Control Design and Load Testing of a 65kW 36600rpm High Speed Electric Drive System

The paper presents critical control designs and a novel load testing setup for a 65kW, 36600rpm high speed Surface mounted Permanent Magnet Synchronous Machine (SPMSM) direct drive system. The multiple core Digital Signal Processor (DSP) combined with Field Programmable Gate Arrays (FPGA) is adopted to meet the high frequency data processing and control design requirements, adaptive control and measurement time delay compensation are designed to keep the machine with stable operation at full speed and full load conditions. In order to simulate the working condition that power is proportional to the cube of rotor speed, a back to back machine testing bench is set up with electrical loads connected to the load machine side to consume the energy generated from the load machine. Capacitive loads are connected to the load machine in parallel with resistors which could compensate the load machine armature reaction at high speed with large current working condition. The selection of resistor and capacitor is based on the minimum internal power factor principle. With the control design and load testing methodologies presented in this paper, the design of a 65kW, 36600rpm SPMSM direct drive system is validated at full speed and full load conditions.