Real-Time HIL Validation of PS-EKF Sensorless FOC Strategy with PI Controllers for PMSM Drive System

This paper introduces a sensorless (SL) control method for PMSMs integrating FOC-PI and Extended Kalman Filter (EKF) for rotor position and speed (PS) estimation. The proposed SLPS-PI-EKF technique eliminates the need for mechanical sensors while maintaining high control performance across various operating conditions. This control system offers a practical solution for industrial applications where system reliability, reduced complexity, and cost-effectiveness are crucial requirements. The EKF algorithm demonstrates excellent capability in accurately estimating PS from measurable electrical parameters, overcoming the drawbacks of physical sensing methods. Both simulation results and real-time experimental validation using a dSPACE DS1104 platform confirm the effectiveness of the proposed strategy. The results show that SLPS-PI-EKF significantly decreases the response time of position and speed tracking while improving estimation accuracy, demonstrating good dynamic response, steady-state precision, and robust performance against parameter variations and external disturbances.