LAUSR

This paper analyzes the influence of non-sinusoidal inductance distortion on the saliency-based position estimation for the permanent magnet (PM) machines. Because of the high-power-density design of PM machines, the flux saturation usually causes the inductance self-saturation, inductance cross-saturation, and most importantly, secondary inductance harmonics. This paper fully investigates the saturation effect on saliency-based drives. Analytical model for the position estimation with saturated inductance is developed to understand the stability of saliency-based drive. It is confirmed that the saturation effect deviates the estimated flux position from actual rotor position. These estimation errors are critical for the saliency-based drive especially under load. This paper defines the feasible estimation region for PM machines with saturated and non-sinusoidal inductances. Considering the position estimation errors due to the saturated and non-sinusoidal inductance, the typical maximum torque per amp (MTPA) current trajectory based on the encoder-based control system should be modified especially for the IPM machines at full load. For the machines where the saturation condition is unknown, q-axis current without negative d-axis current is suggested to maintain control stability while the torque reduction is resultant. By contrast, the modified current trajectory could also be designed once the saturation reflected position estimation errors could be obtained. Finite element analysis (FEA) with inverter co-simulation is used to investigate the inductance distortion at various loads. A 6kW IPM machine prototype with highly non-sinusoidal inductance is tested for the experimental verification.