USOO8410737B2

(12) United States Patent (10) Patent No.: US 8.410,737 B2

Wu et al. (45) Date of Patent: Apr. 2, 2013

(54) DEVICE AND METHOD FOR GENERATING 2.5k-

E: 299; ? th 11
OC-ala
AN INITIAL CONTROLLER LOOKUPTABLE 7,272,302 B2 * 9/2007 Woodward et al. ........... 388,801
FOR AN PMMACHINE 7,472,013 B1* 12/2008 Wiggins et al. ............... TO1,102
7,573.227 B2 8/2009 Kasaoka et al.
(75) Inventors: Long Wu, Fargo, ND (US); Srujan 7,733,044 B2 6/2010 Nakamura et al.
Kusumba, Fargo, ND (US); Zimin W. 7,759,886 B2 * 7/2010 Gallegos-Lopez
s s f. et al. .......................... 3.18/400.2
Vilar, Dubuque, IA (US); Tianjun Fu, 7.923.953 B2 * 4/2011 Gallegos-Lopez
Fargo, ND (US); Robert Shaw, et al. .......................... 3.18/400.2
Moorhead, MN (US) 7,973,505 B2* 7/2011 Suhama et al. ... 318,432
8,175,790 B2 * 5/2012 Stemler et al. ................ TO1,110
(73) Assignee: Deere & Company, Moline, IL (US) (Continued)
(*) Notice: Subject to any disclaimer, the term of this OTHER PUBLICATIONS
past lSESlisted under 35 M. Elbuluk and M. Kankam, “Speed Sensorless Induction Motor
M YW- (b) by ayS. Devices for Electrical Actuators: Schemes, Trends and Tradeoffs.”
National Aerospace and Electronics Conference cosponsored by
(21) Appl. No.: 13/036,382 IEEE. Wright-Patterson AFB, Dayton, OH, Jul. 14-18, 1997.
(22) Filed: Feb. 28, 2011 (Continued)
(65) Prior Publication Data Primary Examiner — Paul Ip
US 2012/O2 1791.6 A1 Aug. 30, 2012 (74) Attorney, Agent, or Firm — Harness, Dickey & Pierce
(51) Int. Cl. (57) ABSTRACT
H02P L/46 (2006.01) Embodiments of the present invention provide a device and
(52) U.S. Cl. ................ 318/400.11; 318/400.2; 318/.430; method for generating initial operating points for controlling
3.18/432: 180/65.265 an interior permanent magnet (IPM) machine. The method
(58) Field of Classification Search ............. 3.18/400.02, includes loading an inductance lookup table, first calculating
318/400.11, 430 434; 388/801, 804; 180/65.265 a maximum torque per Ampere (MTPA) trajectory for a first
See application file for complete search history. threshold speed based on machine parameters of the IPM
machine, second calculating a truncated Voltage limit ellipse
(56) References Cited with monotonically increasing torque for a first speed based
on the machine parameters, if the first speed is higher than the
U.S. PATENT DOCUMENTS first threshold speed, determining an operating trajectory at
4,023,083 A 5, 1977 Plunkett the first speed based on at least one of the calculated MTPA
4,814,677 A 3, 1989 Plunkett trajectory and the calculated truncated Voltage limit ellipse,
5,428.283
5,486,748
A
A
6, 1995 Kalman et al.
1, 1996 Konrad et al.
and generating an II, map that maps an I, value and an I,
5,914,582 A 6, 1999 Takamoto et al.
value to each torque command of a plurality of torque com
6,275,000 B1 8, 2001 Nishimura mands for the first speed based on the determined operating
6,326,750 B1* 12/2001 Marcinkiewicz ............. 318,432 trajectory.
6,801,013 B2 * 10, 2004 Woodward et al. ........... 3 18/804
6,952,088 B2 * 10, 2005 Woodward et al. ........... 318,430 36 Claims, 9 Drawing Sheets

loadachiisarameters including
s inductance look-uptas

Calcuise MPA for bass speed

S20

Calculate woltagernitellipse for

S30 current speed

so
Generate an map based on
detained operating trajectory

Construct integrated
plurality of speeds
map for
 US 8,410,737 B2
Page 2

U.S. PATENT DOCUMENTS OTHER PUBLICATIONS

8,228,016 B2 * 7/2012 Gallegos-Lopez et al. ... 318/609 66TY .
8,269,446 B2 * 9/2012 Suhama et al. ... 318,432 S. Van Haute et al., Design and Control of al Permanent Magnet
2004/0066160 A1* 4/2004 Woodward et al. 318,430 Synchronous Motor Drive for a Hybrid Electric Vehicle.” Katholieke
2004/0067049 A1 4/2004 Woodward et al. ... 388,801 University Leauven, Belgium.
2004/0067050 A1* 4/2004 Woodward et al. ........... 388,804 M.E. Haque et al., “Improved Trajectory Control for an Interior
398,529 A. ck 58 R 3.18.802 Permanent Magnet Synchronous Motor Drive With Extended Oper
2009/0027OOO A1* 1/2009 Gallegos. . . . . . . . . . . . . . . . . . . . . . . . ating Limit' School of Electrical Engineering and Telecommunica

Lopez et al. 318,722 tion, University of New South Wales, Sydney, Australia, whole docu
2009/0234538 A1* 9, 2009 Ta et al. .......................... TO1/41 ment.
2009,0284.195 A1* 11/2009 als 1 318/400.02 J.L. Kirtley Jr., “Class Notes Chapter 12: Permanent Magnet"Brush
OpeZ et al. ............. s s
2010/0038158 A1* 2/2010 Whitney et al. ... 180, 65.265 less DC Motors 6.061 Introduction to Power Systems, Massachu
2010.0045224 A1 2/2010 Suhama et al. .... ... 318,434 setts Institute of Technology, Department of Electrical Engineering
2010.0171456 A1* 7, 2010 Chakrabarti et al. ......... 318, 461 and Computer Science, Feb. 5, 2003, whole document.
2010/0231149 A1* 9/2010 Gallegos- US 7,595,604, 09/2009, Tomigashi (withdrawn)
Lopez et al. ............. 318/400.02
2011/0031919 A1 2/2011 Green ........................... 318,432 * cited by examiner
U.S. Patent Apr. 2, 2013 Sheet 1 of 9 US 8,410,737 B2
U.S. Patent Apr. 2, 2013 Sheet 2 of 9 US 8,410,737 B2

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U.S. Patent Apr. 2, 2013 Sheet 8 of 9 US 8.410,737 B2

118
rversarron-seru-su-un-- FG. 7
Vehicle 104 ---Electronic Data
Rotor magnet Process
Data bus temperature L. J. Processing system (2)
estimation module
O7
Current
TOdule
shaping /
108
Torque Current adjustment Teminal voltage
COTirand ITIOdule (e.g., d-q feedback module
generation axis current
nodule adjustment module) re-r-marrioram
Torque
99 Command
Data (316)
dq-axis current
generation
manager (e.g.,
lookup tables)

Voltage-over-Speed
RatioData (318)
Calculation module Phase Converter sensor (e.g., resolver or
(e.g., adjusted (e.g., 39 - 2p encoder or position
Voltage-over-speed Current Park sensor)
ratio calculation transformation)

Primary Processing Module

(e.g., position and speed
processing module)

Secondary Processing Module ligital Sensing

(e.g., DC bus and 3p currents Converter circuit
processing module)
U.S. Patent Apr. 2, 2013 Sheet 9 of 9 US 8,410,737 B2

FIG. 3
Data Storage
Device (260)

First Data
262 Port
Data bus 270 188
Second Data Inverter
Port Switching Circuit
272 115
Third Data
Port
120-1 274 122
Fourth Data A to D
Port Converter

OCBSSO Fifth Data Sensing

Port Circuit

Terminal Voltage 108

Feedback Module
 US 8,410,737 B2
1. 2
DEVICE AND METHOD FOR GENERATING The determining step may further include the following: if
AN INITIAL CONTROLLER LOOKUPTABLE the first speed is lower than a second threshold speed and
FOR AN PMMACHINE higher than the first threshold speed, the determining step
determines the operating trajectory based on a comparison of
FIELD the calculated MTPA trajectory and the calculated truncated
voltage limit ellipse; if the first speed is the second threshold
Example embodiments are related to a device and method speed or higher than the second threshold speed, the deter
for generating an initial controller lookup table for control mining step determines the operating trajectory based on the
ling an Interior Permanent Magnet (IPM) machine. 10
calculated truncated Voltage limit ellipse with monotonically
increasing torque only; and/or if the first speed is the first
BACKGROUND threshold speed or lower than the first threshold speed, the
determining step determines the operating trajectory based on
AC machines are extensively used in loaders or other heavy the calculated MTPA trajectory.
equipment machinery because they provide a higher effi 15 In some embodiments, the second threshold speed is a
ciency than DC machines. Of the AC machines, an IPM critical speed, the critical speed being a speed at which uncon
machine has a high drive efficiency wide operating speed trolled generation (UCG) voltage from a back-electromotive
range for constant power region. An IPM machine controller force (backemf) of the IPM machine is equal to a direct
also called an inverter, controls operation of the IPM current (DC) bus voltage.
machine. The controller produces ac control signals which If the first speed is lower than the second threshold speed
are applied to the terminals of the IPM machine. Typically the and higher than the first threshold speed, the determining step
controller controls the IPM machine based on information or includes selecting the lesser of an I, value of the calculated
a portion of information characterizing the IPM machine. At MTPA trajectory and an I, value of the calculated truncated
least part of the characterization refers to the operational Voltage limit ellipse for each I value, where the operating
model of the IPM machine that permits translation of input 25 trajectory includes the selected I values.
requests into desired operational output. For example, a The first calculating step may further include determining
desired output torque may be requested, and based on part of an initial table, where the initial table includes II, combina
the characterization, the controller controls the IPM machine tions having values covering all possible values for a preset
to deliver the desired torque. In order to provide the desired current limit, calculating the current peak magnitude, the
output torque, the IPM controller outputs operating points to 30 current control angle, and the L, and L values for each II,
the IPM machine in response to a desired torque. combination of the initial table, calculating torque for each
One conventional method uses theoretical equations to find II, combination of the initial table based on the machine
machine operating points, which may not be accurate. parameters, setting a torque range for each of the plurality of
Another conventional method utilizes finite element analysis torque commands, determining a subset of II, combinations
to find correct operating points, which is very time consum 35 for each torque command based on the calculated torque and
ing. In addition, these conventional methods may not cover the set torque range, selecting an II, combination from each
the full operating range in terms of speed and torque level. Subset that has a calculated current peak magnitude less than
other II, combinations of the subset, and/or calculating the
SUMMARY MTPA trajectory based on the selected sets of II, combina
40 tions.
Embodiments of the present invention provide a method In some embodiment, the calculated torque for each of the
for generating initial operating points for controlling an inte II, combinations in the determined subset falls within the set
rior permanent magnet (IPM) machine. torque range encompassing a respective torque command.
The method includes loading an inductance lookup table, The second calculating step may further include determin
where the inductance lookup table includes sets of a direct 45 ing an I vertex value for the Voltage limit ellipse right vertex
axis inductance (L) value and a quadrature axis inductance at a set shaft speed based on the machine parameters, calcu
(L) value and each set corresponds to a current peak magni lating maximum allowable I, values corresponding to a range
tude and a current control angle. The current control angle of I values, where the range of I values is from the deter
may indicate amounts of the current peak magnitude appear mined I vertex value to a preset minimum I limit, and/or
ing as direct axis current (I) and quadrature axis current (I). 50 calculating the voltage limit ellipse for the first speed based
The method also includes first calculating a maximum on the calculated maximum allowable I, values. Also, the I.
torque per Ampere (MTPA) trajectory for a first threshold vertex value may be forced to zero if the determined I vertex
speed based on machine parameters of the IPM machine, value is greater than Zero.
second calculating a truncated Voltage limit ellipse with The second calculating step may further include calculat
monotonically increasing torque for a first speed based on the 55 ing torque along points of the calculated Voltage limit ellipse
machine parameters, if the first speed is higher than the first at the first speed, and/or truncating the calculated Voltage
threshold speed, determining an operating trajectory at the limit ellipse by disregarding monotonically decreasing
first speed based on at least one of the calculated MTPA torque.
trajectory and the calculated truncated Voltage limit ellipse, In some embodiments, the method may further include
and generating an II, map that maps an I, value and an I, 60 obtaining the L values and the L values using finite element
value to each torque command of a plurality of torque com analysis based simulation, and generating the inductance
mands for the first speed based on the determined operating look-up table based on the obtained inductance parameters.
trajectory. In some embodiments the method may further include
In some embodiments, the first threshold speed is a base generating a different II, map for a plurality of speeds by
speed, the base speed being a maximum shaft speed at which 65 repeating the second calculating step, the determining step,
maximum constant output torque of the IPM machine is and the generating step for each speed, and constructing an
achieved. integrated II, map based on the plurality of II, maps.
 US 8,410,737 B2
3 4
In some embodiments, the IPM machine includes a The second calculating step may include determining an I
machine controller having the II, map, as discussed above. vertex value at the voltage limit ellipse right vertex point at a
In another embodiment, the method includes first calculat set shaft speed based on the machine parameters, calculating
ing a maximum torque per Ampere (MTPA) trajectory for a maximum allowable I, values corresponding to a range of I,
first threshold speed based on machine parameters of the IPM values, where the range of I values is from the determined I
machine, second calculating a truncated Voltage limit ellipse Vertex value to a preset minimum I limit, and/or calculating
with monotonically increasing torque for a first speed based the voltage limit ellipse for the first speed based on the cal
on the machine parameters, if the first speed is higher than the culated maximum allowable I, values. The I, vertex value
first threshold speed, determining an operating trajectory at may be forced to zero if the determined I vertex value is
the first speed based on at least one of the calculated MTPA
10 greater than Zero.
trajectory and the calculated truncated Voltage limit ellipse, The second calculating step may further include calculat
ing torque along points of the calculated Voltage limit ellipse
and generating an II, map that maps a directaxis current (I) at the first speed, and truncating the calculated Voltage limit
value and a quadrature axis current (I) value to each torque ellipse by disregarding monotonically decreasing torque.
command of a plurality of torque commands for the first 15 The method may further include generating a different II,
speed based on the determined operating trajectory. The map for a plurality of speeds by repeating the second calcu
determining step includes determining the operating trajec lating step, the determining step, and the generating step for
tory based on a comparison of the calculated MTPA trajectory each speed, and constructing an integrated II, map based on
and the calculated truncated voltage limit ellipse if the first the plurality of II, maps. In some embodiments, the IPM
speed is lower than a second threshold speed and higher than machine includes a machine controller having the II, map.
the first threshold speed. as described above.
In some embodiments, the first threshold speed is a base Embodiments of the present invention provide a computer
speed, the base speed being a maximum shaft speed at which processing unit for generating initial operating points for
maximum constant output torque of the IPM machine is controlling an interior permanent magnet (IPM) machine.
achieved, and the second threshold speed is a critical speed, 25 The computer processing unit includes a memory config
where the critical speed is a speed at which uncontrolled ured to store machine parameters. The machine parameters
generation (UCG) voltage from a back-electromotive force include an inductance lookup table. the inductance lookup
(backemf) of the IPM machine is equal to a direct current table includes sets of a direct axis inductance (L) value and
(DC) bus voltage. a quadrature axis inductance (L) value. Each set may corre
In some embodiments, the machine parameters include an 30 spond to a current peak magnitude and a current control
inductance lookup table. The inductance lookup table angle. The current control angle may indicate amounts of the
includes sets of a direct axis inductance (L) value and a current peak magnitude appearing as direct axis current (I)
quadrature axis inductance (L) value, and each set corre and quadrature axis current (I).
sponds to a current peak magnitude and a current control The computer processing unit may also include a processor
angle, where the current control angle may include amounts 35 configured to first calculate a maximum torque per Ampere
of the current peak magnitude appearing as I, and I. (MTPA) trajectory for a first threshold speed based on the
The determining step may further include the following: if machine parameters. The processor is configured to second
the first speed is the second threshold speed or higher than the calculate a truncated Voltage limit ellipse with monotonically
second threshold speed, the determining step determines the increasing torque for a first speed based on the machine
operating trajectory based on the calculated truncated Voltage 40 parameters, if the first speed is higher than the first threshold
limit ellipse with monotonically increasing torque only; and/ speed. The processor is configured to determine an operating
or if the first speed is the first threshold speed or lower than the trajectory at the first speed based on at least one of the calcu
first threshold speed, the determining step determines the lated MTPA trajectory and the calculated truncated voltage
operating trajectory based on the calculated MTPA trajectory. limit ellipse. The processor is configured to generate an II,
The determining step may further include selecting the lesser 45 map that maps an I, value and an I, value to each torque
of an I, value of the calculated MTPA trajectory and an I, command of a plurality of torque commands for the first
value of the calculated truncated voltage limit ellipse for each speed based on the determined operating trajectory.
I value, where the operating trajectory includes the selected In some embodiments, the first threshold speed is a base
I values. speed, where the base speed is a maximum shaft speed at
The first calculating step may include determining an ini 50 which maximum constant output torque of the IPM machine
tial table, where the initial table includes II, combinations is achieved.
having values covering all possible values for a preset current In some embodiment, if the first speed is lower than a
limit, calculating the current peak magnitude, the current second threshold speed and higher than the first threshold
control angle, and the L, and L values for each II, combi speed, the processor is configured to determine the operating
nation of the initial table, calculating torque for each II, 55 trajectory based on a comparison of the calculated MTPA
combination of the initial table based on the machine param trajectory and the calculated truncated Voltage limit ellipse; if
eters, setting a torque range for each of the plurality of torque the first speed is the second threshold speed or higher than the
commands, determining a subset of II, combinations for second threshold speed, the processor is configured to deter
each torque command based on the calculated torque and the mine the operating trajectory based on the calculated trun
set torque range, selecting an II, combination from each 60 cated Voltage limit ellipse with monotonically increasing
Subset that has a calculated current peak magnitude less than torque only; and/or if the first speed is the first threshold speed
other II, combinations of the subset, and calculating the or lower than the first threshold speed, the processor is con
MTPA trajectory based on the selected sets of II, combina figured to determine the operating trajectory based on the
tions. calculated MTPA trajectory.
In some embodiments, the calculated torque for each of the 65 In some embodiments, the second threshold speed is a
II, combinations in the determined subset falls within the set critical speed, where the critical speed is a speed at which
torque range encompassing a respective torque command. uncontrolled generation (UCG) voltage from a back-electro
 US 8,410,737 B2
5 6
motive force (backemf) of the IPM machine is equal to a FIG. 4 illustrates a method for calculating the MTPA tra
direct current (DC) bus voltage. jectory for the first threshold speed or a speed below the first
If the first speed is lower than the second threshold speed threshold speed according to an embodiment of the present
and higher than the first threshold speed, the processor is invention;
configured to select lesser of an I, value of the calculated 5
FIG. 5 illustrates a method for generating the II, map
MTPA trajectory and an I, value of the calculated truncated using the voltage limit ellipse or a combination of the MTPA
Voltage limit ellipse for each I value, where the operating trajectory and the Voltage limit ellipse for operating speeds
trajectory includes the selected I, values. above the first threshold speed according to an embodiment of
Also, the processor may be configured to determine an the present invention;
initial table, where the initial table includes II, combina
10 FIG. 6 illustrates a method for calculating operating tra
tions having values covering all possible values for a preset jectories for a plurality of speeds and generating a plurality of
current limit, to calculate the current peak magnitude, the integrated II, maps based on the operating trajectories
according to an embodiment of the present invention;
current control angle, and the L, and L values for each II, FIG. 7 is a block diagram of one embodiment of a system
combination of the initial table, to calculate torque for each 15 for controlling an electrical IPM machine; and
II, combination of the initial table based on the machine FIG. 8 is a block diagram of an electronic data processing
parameters, to set a torque range for each of the plurality of system consistent with FIG. 7.
torque commands, to determine a subset of II, combinations
for each torque command based on the calculated torque and DETAILED DESCRIPTION OF EXAMPLE
the set torque range, to select an II, combination from each EMBODIMENTS
Subset that has a calculated current peak magnitude less than
other II, combinations of the Subset, and to calculate the Various example embodiments will now be described more
MTPA trajectory based on the selected sets of II, combina fully with reference to the accompanying drawings in which
tions. The calculated torque for each of the II, combinations Some example embodiments are shown. Like numbers refer
in the determined Subset may fall within the set torque range 25 to like elements throughout the description of the figures.
encompassing a respective torque command. It will be understood that, although the terms first, second,
Also, the processor may be configured to determine an I etc. may be used herein to describe various elements, these
vertex value for the voltage limit ellipse right vertex at a set elements should not be limited by these terms. These terms
shaft speed based on the machine parameters, to calculate are only used to distinguish one element from another. For
maximum allowable I, values corresponding to a range of I, 30 example, a first element could be termed a second element,
values, where the range of I values is from the determined I, and, similarly, a second element could be termed a first ele
vertex value to a preset minimum I limit, and to calculate the ment, without departing from the scope of example embodi
voltage limit ellipse for the first speed based on the calculated ments. As used herein, the term “and/or” includes any and all
combinations of one or more of the associated listed items.
maximum allowable I, values. Also, the I, vertex value may 35 The terminology used herein is for the purpose of describ
be forced to zero if the determined I vertex value is greater ing particular embodiments only and is not intended to be
than Zero. limiting of example embodiments. As used herein, the singu
Also, the processor may be configured to calculate torque lar forms “a,” “an and “the are intended to include the plural
along points of the calculated Voltage limit ellipse at the first forms as well, unless the context clearly indicates otherwise.
speed, and to truncate the calculated Voltage limit ellipse by 40 It will be further understood that the tennis “comprises.”
disregarding monotonically decreasing torque. The processor “comprising.” “includes” and/or “including,” when used
is configured to generate a different II, map for a plurality of herein, specify the presence of stated features, integers, steps,
speeds by repeating the second calculating step, the determin operations, elements and/or components, but do not preclude
ing step, and the generating step for each speed, and to con the presence or addition of one or more other features, inte
struct an integrated II, map based on the plurality of II, 45 gers, steps, operations, elements, components and/or groups
maps. thereof.
It should also be noted that in some alternative implemen
BRIEF DESCRIPTION OF THE DRAWINGS tations, the functions/acts noted may occur out of the order
noted in the figures. For example, two figures shown in Suc
Example embodiments will become more fully understood 50 cession may in fact be executed concurrently or may some
from the detailed description given herein below and the times be executed in the reverse order, depending upon the
accompanying drawings, wherein like elements are repre functionality/acts involved.
sented by like reference numerals, which are given by way of Unless otherwise defined, all terms (including technical
illustration only and thus are not limiting, and wherein: and Scientific terms) used herein have the same meaning as
FIG. 1 illustrates a method for constructing an II, map for 55 commonly understood by one of ordinary skill in the art to
a plurality of speeds according to an embodiment of the which example embodiments belong. It will be further under
present invention; stood that terms, e.g., those defined in commonly used dic
tionaries, should be interpreted as having a meaning that is
FIG. 2 illustrates a device 200 for constructing an II, map consistent with their meaning in the context of the relevant art
for a plurality of speeds according to an embodiment of the 60 and will not be interpreted in an idealized or overly formal
present invention; sense unless expressly so defined herein.
FIG. 3A includes a plurality of curves and a plurality of In the following description, illustrative embodiments will
Voltage limit ellipses in a d-q plane according to an embodi be described with reference to acts and symbolic representa
ment of the present invention; tions of operations (e.g., in the form of flowcharts) that may
FIG. 3B illustrates a plurality of voltage limit ellipses and 65 be implemented as program modules or functional processes
a plurality of curves in a d-q plane according to an embodi that include routines, programs, objects, components, data
ment of the present invention; structures, etc., that when executed perform particular tasks
 US 8,410,737 B2
7 8
or implement particular abstract data types and may be imple tune machine current loop, speed loop, Voltage loop propor
mented using existing hardware at existing network elements. tional integral (PI) gains, (c) test machine thermal perfor
Such existing hardware may include one or more Central mance and limitations, (d) evaluate power electronics losses
Processing Units (CPUs), digital signal processors (DSPs), and select optimal pulse-width modulation (PWM) switching
application-specific-integrated-circuits, field programmable frequencies, and (e) establish a foundation for position cali
gate arrays (FPGAs) computers or the like machines that once bration and motor characterization, for example.
programmed become particular machines. According to some embodiments, the generated initial
It should be borne in mind, however, that all of these and operating points may provide operating points for the full
similar terms are to be associated with the appropriate physi operating range (e.g., full torque and full speed range) of the
cal quantities and are merely convenient labels applied to 10
IPM machine, while meeting specified current and voltage
these quantities. Unless specifically stated otherwise, or as is limitations. In addition, the generation of the initial operating
apparent from the discussion, terms such as "obtaining. points uses given machine parameters of the IPM machine
“determining', 'calculating”, “selecting”, “setting”, “trun Such as actual inductance values that are not assumed to be
cating', 'generating, or the like, refer to the action and
processes of a computer system, or similar electronic com 15 constant and are heavily coupled between dd-axes. As a
puting device, that manipulates and transforms data repre result, the generated initial operating points may be beneficial
sented as physical, electronic quantities within the computer for understanding how well the IPM machine is designed for
system's registers and memories into other data similarly a specific application purpose such as (a) whether the IPM
represented as physical quantities within the computer sys machine is oversized or short of torque generation capability,
tem memories or registers or other Such information storage, (b) whether the required current for low speed full torque
transmission or display devices. operation is too large, (c) whether Sufficient Voltage exists for
Embodiments of the present invention provide a device and high speed operation and corresponding angle is too large,
method for generating initial operating points for an interior and (d) whether the sensitivity of torque versus position is too
permanent magnet (IPM) machine. The IPM machine may be large, for example.
any type of IPM machine that is well known to one of ordinary 25 FIG. 1 illustrates a method for constructing an II, map for
skill in the art. For example, an IPM machine may include a a plurality of speeds according to an embodiment of the
stator with slots and a rotor with permanent magnet poles, as present invention. The method may be performed by any type
well as a controller configured to control the IPM machine. of computer processing unit having a memory and a proces
The initial operating points may be stored in at least one sor, as explained below with reference to FIG. 2.
lookup table, which is used in the operation of the IPM 30 FIG. 2 illustrates a device 200 for constructing an II, map
machine. for a plurality of speeds according to an embodiment of the
Each operating point includes a direct axis current (I) present invention. The device 200 includes a processor 205
value and quadrature axis current (I) value, which also may and at least one memory 210. The device 200 may include
be referred to as a flux current command and a torque current other components that are well known to one of ordinary skill
command, respectively. The current commands, I, and I are 35 in the art. The processor 205 may be any type of processor
components of a current peak magnitude (I) and a current configured to execute program codes stored in the at least one
control angle (Y). The current control angle (Y) indicates memory 210. The memory 210 may be any type of memory
amounts of I appearing as I, and I in the d-q plane. In one Such as Random-access memory (RAM) and Read-only
embodiment, the current control angle (Y) is the angle of the memory (ROM), for example. The device 200 may perform in
current peak magnitude (I) in relation to the positive q-axis of 40 any of the operations in FIGS. 1 and 4-6 of the present
the d-q plane. The relationship between the current peak application, as further explained below.
magnitude I, and the current control angle (Y) and I, and I are Referring back to FIG. 1, in step S110, the processor 205
as follows. loads the machine parameters of the IPM machine from the at
least one memory 210. The machine parameters may include
Is=Vi’+i," Eq. (1) 45 a back electromotive force (backemf) constant (7), a current
limit, a number of pole pairs of the IPM machine, a direct
I=-I, sin Y and I-I, cos Y Eq. (2) current (DC) bus Voltage level, an inductance lookup table, a
The current command I may have a positive or negative stator resistance, and/or a permanent magnet strength coeffi
sign (+/-) depending on the torque command sign. The cur cient with respect to temperature, for example. Further, the
rent commands indicate the appropriate amount of current to 50 machine parameters may include any other type of parameter
be applied to the IPM machine in response to a torque com that is well known to one of ordinary skill in the art.
mand (e.g., 50 Nm) and an operating speed. According to an The inductance lookup table may include sets of a direct
embodiment, an operating point is mapped to each torque axis inductance (L) value and a quadrature axis inductance
command for a plurality of speeds encompassing the full (L) value. Each set corresponds to a current peak magnitude
range of the IPM machine. The torque command may be 55 (I) and a current control angle (Y). Tables 1 and 2, shown
expressed in terms of a torque percentage of the full range below, illustrate one embodiment of the inductance lookup
(e.g., 0%. 5%, 10%, 15%). The operating points and corre table.
sponding torque commands are stored in at least one lookup
table having II, maps. Therefore, in response to a particular TABLE 1
torque command and operating speed, the IPM machine 60
Oo 5o 10° 15o 20° 25o 30° 90°
selects the corresponding operating point (e.g., I, value, I,
value) based on the appropriate II, map in the at least one 0A La La La La La La La La La
lookup table. 25A La La La La La La La La La
The initial operating points may be used to test the perfor 50A. L. L. L. L. L. L. L. L. L.
75A La La La La La La La La La
mance of the IPM machine. For example, based on the initial 65 100 A La La La La La La La La La
operating points, a user may (a) test basic torque control, 125A La La La La La La La La La
speed control and voltage control on the IPM machine, (b)
 US 8,410,737 B2
10
TABLE 1-continued high speed region, the DC bus voltage level directly deter
mines the voltage limit boundary which further limits output
Oo 5o 10° 15'o 20 25o 30° 90° torque at higher speeds.
to La La La La La La La La La Also, depending on the machine size and the DC bus volt
400A. L. L. L. L. L. L. L. L. L. age level, a stator resistance may or may not be important for
the initial operating points. Basically, for high power
machines with a high DC bus Voltage level (e.g. a traction
TABLE 2
machine for a heavy off-road vehicle), the Voltage drop across
the phase resistance is usually negligible. However, for low
Oo 5o 10° 15'o 20 25o 30° 90° 10 power low Voltage machines (e.g., turf care machine), the
Voltage drop across the phase resistance may be considered
0A La La La La La La La La La for Voltage limit evaluation.
25 A La La La La La La La La La For more advanced/accurate IPM motor control evalua
50 A La La La La La La La La La
75 A La La La La La La La La La tion, the permanent magnet strength coefficient with respect
100 A La La La La La La La La La 15 to temperature may be required, e.g., -0.11% per degree C.
125 A La La La La La La La La La The permanent magnet strength coefficient may be helpful to
to La La La La La La La La La properly compensate output torque variation due to magnet
400A La La La La La La La La La temperature change.
In step S120, the processor 205 calculates a maximum
Table 1 provides the inductance value for L, while Table 2 torque per Ampere (MTPA) trajectory for a first threshold
provides the inductance value for L. However, embodiments speed based on the machine parameters of the IPM machine,
of the present invention encompass any type of arrangement which include the inductance lookup table. The first threshold
that maps the peak current magnitude and the current control speed may be a base speed, which is the maximum shaftspeed
angle to inductance values of L, and L. For example, in at which constant maximum output torque of the IPM
another embodiment, Table 1 and Table 2 may be embodied 25 machine is achieved. For operating speeds at the base speed or
into one table. below the base speed, the operating points (II) are deter
Each row corresponds to a specified peak current magni mined based only on the MTPA trajectory. However, in some
tude (I) (e.g. 0A, 25 A, 50A, etc.). The highest peak current instances, for operating speeds above the base speed, the
magnitude level in Tables 1 and 2 should exceeded the maxi calculated MTPA for the base speed is used in the determin
mum current limit for the IPM machine, which is determined 30 ing of the operating trajectory for the current speed. The
by either a machine winding thermal limit or a hardware details of step S120 are further explained with reference to
Switching component current limit. Although Tables 1 and 2 FIG. 4 of the present invention.
illustrate 400 A as the highest peak current magnitude, In step S130, the processor 205 calculates a truncated
embodiments of the present invention may encompass any Voltage limit ellipse with monotonically increasing torque for
value. 35 a first speed based on the machine parameters, if the first
Each column corresponds to a specified current control speed is higher than the first threshold speed. For example, for
angle (Y) (e.g., 0°, 5, 10°. . . . , 85°, 90°). Because IPM operating speed higher than the first threshold speed, the
machine operation is assumed to be symmetrical in the sec operation of the IPM machine may be limited by the voltage
ond and third quadrants of the d-qplane, providing the Land limit ellipse. The first speed may be any speed within a plu
L values for the current control angles from 90 to 180 is not 40 rality of speeds that encompass the full operating range of the
required. IPM machine. If the first speed is higher than the first thresh
Each L, and L value corresponding to a specific peak old speed, the processor 205 calculates the truncated voltage
current magnitude (I) and a current control angle (Y) may be limit ellipse. The details of step S130 are further explained
obtained using finite element analysis (FEA) based simula with reference to FIG. 5 of the present invention.
tion tools such as SPEED, JMAG, Ansys, or Ansoft, for 45 In step S140, the processor 205 determines an operating
example. The FEA based simulation electromagnetically trajectory based on at least one of the calculated MTPA tra
analyzes the IPM machine to generate the Land L values for jectory and the calculated truncated voltage limit ellipse. For
the lookup inductance table. In other words, a machine example, if the first speed is lower than a second threshold
designer may fill in the inductance lookup table by executing speed and higher than the first threshold speed, step S140
an iterative FEA based simulation for the IPM machine. 50 determines the operating trajectory based on a comparison of
The backemf constant () may be defined as follows: the calculated MTPA trajectory and the calculated truncated
voltage limit ellipse. The second threshold speed may be a
critical speed, which is a speed at which uncontrolled genera
V3 Eq. (3) tion (UCG) voltage from the backemf of the IPM machine is
Vine line_ms = - F - coelec. Af 55 equal to the DC bus voltage. If the first speed is the second
threshold speed or higher than the second threshold speed,
step S140 determines the operating trajectory based on the
The parameter, is the backemfconstant and has the unit of calculated truncated Voltage limit ellipse with monotonically
Volts per electric radians/second, the parameter () is the increasing torque only. If the first speed is the first threshold
electrical frequency, and the parameter V. is the 60 speed or lower than the first threshold speed, step S140 deter
fundamental root mean square (rms) of the machine terminal mines the operating trajectory based only on the calculated
line to line Voltage. The machine terminal line to line Voltage MTPA trajectory. The details of step S140 are further
is the voltage applied to the IPM machine. explained with reference to FIG. 5 of the present invention.
The DC bus voltage level for a particular application may In S150, the processor 205 generates an II, map for the
be used. The DC bus voltage is the voltage supply from the 65 first speed based on the determined operating trajectory. The
power supply to the controller of the IPM machine. For II, map may be a lookup table that includes torque com
example, when the IPM machine operates in the medium to mands (T,) Versus direct axis current commands (i, )
 US 8,410,737 B2
11 12
and torque commands (T) versus quadrature axis current ating along the MTPA trajectory until reaching the Voltage
commands (i). As explained above, the torque com limit boundary point G. After that, the IPM machine switches
mands may be expressed in torque percentage. For example, to the voltage limit ellipse trajectory until reaching the SCL
a torque value such as 50 Nm may be converted to a torque boundary point C. The operating trajectory at speed () is the
percentage such as 5%, and the torque percentage may be 5 curve OEGC and the output torque is monotonically increas
stored in association with the current commands. The details ing along this operating curve. The peak torque at this speed
of step S150 are further explained with reference to FIGS.5-6 is determined by the stator current limit boundary. The case
of the present invention. belongs to partial flux weakening region. As explained with
Steps 130, 140 and 150 are repeated for each speed for the reference to FIG. 1, when the operating speed is greater than
plurality of speeds. As a result, the processor 205 generates a 10
the base speed and less than the critical speed, the operating
different II, map for the plurality of speeds. In step S160, the trajectory may be based on a comparison of the Voltage limit
processor constructs an integrated II, map based on the ellipse and the MTPA trajectory. These features are further
plurality of II, maps. For example, the integrated II, map explained with reference to FIG. 5. However, depending on
may include a plurality of lookup tables, where each lookup
table provides the torque commands (T) versus directaxis 15 the current limit value and the machine design parameters, the
current commands (i, ) and the torque commands (T) transition speed may or may not exist. For example, if the
Versus quadrature axis current commands (i) for a cor current limit value is relatively substantially large, then the
responding speed. The details of step S160 are further transition speed in FIG. 3B may not have to be considered. In
explained with reference to FIGS. 5-6 of the present inven this case, the peak torque above the base speed is always
tion. limited by the MVPT curve, not the stator current limit curve.
FIGS. 3A and 3B provide a graphical explanation of the Third, when the operating speed of the IPM machine is
Voltage limit ellipses for a plurality of speeds (including the greater than the transition speed and less than the critical
critical speed and base speed) and the MTPA trajectory for the speed such as ()), the IPM machine is operating (e.g.,
base speed. (Dasiziososocritical such as (o), the IPM machine is oper
FIG. 3A includes a plurality of curves and a plurality of 25 ating along the MTPA trajectory until reaching the Voltage
Voltage limit ellipses in a d-q plane according to an embodi limit boundary point E. After that, the IPM machine is further
ment of the present invention. The plurality of curves includes operating along the Voltage limit ellipse until reaching the
the MTPA trajectory (OB), the minimum voltage per torque MVPT boundary point K. The operating trajectory at speed
(MVPT) trajectory (MJ), and stator current limit (SCL) tra () is the curve OEK, and output torque is monotonically
jectory (ABJD). The plurality of voltage limit ellipses 30
increasing along this operating curve. The peak torque at this
includes the base speed (c)), the transition speed (c),), speed is determined by MVPT boundary. This case also
and the critical Speed (()). belongs to partial flux weakening region. As explained with
The MVPT trajectory determines the peak output torque at reference to FIG. 1, when the operating speed is greater than
each speed from a voltage limitation standpoint. The SCL the base speed and less than the critical speed, the operating
trajectory determines the peak allowable current running 35
trajectory may be based on a comparison of the Voltage limit
through the stator windings of the IPM machine. Point B is
the intersection point of the MTPA trajectory and the SCL ellipse and the trajectory. These features are further explained
trajectory, and point J is the intersection point of the SCL with reference to FIG. 5.
trajectory and the MVPT trajectory. Fourth, when the operating speed of the IPM machine is
The base speed (co) is defined as when the Voltage limit 40 greater than the critical speed (e.g., () (). Such as ()).
ellipse crossed point B. When the voltage limitellipse crosses the IPM machine is always operating along the Voltage limit
point J, the corresponding speed is defined as the transition ellipse until reaching the MVPT boundary point L. The oper
speed, (), Finally, when the Voltage limit ellipse ating trajectory at speed () is the curve NL and output torque
crosses point O, the corresponding motor speed is defined as is monotonically increasing along this operating curve. This
the critical speed. (). 45 case belongs to full flux weakening region. As explained with
The IPM machine is operating along the MTPA trajectory reference to FIG. 1, if the operating speed is above the critical
without Voltage constraint or along the Voltage limit ellipse speed, the operating trajectory is determined based only on
when flux weakening is required. the Voltage limit ellipse with monotonically increasing
FIG. 3B illustrates a plurality of voltage limit ellipses and torque.
a plurality of curves in a d-q plane according to an embodi 50 FIGS. 4-6 illustrate methods for determining the operating
ment of the present invention. The plurality of curves includes trajectories and generating operating points for a plurality
the same trajectories as described above with reference to speeds that may fall within anyone of the above identified
FIG.3A. The plurality of voltage limitellipses corresponds to regions according to embodiments of the present invention.
first, second, third and fourth operating speeds, which are FIG. 4 illustrates a method for calculating the MTPA tra
included into four main operation regions, respectively, as 55 jectory for the first threshold speed or a speed below the first
further described below. threshold speed according to an embodiment of the present
First, when an operating speed is less than the base speed invention (e.g., step S120 in FIG. 1).
(e.g., (i)<0), Such as ()), the IPM machine is operating In step 410, the processor 205 loads the IPM machine
along the MTPA trajectory (OEGB) without a limit on volt parameters including the inductance look-up table, the back
age limitation. This case belongs to non flux weakening 60 emf constant, and/or the current limit, for example. The pro
region. As explained with reference to FIG. 1, if the operating cessor 205 may be configured to load other IPM machine
speed is the base speed or below the base speed, the operating parameters that are well known to one of ordinary skill in the
trajectory is determined based on the MTPA. In this case, the art.
operating trajectory is OEGB. In step 415, the processor 205 determines an initial table.
Second, when the operating speed of the IPM machine is 65 The initial table includes II, combinations having values
greater than the base speed and less than the transition speed covering all possible values for a preset current limit. For
(e.g., (Osso), is Such as (D2), the IPM machine is oper example, when the preset current limit is 500 A, there are
 US 8,410,737 B2
13 14
501x501 combinations of (II). Therefore, the initial table For speeds at the first threshold speed or below the first
includes each of the possible combination such as (OA, 1A: threshold speed, the processor 205 determines the calculated
0 A, 2A, ... 500 A, 500 A). MPTA trajectory as the operating trajectory for that speed.
In step S420, the processor 205 calculates the current peak Based on the operating trajectory that includes the selected
magnitude (I), the current control angle (Y), the L, and L, 5 II, combinations, the processor 205 generates the II, map
values for each II, combination of the initial table. For for the first threshold speed or below the first threshold speed
example, processor 205 calculates the current peak magni that maps the selected II, combination to each torque com
tude (I) and the current control angle (Y) for each II, com mand of the plurality of torque commands. For example, the
bination based on Eq. 1 and Eq. 2. Then, the processor 205 II, map includes the selected II, combination correspond
obtains the L, and L values for each II, combination using 10 ing to each torque percentage (e.g., 5%, 10%, etc.) for the full
the inductance lookup table and the calculated current peak torque operating range.
magnitude and the current control angle. For example, using FIG. 5 illustrates a method for generating the II, map
the calculated current peak magnitude (I) and the current using the voltage limit ellipse or a combination of the MTPA
control angle (Y) as inputs, the processor 205 looks up the trajectory and the Voltage limit ellipse for operating speeds
corresponding L, and L values in the inductance lookup 15 above the first threshold speed according to an embodiment of
table. Also, in step S420, the processor calculates torque for the present invention. FIG. 5 illustrates a method for gener
each II, combination of the initial table based on the follow ating the II, map for one operating speed. However, FIG. 6
ing equation, for example. further expands on the method of FIG. 5 by extending the
Torque=1.5 p(y--(L-L). I.) I., Eq. (4)
operation of FIG. 5 for a plurality of speeds.
In S510, the processor 205 loads the machine parameters
The parameter p is the number of pole pairs, , is the and the MTPA coefficients that were determined in FIG. 4
backemf constant, the parameters L, and L are the induc from the at least one memory 210.
tance values obtained from the inductance lookup table, and In S515, the processor 205 selects one speed among a
the parameters I, and I are obtained from the initial table. plurality of speeds ranging from above the first threshold
In step S425, the processor 205 sets a range for a respective 25 speed to the highest speed of the IPM machine. The processor
torque command. For instance, for a specific torque com 205 calculates the corresponding electrical frequency based
mand, e.g. 100 Nm, the processor sets a torque range, e.g., on the following equation.
99.5 Nm to 100.5 Nm. As further explained below, the pro (Detectin/60p 2 (pi) Eq. (5)
cessor 205 will repeat this step in order to obtain an optimal
operating point for each torque command among a plurality 30 The parameters n is the speed of the rotor in rpm, and p is
of torque commands. the number of pole pairs.
In step S430, the processor 205 determines a subset of II, In step S520, the processor 205 calculates the phase termi
combinations from the initial table for a torque command that nal voltage limit based on the DC bus voltage level based on
can generate torque within the set range, and not exceed the the following equation.
current limit. For example, using the results of step S420, the 35
processor 205 searches for all II, combinations which can Vic Eq. (6)
generate torque within the torque range. The calculated Vinil =
torque for each of the II, combinations in the determined VA in
Subset falls within the set torque range encompassing the
respective torque command. 40
V, it is the phase terminal Voltage limit, V is the DC
In step S435, using the results from step S430, the proces bus Voltage, and the parameterm is a coefficient to account for
sor 205 selects the II, combination with the minimum cur operating conditions. For example, the coefficient m may be a
rent peak magnitude (I). The selected II, combination may percentage such as 92%. The value of the coefficient m may be
represent the operating point with the minimum copper loss any percentage indicating a range or Voltage margin. For
among this subset. As such, the selected II, combination 45
example, the coefficient m may be any value between 90% and
may be the optimal operating point for the respective torque 95%. In one particular embodiment, the coefficient n may be
command level.
In step S440, the processor 205 determines whether the 92% in order make 8% room for a voltage margin such that a
torque command is the last torque command within the plu range of events may be taken into consideration Such as
rality of torque comments, which represents the full torque 50
magnet strength variation due to ambient temperature, fast
range. If the processor 205 determines that the torque com torque command dynamics request additional Voltage during
mand is not the last torque command (NO), the process transient, and/or imperfect DC bus Voltage measurements, for
example.
returns to step S425. In other words, steps S425, S430 and In S525, the processor 205 determines an Ivertex value for
S435 are repeated for the full range of torque commands, e.g. the voltage limit ellipse right vertex for the selected operating
5 Nm, 10 Nm, 15 Nm . . . . until maximum output torque is 55
speed. For example, the right vertex point can be initialized as
assigned an optimal operating point.
In step S450, the processor 205 stores the selected II, (0,0). Next, the terminal voltage for the initialized points are
combinations corresponding to the plurality of torque com calculated based on the following equations.
mands in the at least one memory 210. Varsii-o-Li, Eq. (7)
In step S455, the processor 205 calculates the MTPA tra 60
jectory, which include the selected II, combinations, using a Vriho Li?t-Cow Eq. (8)
polynomial curve fitting operation. The polynomial cure fit
ting operation may be any type of operation that generates a v=Vvv, Eq. (9)
curve based on a number of points. Referring back to FIG.3B, The parameter v is the d-axis Voltage, v, is the q-axis
the MTPA trajectory may be the OEGB curve. 65 voltage, r is the stator resistance, i, is the d-axis current, i? is
In step S460, the processor 205 stores the calculated MTPA the q-axis current, L, is the d-axis inductance, L, is the q-axis
trajectory coefficients in the at least one memory 210. inductance, (), is the electrical frequency of the IPM and is
 US 8,410,737 B2
15 16
the strength of the permanent magnet on the rotor of the IPM. higher than the first threshold speed (e.g., base speed). As
L., and L are obtained from the lookup table. such, the processor 205 determines the operating trajectory
If the resulting terminal Voltage V, from Eqs. (7)-(9), is based on a comparison of the MTPA trajectory and the cal
lower than the phase terminal Voltage limit V, from Eq.(6), culated truncated Voltage limit ellipse, as further explained
the I vertex value is larger than Zero. Otherwise, while keep 5 below.
ing I-0, the processor 205 gradually increases the I, value In step S565, the processor 205 calculates the MTPA tra
magnitude along the negative d-axis (e.g., from 0 to -1, -2, jectory from FIG. 4 in the same d-axis current range. Next, in
etc.) until the resulting terminal Voltage V, is equal or step S570, the processor 205 compares the calculated MTPA
approximately equal to the phase terminal Voltage limit V. trajectory with the calculated truncated voltage limit ellipse.
Then, the processor 205 sets the closest integer value to 10 In step S575, the processor 205 selects the lesser of the I,
achieve this condition as I vertex value which is a negative value of the calculated MTPA trajectory and the I value of the
number. calculated truncated Voltage limit ellipse for each I value. As
In S525, the processor 205 determines whether the deter Such, the operating trajectory for the selected speed includes
mined I vertex value is greater than Zero. If the processor 205 the selected I values.
determines that the determined I vertex value is greater than 15 FIG. 6 illustrates a method for calculating operating tra
Zero (YES), the processor 205 forces the I vertex value to jectories for a plurality of speeds and generating a plurality of
Zero, and the process proceeds to step S540. If the processor integrated II, maps based on the operating trajectories
205 determines that the determined I vertex value is less than according to an embodiment of the present invention.
or equal to Zero (NO), the process uses the determined I In step 610, the processor 210 loads the machine param
vertex value in step S540. eters from the at least one memory 210. In step 615, the
In S540, the processor 205 calculates the maximum allow processor 210 loads the MTPA trajectory for the first thresh
able I, values corresponding to a range of I, values, where the old speed that was calculated in FIG. 4. In step 620, the
range of I values is from the determined I vertex value to a processor 205 constructs a speed vector from the highest
preset minimum I limit. The preset minimum I limit should speed vector to the first threshold speed. In step 625, the
be selected Such that the generated maximum torque at that I 25 processor 205 selects one of the speed vectors and calculates
limit will equal or exceed the specified peak toque at the the operating trajectory for that speed using the method
selected speed. For example, if I, is -50A, then the I value is described in FIG. 5. In step S630, the processor generates an
increased from 0 to 1, and the processor evaluates at least two II, map based on the calculated operating trajectory.
conditions: (1) whether the corresponding terminal Voltage In step S635, the processor 205 determines whether the
V is below the phase terminal voltage limit V, and (2) 30 selected speed vector is the last vector. If the processor 205
whether the peak current magnitude is below the current determines that the selected speed vector is not the last vector
limit. If the resultisyes for both conditions, the processor 205 (NO), the processor returns to step S625. As such, the pro
increases the I magnitude (e.g. to 2,3,4,etc.) until the result cessor 205 repeats steps S625 and S630 for each speed of the
from at least one of the above conditions is no. As a result, the plurality of speeds in the vector. As a result, the processor 205
processor 205 calculates the maximum allowable I, value for 35 generates a plurality of II, maps for the plurality of speeds.
every I value in the range. It is noted that the above procedure If the processor 205 determines that the selected speed vector
applies to the following two cases, as explained above with is the last vector (YES), the process continues to step 645 to
(bases00,ransition and Otransitions critical aS explained construct an integrated II, map at all evaluated speeds in the
above with reference to FIG.3(b). speed vector.
In step S545, the processor 205 calculates torque at differ 40 Optionally, in step 650, the processor 205 may plot I,
ent points of the Voltage limit ellipse. As explained above, in Versus I trajectories at all speeds in the same d-q plane to
the set I range, the processor 205 calculates the maximum validate the authenticity of the obtained data.
possible I, value for each corresponding I, value. Then, for Next, an application of the characterization and in particu
every (I, I) combination, the processor 205 obtains the lar, the initial lookup table generated according to the above
corresponding current peak magnitude I, the current control 45 described procedures will be described with respect to FIG.7
angle, the inductance values L.L and then calculates the below.
torque at each found point along the Voltage limit ellipse In accordance with one embodiment, FIG. 7 discloses a
based on Eqs. (1)–(4). system for controlling a IPM machine 117 (e.g., an interior
In step S550, the processor 205 truncates the calculated permanent magnet (IPM) IPM machine) or another alternat
Voltage limit ellipse by finding the monotonically increasing 50 ing current machine. In one embodiment, the system, aside
torque of the Voltage limit ellipse, and Subsequently discard from the IPM machine 117, may be referred to as an inverter
ing the monotonically decreasing torque. For example, or a IPM machine controller.
because the torque value at every point along the Voltage limit The system comprises electronic modules, software mod
ellipse is known from step S545, the processor 205 truncates ules, or both. In one embodiment, the IPM machine controller
the Voltage limit ellipse when the calculated torque stops 55 comprises an electronic data processing system 120 to Sup
increasing. port storing, processing or execution of software instructions
In step S555, the processor 205 determines whether the I. of one or more software modules. The electronic data pro
vertex value is less than Zero. If the processor 205 determines cessing system 120 is indicated by the dashed lines in FIG. 7
that the I vertex value is less than Zero (YES), this indicates and is shown in greater detail in FIG. 8.
that the selected speed is equal to or higher than the second 60 The data processing system 120 is coupled to an inverter
threshold speed (e.g., the critical speed). As such, in step circuit 188. The inverter circuit 188 comprises a semiconduc
S560, the processor 205 selects the truncated voltage limit tor drive circuit that drives or controls Switching semiconduc
ellipse as the operating trajectory, and generates the II, map tors (e.g., insulated gate bipolar transistors (IGBT) or other
based on the truncated voltage limit ellipse. If the processor power transistors) to output control signals for the IPM
205 determines that the I vertex value is equal to or greater 65 machine 117. In turn, the inverter circuit 188 is coupled to the
than Zero (NO), this indicates that the selected speed is lower IPM machine 117. The IPM machine 117 is associated with a
than the second threshold speed (e.g., critical speed) and sensor 115 (e.g., a position sensor, a resolver or encoder
 US 8,410,737 B2
17 18
position sensor) that is associated with the IPM machine shaft two-phase current Park transformation module) that converts
126 or the rotor. The sensor 115 and the IPM machine 117 are respective three-phase digital representations of measured
coupled to the data processing system 120 to provide feed current into corresponding two-phase digital representations
back data (e.g., current feedback data, such as i. i. i.), raw of measured current. A second output (e.g., speed data) of the
position signals, among other possible feedback data or sig primary processing module 114 is communicated to the cal
nals, for example. Other possible feedback data includes, but culation module 110 (e.g., adjusted Voltage over speed ratio
is not limited to, winding temperature readings, semiconduc module).
tor temperature readings of the inverter circuit 188, three An input of a sensing circuit 124 is coupled to terminals of
phase Voltage data, or other thermal or performance informa the IPM machine 117 for sensing at least the measured three
tion for the IPM machine 117. 10 phase currents and a voltage level of the direct current (DC)
In one embodiment, the torque command generation mod bus (e.g., high voltage DC bus which may provide DC power
ule 105 is coupled to a d-q axis current generation manager to the inverter circuit 188). An output of the sensing circuit
109 (e.g., d-q axis current generation look-up tables) along 124 is coupled to an analog-to-digital converter 122 for digi
with an adjusted Voltage over speed ratio from the calculation tizing the output of the sensing circuit 124. In turn, the digital
module 110. The d-q axis current generation manager 109 15 output of the analog-to-digital converter 122 is coupled to the
may store any one of the above described lookup tables. The secondary processing module 116 (e.g., Direct current (DC)
output of the d-qaxis current generation manager 109 and the bus and three phase current processing module). For example,
output of a current adjustment module 107 (e.g., d-q axis the sensing circuit 124 is associated with the IPM machine
current adjustment module 107) are fed to a summer 119. In 117 for measuring three phase currents (e.g., current applied
turn, one or more outputs (e.g., direct axis current data (i.) to the windings of the IPM machine 117, back EMF induced
and quadrature axis current data (i)) of the summer 119 are into the windings, or both).
provided or coupled to a current regulation controller 111. Certain outputs of primary processing module 114 and the
The current regulation controller 111 is capable of com secondary processing module 116 feed the phase converter
municating with the pulse-width modulation (PWM) genera 113. For example, the phase converter 113 may apply a Park
tion module 112 (e.g., space vector PWM generation mod 25 transformation or other conversion equations (e.g., certain
ule). The current regulation controller 111 receives respective conversion equations that are Suitable are known to those of
d-q axis current commands (e.g. i* and i) and actual d-q ordinary skill in the art) to convert the measured three-phase
axis currents (e.g., i, and i) and outputs corresponding d-q representations of current into two-phase representations of
axis Voltage commands (e.g., V* and V* commands) for current based on the digital three-phase current data from the
input to the PWM generation module 112. 30 secondary processing module 116 and position data from the
In one embodiment, the PWM generation module 112 sensor 115. The output of the phase converter 113 module is
converts the direct axis voltage and quadrature axis voltage coupled to the current regulation controller 111.
data from two phase data representations into three phase Other outputs of the primary processing module 114 and
representations (e.g., three phase Voltage representations, the secondary processing module 116 may be coupled to
such as V, V, and V*) for control of the IPM machine 117, 35 inputs of the calculation module 110 (e.g., adjusted Voltage
for example. Outputs of the PWM generation module 112 are over-speed ratio calculation module). For example, the pri
coupled to the inverter 188. mary processing module 114 may provide speed data (e.g.,
The inverter circuit 188 comprises power electronics, such IPM machine shaft 126 revolutions per minute), whereas the
as Switching semiconductors to generate, modify and control secondary processing module 116 may provide a measured
pulse-width modulated signals or other alternating current 40 level of direct current voltage (e.g., on the direct current (DC)
signals (e.g., pulse, square wave, sinusoidal, or other wave bus of a vehicle). The direct current voltage level on the DC
forms) applied to the IPM machine 117. The PWM genera bus that supplies the inverter circuit 188 with electrical energy
tion module 112 provides inputs to a driver stage within the may fluctuate or vary because of various factors, including,
inverter circuit 188. An output stage of the inverter circuit 188 but not limited to, ambient temperature, battery condition,
provides a pulse-width modulated voltage waveform or other 45 battery charge state, battery resistance or reactance, fuel cell
voltage signal for control of the IPM machine. In one embodi state (if applicable), IPM machine load conditions, respective
ment, the inverter 188 is powered by a direct current (DC) IPM machine torque and corresponding operational speed,
Voltage bus. and vehicle electrical loads (e.g., electrically driven air-con
The IPM machine 117 is associated with a sensor 115 (e.g., ditioning compressor). The calculation module 110 is con
a resolver, encoder, speed sensor, or another position sensor 50 nected as an inter between the secondary processing module
or speed sensors) that estimates at least one of an angular 116 and the da-axis current generation manager 109. The
position of the IPM machine shaft 126, a speed or velocity of output of the calculation module 110 can adjust or impact
the IPM machine shaft 126, and a direction of rotation of the current commands generated by the d-q axis current genera
IPM machine shaft 126. The sensor 115 may be mounted on tion manager 109 to compensate for flu or variation in direct
or integral with the IPM machine shaft 126. The output of the 55 current bus Voltage, among other things. The structure and
sensor 115 is capable of communication with the primary operation of the calculation module 110 is described in detail
processing module 114 (e.g., position and speed processing in U.S. application Ser. No. Unknown, entitled “”, filed Feb.
module). In one embodiment, the sensor 115 may be coupled 28, 2011 by the inventor of the subject application; the entire
to an analog-to-digital converter (not shown) that converts contents of which are hereby incorporated by reference.
analog position data or Velocity data to digital position or 60 The rotor magnet temperature estimation module 104, the
Velocity data, respectively. In other embodiments, the sensor current shaping module 106, and the terminal Voltage feed
115 (e.g., digital position encoder) may provide a digital data back module 108 are coupled to or are capable of communi
output of position data or velocity data for the IPM machine cating with the dq-axis current adjustment module 107. In
shaft 126 or rotor. turn, the d-q axis current module 107 may communicate with
A first output (e.g., position data and speed data for the IPM 65 the da-axis current generation manager or the Summer 119.
machine 117) of the primary processing module 114 is com The rotor magnet temperature module 104 estimates or
municated to the phase converter 113 (e.g., three-phase to determines the temperature of the rotor peg magnet or mag
 US 8,410,737 B2
19 20
nets. In one embodiment, the rotor magnet temperature esti 115 comprises a position sensor, where position data and
mation module 104 may estimate the temperature of the rotor associated time data are processed to determine speed or
magnets from, one or more sensors located on the stator, in velocity data for the IPM machine shaft 126. In another con
thermal communication with the stator, or secured to the figuration, the sensor 115 comprises a speed sensor, or the
housing of the IPM machine 117. combination of a speed sensor and an integrator to determine
In another embodiment, the rotor magnet temperature esti the position of the IPM machine shaft.
mation module 104 may be replaced with a temperature In yet another configuration, the sensor 115 comprises an
detector (e.g., a thermistor and wireless transmitter like infra auxiliary, compact direct current generator that is coupled
red thermal sensor) mounted on the rotor or the magnet, mechanically to the IPM machine shaft 126 of the IPM
where the detector provides a signal (e.g., wireless signal) 10 machine 117 to determine speed of the IPM machine shaft
indicative of the temperature of the magnet or magnets. 126, where the direct current generator produces an output
In one embodiment, the method or system may operate in voltage proportional to the rotational speed of the IPM
the following manner. The torque command generation mod machine shaft 126. In still another configuration, the sensor
ule 105 receives an input control data message. Such as a 115 comprises an optical encoder with an optical source that
speed control data message, a Voltage control data message, 15 transmits a signal toward a rotating object coupled to the shaft
or a torque control data message, over a vehicle data bus 118. 126 and receives a reflected or diffracted signal at an optical
The torque command generation module 105 converts the detector, where the frequency of received signal pulses (e.g.,
received input control message into torque control command square waves) may be proportional to a speed of the IPM
data 316. machine shaft 126. In an additional configuration, the sensor
The d-q axis current generation manager 109 selects or 115 comprises a resolver with a first winding and a second
determines the direct axis current command data and the winding, where the first winding is fed with an alternating
quadrature axis current command data associated with current, where the Voltage induced in the second winding
respective torque control command data and respective varies with the frequency of rotation of the rotor.
detected IPM machine shaft 126 speed data. For example, the In FIG. 8, the electronic data processing system 120 com
d-q axis current generation manager 109 selects or deter 25 prises an electronic data processor 264, a data bus 262, a data
mines the direct axis current command, the quadrature axis storage device 260, and one or more data ports (268,270,272.
current command by accessing control lookup tables such as 274 and 276). The data processor 264, the data storage device
the above-described lookup tables. The sensor 115 on the 260 and one or more data ports are coupled to the data bus 262
IPM machine 117 facilitates provision of the detected speed to Support communications of data between or among the
data for the IPM machine shaft 126, where the primary pro 30 data processor 264, the data storage device 260 and one or
cessing module 114 may convert position data provided by more data ports.
the sensor 115 into speed data. In one embodiment, the data processor 264 may comprise
The current adjustment module 107 (e.g., d-q axis current an electronic data processor, a microprocessor, a microcon
adjustment module) provides current adjustment data to troller, a programmable logic array, a logic circuit, an arith
adjust the direct axis current command data and the quadra 35 metic logic unit, an application specific integrated circuit, a
ture axis current command databased on input data from the digital signal processor, a proportional-integral-derivative
rotor magnet temperature estimation module 104, the current (PID) controller, or another data processing device.
shaping module 106, and terminal Voltage feedback module The data storage device 260 may comprise any magnetic,
108. electronic, or optical device for storing data. For example, the
The current shaping module 106 may determine a correc 40 data storage device 260 may comprise an electronic data
tion or preliminary adjustment of the quadrature axis (q-axis) storage device, an electronic memory, non-volatile electronic
current command and the direct axis (d-axis) current com random access memory, one or more electronic data registers,
mand based on one or more of the following factors: torque data latches, a magnetic disc drive, a hard disc drive, an
load on the IPM machine 117 and speed of the IPM machine optical disc drive, or the like.
117, for example. The rotor magnet temperature estimation 45 As shown in FIG. 8, the data ports comprise a first data port
module 104 may generate a secondary adjustment of the 268, a second data port 270, a third data port 272, a fourth data
q-axis current command and the d-axis current command port 274 and a fifth data port 276, although any suitable
based on an estimated change in rotor temperature, for number of data ports may be used. Each data port may com
example. The terminal voltage feedback module 108 may prise a transceiver and buffer memory, for example. In one
provide a third adjustment to d-axis and q-axis current based 50 embodiment, each data port may comprise any serial or par
on controller Voltage command versus Voltage limit. The allel input/output port.
current adjustment module 107 may provide an aggregate In one embodiment as illustrated in FIG. 8, the first data
current adjustment that considers one or more of the follow port 268 is coupled to the vehicle data bus 118. In turn, the
ing adjustments: a preliminary adjustment, a secondary vehicle data bus 118 is coupled to the controller 266. In one
adjustment, and a third adjustment. 55 configuration, the second data port 270 may be coupled to the
In one embodiment, the IPM machine 117 may comprise inverter circuit 188; the third data port 272 may be coupled to
an interior permanent magnet (IPM) machine or a synchro the sensor 115; the fourth data port 274 may be coupled to the
nous IPM machine (IPMSM). An IPMSM has many favor analog-to-digital converter 122; and the fifth data port 276
able advantages compared with conventional induction may be coupled to the terminal voltage feedback module 108.
machines or surface mounted PM machines (SMPM) such as 60 The analog-to-digital converter 122 is coupled to the sensing
high efficiency, high power density, wide constant power circuit 124.
operating region, maintenance free, for instance. In one embodiment of the data processing system 120, the
The sensor 115 (e.g., shaft or rotor speed detector) may torque command generation module 105 is associated with or
comprise one or more of the following: a direct current IPM supported by the first data port 268 of the electronic data
machine, an optical encoder, a magnetic field sensor (e.g., 65 processing system 120. The first data port 268 may be
Hall Effect sensor), magneto-resistive sensor, and a resolver coupled to a vehicle data bus 118, such as a controller area
(e.g., a brushless resolver). In one configuration, the sensor network (CAN) data bus. The vehicle data bus 118 may
 US 8,410,737 B2
21 22
provide data bus messages with torque commands to the selecting lesser of an I, value of the calculated MTPA
torque command generation module 105 via the first data port trajectory and an I, value of the calculated truncated
268. The operator of a vehicle may generate the torque com Voltage limit ellipse for each I value, wherein the oper
mands via a user interface, such as a throttle, a pedal, a ating trajectory includes the selected I, values.
controller 266, or other control device. 5 6. The method of claim 1, wherein the first calculating step
In certain embodiments, the sensor 115 and the primary includes:
processing module 114 may be associated with or Supported determining an initial table, the initial table including II,
by a third data port 272 of the data processing system 120. combinations having values covering all possible values
The invention being thus described, it will be obvious that for a preset current limit;
the same may be varied in many ways. Such variations are not 10 calculating the current peak magnitude, the current control
to be regarded as a departure from the invention, and all Such angle, and the L, and L values for each II, combina
modifications are intended to be included within the scope of tion of the initial table;
the invention. calculating torque for each II, combination of the initial
What is claimed: table based on the machine parameters;
1. A method for generating initial operating points for 15 setting a torque range for each of the plurality of torque
controlling an interior peg magnet (IPM) machine, the commands;
method comprising: determining a subset of II, combinations for each torque
loading an inductance lookup table, the inductance lookup command based on the calculated torque and the set
table including sets of a directaxis inductance (L) value torque range;
and a quadrature axis inductance (L) value, each set selecting an II, combination from each subset that has a
corresponding to a current peak magnitude and a current calculated current peak magnitude less than other II,
control angle, the current control angle indicating combinations of the Subset; and
amounts of the current peak magnitude appearing as calculating the MTPA trajectory based on the selected sets
direct axis current (I) and quadrature axis current (I); of II, combinations.
first calculating a maximum torque per Ampere (MTPA) 25 7. The method of claim 6, wherein the calculated torque for
trajectory for a first threshold speed based on machine each of the II, combinations in the determined subset falls
parameters of the IPM machine, the machine parameters within the set torque range encompassing a respective torque
including the inductance lookup table; command.
second calculating a truncated Voltage limit ellipse with 8. The method of claim 1, wherein the second calculating
monotonically increasing torque for a first speed based 30 step includes:
on the machine parameters, if the first speed is higher determining an I vertex value for the Voltage limit ellipse
than the first threshold speed: right vertex at a set shaft speed based on the machine
determining an operating trajectory at the first speed based parameters;
on at least one of the calculated MTPA trajectory and the calculating maximum allowable I, values corresponding to
calculated truncated Voltage limit ellipse; and 35 a range of I values, the range of I values being from the
generating an II, map that maps an I, Value and an I, value determined I vertex value to a preset minimum I limit;
to each torque command of a plurality of torque com and
mands for the first speed based on the determined oper calculating the Voltage limit ellipse for the first speed based
ating trajectory. on the calculated maximum allowable I, values.
2. The method of claim 1, wherein the first threshold speed 40 9. The method of claim 8, wherein the I vertex value is
is a base speed, the base speed being a maximum shaft speed forced to zero if the determined I vertex value is greater than
at which maximum constant output torque of the IPM ZO.
machine is achieved. 10. The method of claim 8, wherein the second calculating
3. The method of claim 1, wherein the determining step step further includes:
includes: 45 calculating torque along points of the calculated Voltage
if the first speed is lower than a second threshold speed and limit ellipse at the first speed; and
higher than the first threshold speed, the determining truncating the calculated Voltage limitellipse by disregard
step determines the operating trajectory based on a com ing monotonically decreasing torque.
parison of the calculated MTPA trajectory and the cal 11. The method of claim 1, further comprising:
culated truncated Voltage limit ellipse; 50 obtaining the L values and the L values using finite ele
if the first speed is the second threshold speed or higher ment analysis based simulation; and
than the second threshold speed, the determining step generating the inductance look-up table based on the
determines the operating trajectory based on the calcu obtained inductance parameters.
lated truncated voltage limit ellipse with monotonically 12. The method of claim 1, further comprising:
increasing torque only; and 55 generating a different II, map for a plurality of speeds by
if the first speed is the first threshold speed or lower than the repeating the second calculating step, the determining
first threshold speed, the determining step determines step, and the generating step for each speed; and
the operating trajectory based on the calculated MTPA constructing an integrated II, map based on the plurality
trajectory. of II, maps.
4. The method of claim 3, wherein the second threshold 60 13. The IPM machine including a machine controller hav
speed is a critical speed, the critical speed being a speed at ing the II, map generated in claim 1.
which uncontrolled generation (UCG) voltage from a back 14. A method for generating initial operating points for
electromotive force (backemf) of the IPM machine is equal to controlling an interior permanent magnet (IPM) machine, the
a direct current (DC) bus voltage. method comprising:
5. The method of claim3, wherein if the first speed is lower 65 first calculating a maximum torque per Ampere (MTPA)
than the second threshold speed and higher than the first trajectory for a first threshold speed based on machine
threshold speed, the determining step includes: parameters of the IPM machine;
 US 8,410,737 B2
23 24
second calculating a truncated Voltage limit ellipse with selecting an II, combination from each subset that has a
monotonically increasing torque for a first speed based calculated current peak magnitude less than other II,
on the machine parameters, if the first speed is higher combinations of the Subset; and
than the first threshold speed; calculating the MTPA trajectory based on the selected sets
determining an operating trajectory at the first speed based 5
of II, combinations.
on at least one of the calculated MTPA trajectory and the 20. The method of claim 19, wherein the calculated torque
calculated truncated Voltage limit ellipse, the determin for each of the II, combinations in the determined subset
ing step including, falls within the set torque range encompassing a respective
determining the operating trajectory based on a com 10
torque command.
parison of the calculated MTPA trajectory and the 21. The method of claim 14, wherein the second calculat
calculated truncated voltage limit ellipse if the first ing step includes:
speed is lower than a second threshold speed and determining an I vertex value at the Voltage limit ellipse
higher than the first threshold speed; and right vertex point at a set shaft speed based on the
generating an II, map that maps a direct axis current (I) 15 machine parameters;
value and a quadrature axis current (I) value to each calculating maximum allowable I, values corresponding to
torque command of a plurality of torque commands for a range of I values, the range of I values being from the
the first speed based on the determined operating trajec determined I vertex value to a preset minimum I limit;
tory. and
15. The method of claim 14, wherein calculating the Voltage limit ellipse for the first speed based
the first threshold speed is a base speed, the base speed on the calculated maximum allowable I, values.
being a maximum shaft speed at which maximum con 22. The method of claim 21, wherein the I vertex value is
stant output torque of the IPM machine is achieved, forced to zero if the determined I vertex value is greater than
the second threshold speed is a critical speed, the critical ZO.
speed being a speed at which uncontrolled generation 25 23. The method of claim 21, wherein the second calculat
(UCG) voltage from a back-electromotive force (back ing step further includes:
emf) of the IPM machine is equal to a direct current (DC) calculating torque along points of the calculated Voltage
bus Voltage. limit ellipse at the first speed; and
16. The method of claim 14, wherein the machine param truncating the calculated Voltage limitellipse by disregard
eters include an inductance lookup table, the inductance 30 ing monotonically decreasing torque.
lookup table including sets of a direct axis inductance (L) 24. The method of claim 14, further comprising:
value and a quadrature axis inductance (L) value, each set generating a different II, map for a plurality of speeds by
corresponding to a current peak magnitude and a current repeating the second calculating step, the determining
control angle, the current control angle indicating amounts of step, and the generating step for each speed; and
the current peak magnitude appearing as I, and I. 35 constructing an integrated II, map based on the plurality
17. The method of claim 14, wherein the determining step of II, maps.
further includes: 25. The IPM machine including a machine controller hav
if the first speed is the second threshold speed or higher ing the II, map generated in claim 14.
than the second threshold speed, the determining step 26. A computer processing unit for generating initial oper
determines the operating trajectory based on the calcu 40 ating points for controlling an interior permanent magnet
lated truncated voltage limit ellipse with monotonically (IPM) machine, the computer processing unit comprising:
increasing torque only; and a memory configured to store machine parameters, the
if the first speed is the first threshold speed or lower than the machine parameters including an inductance lookup
first threshold speed, the determining step determines table, the inductance lookup table including sets of a
the operating trajectory based on the calculated MTPA 45 direct axis inductance (L) value and a quadrature axis
trajectory. inductance (L) value, each set corresponding to a cur
18. The method of claim 14, wherein the determining step rent peak magnitude and a current control angle, the
further includes: current control angle indicating amounts of the current
selecting lesser of an I, value of the calculated MTPA peak magnitude appearing as direct axis current (I) and
trajectory and an I, value of the calculated truncated 50 quadrature axis current (I); and
Voltage limit ellipse for each I value, wherein the oper a processor configured to first calculate a maximum torque
ating trajectory includes the selected I values. per Ampere (MTPA) trajectory for a first threshold speed
19. The method of claim 14, wherein the first calculating based on the machine parameters,
step includes: the processor configured to second calculate a truncated
determining an initial table, the initial table including II, 55 Voltage limit ellipse with monotonically increasing
combinations having values covering all possible values torque for a first speed based on the machine parameters,
for a preset current limit; if the first speed is higher than the first threshold speed,
calculating the current peak magnitude, the current control the processor configured to determine an operating trajec
angle, and the L, and L values for each II, combina tory at the first speed based on at least one of the calcu
tion of the initial table; 60 lated MTPA trajectory and the calculated truncated volt
calculating torque for each II, combination of the initial age limit ellipse,
table based on the machine parameters; the processor configured to generate an II, map that maps
setting a torque range for each of the plurality of torque an I, value and an I, value to each torque command of a
commands; plurality of torque commands for the first speed based on
determining a subset of II, combinations for each torque 65 the determined operating trajectory.
command based on the calculated torque and the set 27. The computer processing unit of claim 26, wherein the
torque range; first threshold speed is a base speed, the base speed being a
 US 8,410,737 B2
25 26
maximum shaft speed at which maximum constant output the processor is configured to determine a subset of II,
torque of the IPM machine is achieved. combinations for each torque command based on the
28. The computer processing unit of claim 26, wherein calculated torque and the set torque range;
if the first speed is lower than a second threshold speed and the processor is configured to select an II, combination
higher than the first threshold speed, the processor is 5 from each Subset that has a calculated current peak mag
configured to determine the operating trajectory based nitude less than other II, combinations of the subset;
and
on a comparison of the calculated MTPA trajectory and
the calculated truncated Voltage limit ellipse; the processor is configured to calculate the MTPA trajec
if the first speed is the second threshold speed or higher tory based on the selected sets of II, combinations.
than the second threshold speed, the processor is con 10 32. The computer processing unit of claim 31, wherein the
figured to determine the operating trajectory based on calculated torque for each of the II, combinations in the
the calculated truncated Voltage limitellipse with mono determined Subset falls within the set torque range encom
tonically increasing torque only; and passing a respective torque command.
if the first speed is the first threshold speed or lower than the 33. The computer processing unit of claim 26, wherein
first threshold speed, the processor is configured to 15 the processor is configured to determine an I vertex value
determine the operating trajectory based on the calcu for the voltage limit ellipse right vertex at a set shaft
lated MTPA trajectory. speed based on the machine parameters;
29. The computer processing unit of claim 28, wherein the the processor is configured to calculate maximum allow
second threshold speed is a critical speed, the critical speed able I, values corresponding to a range of I, values, the
being a speed at which uncontrolled generation (UCG) volt range of I values being from the determined I vertex
age from a back-electromotive force (backemf) of the IPM value to a preset minimum I limit; and
machine is equal to a direct current (DC) bus Voltage. the processor is configured to calculate the Voltage limit
30. The computer processing unit of claim 28, wherein if ellipse for the first speed based on the calculated maxi
the first speed is lower than the second threshold speed and mum allowable I, values.
higher than the first threshold speed, the processor is config 25 34. The computer processing unit of claim 33, wherein the
I vertex value is forced to Zero if the determined I vertex
ured to select lesser of an I, value of the calculated MTPA value is greater than Zero.
trajectory and an I, value of the calculated truncated voltage 35. The computer processing unit of claim 33, wherein
limitellipse for each I value, wherein the operating trajectory the processor is configured to calculate torque along points
includes the selected I, values. 30 of the calculated voltage limit ellipse at the first speed;
31. The computer processing unit of claim 26, wherein the processor is configured to truncate the calculated Volt
the processor is configured to determine an initial table, the age limitellipse by disregarding monotonically decreas
initial table including II, combinations having values ing torque.
covering all possible values for a preset current limit; 36. The computer processing unit of claim 26, wherein
the processor is configured to calculate the current peak 35 the processor is configured to generate a different II, map
magnitude, the current control angle, and the La and L, for a plurality of speeds by repeating the second calcu
values for each II, combination of the initial table: lating step, the determining step, and the generating step
the processor is configured to calculate torque for each II, for each speed; and
combination of the initial table based on the machine
parameters; the processor is configured to construct an integrated II,
the processor is configured to set a torque range for each of 40 map based on the plurality of II, maps.
the plurality of torque commands; k k k k k