Sensorless Field Oriented Control of

3-Phase Induction Motors

Bilal Akin C2000 Systems and Applications Team
Manish Bhardwaj

Abstract

This application note presents a solution to control an AC induction motor using the TMS320F2803x
microcontrollers. TMS320F2803x devices are part of the family of C2000 microcontrollers which enable
cost-effective design of intelligent controllers for three phase motors by reducing the system components
and increase efficiency With these devices it is possible to realize far more precise digital vector control
algorithms like the Field Orientated Control (FOC). This algorithms implementation is discussed in this
document. The FOC algorithm maintains efficiency in a wide range of speeds and takes into
consideration torque changes with transient phases by processing a dynamic model of the motor. Among
the solutions proposed are ways to eliminate the phase current sensors and use an observer for speed
sensorless control.

This application note covers the following:

A theoretical background on field oriented motor control principle.
Incremental build levels based on modular software blocks.
Experimental results


Table of Contents

Introduction ............................................................................................................................................................................... 2
Induction Motors ....................................................................................................................................................................... 2
Field OrientedControl................................................................................................................................................................ 4
Benefits of 32-bit C2000 Controllers for Digital Motor Control ............................................................................................... 10
TI Motor Control Literature and DMC Library.......................................................................................................................... 11
System Overview.................................................................................................................................................................... 12
Hardware Configuration.......................................................................................................................................................... 16
Software Setup Instructions to Run HVACI_Sensorless Project ............................................................................................ 18
Incremental System Build ....................................................................................................................................................... 20






1
Version 1.1 Feb 2010
Introduction

The motor control industry is a strong, aggressive sector. To remain competitive new products must
address several design constraints including cost reduction, power consumption reduction, power factor
correction, and reduced EMI radiation. In order to meet these challenges advanced control algorithms
are necessary. Embedded control technology allows both a high level of performance and system cost
reduction to be achieved. According to market analysis, the majority of industrial motor applications use
AC induction motors. The reasons for this are higher robustness, higher reliability, lower prices and higher
efficiency (up to 80%) on comparison with other motor types. However, the use of induction motors is
challenging because of its complex mathematical model, its non linear behavior during saturation and the
electrical parameter oscillation which depends on the physical influence of temperature. These factors
make the control of induction motor complex and call for use of a high performance control algorithms
such as vector control and a powerful microcontroller to execute this algorithm.

During the last few decades the field of controlled electrical drives has undergone rapid expansion due
mainly to the benefits of microcontrollers. These technological improvements have enabled the
development of very effective AC drive control with lower power dissipation hardware and more accurate
control structures. The electrical drive controls become more accurate in the sense that not only are the
DC quantities controlled but also the three phase AC currents and voltages are managed by so-called
vector controls. This document briefly describes the implementation of the most efficient form of a vector
control scheme: the Field Orientated Control method. It is based on three major points: the machine
current and voltage space vectors, the transformation of a three phase speed and time dependent system
into a two co-ordinate time invariant system and effective Space Vector Pulse Width Modulation pattern
generation. Thanks to these algortihms, the control of AC machine acquires every advantage of DC
machine control and frees itself from mechanical commutation drawbacks. Furthermore, this control
structure, by achieving a very accurate steady state and transient control, leads to high dynamic
performance in terms of response times and power conversion.


Induction Motors

Induction motors derive their name from the way the rotor magnetic field is created. The rotating stator
magnetic field induces currents in the short circuited rotor. These currents produce the rotor magnetic
field, which interacts with the stator magnetic field, and produces torque, which is the useful mechanical
output of the machine.

The three phase squirrel cage AC induction motor is the most widely used motor. The bars forming the
conductors along the rotor axis are connected by a thick metal ring at the ends, resulting in a short circuit
as shown in Fig.1. The sinusoidal stator phase currents fed in the stator coils create a magnetic field
rotating at the speed of the stator frequency (
s
). The changing field induces a current in the cage
conductors, which results in the creation of a second magnetic field around the rotor wires. As a
consequence of the forces created by the interaction of these two fields, the rotor experiences a torque
and starts rotating in the direction of the stator field.

As the rotor begins to speed up and approach the synchronous speed of the stator magnetic field, the
relative speed between the rotor and the stator flux decreases, decreasing the induced voltage in the
stator and reducing the energy converted to torque. This causes the torque production to drop off, and the
motor will reach a steady state at a point where the load torque is matched with the motor torque. This
point is an equilibrium reached depending on the instantaneous loading of the motor. In brief:







2


3
x Rotor flu
A
A
B
C
C
B
ia
Rotor rotation
Stator flux
O
O = O . s
R
S
O
Aluminum bar















End Rings
Skewed Cage Bars
Fig.1 Induction Motor Rotor

Owing to the fact that the induction mechanism needs a relative difference between the motor speed
and the stator flux speed, the induction motor rotates at a frequency near, but less than that of the
synchronous speed.
This slip must be present, even when operating in a field-oriented control regime.
The rotor in an induction motor is not externally excited. This means that there is no need for slip rings
and brushes. This makes the induction motor robust, inexpensive and need less maintenance.
Torque production is governed by the angle formed between the rotor and the stator magnetic fluxes.

In Fig.2 the rotor speed is denoted by . Stator and rotor frequencies are linked by a parameter called
the slip s, expressed in per unit as
s r s
s e e e / ) ( = .













Fig2. Squirrel cage rotor AC induction motor cutaway view


p
s s s rad
p
s rad
p
s rad
S
S
S
S
S
e
e
e
) 1 ( ). 1 ( ) /
:
) / :
) /
= O = O

= O
: ( speed rotating rotor -
number pairs poles stator
( freq supply AC
. : ( speed field rotating stator -




where s is called the slip: it represents the difference between the synchronous frequency and the
actual motor rotating speed.


Field Oriented Control

Introduction

A simple control such as the V/Hz strategy has limitations on the performance. To achieve better dynamic
performance, a more complex control scheme needs to be applied, to control the induction motor. With
the mathematical processing power offered by the microcontrollers, we can implement advanced control
strategies, which use mathematical transformations in order to decouple the torque generation and the
magnetization functions in an AC induction motor. Such de-coupled torque and magnetization control is
commonly called rotor flux oriented control, or simply Field Oriented Control (FOC).

The main philosophy behind the FOC

In order to understand the spirit of the Field Oriented Control technique, let us start with an overview of
the separately excited direct current (DC) Motor. In this type of motor, the excitation for the stator and
rotor is independently controlled. An electrical study of the DC motor shows that the produced
torque and the flux can be independently tuned. The strength of the field excitation (i.e. the magnitude
of the field excitation current) sets the value of the flux. The current through the rotor windings determines
how much torque is produced. The commutator on the rotor plays an interesting part in the torque
production. The commutator is in contact with the brushes, and the mechanical construction is designed
to switch into the circuit the windings that are mechanically aligned to produce the maximum torque. This
arrangement then means that the torque production of the machine is fairly near optimal all the time. The
key point here is that the windings are managed to keep the flux produced by the rotor windings
orthogonal to the stator field.

) (
. .
. .
e
em
I f
K E
I K T
= u
O u =
= u
Inductor (field
excitation)
Armature Circuit
Fig 3. Separated excitation DC motor model, flux and torque are independently controlled
and the current through the rotor windings determines how much torque is produced.


Induction machines do not have the same key features as the DC motor. However, in both cases we have
only one source that can be controlled which is the stator currents. On the synchronous machine, the
rotor excitation is given by the permanent magnets mounted onto the shaft. On the synchronous motor,
the only source of power and magnetic field is the stator phase voltage. Obviously, as opposed to the DC
motor, flux and torque depend on each other.

The goal of the FOC (also called vector control) on synchronous and asynchronous machine is to be able
to separately control the torque producing and magnetizing flux components. The control technique goal
is to (in a sense) imitate the DC motors operation.

Why Field Oriented Control

As a well know fact about the asynchronous machine, we face some natural limitations with a V/Hz
control approach. FOC control will allow us to get around these limitations, by decoupling the effect of the
torque and the magnetizing flux. With decoupled control of the magnetization, the torque producing
component of the stator flux can now be thought of as independent torque control. Now, decoupled
control, at low speeds, the magnetization can be maintained at the proper level, and the torque can be
controlled to regulate the speed.

4
To decouple the torque and flux, it is necessary to engage several mathematical transforms, and this is
where the microcontrollers add the most value. The processing capability provided by the microcontrollers
enables these mathematical transformations to be carried out very quickly. This in turn implies that the
entire algorithm controlling the motor can be executed at a fast rate, enabling higher dynamic
performance. In addition to the decoupling, a dynamic model of the motor is now used for the
computation of many quantities such as rotor flux angle and rotor speed. This means that their effect is
accounted for, and the overall quality of control is better.

Technical Background

The Field Orientated Control consists of controlling the stator currents represented by a vector. This
control is based on projections which transform a three phase time and speed dependent system into a
two co-ordinate (d and q co-ordinates) time invariant system. These projections lead to a structure similar
to that of a DC machine control. Field orientated controlled machines need two constants as input
references: the torque component (aligned with the q co-ordinate) and the flux component (aligned with d
co-ordinate). As Field Orientated Control is simply based on projections the control structure handles
instantaneous electrical quantities. This makes the control accurate in every working operation (steady
state and transient) and independent of the limited bandwidth mathematical model. The FOC thus solves
the classic scheme problems, in the following ways:

The ease of reaching constant reference (torque component and flux component of the stator current)
The ease of applying direct torque control because in the (d,q) reference frame the expression of the
torque is:
Sq R
i m

By maintaining the amplitude of the rotor flux (
R

) at a fixed value we have a linear relationship between

torque and torque component (i
Sq
). We can then control the torque by controlling the torque component of
stator current vector.

Space Vector Definition and Projection

The three-phase voltages, currents and fluxes of AC-motors can be analyzed in terms of complex space
vectors. With regard to the currents, the space vector can be defined as follows. Assuming that i
a
, i
b
, i
c
are
the instantaneous currents in the stator phases, then the complex stator current vector
s
i is defined by:

c b a s
i i i i
2
o o + + =
where
t
o
3
2
j
e = and
t
o
3
4
2
j
e = , represent the spatial operators. The following diagram shows the stator
current complex space vector:


Fig.4 Stator current space vector and its component in (a,b,c)

5
where (a,b,c) are the three phase system axes. This current space vector depicts the three phase
sinusoidal system. It still needs to be transformed into a two time invariant co-ordinate system. This
transformation can be split into two steps:

(a,b,c) ) , ( | o (the Clarke transformation) which outputs a two co-ordinate time variant system
) , ( | o (d,q) (the Park transformation) which outputs a two co-ordinate time invariant system

The (a,b,c) ) , ( | o Projection (Clarke transformation)

The space vector can be reported in another reference frame with only two orthogonal axis called ) , ( | o .
Assuming that the axis a and the axis o are in the same direction we have the following vector diagram:


Fig.5 Stator current space vector and its components in the stationary reference frame

The projection that modifies the three phase system into the ) , ( | o two dimension orthogonal system is
presented below.

+ =
=
b a s
a s
i i i
i i
3
2
3
1
|
o


The two phase ) , ( | o currents are still depends on time and speed.

The ) , ( | o (d,q) Projection (Park Transformation)

This is the most important transformation in the FOC. In fact, this projection modifies a two phase
orthogonal system ) , ( | o into the d,q rotating reference frame. If we consider the d axis aligned with the
rotor flux, the next diagram shows, for the current vector, the relationship from the two reference frame:


6

Fig.6 Stator current space vector and its component in ) , ( | o and in the d,q
rotating reference frame

where is the rotor flux position. The flux and torque components of the current vector are determined by
the following equations:

+ =
+ =
u u
u u
| o
| o
cos sin
sin cos
s s sq
s s sd
i i i
i i i


These components depend on the current vector ) , ( | o components and on the rotor flux position; if we
know the right rotor flux position then, by this projection, the d,q component becomes a constant. Two
phase currents now turn into dc quantity (time-invariant). At this point the torque control becomes easier
where constant i
sd
(flux component) and i
sq
(torque component) current components controlled
independently.































7
The Basic Scheme for the FOC

The following diagram summarizes the basic scheme of torque control with FOC:


Fig7 Basic scheme of FOC for ACI motor

Two motor phase currents are measured. These measurements feed the Clarke transformation module.
The outputs of this projection are designated i
s
and i
s
. These two components of the current are the
inputs of the Park transformation that gives the current in the d,q rotating reference frame. The i
sd
and i
sq

components are compared to the references i
sdref
(the flux reference) and i
sqref
(the torque reference). At
this point, this control structure shows an interesting advantage: it can be used to control either
synchronous or induction machines by simply changing the flux reference and obtaining rotor flux position.
In a synchronous permanent magnet motor, the rotor flux is fixed (determined by the magnets) and there
is no need to create additional flux. Hence, when controlling a PMSM, i
sdref
should be set to zero. Since
induction motors need a rotor flux creation in order to operate, the flux reference must not be zero. This
conveniently solves one of the major drawbacks of the classic control structures: the portability from
asynchronous to synchronous drives.

The torque command i
sqref
could be the output of the speed regulator when we use a speed FOC. The
outputs of the current regulators are V
sdref
and V
sqref
; they are applied to the inverse Park transformation.
The outputs of this projection are V
sref
and V
sref
which are the components of the stator vector voltage in
the ) , ( | o stationary orthogonal reference frame. These are the inputs of the Space Vector PWM. The
outputs of this block are the signals that drive the inverter. Note that both Park and inverse Park
transformations need the rotor flux position. Obtaining this rotor flux position depends on the AC machine
type (synchronous or asynchronous machine). Rotor flux position considerations are made in a following
paragraph.


Rotor Flux Position

Knowledge of the rotor flux position is the core of the FOC. In fact if there is an error in this variable the
rotor flux will not be aligned with the d-axis and i
sd
and i
sq,
the flux and torque components of the stator
current, will be incorrect. The following diagram shows the (a,b,c), ) , ( | o and (d,q) reference frames, and
the correct position of the rotor flux, the stator current and stator voltage space vector that rotates with d,q
reference at synchronous speed.

8

Fig.8 Current, voltage and rotor flux space vectors in the d,q rotating reference frame and their relationship with
a,b,c and ) , ( | o stationary reference frame

The measure of the rotor flux position is different if we consider synchronous or induction motor:
In the synchronous machine the rotor speed is equal to the rotor flux speed. Then (rotor flux position)
is directly measured by position sensor or by integration of rotor speed.
In the induction machine the rotor speed is not equal to the rotor flux speed (there is a slip speed), then
it needs a particular method to calculate . The basic method is the use of the current model which
needs two equations of the motor model in d,q reference frame.

Theoretically, the field oriented control for an induction motor drive can be mainly categorized into two
types; indirect and direct schemes. The field to be oriented could be a rotor, stator, or airgap flux linkage.
In the indirect field oriented control, the slip estimation with measured or estimated rotor speed is required
in order to compute the synchronous speed. There is no flux estimation appearing in the system. For the
direct scheme, the synchronous speed is computed basing on the flux angle which is available from flux
estimator or flux sensors (e.g., Hall effects). In this implementing system, the direct (rotor) flux oriented
control system with flux and open-loop speed estimators is described. The key module of this system is
the flux estimator (refer to this module document for details). The overall block diagram of this project can
be depicted in Fig. 9.












Fig.9 Overall block diagram of direct rotor flux oriented control

9
Benefits of 32-bit C2000 Controllers for Digital Motor Control (DMC)

C2000 family of devices posses the desired computation power to execute complex control algorithms
along with the right mix of peripherals to interface with the various components of the DMC hardware like
the ADC, ePWM, QEP, eCAP etc. These peripherals have all the necessary hooks for implementing
systems which meet safety requirements, like the trip zones for PWMs and comparators. Along with this
the C2000 ecosystem of software (libraries and application software) and hardware (application kits) help
in reducing the time and effort needed to develop a Digital Motor Control solution. The DMC Library
provides configurable blocks that can be reused to implement new control strategies. IQMath Library
enables easy migration from floating point algorithms to fixed point thus accelerating the development
cycle.

Thus, with C2000 family of devices it is easy and quick to implement complex control algorithms
(sensored and sensorless) for motor control. The use of C2000 devices and advanced control schemes
provides the following system improvements:
Favors system cost reduction by an efficient control in all speed range implying right dimensioning of
power device circuits
Use of advanced control algorithms it is possible to reduce torque ripple, thus resulting in lower
vibration and longer life time of the motor
Advanced control algorithms reduce harmonics generated by the inverter thus reducing filter cost.
Use of sensorless algorithms eliminates the need for speed or position sensor.
Decreases the number of look-up tables which reduces the amount of memory required
The Real-time generation of smooth near-optimal reference profiles and move trajectories, results in
better-performance
Generation of high resolution PWMs is possible with the use of ePWM peripheral for controlling the
power switching inverters
Provides single chip control system
For advanced controls, C2000 controllers can also perform the following:
Enables control of multi-variable and complex systems using modern intelligent methods such as neural
networks and fuzzy logic.
Performs adaptive control. C2000 controllers have the speed capabilities to concurrently monitor the
system and control it. A dynamic control algorithm adapts itself in real time to variations in system
behaviour.
Performs parameter identification for sensorless control algorithms, self commissioning, online
parameter estimation update.
Performs advanced torque ripple and acoustic noise reduction.
Provides diagnostic monitoring with spectrum analysis. By observing the frequency spectrum of
mechanical vibrations, failure modes can be predicted in early stages.
Produces sharp-cut-off notch filters that eliminate narrow-band mechanical resonance. Notch filters
remove energy that would otherwise excite resonant modes and possibly make the system unstable.

10
TI Literature and DMC Library

Literature distinguishes two types of FOC control:

Direct FOC control: In this case we try to directly estimate the rotor flux based upon the measurements
of terminal voltages and currents.

Indirect FOC control: in this case the goal is to estimate the slip based upon the motor model in FOC
condition and to recalculate the rotor flux angle from the integration of estimated slip and measured
rotor speeds. Again knowing the motor parameters, especially rotor time constant, is key in order to
achieve the FOC control

In this document the Direct FOC Control is discussed.

The Digital Motor Control (DMC) library is composed of functions represented as blocks. These blocks
are categorized as Transforms & Estimators (Clarke, Park, Sliding Mode Observer, Phase Voltage
Calculation, and Resolver, Flux, and Speed Calculators and Estimators), Control (Signal Generation, PID,
BEMF Commutation, Space Vector Generation), and Peripheral Drivers (PWM abstraction for multiple
topologies and techniques, ADC drivers, and motor sensor interfaces). Each block is a modular software
macro is separately documented with source code, use, and technical theory. Check the folders below for
the source codes and explanations of macro blocks:

C:\TI\controlSUITE\libs\app_libs\motor_control\math_blocks\fixed
C:\TI\controlSUITE\libs\app_libs\motor_control\drivers\f2803x

These modules allow users to quickly build, or customize, their own systems. The Library supports the
three motor types: ACI, BLDC, PMSM, and comprises both peripheral dependent (software drivers) and
target dependent modules.

The DMC Library components have been used by TI to provide system examples. At initialization all DMC
Library variables are defined and inter-connected. At run-time the macro functions are called in order.
Each system is built using an incremental build approach, which allows some sections of the code to be
built at a time, so that the developer can verify each section of their application one step at a time. This is
critical in real-time control applications where so many different variables can affect the system and many
different motor parameters need to be tuned.

Note: TI DMC modules are written in form of macros for optimization purposes (refer to application note
SPRAAK2 for more details at TI website). The macros are defined in the header files. The user can open
the respective header file and change the macro definition, if needed. In the macro definitions, there
should be a backslash \ at the end of each line as shown below which means that the code continue in
the next line. Any character including invisible ones like space after the backslash will cause compilation
error. Therefore, make sure that the backslash is the last character in the line. In terms of code
development, the macros are almost identical to C function, and the user can easily convert the macro
definition to a C functions.

#define PARK_MACRO(v) \
\
v.Ds = _IQmpy(v.Alpha,v.Cosine) + _IQmpy(v.Beta,v.Sine); \
v.Qs = _IQmpy(v.Beta,v.Cosine) - _IQmpy(v.Alpha,v.Sine);






A typical DMC macro definition



11
System Overview

This document describes the C real-time control framework used to demonstrate the sensorless field
oriented control of induction motors. The C framework is designed to run on TMS320C2803x based
controllers on Code Composer Studio. The framework uses the following modules
1
:

Macro Names Explanation
CLARKE Clarke Transformation
PARK / IPARK Park and Inverse Park Transformation
PID PID Regulators
RC Ramp Controller (slew rate limiter)
RG Ramp / Sawtooth Generator
QEP / CAP QEP and CAP Drives (optional for speed loop tuning with a speed sensor)
SPEED_PR Speed Measurement (based on sensor signal period)
SPEED_FR Speed Measurement (based on sensor signal frequency)
ACI_SE / ACI_FE Flux and Speed Estimators for Sensorless Applications
SVGEN Space Vector PWM with Quadrature Control (includes IClarke Trans.)
VOLT Phase Voltage Calculator
PWM / PWMDAC PWM and PWMDAC Drives
1
Please refer to pdf documents in motor control folder explaining the details and theoretical background of each macro


In this system, the sensorless Direct Field Oriented Control (DFOC) of Induction Motor will be
experimented with and will explore the performance of the speed controller. The induction motor is driven
by a conventional voltage-source inverter. The TMS320F2803x control card is used to generate three
pulse width modulation (PWM) signals. The motor is driven by an integrated power module by means of
space vector PWM technique. Two phase currents of induction motor (ia and ib) are measured from the
inverter and sent to the TMS320x2803x via two analog-to-digital converters (ADCs). In addition, the DC-
bus voltage in the inverter is measured and sent to the TMS320x2803x via an ADC. This DC-bus voltage
is necessary to calculate the three phase voltages when the switching functions are known.

HVACI_Sensorless project has the following properties:


C Framework
System Name
Program Memory Usage
2803x
Data Memory Usage
1
2803x
HVACI_Sensorless 4921 words
2
1392 words



1
Excluding the stack size
2
Excluding IQmath Look-up Tables











12
CPU Utilization of Sensorless FOC of ACI
Name of Modules * Number of Cycles
Ramp Controller 29
Clarke Tr. 28
Park Tr. 142
I_Park Tr. 41
ACI_Speed Est 201
ACI_Flux Est. 547
Phase Volt Calc. 115
3 x Pid 167
Space Vector Gen. 137
Pwm Drv 74
Contxt Save etc. 53
Pwm Dac (optional)
DataLog (optional)
Ramp Gen (optional)

Total Number of Cycles 1534 **
CPU Utilization @ 60 Mhz 25.6% ***
CPU Utilization @ 40 Mhz 38.4% ***


* The modules are defined in the header files as macros
** 1731 including the optional modules
*** At 10 kHz ISR freq.




System Features
Development /Emulation Code Composer Studio v4.0 (or above) with Real Time debugging
Target Controller TMS320F2803x
PWM Frequency 10kHz PWM (Default), 60kHz PWMDAC
PWM Mode Symmetrical with a programmable dead band
Interrupts EPWM1 Time Base CNT_Zero Implements 10 kHz ISR execution rate
Peripherals Used PWM 1 / 2 / 3 for motor control
PWM 5A, 6A, 7A & 7B for DAC outputs
QEP1 A,B, I or CAP1 (optional for tuning the speed loop)
ADC A1 for DC Bus voltage sensing, B4 & B6 for phase current sensing












13
The overall system implementing a 3-ph induction motor control is depicted in Fig.10. The induction motor
is driven by the conventional voltage-source inverter. The TMS320F2803x is being used to generate the
six pulse width modulation (PWM) signals using a space vector PWM technique, for six power switching
devices in the inverter. Two input currents of the induction motor (ia and ib) are measured from the
inverter and they are sent to the TMS320F2803x via two analog-to-digital converters (ADCs). In addition,
the DC-bus voltage in the inverter is measured and sent to the TMS320F2803x via an ADC as well. This
DC-bus voltage is necessary in order to calculate three phase voltages of induction motor when the
switching functions are known.













Fig 10 A 3-ph induction motor drive implementation

The software flow is described in the Figure 11 below.

14



Interrupt INT3
ePWM1_ INT_ ISR
Save contexts and clear
interrupt flags
Execute the ADC
conversion ( phase
currents and dc bus
voltage )
Execute the clarke / park
transformations
Execute the PID
modules ( iq , id and
speed )
Execute the ipark and
svgen _ dq modules
Execute the pwm
modules
Execute the voltage
calculation modules
Execute ACI_FE and
ACI_SE modules
Restore context Return
c_ int 0
Initialize S / W
modules
Initialize time
bases
Enable ePWM time
base CNT _ zero
and core interrupt
Initialize other
system and
module parameters
Background
loop
INT 3
Fig.11 System software flowchart


























15
Hardware Configuration (HVDMC Kit)

Please refer to the HVMotorCtrl+PFC How to Run Guide and HW Reference Guide found:

C:\TI\controlSUITE\development_kits\HVMotorCtrl+PfcKit\~Docs

for an overview of the kits hardware and steps on how to setup this kit. Some of the hardware setup
instructions are captured below for quick reference

HW Setup Instructions
1. Open the Lid of the HV Kit
2. Install the Jumpers [Main]-J6, J7 and J8, J9 for 3.3V, 5V and 15V power rails and JTAG reset line,
make sure that the jumpers [Main]-J3, J4 andJ5 are not populated.
3. Unpack the DIMM style controlCARD and place it in the connector slot of [Main]-J1. Push vertically
down using even pressure from both ends of the card until the clips snap and lock. (to remove the
card simply spread open the retaining clip with thumbs)
4. Connect a USB cable to connector [M3]-JP1. This will enable isolated JTAG emulation to the
C2000 device. [M3]-LD1 should turn on. Make sure [M3]-J5 is not populated. If the included Code
Composer Studio is installed, the drivers for the onboard JTAG emulation will automatically be
installed. If a windows installation window appears try to automatically install drivers from those
already on your computer. The emulation drivers are found at
http://www.ftdichip.com/Drivers/D2XX.htm. The correct driver is the one listed to support the FT2232.
5. If a third party JTAG emulator is used, connect the JTAG header to [M3]-J2 and additionally [M3]-J5
needs to be populated to put the onboard JTAG chip in reset.
6. Ensure that [M6]-SW1 is in the Off position. Connect 15V DC power supply to [M6]-JP1.
7. Turn on [M6]-SW1. Now [M6]-LD1 should turn on. Notice the control card LED would light up as well
indicating the control card is receiving power from the board.
8. Note that the motor should be connected to the [M5]-TB3 terminals after you finish with the first
incremental build step.
9. Note the DC Bus power should only be applied during level 1 when instructed to do so. The two
options to get DC Bus power are discussed below,
(i) To use DC power supply, set the power supply output to zero and connect [Main]-BS5 and BS6 to DC
power supply and ground respectively.
(ii) To use AC Mains Power, Connect [Main]-BS1 and BS5 to each other using banana plug cord. Now
connect one end of the AC power cord to [Main]-P1. The other end needs to be connected to output
of a variac. Make sure that the variac output is set to zero and it is connected to the wall supply
through an isolator.

1
Since the motor is rated at 220V, the motor can run only at a certain speed and torque range properly without saturating the
PID regulators in the control loop when the DC bus is fed from 110V AC entry. As an option, the user can run the PFC on HV
DMC drive platform as boost converter to increase the DC bus voltage level or directly connect a DC power supply.





16
For reference the pictures below show the jumper and connectors that need to be connected for this lab.


















CAUTION: The inverter bus capacitors remain charged for a long time after the high
power line supply is switched off/disconnected. Proceed with caution!




ACI
Motor
AC
Entry
J6 J8 J7
J9
15V DC
Fig. 12 Using AC Power to generate DC Bus Power
Encoder
or

Tacho


17


DC Power Supply (max. 350V)
+
-
ACI
Motor
15V DC
J6 J7 J8
J9
Fig. 13 Using External DC power supply to generate DC-Bus for the inverter


Encoder
or

Tacho















CAUTION: The inverter bus capacitors remain charged for a long time after the high
power line supply is switched off/disconnected. Proceed with caution!

18
Software Setup Instructions to Run HVACI_Sensorless Project
Please refer to the Generic Steps for Software Setup for HVMotorCtrl+PFC Kit Projects section in the
HVMotorCtrl+PFC Kit How To Run Guide
C:\TI\controlSUITE\development_kits\HVMotorCtrl+PfcKit\~Docs
This section goes over how to install CCS and set it up to run with this project.
Select the HVACI_Sensorless as the active project. Verify that the build level is set to 1, and then right
click on the project name and select Rebuild Project. Once build completes, launch a debug session to
load the code into the controller. Now open a watch window and add the critical variables as shown in the
table below and select the appropriate Q format for them.

Table 1 Watch Window Variables

Setup time graph windows by importing Graph1.graphProp and Graph2.graphProp from the following
location C:\TI\ControlSUITE\developement_kits\HVMotorCtrl+PfcKit\HVACI_sensorless\ . Click on
Continuous Refresh button on the top left corner of the graph tab to enable periodic capture of data
from the microcontroller.










19
Incremental System Build for ACI Sensorless project
The system is gradually built up in order for the final system can be confidently operated. Six phases of
the incremental system build are designed to verify the major software modules used in the system. Table
1 summarizes the modules testing and using in each incremental system build.


Software Module Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 Phase 6
PWMDAC_MACRO
RC_MACRO
RG_MACRO
IPARK_MACRO
SVGEN_MACRO
PWM_MACRO
CLARKE_MACRO
PARK_MACRO
VOLT_MACRO
CAP_MACRO
SPEED_PR_MACRO
QEP_MACRO
PEED_FR_MACRO
PID_MACRO (IQ)
PID_MACRO (ID)
ACI_FE
ACI_SE
PID_MACRO (SPD)
Note: the symbol means this module is using and the symbol means this module is testing in this phase.

Table 2 Testing modules in each incremental system build














20
Level 1 Incremental Build
At this step keep the motor disconnected. Assuming the load and build steps described in the
HVMotorCtrl+PFC Kit How To Run Guide completed successfully, this section describes the steps for a
minimum system check-out which confirms operation of system interrupt, the peripheral & target
independent I_PARK_MACRO (inverse park transformation) and SVGEN_MACRO (space vector
generator) modules and the peripheral dependent PWM_MACRO (PWM initializations and update)
modules. Open HVACI_Sensorless-Settings.h and select level 1 incremental build option by setting the
BUILDLEVEL to LEVEL1 (#define BUILDLEVEL LEVEL1). Now right click on the project name and click
Rebuild Project. Once the build is complete click on debug button, reset CPU, restart, enable real time
mode and run. Set EnableFlag to 1 in the watch window. The variable named IsrTicker will now keep
on increasing, confirm this by watching the variable in the watch window. This confirms that the system
interrupt is working properly.

In the software, the key variables to be adjusted are summarized below.
SpeedRef (Q24): for changing the rotor speed in per-unit.
VdTesting (Q24): for changing the d-qxis voltage in per-unit.
VqTesting (Q24): for changing the q-axis voltage in per-unit.

Level 1A (SVGEN_MACRO Test)

In this level we would test the Space Vector Generator Macro(SVGEN_MACRO). The SpeedRef value is
specified to the RG_MACRO module via RC_MACRO module. The IPARK_MACRO module is
generating the outputs to the SVGEN_MACRO module. Three outputs from SVGEN_MACRO module are
monitored via the graph window as shown in Fig. 15 where Ta, Tb, and Tc waveform are 120
o
apart from
each other. Specifically, Tb lags Ta by 120
o
and Tc leads Ta by 120
o
. Check the PWM test points on the
board to observe PWM pulses (PWM-1H to 3H and PWM-1L to 3L) and make sure that the PWM module
is running properly.

















Fig.15 SVGEN duty cycle outputs Ta, Tb, Tc and Tb-Tc






21
Level 1B (testing The PWMDAC Macro)

To monitor internal signal values in real time PWM DACs are very useful tools. Present on the HV DMC
board are PWM DACs which use an external low pass filter to generate the waveforms ([Main]-J14, DAC-1
to 4). A simple 1
st
order low-pass filter RC circuit is used to filter out the high frequency components. The
selection of R and C value (or the time constant, ) is based on the cut-off frequency (f
c
), for this type of
filter; the relation is as follows:
c
f
RC
t
t
2
1
= =
For example, R=1.8k and C=100nF, it gives f
c
= 884.2 Hz. This cut-off frequency has to be below the
PWM frequency. Using the formula above, one can customize low pass filters used for signal being
monitored.

The DAC circuit low pass filters ([Main]-R10 to13 & [Main]-C15 to18) is shipped with 2.2k and 220nF on
the board. Refer to application note SPRAA88A for more details at TI website.









Fig.16 DAC-1-4 outputs showing Ta, Tb, Tc and Tb-Tc waveforms

Level 1C (PWM_MACRO and INVERTER Test)

After verifying SVGEN_MACRO module in level 1a, the PWM_MACRO software module and the 3-phase
inverter hardware are tested by looking at the low pass filter outputs. For this purpose, if using the external
DC power supply gradually increase the DC bus voltage and check the Vfb-U, V and W test points using an
oscilloscope or if using AC power entry slowly change the variac to generate the DC bus voltage. Once the
DC Bus voltage is greater than 15 to 20V you would start observing the Inverter phase voltage dividers and
waveform monitoring filters ([M5]-R19 to27 & [M5]-C21 to 23) enable the generation of the waveform and
ensures thata the inverter is working appropriately. Note that the default RC values are optimized for BLDC
back-emf sensing and high frequency noise filtering. A value closer to 0.1uf for the [M5]-C21 to C23 would
give better waveforms.

After verifying this, reduce the DC Bus voltage, take the controller out of real time mode (disable),
reset the processor (see HVMotorCtrl+PFC Kit How To Run Guide for details). Note that
after each test, this step needs to be repeated for safety purposes. Also note that improper
shutdown might halt the PWMs at some certain states where high currents can be drawn, hence caution
needs to be taken while doing

22
IPARK
MACRO
ipark_Q
ipark_D
theta_ip
ipark_q
ipark_d
PWM
MACRO
Q0 / HW
Mfunc_c1
PWM 1A
Mfunc_c2
Mfunc_c3
Mfunc_p
SVGEN
MACRO
Ubeta
Ualfa
Ta
Tb
Tc
EV
HW
RG
MACRO
rmp_freq
rmp_offset
rmp_gain
RC
MACRO
trgt_value
set_value
set_eq_trgt
Graph Window
VdTesting
R
C
rmp_out
Level 1 - Incremental System Build Block Diagram
VqTesting
Scope
SpeedRef
Level 1 verifies the target independent modules, duty cycles and PWM update. The motors are disconnected at this level.
PWM 1B
PWM 2A
PWM 2B
PWM 3A
PWM 3B
Inverter Phase
Outputs U,V or W
or
PWMDAC channels
PWM 5A, 6A, 7A, 7B
[M5] Vfb-U, V, W test points
or DAC1 to 4
DLOG
Dlog 1
Dlog 2
Dlog 3
Dlog 4
svgen._Ta
svgen._Tb
svgen._Tc
svgen._Ta-svgen._Tb
PWMDAC
MACRO
Scope
PwmDacPointer0
Low
Pass
Filter
Cct
PwmDacPointer1
PwmDacPointer2
PwmDacPointer3
DAC 1
DAC 2
DAC 3
DAC 4
Pwm5A
Pwm6A
Pwm7A
Pwm7B

23
Level 2 Incremental Build
Assuming the Level1 incremental build 1 is completed successfully, this section verifies the analog-to-
digital conversion, Clarke / Park transformations and phase voltage calculations. Connect the motor to the
board.In the software, the key variables to be adjusted are summarized below.

SpeedRef (Q24): for changing the rotor speed in per-unit.
VdTesting(Q24): for changing the d-qxis voltage in per-unit.
VqTesting(Q24): for changing the q-axis voltage in per-unit.

Open HVACI_Sensorless-Settings.h and select level 2 incremental build option by setting the
BUILDLEVEL to LEVEL2 (#define BUILDLEVEL LEVEL2) and save the file. Now Right Click on the
project name and click Rebuild Project. Once the build is complete click on debug button, reset CPU,
restart, enable real time mode and run. Set EnableFlag to 1 in the watch window. The variable named
IsrTicker will be incrementally increased as seen in watch windows to confirm the interrupt working
properly.

Level 2A Testing the Phase Voltage module

In this part, the phase voltage calculation module, VOLT_MACRO, will be tested. Gradually increase the
DC bus voltage. The following waveforms should be observed.




















Fig 17 Calculated phase A&B voltages by volt1 module, rg1.Out and svgen_dq1.Ta

The VphaseA, VphaseB, and VphaseC waveforms should be 120
o
apart from each other. Specifically,
VphaseB lags VphaseA by120
o
(Figure 17) and VphaseC leads VphaseA by 120.
Alternatively user can modify the datalog setting to verify the following relation between the signals
The Valpha waveform should be same as the VphaseA waveform.
The Valpha waveform should be leading the Vbeta waveform by 90
o
at the same magnitude.

Note that the open loop experiments are meant to test the ADCs, inverter stage, sw modules etc.
Therefore running motor under load or at various operating points is not recommended.


24
Phase 2B Testing the Clarke module

In this part the Clarke module will be tested. The three measured line currents are transformed to two
phase dq currents in a stationary reference frame. The outputs of this module can be checked from graph
window.

Verify the followings:

The clark1.Alpha waveform should be leading the clark1.Beta waveform by 90
o
at the same magnitude.
The clark1.Alpha waveform should be same as the clark1.As waveform.

It is important that the measured line current must be lagging with the reconstructing phase voltage
because of the nature of the ACI motor. As mentioned in the previous section, three input switching
functions may not be functioning correctly (see this module documentation for details). This can be easily
checked as follows (Note you may need to modify datalog settings and/or graph windows settings to
observe these signals):

The clark1.Alpha waveform should be lagging the Valpha waveform at an angle by nature of the
reactive load of Induction motor.
The clark1.Beta waveform should be lagging the Vbeta waveform at the same angle.
If the clark1.Alpha and Valpha or clark1.Beta and Vbeta waveforms in the previous step are not truly
affecting the lagging relationship, then set OutofPhase to 1 at the beginning of the VOLT_MACRO
module.



















Fig 18 The waveforms of phase A voltage & current and phase B voltage & current












25
Since the low side current measurement technique is used employing shunt resistors on inverter phase
legs, the phase current waveforms observed from current test points ([M5]-Ifb-U, and [M5]-Ifb-V) are
composed of pulses as shown in Fig 19.

















Fig.19 Amplified Phase A current


Level 2C Calibrating the Phase Current Offset

Note that especially the low power motors draw low amplitude current after closing the speed loop under
no-load. The performance of the sensorless control algorithm becomes prone to phase current offset
which might stop the motors or cause unstable operation. Therefore, the phase current offset values need
to be minimized at this step.

Set VqTesting, VdTesting and SpeedRef to zero in the code, recompile and run the system and watch the
clarke1.As & clarke1.Bs from watch window. Make sure that the clarke1.As & clarke1.Bs values are less
than 0.001 or minimum possible. If not, adjust the offset value in the code by going to :

clarke1.As =_IQ15toIQ((AdcResult.ADCRESULT0<<3)-_IQ15(0.50))<<1;

and changing IQ15(0.50) offset value (e.g. IQ15(0.5087) or IQ15(0.4988) depending
on the sign and amount of the offset)

Rebuild the project and then repeat the calibration procedure again until the clarke1.As and clarke1.Bs
offset values are minimum.

Hint: If the value of clarke1.As is greater than zero, then increase the offset term by the half of the
clarke1.As value in the watch window. If the value of clarke1.As is less than zero, then decrease the
offset term by the half of the clarke1.As in the watch window.

Note: Piccolo devices have 12-bit ADC and 16-bit ADC registers. The AdcResult.ADCRESULT
registers are right justified for Piccolo devices; therefore, the measured phase current value is firstly left
shifted by three to convert into Q15 format (0 to 1.0), and then converted to ac quantity ( 0.5) following
the offset subtraction. Finally, it is left shifted by one (multiplied by two) to normalize the measured phase
current to 1.0 pu.


Bring the system to a safe stop as described at the end of build 1 by reducing the bus voltage, taking the
controller out of realtime mode and reset.

26
3-Phase
Inverter
ACI
Motor
IPARK
MACRO
ipark_Q
ipark_D
theta_ip
ipark_q
ipark_d
CLARKE
MACRO
clark_a
clark_b
clark_d
clark_q
PARK
MACRO
park_d
park_q
theta_p
park_D
park_Q
PWM
MACRO
Q0 / HW
Mfunc_c1
PWM1A
PWM1B
PWM2A Mfunc_c2
Mfunc_c3
Mfunc_p
AdcResult 0 ADCINx (Ia)
ADCINy (Ib)
SVGEN
MACRO
Ubeta
Ualfa
Ta
Tb
Tc
EV
HW
ADC
HW
RG
MACRO
rmp_freq
rmp_offset
rmp_gain
RC
MACRO
trgt_value
set_value
set_eq_trgt
VdTesting
rmp_out
Level 2 - Incremental System Build Block Diagram
SpeedRef
AdcResult 1
ADC
CONV
VOLT
MACRO
Mfunc_V1
Mfunc_V1
Mfunc_V1
DcBusVolt
Tb
Ta
Tc
AdcResult 2
ADCINz (Vdc) AdcResult 2
VPhase_ABC
Valpha
Vbeta
VqTesting
PWMDAC
MACRO
DLOG
Dlog 1
Dlog 2
Graph
Window
Dlog 3
Dlog 4
PwmDacPointer0
Scope
Low
Pass
Filter
Cct
PwmDacPointer1
PwmDacPointer2
PwmDacPointer3
PWM2B
PWM3A
PWM3B
Level 2 verifies the analog-to-digital conversion, offset compensation, clarke / park transformations, phase voltage calculations

27
Level 3 Incremental Build
Assuming the previous section is completed successfully, this section verifies the dq-axis current
regulation performed by PID_REG3 modules and speed measurement modules (optional). To confirm the
operation of current regulation, the gains of these two PID controllers are necessarily tuned for proper
operation.

Open HVACI_Sensorless-Settings.h and select level 3 incremental build option by setting the
BUILDLEVEL to LEVEL3 (#define BUILDLEVEL LEVEL3). Now Right Click on the project name and
click Rebuild Project. Once the build is complete click on debug button, reset CPU, restart, enable real
time mode and run. Set EnableFlag to 1 in the watch window. The variable named IsrTicker will be
incrementally increased as seen in watch windows to confirm the interrupt working properly.

SpeedRef (Q24): for changing the rotor speed in per-unit.
IdRef(Q24): for changing the d-qxis voltage in per-unit.
IqRef(Q24): for changing the q-axis voltage in per-unit.

In this build, the motor is supplied by AC input voltage and the (AC) motor current is dynamically
regulated by using PID_REG3 module through the park transformation on the motor currents.

The steps are explained as follows:
Launch a debug session, enable time mode and run the project.
Set SpeedRef to 0.3 pu (or another suitable value if the base speed is different), Idref to a certain value
to generate rated flux
Gradually increase voltage at variac / dc power supply to get an appropriate DC-bus voltage.
Check pid1_id.Fdb in the watch windows with continuous refresh feature whether or not it should be
keeping track pid1_id.Ref for PID_REG3 module. If not, adjust its PID gains properly.
Check pid1_iq.Fdb in the watch windows with continuous refresh feature whether or not it should be
keeping track pid1_iq.Ref for PID_REG3 module. If not, adjust its PID gains properly.
To confirm these two PID modules, try different values of pid1_id.Ref and pid1_iq.Ref or SpeedRef.
For both PID controllers, the proportional, integral, derivative and integral correction gains may be re-
tuned to have the satisfied responses.
Bring the system to a safe stop as described at the end of build 1 by reducing the bus voltage, taking
the controller out of realtime mode and reset.

28
During running this build, the current waveforms in the CCS graphs should appear as follows:














Fig.20 Svgen_dq1.Ta, phase A voltage, and phase A& B current waveforms.


Level 3B QEP / SPEED_FR test (optional for speed-loop tuning)

This section verifies the QEP1 driver and its speed calculation. Qep drive macro determines the rotor
position and generates a direction (of rotation) signal from the shaft position encoder pulses. Make sure
that the output of the incremental encoder is connected to [Main]-J10 and QEP/SPEED_FR macros are
initialized properly in the HVACI_Sensorless.c file depending on the features of the speed sensor. Refer
to the pdf files regarding the details of related macros in motor control folder
(C:\TI\controlSUITE\libs\app_libs\motor_control). The steps to verify these two software modules related
to the speed measurement can be described as follows:
Set SpeedRef to 0.3 pu (or another suitable value if the base speed is different).
Compile/load/run program with real time mode and then increase voltage at variac / dc power supply to
get the appropriate DC-bus voltage. Now the motor is running close to reference speed.
Check the speed1.Speed in the watch windows with continuous refresh feature whether or not the
measured speed is less than SpeedRef a little bit due to a slip of motor.
To confirm these modules, try different values of SpeedRef to test the Speed.
Use oscilloscope to view the electrical angle output, ElecTheta, from QEP_MACRO module and the
emulated rotor angle, Out, from RG_MACRO at PWMDAC outputs with external low-pass filters.
Check that both ElecTheta and Out are of saw-tooth wave shape and have the same period. If the
measured angle is in opposite direction, then change the order of motor cables connected to inverter
output (TB3 for HVDMC kit).
Check from Watch Window that qep1.IndexSyncFlag is set back to 0xF0 every time it reset to 0 by
hand. Add the variable to the watch window if it is not already in the watch window.
Bring the system to a safe stop as described at the end of build 1 by reducing the bus voltage, taking
the controller out of realtime mode and reset.

29
Level 3C CAP / SPEED_PR test (optional for speed-loop tuning)

In this case, the CAP1 input is chosen to detect the edge. If available, make sure that the sensor output is
connected to [Main]-J15 (first pin) and CAP/SPEED_PR macros are initialized properly in the
HVACI_Sensorless.c file depending on the features of the speed sensor. Typically the capture is used to
measure speed when a simple low cost speed sensing system is available. The sensor generates pulses
when detecting the teeth of a sprocket or gear and the capture drive provides the instantaneous value of
the selected time base (GP Timer) captured on the occurrence of an event. Refer to the pdf files
regarding the details of related macros in motor control folder
(C:\TI\controlSUITE\libs\app_libs\motor_control). The steps to verify these two software modules related
to the speed measurement can be described as follows:Set SpeedRef to 0.3 pu (or another suitable value
if the base speed is different).
Compile/load/run program with real time mode and then increase voltage at variac / dc power supply to
get the appropriate DC-bus voltage. Now the motor is running reference speed.
Check the speed2.Speed in the watch windows with continuous refresh feature whether or not they
should be less than SpeedRef a little bit due to a slip of motor.
To confirm these modules, try different values of SpeedRef to test the Speed.
Reduce voltage at variac / dc power supply to zero, halt program and stop real time mode. Now the
motor is stopping.
An alternative to verify these two software modules without running the motor can be done by using a
function generator. The key steps can be explained as follows:
Use a function generator to generate the 3.3V (DC) square-wave with the desired frequency
corresponding to the number of teeth in sprocket and the wanted speed in rpm. Then, connect only the
pulse signal and ground wires from the function generator to HVDMC board. The desired frequency of
the square-wave produced by function generator can be formulated as:
Hz f
wave square
60
_
TEETH RPM
=
where RPM is the wanted speed in rpm, and TEETH is the number of teeth in sprocket.
Compile/load/run program with real time mode and then increase voltage at variac to get the
appropriate DC-bus voltage. Now the motor is running. Note that the SpeedRef could be set to any
number.
Check the speed2.Speed and speed2.SpeedRpm in the watch windows with continuous refresh feature
whether or not they should be corresponding to the wanted speed that is chosen before.
To confirm these modules, change different frequencies of square-wave produced by function
generator with corresponding wanted (known) speed to check the Speed and SpeedRpm.
Bring the system to a safe stop as described at the end of build 1 by reducing the bus voltage, taking
the controller out of realtime mode and reset.



30
ACI
3-Phase
Inverter
IPARK
MACRO
ipark_Q
ipark_D
theta_ip
ipark_q
ipark_d
CLARKE
MACRO
clark_a
clark_b
clark_d
clark_q
PARK
MACRO
park_d
park_q
theta_p
park_D
park_Q
PID MACRO
Iq reg.
i_ref_q
i_fdb_q
u_out_q
i_ref_d
i_fdb_d
u_out_d
IdRef
PWM
MACRO
Q0 / HW
Mfunc_c1
Mfunc_c2
Mfunc_c3
Mfunc_p
SVGEN
MACRO
Ubeta
Ualfa
Ta
Tb
Tc
EV
HW
RG
MACRO
rmp_freq
rmp_offset
rmp_gain
RC
MACRO
trgt_value
set_value
set_eq_trgt
rmp_out
Level 3 - Incremental System Build Block Diagram
SpeedRef
AdcResult 0 ADCINx (Ia)
ADCINy (Ib)
ADC
HW
AdcResult 1
ADC
CONV
ADCINz (Vdc) AdcResult 2
Level 3 verifies the dq-axis current regulation performed by pid_id, pid_iq and speed measurement modules
VOLT
MACRO
Mfunc_V1
Mfunc_V2
Mfunc_V3
DcBusVolt
Tb
Ta
Tc
VPhase_ABC
Valpha
Vbeta
IqRef
DLOG
Dlog 1
Dlog 2
PWM1A
PWM1B
PWM2A
Graph
Window
clarke.Bs
clarke.As Dlog 3
Dlog 4
rg1.out
svgen.Ta
PID MACRO
Id reg.
PWM2B
PWM3A
PWM3B
CAP
HW
CAP
MACRO
QEP
HW
QEP
MACRO
SPEED PR
MACRO
SPEED FR
MACRO
Motor
Time
Stamp
Speed
Speed
Rpm
QEP A
QEP B
Index
CAPn
Direction
Elec
Theta
Speed
Speed
Rpm

31
Level 4 Incremental Build
Assuming the previous section is completed successfully; this section verifies flux estimation (ACI_FE)
and open-loop speed estimation (ACI_SE), respectively.

Open HVACI_Sensorless-Settings.h and select level 4 incremental build option by setting the
BUILDLEVEL to LEVEL4 (#define BUILDLEVEL LEVEL4). Now Right Click on the project name and
click Rebuild Project. Once the build is complete click on debug button, reset CPU, restart, enable real
time mode and run. Set EnableFlag to 1 in the watch window. The variable named IsrTicker will be
incrementally increased as seen in watch windows to confirm the interrupt working properly.

SpeedRef (Q24): for changing the rotor speed in per-unit.
IdRef (Q24): for changing the d-qxis voltage in per-unit.
IqRef (Q24): for changing the q-axis voltage in per-unit.

The tuning of proportional and integral gains (Kp_fe and Ki_fe) inside the flux estimator may be critical for
very low speed operation. The key steps can be explained as follows:
Set SpeedRef to 0.3 pu (or another suitable value if the base speed is different).
Compile/load/run program with real time mode and then increase voltage at variac / dc power supply to
get the appropriate DC-bus voltage. Now the motor is running close to reference speed.
Compare fe1.ThetaFlux with rg1.Out via PWMDAC with external low-pass filter and an oscilloscope.
They should be identical with a small phase shift.
If fe1.ThetaFlux does not give the ramp waveform, the Kp and Ki inside the flux estimator are required
to be re-tuned (likely to be reduced).
To confirm this flux estimator, try different values of SpeedRef.
Compare se1.WrHat with reference speed or measured speed in the watch windows with continuous
refresh feature whether or not it should be nearly the same.
To confirm this open-loop speed estimator, try different values of SpeedRef











32
During running this build, the current waveforms in the CCS graphs should appear as follows:

Fig.21 Estimated d&q fluxes,estimated theta and phase A current waveform

















33

34
rmp_out
ACI
Motor
IPARK
MACRO
ipark_Q
ipark_D
theta_ip
ipark_q
ipark_d
CLARKE
MACRO
clark_a
clark_b
clark_d
clark_q
PARK
MACRO
park_d
park_q
theta_p
park_D
park_Q
PID MACRO
Iq reg.
i_ref_q
i_fdb_q
u_out_q
PID MACRO
Id reg.
i_ref_d
i_fdb_d
u_out_d
IqRef
IdRef
PWM
MACRO
Q0 / HW
Mfunc_c1
Mfunc_c2
Mfunc_c3
Mfunc_p
SVGEN
MACRO
Ubeta
Ualfa
Ta
Tb
Tc
EV
HW
vsalfa
ThetaFlux
vsbeta
isalfa
isbeta
RG
MACRO
rmp_freq
rmp_offset
rmp_gain
RC
MACRO
trgt_value
set_value
set_eq_trgt
Level 4 - Incremental System Build Block Diagram
SpeedRef
AdcResult 0 ADCINx (Ia)
ADCINy (Ib)
ADC
HW
AdcResult 1
ADC
CONV
ADCINz (Vdc)
AdcResult 2
3-Phase
Inverter
Mfunc_V1
Mfunc_V2
Mfunc_V3
DcBusVolt
Valpha
Vbeta
ACI_SE
MACRO
Estimated
Speed
Level 4 verifies the flux and speed estimation performed by ACI_FE and ACI_SE modules.
PWM1A
PWM1B
PWM2A
PWM2B
PWM3A
PWM3B
ACI_FE
MACRO
PsiDrS
PsiQrS
isalfa
isbeta QEP
HW
QEP
MACRO
SPEED FR
MACRO
QEP A
QEP B
Index
Direction
Elec
Theta
Speed
Speed
Rpm
VOLT
MACRO
Level 5 Incremental Build
Assuming the previous section is completed successfully, this section verifies the speed regulator
performed by PID_REG3 module. The system speed loop is closed by using the measured speed as a
feedback.

Open HVACI_Sensorless-Settings.h and select level 5 incremental build option by setting the
BUILDLEVEL to LEVEL5 (#define BUILDLEVEL LEVEL5). Now Right Click on the project name and
click Rebuild Project. Once the build is complete click on debug button, reset CPU, restart, enable real
time mode and run. Set EnableFlag to 1 in the watch window. The variable named IsrTicker will be
incrementally increased as seen in watch windows to confirm the interrupt working properly.

SpeedRef (Q24): for changing the rotor speed in per-unit.
IdRef (Q24): for changing the d-qxis voltage in per-unit.

The speed loop is closed by using measured speed. It should be emphasized that the motor can spin only
one direction when the measured speed (from capture driver) does not give information about the
direction like QEP based speed measurement. Therefore, if the speed sensor is not an incremental
encoder, the SpeedRef is required to be positive. The key steps can be explained as follows:

Level 5A
Compile/load/run program with real time mode.
Set SpeedRef to 0.3 pu (or another suitable value if the base speed is different).
Add the soft-switch variables lsw to the watch window in order to switch from current loop to
speed loop. In the code lsw manages the loop setting as follows:
- lsw=0, close the current loop.
- lsw=1, close the speed loop.
Set lsw to 1. Gradually increase voltage at variac / dc power supply to get an appropriate DC-bus
voltage and now the motor is running around the reference speed (0.3 pu).
Gradually increase voltage at variac / dc power supply to get an appropriate DC-bus voltage and now
the motor is running around the reference speed (0.3 pu).
Compare Speed with SpeedRef in the watch windows with continuous refresh feature whether or not it
should be nearly the same.
To confirm this speed PID module, try different values of SpeedRef (positive only).
For speed PID controller, the proportional, integral, derivative and integral correction gains may be re-
tuned to have the satisfied responses.
At very low speed range, the performance of speed response relies heavily on the good rotor flux angle
computed by flux estimator.
Bring the system to a safe stop as described at the end of build 1 by reducing the bus voltage, taking
the controller out of realtime mode and reset.
Note that the IdRef is set to be constant at a certain value that is not too much for driving the motor.
Practically, it may be calculated from the rated flux condition.



35

36
Level 5B (Alternative method)
In order to test ACI_FE only, disconnect the speed PID and Iq PID modules, and apply constant Iqref as
the reference to Iq PID as shown in Level 5B. If the ACI_FE runs properly, the motor should spin
smoothly. If not, check the parameters in HVACI_Sensorless-Settings.h. Make sure that the base (pu)
quantities are set to maximum measurable current, voltage etc., and motor electrical parameters are
correct. The DC bus voltage should be high enough in order not to saturate the PID outputs. Run the
same experiment again and keep tuning ACI_FE gains. Note that, in this scheme the speed is not
controlled, therefore a non-zero torque (Iq) reference will spin the motor very fast unless loaded.
Therefore keep the Iqref low (typically less than 0.1 pu depending on the experimental setup) and load
the motor using a brake, generator etc. Increase Iqref or reduce the amount of load, if the motor speed is
too low or the generated torque by the motor is not enough to handle the applied load. After tuning the
ACI_FE, add speed PID into the system as shown in the block diagram and tune it, if needed. This
method will help the user tune ACI_FE and speed PID separately.

ACI
Motor
IPARK
MACRO
ipark_Q
ipark_D
theta_ip
ipark_q
ipark_d
CLARKE
MACRO
clark_a
clark_b
clark_d
clark_q
PARK
MACRO
park_d
park_q
theta_p
park_D
park_Q
PID MACRO
Iq reg.
i_ref_q
i_fdb_q
u_out_q
PID MACRO
Id reg.
i_ref_d
i_fdb_d
u_out_d
SpeedRef
IdRef
PWM
MACRO
Q0 / HW
Mfunc_c1
Mfunc_c2
Mfunc_c3
Mfunc_p
SVGEN
MACRO
Ubeta
Ualfa
Ta
Tb
Tc
EV
HW
vsalfa
ThetaFlux
vsbeta
isalfa
isbeta
Level 5A - Incremental System Build Block Diagram
AdcResult 0 ADCINx (Ia)
ADCINy (Ib)
ADC
HW
AdcResult 1
ADC
CONV
ADCINz (Vdc) AdcResult 2
3-Phase
Inverter
Mfunc_V1
Mfunc_V2
Mfunc_V3
DcBusVolt
Valpha
Vbeta
ACI_SE
MACRO
Estimated
Speed
Level 5A verifies the speed PID module and estimated theta (lsw =1).
PWM1A
PWM1B
PWM2A
PWM2B
PWM3A
PWM3B
ACI_FE
MACRO
PsiDrS
PsiQrS
isalfa
isbeta
QEP
HW
QEP
MACRO
SPEED FR
MACRO
QEP A
QEP B
Index
Direction
Elec
Theta
Speed
Speed
Rpm
VOLT
MACRO
PID MACRO
Spd reg. Fdb

37

38
ACI
Motor
IPARK
MACRO
ipark_Q
ipark_D
theta_ip
ipark_q
ipark_d
CLARKE
MACRO
clark_a
clark_b
clark_d
clark_q
PARK
MACRO
park_d
park_q
theta_p
park_D
park_Q
PID MACRO
Iq reg.
i_ref_q
i_fdb_q
u_out_q
PID MACRO
Id reg.
i_ref_d
i_fdb_d
u_out_d
IdRef
PWM
MACRO
Q0 / HW
Mfunc_c1
Mfunc_c2
Mfunc_c3
Mfunc_p
SVGEN
MACRO
Ubeta
Ualfa
Ta
Tb
Tc
ACI_FE
MACRO
vsalfa
vsbeta
isalfa
isbeta
RC
MACRO
Level 5B Incremental System Build Block Diagram
AdcResult 0 ADCINx (Ia)
ADCINy (Ib)
ADC
HW
AdcResult 1
ADCINz (Vdc) AdcResult 2
3-Phase
Inverter
VOLT
MACRO
Mfunc_V1
Mfunc_V2
Mfunc_V3
DcBusVolt
Valpha
Vbeta
Level 5B verifies the estimated theta.
RG
MACRO
rmp_freq
rmp_offset
rmp_gain
trgt_value
set_value
set_eq_trgt
rmp_out
(lsw=0)
Switched manually
in CC watch
window
IqRef
(lsw=1)
ADC
CONV
SpeedRef
ThetaFlux
Speed
PsiDrS
PsiQrS
isalfa
isbeta
SpeedRpm
ACI_SE
MACRO
PWM1A
PWM1B
PWM2A
PWM2B
PWM3A
PWM3B
EV
HW
Level 6 Incremental Build
Assuming the previous section is completed successfully, this section verifies the speed regulator
performed by PID_REG3 module. The system speed loop is closed by using the estimated speed as a
feedback.

Open HVACI_Sensorless-Settings.h and select level 6 incremental build option by setting the
BUILDLEVEL to LEVEL6 (#define BUILDLEVEL LEVEL6). Now Right Click on the project name and
click Rebuild Project. Once the build is complete click on debug button, reset CPU, restart, enable real
time mode and run. Set EnableFlag to 1 in the watch window. The variable named IsrTicker will be
incrementally increased as seen in watch windows to confirm the interrupt working properly.

SpeedRef (Q24): for changing the rotor speed in per-unit.
IdRef (Q24): for changing the d-qxis voltage in per-unit.

The speed loop is closed by using estimated speed. Unlike the Capture based sensored system in
previous build, the motor can spin both directions because the estimated speed (from open-loop speed
estimator) gives information about the direction. Therefore, the SpeedRef can be either positive or
negative value. The key steps can be explained as follows:
Compile/load/run program with real time mode.
Set SpeedRef to 0.3 pu (or another suitable value if the base speed is different).
Set lsw to 1. Gradually increase voltage at variac / dc power supply to get an appropriate DC-bus
voltage and now the motor is running with this reference speed (0.3 pu).
Compare se1.WrHat with SpeedRef in the watch windows with continuous refresh feature whether or
not it should be nearly the same.
To confirm this speed PID module, try different values of SpeedRef (positive or negative).
For speed PID controller, the proportional, integral, derivative and integral correction gains may be re-
tuned to have the satisfied responses.
At very low speed range, the performance of speed response relies heavily on the good rotor flux angle
computed by flux estimator.
Bring the system to a safe stop as described at the end of build 1 by reducing the bus voltage, taking
the controller out of realtime mode and reset.
Note that the IdRef is set to be constant at a certain value that is not too much for driving the motor.
Practically, it may be calculated from the rated flux condition and follow a flux weakening profile at high
speed region.
Note: Using scheme 6B is recommended until completing the loop-tuning process to achieve smooth
start-up. This scheme employs a soft loop-switch in the code for sensorless speed loop transient. For this
purpose, add soft-switch variable lsw to watch window and set it to 1 in order close the speed loop.
Each time close the speed loop earlier manually from watch window until achieving direct sensorless
start-up.

As a mid-step in between level 5 and level 6, a soft switch can be used in level 5A to change the speed
PID feedback from sensor based speed measurement to estimated speed. In this case, the initial speed
estimation ambiguities will be handled by measured speed until the system is perfectly tuned.


39
During running this build, the current waveforms in the CCS graphs should appear as follows:

Fig.22 Phase A&B current, estimated theta and phase A voltage waveforms













Fig23 Flux and torque components of the stator current in the synchronous reference frame under
1.0 pu step- load and 0.3 pu speed monitored from PWMDAC outputs

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41
ACI
Motor
IPARK
MACRO
ipark_Q
ipark_D
theta_ip
ipark_q
ipark_d
CLARKE
MACRO
clark_a
clark_b
clark_d
clark_q
PARK
MACRO
park_d
park_q
theta_p
park_D
park_Q
PID MACRO
Iq reg.
i_ref_q
i_fdb_q
u_out_q
PID MACRO
Id reg.
i_ref_d
i_fdb_d
u_out_d
SpeedRef
IdRef
PWM
MACRO
Q0 / HW
Mfunc_c1
Mfunc_c2
Mfunc_c3
Mfunc_p
SVGEN
MACRO
Ubeta
Ualfa
Ta
Tb
Tc
vsalfa
ThetaFlux
vsbeta
isalfa
isbeta
Level 6A Incremental System Build Bloc
EV
HW
k Diagram
AdcResult 0 ADCINx (Ia)
ADCINy (Ib)
ADC
HW
AdcResult 1
AD
CO
C
NV
PWM1A
PWM1B
PWM2A
ADCINz (Vdc)
AdcResult 2
3-Phase
Inverter
Mfunc_V1
Mfunc_V2
Mfunc_V3
DcBusVolt
Valpha
Vbeta
Speed
Level 6A verifies the complete system.
PWM2B
PWM3A
PWM3B
ACI_FE
MACRO
PsiDrS
PsiQrS
isalfa
isbeta
VOLT
MACRO
PID MACRO
Spd reg. Fdb
SpeedRpm
ACI_SE
MACRO

42
ACI
Motor
IPARK
MACRO
ipark_Q
ipark_D
theta_ip
ipark_q
ipark_d
CLARKE
MACRO
clark_a
clark_b
clark_d
clark_q
PARK
MACRO
park_d
park_q
theta_p
park_D
park_Q
PID MACRO
Iq reg.
i_ref_q
i_fdb_q
u_out_q
PID MACRO
Id reg.
i_ref_d
i_fdb_d
u_out_d
IdRef
PWM
MACRO
Q0 / HW
c_c1 Mfun
Mfun
Mfun
Mfun
c_c2
c_c3
c_p
SVGEN
MACRO
Ubeta
Ualfa
Ta
Tb
Tc
ACI_FE
MACRO
vsalfa
vsbeta
isalfa
isbeta
RC
MACRO
Level 6B Incremental System Build Block Diagram
AdcResult 0 ADCINx (Ia)
ADCINy (Ib)
ADC
HW
AdcResult 1
ADCINz (Vdc) AdcResult 2
3-Phase
Inverter
VOLT
MACRO
Mfunc_V1
Mfunc
Mfunc
_V2
_V3
DcBusVolt
Valpha
Vbeta
Level 6 verifies the complete system.
PID MACRO
Spd reg
RG
MACRO
rmp_freq
rmp_offset
rmp_gain
trgt_value
set_value
set_eq_trgt
rmp_out
(lsw=0)
SpeedRef
Switched manually
in CC watch
window
Fbd
IqRef (lsw=0)
(lsw=1)
(lsw=1)
u_out_spd
PWM1A
ADC
CONV
SpeedRef
ThetaFlux
Speed
PsiDrS
PsiQrS
isalfa
isbeta
SpeedRpm
ACI_SE
MACRO
PWM1B
PWM2A
EV
HW
PWM2B
PWM3A
PWM3B


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