Design of High-Speed Permanent Magnet Synchronous Motor for Advanced and Sensorless Control Techniques Validation

This paper presents a design of a high-speed (HS) permanent magnet synchronous motor (PMSM) for advanced and sensorless control techniques validation. First, an electromechanical design of the motor is introduced. It consists of a rotor, a stator core and a motor housing design. FEM software is used for electromagnetic design and two different versions of the stator core are proposed. A key element of the design process is the feasibility of the motor manufacturing using materials available in the market for a single unit production. Therefore, to lower maintenance requirements and motor complexity, the stator core with lower power losses is chosen. To be able to operate the HS PMSM at a nominal speed suitable bearings are selected. For verification of control techniques such as a sensorless control, the motor is equipped with a 12-bit angular Hall encoder. The paper contains an overview of the manufacturing process and a price range of used components as well. After the manufacturing process, the Luenberger observer with quadrature phase locked loop is designed for the sensorless control of HS PMSM. The influence of time delays is reduced with a multisampled PWM and the algorithm is implemented on a FPGA and tested with the manufactured HS PMSM. The experimental results are analyzed for future improvements.