New ECE Motor Model Considering Tolerance of Manufacturing and Material for High Speed Application Under Field Weakening Control

A new ECE model is proposed to reflect the tolerance of manufacturing and material, etc. The proposed new ECE model is developed by combining the ECE model derived from ANSYS in the motor design (original ECE model) and calibration of flux linkage and inductor parameters from real motor test. The calibration of flux linkage and inductor parameters are carried out based upon back EMF coefficient calibration under no load condition and MTPA test with current excitation under zero, 45 degrees and 90 degrees. The former one is used to correct the flux without excitation current to the motor. The later one is used to consider the self- and mutual- cross-coupling inductances and saturation effect. The proposed method provides accurate results while not requiring intensive tests. The proposed new ECE model can be applied to motor drives control. A 60kW IPM motor with maximum speed of 13000 rpm is designed for verification. The results for the proposed new ECE model, original ECE model and real motor are presented. And the error for the original ECE model and real motor is reduce from 10% to 1% for using the proposed new ECE model. The improvement becomes more relevant under high speed application with field weakening control by considering the tolerance of manufacturing and material etc.