Angular Position Sensor Calibration During Synchronous Motor Rotation
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Solution Overview
Problem
Existing methods for correcting position sensor setting errors in electric machines, such as those used in aircraft propulsion units, are inefficient and risk damaging components due to high amplitude static currents required for error detection, and involve lengthy procedures.
Innovation Solution
A method that estimates the angular position of a rotor relative to a stator while rotating, using a control loop to identify and correct position sensor errors by calculating an adjusted angle through direct and quadrature current components, allowing for precise torque control without damaging components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a static position error search method is used to identify position sensor setting errors, then measurement precision is improved, but use of energy increases and temperature rises due to high amplitude static currents
Solution Approach 1:
The patent changes the operating parameters from static high-amplitude currents to dynamic rotating currents at predetermined speeds. The method identifies position sensor errors by analyzing current signatures during rotation, thereby reducing thermal stress while maintaining measurement accuracy through dynamic operational conditions rather than static high-power states.
Solution Approach 2:
The patent employs periodic rotation of the rotor at predetermined speeds to generate position sensor error identification data. By using periodic dynamic action instead of continuous static high-current injection, the method achieves error detection with reduced thermal impact on coiling and power electronic components.
2Measurement precision
If a static position error search method is used to identify position sensor setting errors, then measurement precision is improved, but loss of time increases due to lengthy procedures
Solution Approach 1:
The patent uses periodic rotor rotation at predetermined speeds to rapidly identify position sensor errors. By leveraging the periodic nature of electromagnetic interactions during rotation, the method accelerates error detection compared to static methods, reducing procedural time while maintaining identification accuracy through dynamic signal analysis.
Solution Approach 2:
The patent enables continuous error identification during motor operation rather than requiring separate static calibration procedures. The useful action of motor rotation is continuously utilized to detect position sensor errors, eliminating idle time and integrating error identification into normal operational cycles.
3Measurement precision
If high amplitude static currents are used for position sensor error identification, then measurement precision is improved, but object-generated harmful factors increase due to risk of component damage
Solution Approach 1:
The patent changes the current parameters from high-amplitude static currents to lower-amplitude dynamic currents during rotation. This parameter change reduces the harmful thermal and electrical stress on components while maintaining error identification capability through the dynamic electromagnetic signatures generated during motor operation.
Solution Approach 2:
The patent converts the harmful high-current static state into a beneficial dynamic rotating state. By utilizing the natural electromagnetic interactions during motor rotation, the method transforms what would be a damaging static condition into a useful dynamic measurement opportunity, reducing component stress while enabling error detection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick and accurate correction of position sensor errors with reduced risk of damage, operating efficiently in both directions of rotation and optimizing motor torque control.
Implementation Method 1
an angular position sensor for measuring an angular position of a rotor relative to a stator
Implementation Method 2
a hall-effect sensor
Implementation Method 3
a resolver or hall-effect sensor is mounted. The angular position sensor comprises a fixed part and a movable part mounted to the shaft of the rotor
Data Source
AI summary
A method for automatically setting an angular position sensor of a magnet rotor in relation to a stator of a synchronous machine, including an angle error compensator which adjusts the angles measured by the angular position sensor by an angular difference calculated by imposing a direct setpoint current equal to zero and by comparing a setpoint voltage with a quadrature return current, a direct return current resulting from a direct Park transform of current measured at the stator phase outputs and a rotor electrical speed, a predetermined value corresponding to the rotor magnet flux, and a quadrature inductance.