Holistic Rotor Position Sensor System Characterization for Automotive Powertrains

Electrified automotive traction drives require precise, reliable and efficient control in order to meet operational safety-, comfort- and efficiency demands. In this context, sensor systems are utilized to determine the current rotor shaft position of Permanent Magnet Synchronous Motors, whereby potential measurement deviations may have impact on the quality of motor control. Since the integration involves functional-, reliability- and space requirements, various measurement principles and sensor system technologies are available (e.g. resolver, inductive or Hall-based). Identification of potential error sources in the holistic sensor measurement chain is vital to provide an accurate determination of the rotor shaft position under real-time conditions. In this context, the present paper introduces a generic procedure for holistic angular error characterization of rotor position sensor systems in Permanent Magnet Synchronous Motor-based powertrains. The presented approach includes an examination of state-of-the-art rotor position sensor systems and their potential arising errors, which can lead to a distortion of the angular information. Besides a consideration of mechanical deviations and thermal influences, special focus is put on sensor signal processing to elaborate origins of potential errors in a high level of details. The introduced methodology is exemplary applied in the course of experimental-based error characterization for an arbitrary rotor position sensor system.