Insights and Challenges of Co-Simulation-Based Optimal Pulse Pattern Evaluation for Electric Drives

In-depth evaluations of an electric drive's behavior typically result from co-simulation, combining models of motor, power electronics and control software. This approach can be used to evaluate pulse patterns for a given operating point, e.g., for electric vehicle applications, preventing real-world experiments. Here, the co-simulation model is fed with offline calculated optimized pulse patterns (OPPs) that are used to increase, among others, the drive's efficiency. Due to the large motor time constant compared to the fundamental wave period, reaching steady state using a simple open-loop control requires unnecessary long simulation times. Hence, a model predictive closed-loop control implementation of the OPPs is proposed which reduced the overall computational effort significantly. However, it turns out that the OPP evaluation using a finite-element-method-based co-simulation for a permanent magnet synchronous motor remains largely uncertain in terms of the predicted power losses which led to the development of a semi-analytical model to further reduce the required computational time. As none of the approaches was able to deliver a suitable trade-off between model accuracy and calculation time, this investigation highlights the remaining challenges of evaluating OPPs based on drive co-simulations motivating further research towards the surrogate-assisted or direct experimental OPP optimization in the future.