axis

R I
s q
F
H
R I
s d
q
L I
I
m
E
m

Figure 6 Voltage and current vector diagram at steady state.


319
sin
$
cos
$
$
T
e
r
d
I
q
I
dc
i
*
s
v
*
ds
v
*
qs
v

q d
*
s
v

Figure 7 Block diagram of inner current loop test for measuring inertia J .

320
0 0.5 1 1.5 2 2.5 3 3.5
-8
0
8
0 0.5 1 1.5 2 2.5 3 3.5
0
0.2
0.4
0.6
0 0.5 1 1.5 2 2.5 3 3.5
0
100
200
Time(sec)
T
o
r
q
u
e

(
N
m
)

S
p
e
e
d

(
r
p
m
)

F
l
u
x

(
W
b
)

(a)
0 0.5 1 1.5 2 2.5 3 3.5
-8
0
8
0 0.5 1 1.5 2 2.5 3 3.5
0
0.2
0.4
0.6
0 0.5 1 1.5 2 2.5 3 3.5
0
100
200
Time(sec)
T
o
r
q
u
e

(
N
m
)

S
p
e
e
d

(
r
p
m
)

F
l
u
x

(
W
b
)

(b)
Figure 8 Inner current loop test for measuring inertia J :
(a) simulation results (b) experimental results.

321

$
T
e
sin
$
cos
$
$
r
$
s
R
r
R
s
L
r
L
m
L
s
$
T
e
$
s
dc
i
dq
i

Figure 9 Block diagram of stator-flux-oriented sensorless control system.

Figure 10 Relationship between the dc link and motor line currents for various inverter
switching states.

State
dc
i
1 (1,0,0)
a
i +
2 (1,1,0)
c
i
3 (0,1,0)
b
i +
4 (0,1,1)
a
i
5 (0,0,1)
c
i +
6 (1,0,1)
b
i
7 (1,1,1)
8 (0,0,0)
0
dc
i
dc
V
a
i
b
i
c
i
L
A
U
A
A
U
B
L
B
B
U
C
C
L
C
State 1
322

Figure 11 Sample time of
dc
i at state 1 and state 2.

2
dc
V
2
dc
V
t
An
V
2
dc
V
2
dc
V
t
Bn
V
2
dc
V
2
dc
V
t
Cn
V
2
Z
T
X
T
Y
T
State 1
(1,0,0)
State 2
(1,1,0)
State 7
(1,1,1)
State 8
(0,0,0)
a dc
i i =
c dc
i i =
T

T
Sampling Sampling

323
-1200.00
-600.00
-1200.00
0.00
1200.00
600.00
-600.00
0.00
-1200.00
1200.00 1200.00
20.00 25.00 30.00
-1200.00
-900.00
-600.00
-300.00
0.00
300.00
600.00
900.00
20.00 25.00 30.00
-900.00
-300.00
300.00
900.00
20.00 25.00 30.00
-900.00
-300.00
300.00
600.00
900.00
20.00 25.00 30.00
-900.00
-600.00
-300.00
0.00
300.00
600.00
900.00
1200.00
) (rpm
r
) (rpm
r
) ( rpm
r
) ( rpm
r
time(sec)
time(sec)
time(sec)
time(sec)
(a)
(b)
(c) (d)
20.00 25.00 30.00
-15.00
-10.00
-5.00
0.00
5.00
10.00
15.00
20.00 25.00 30.00
-15.00
-10.00
-5.00
0.00
5.00
10.00
15.00
) ( A i
e
qs
) ( A i
e
qs
time(sec) time(sec) (g) (h)
20.00 25.00 30.00
-15.00
-10.00
-5.00
0.00
5.00
10.00
15.00
20.00 25.00 30.00
-15.00
-10.00
-5.00
0.00
5.00
10.00
15.00
) ( A i
as
) ( A i
as
time(sec) time(sec) (e) (f)

Figure 12 Speed reversal operation of =
*
r
900rpm
(a) actual speed in simulation
(b) actual speed in experiment
(c) estimated rotor speed in simulation
(d) estimated rotor speed in experiment
(e) A-phase current in simulation
(f) A-phase current in experiment
(g) torque current in simulation
(h) torque current in experiment
324

0.00 2.00 4.00
-40.00
0.00
40.00
80.00
0.00 2.00 4.00
0.00
40.00
80.00
0.00 2.00 4.00
-20.00
-10.00
0.00
10.00
20.00
0.00 2.00 4.00
-40.00
0.00
40.00
80.00
0.00 2.00 4.00
0.00
40.00
80.00
0.00 2.00 4.00
-20.00
-10.00
0.00
10.00
20.00
) (rpm
rm
) (rpm
rm
) ( rpm
rm
) ( rpm
rm
) (A i
as
) (A i
as
time(sec)
time(sec)
time(sec)
time(sec)
time(sec)
time(sec)
(a)
(b)
(c)
(d)
(e) (f)

Figure 15 Speed operation of =
*
r
36rpm
(a) actual speed in simulation
(b) actual speed in experiment
(c) estimated rotor speed in simulation
(d) estimated rotor speed in experiment
(e) a-phase current in simulation
(f) a-phase current in experiment


325
Table I. Results of self-commissioning and simulations.
Tuning method Manual
method
Computer
simulation
Self-commissioning
without compensation
Self-commissioning
with compensation
s
R ( ) 2.5 2.5 5.625 2.48
r
R ( ) 1.59 1.465 1.12 1.529
s
L (H) 0.0201 0.0202 0.0253 0.0215
r s
L L , (H) 0.258 0.256 0.244 0.263
m
L (H) 0.248 0.246 0.231 0252
J (
2
m Kg )
0.033 0.0303 0.0302 0.0302

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Journal of China Institute of Technology V.40-2009.

are stator voltage commands expressed in a stationary

Sensorless Vector-Controlled Induction Motor Drive with a Self-Commissioning

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