Rapid Prototyping of a SiC-Based PMSM Motor Drive for Aerospace Applications

Researchers from the UA successfully developed a Silicon Carbide (SiC) inverter which was approved by the Federal Aviation Administration (FAA) for flight testing, a first for a university team. Researchers at the university test facility worked with the team to develop a custom Printed Circuit Board (PCB) which allowed for advanced control of a high-power Permanent Magnet Synchronous Machine (PMSM) with resolver feedback as well as CAN communications for control and monitoring. These controls were developed using a rapid prototyping methodology which included initial simulations as well as Controller Hardware-in-the-Loop (cHIL) emulation activities using Typhoon-HIL equipment. Once the researchers designed the PCB and sent it for fabrication, they modeled the inverter and motor using the Typhoon-HIL real-time platform. The team was then able to test control algorithms as well as communications and feedback circuits prior to having the hardware assembled. This activity enabled the researchers to spin the PMSM within a day of the boards being fabricated and integrated into the power electronics platform. Once cHIL testing was completed, high-power testing at the University’s test facility commenced using a 100-kW dynamometer along with equipment to emulate flight testing at elevated temperatures. Finally, the SiC inverter was integrated into a prototype airframe and was successfully flight-tested.