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Stator current and power factor optimization in an IPMSM for railway traction                LOPEZ DE HEREDIA Amaia
application




             Stator current and power factor optimization in an IPMSM
                           for railway traction application
       A. Lopez-de-Heredia, C. Calleja,                                A. Lertxundi, A. Aranburu, T. Nieva
                IKERLAN-IK4                                                     TRAINELEC S. L.
     Pº. J. M. Arizmendiarrieta, 2 - 20500                             Poligono Katategi, 3 bis nº 1 - 20271
          Arrasate-Mondragón, Spain                                                 Irura, Spain
            Tel.: +34 / 943 71 24 00                                         Tel.: +34 / 943 69 08 70
            Fax: +34 / 943 79 69 44                                          Fax: +34 / 943 69 09 12
           alopezheredia@ikerlan.es,                                        alerchundi@trainelec.com
             http://www.ikerlan.es                                          http://www.trainelec.com/


Aknowledgments
The authors gratefully acknowledge the support of the Centre for the Development of Industrial
Technology (CDTI) of the Spanish Ministry of Science, through the Strategic Consortium for
Technology Research, CENIT, called ECOTRANS.
Keywords
Traction Application, Permanent magnet motor, Rail vehicle, Control of drive

Abstract
The objective of this paper is to compare two control strategies aimed at optimizing stator current and
power factor in the constant torque operation zone on railway traction applications when interior
permanent magnet synchronous machines (IPMSM) are used. Both control strategies are the classical
“zero d-current”, which is used in most of industrial applications, and the Most Torque per Amp
(MTPA) technique, which optimizes the torque with the lowest current.
A simulation study has been carried out with different saliency interior permanent magnet syncronous
machines, in order to demonstrate that MTPA control strategy allows stator current and power factor
optimization, specially if high saliency IPMSM are used. Finally, experimental results with a full-scale
100kW prototype have been carried out, confirming the study fulfilled in simulation.

1. Introduction
At present, the squirrel cage induction machine is the preferred solution for railway traction applications
as it is considered a very robust and well-established technology. However, the cost reduction of
permanent magnets and the new quality and environmental requirements have made industry evolve
towards permanent magnet synchronous machines (PMSMs) and more and more train manufactures are
developing new traction units based on PMSMs [1] [2] [3] [4].
PMSMs provide high power density, high efficiency and small torque ripple. Besides, they are smaller
and lighter. Nevertheless, they also have some disadvantages: only one motor can be connected to an
inverter (which increases the final global cost value, even if their power is smaller) and additional
contactors are needed in order to isolate the induced voltage created by the rotating magnets from the
inverter in case of failure.
As it is well-known, radial PMSMs can be divided in two groups depending on the way the magnets are
buried. On the one hand, if permanent magnets are buried on the surface of the rotor, the machine is
called Surface PMSM (SPMSM). In this case, the machine has no saliency, so Ld=Lq (where Ld and Lq
are the longitudinal and transversal inductances respectively). On the other hand, if magnets are buried
inside the rotor, the machine is called Interior PMSM (IPMSM) and has a saliency effect, so Ld≠Lq. In
this case Lq is bigger than Ld. If the difference between the inductances is important (Lq-Ld), it is said
that the machine has big saliency. However, if the difference is small, the machine has low saliency.



                                                                                                                1
EPE 2011 - Birmingham                                ISBN: 9789075815153                                        P.1
Stator current and power factor optimization in an IPMSM for railway traction              LOPEZ DE HEREDIA Amaia
application




In the IPMSM, besides the electromagnetic torque, the machine presents a reluctant torque effect, which
allows a higher torque. In addition, as magnets are inside the rotor, they are better protected against
demagnetization.
As it is well-known, the torque/speed diagram defines the working area of a drive. This characteristic
can be associated with the power/speed curve. As it is shown in Figure 1, in the first zone, the drive
works with constant torque and flux and the voltage increases with the rotating speed. Once a specific
speed is attained (base speed), the second zone starts reducing the torque value while power remains
constant due to the energy source voltage limitations. This second zone is called constant power
operation zone, where the magnetic field is reduced by injecting a flux component in opposite direction
to the magnet flux, maintaning a constant power value.
                                TO RQ U E




                                            Fig. 1: Torque/speed and power/speed curves.
Railway traction application most important requirements are: field weakening possibility to operate at
high speed, capability to cope with high catenary voltage variation, limitations on the converter
switching frequency in order to limit power looses and the wide range of possible existing applications:
trams, subways, suburban trains, high-speed trains, etc. Because of these characteristics, it is often said
that IPMSM is better suited for traction applications, where field weakening is required over a wide
speed range [5] [6].
However, the use of IPMSMs not only improves constant power operation zone, but also constant
torque operation zone if an appropriate control structure is used [6]. In the constant torque zone,
although most of industrial drives use the classical zero d-current control strategy [7] [8], the Most
Torque per Amp (MTPA) strategy is also often proposed as an alternative for IPMSM [9] [10].
The objective of this paper is to compare these two control strategies, zero d-current and MTPA, in the
constant torque operation zone for a railway application IPMSM. After a short explanation of both
control strategies, a simulation study has been carried out with different saliency interior permanent
magnet syncronous machines, in order to demonstrate that MTPA control strategy allows stator current
and power factor optimization, specially if high saliency IPMSM are used. Finally, experimental results
with a a full-scale 100kW prototype have been carried out, confirming the study fulfilled in simulation.

2. PMSM Control Strategy
The electric equations of stator voltage on a PMSM (d-q reference frame) are expressed as:
 ⎧                     di d
 ⎪ V d = R s i d + L d dt − ω L q i q
 ⎪
 ⎨                                             ,                                                     (eq. 1)
 ⎪ V = R i + L di q + ωϕ
 ⎪ q       s q      q           PM + ω L d i d
 ⎩                     dt
where Vd and Vq are the d and q axis stator voltages, id and iq are the d and q axis stator currents, Ld and
Lq are the d and q axis inductances, ω is the electrical speed and ϕ PM the permanent magnet flux.
Stator flux module ( ϕ S ) and electromagnetic torque (T) on a PMSM (d-q reference frame) can be
represented by the following mathematical equations:


                                                                                                               2
EPE 2011 - Birmingham                                     ISBN: 9789075815153                                  P.2
Stator current and power factor optimization in an IPMSM for railway traction        LOPEZ DE HEREDIA Amaia
application




                                      3                                                          (eq. 2)
                               T =      . p .[ϕ PM .i q − ( L q − L d ).i d .i q ]
                                      2
                                ϕS =      ( L d .i d + ϕ PM ) 2 + ( L q .i q ) 2                 (eq. 3)

where p are the pole pairs. As it can be seen, the electromagnetic torque expression is composed of two
terms: a magnetic component and a reluctant component. Figure 2 shows the vector representation of a
PMSM.




                                         Fig. 2: Vector diagram of a PMSM.
where Is is the stator current module, the Vs is the stator voltage module and E is the electromotive
force (j ϕ PM ω).
Regarding the PMSMs control strategy, as it is typical in the constant torque operation zone in PMSM
traction applications [2] [3], a Field-Oriented Control (FOC) with space vector modulation is used (see
Figure 3).




                            Fig. 3: Block diagram of FOC control strategy in PMSM.
In the literature several authors highlight the advantages of controlling the drive with optimal values, in
other words, with the optimum stator current depending on the maximum torque (MTPA) [9] on the
constant torque operation zone or with Maximum Torque per Flux (MTPF) [11] or Maximum Torque
per Voltage (MTPV) [12] in the constant power operation zone. The most widespread technique is
Maximum torque per Ampere (MTPA), which permits to obtain the maximum torque with the
minimum available current, causing less heating on the drive and consequently, a better global
efficiency. In the following lines the classical zero-d current and the MTPA techniques are introduced.

2.1.    Zero d-current control strategy
This control strategy is based on the principle that in the constant torque zone, and as the permanent
magnet flux is constant, id is made equal to zero and therefore torque is just proportional to iq,
simplifying the system (eliminating the reluctant torque, see equations 4 and 5) and reducing the
computational cost.



                                                                                                           3
EPE 2011 - Birmingham                                 ISBN: 9789075815153                                  P.3
Stator current and power factor optimization in an IPMSM for railway traction                        LOPEZ DE HEREDIA Amaia
 application




                                                    3
                                              T =     . p .ϕ PM .i q                                              (eq. 4)
                                                    2
                                        ϕ S = ϕ PM 2 + ( L q .i q ) 2                                             (eq. 5)

This technique is very used in industry, because of its simplicity. The main disadvantage of this control
strategy is that with interior PMSM, the obtained torque is not optimized, as the reluctant torque is not
used.
2.2      MTPA control strategy
With the maximum torque per ampere (MTPA) control strategy, the maximum torque with the
minimum total current is obtained. This current minimization improves the inverter operation, as there
are less power losses, and optimizes the machine efficiency [10]. In this case, d-axe current, id, is not
zero, and it has a negative value. Equations 6 to 9 present the mathematical representation of the torque
based on the stator current amplitude (Is) and the δ angle of the vector current so as to obtain the
position of the current vector that generates the maximum torque [9].
                                         ⎧ i d = − I s . sin δ                                                    (eq. 6)
                                         ⎨
                                         ⎩ i q = I s . cos δ
                             3                         1               2
                          T = . p.[ϕ PM .I s . cos δ − .( Lq − Ld ).I s . sin 2δ ]                                (eq. 7)
                             2                         2
The next step is to calculate the ‘sinβ’ value that gives the maximum torque for a specific current value.
Deriving the torque with respect to the δ angle and making it equal to 0, the required ‘sinδ’ is obtained.
This variable is positive so that id<0.
                 dT                      2                                      2                                   (eq. 8)
                    = 0 = ( Lq − Ld ).I s − ϕ PM .I s . sin δ + 2( Lq − Ld ).I s . sin 2 δ
                 dδ
With:
                                                                 2                                2
                                          − ϕ PM +        ϕ PM         + 8 ( L q − L d ) 2 .I s
                              sin δ =                                                                               (eq. 9)
                                                          4 ( L q − L d ). I s

3.       Simulation analysis
A simulation study has been carried out to compare both control strategies, zero d-current and MTPA,
for IPMSMs in the constant torque operation zone. As a case study a tram application has been
considered, with a 750V DC bus voltage, a traction inverter and a 100kW IPMSM. Two different
IPMSMs have been analyzed. The first one with low saliency, Lq=1.4*Ld, and the second one with high
saliency, Lq=2.8*Ld (see Table I). These values can be considered as typical for railway traction
applications [13] [14].
                                                            TABLE I.
                                                 SIMULATIONS MAIN PARAMETERS

                                                Parameter                        Value
                                              DC bus voltage                     750V
                                                Power (P)                       100kW
                                               Torque (T)                       500Nm
                                                Speed (ω)                      2300rpm
                                              PM Flux( ϕ PM )                  0.514Wb
                                                IPMSM                          Lq=1.4*Ld
                                               IPMSM 2                         Lq=2.8*Ld

3.1.     Calcul of MTPA current values
In MTPA control strategy, id and iq must be calculated in order to obtain the optimized stator current.
Using equation 7 and equation 9, the optimal current (in d and q axis is calculated. In order to avoid the
implementation of the complete table of calculations, which is quite hard from the computational load

                                                                                                                            4
 EPE 2011 - Birmingham                                ISBN: 9789075815153                                                   P.4
Stator current and power factor optimization in an IPMSM for railway traction                                                                                                                                                                                            LOPEZ DE HEREDIA Amaia
application




point of view, an approximation to a thirth order polynomial is used. Figure 4 and 5 show how both
values (calculations and approximations) fix well for both low saliency machine (see Figure 4) and high
saliency machine (see Figure 5). The implementation of the MTPA control carried out with
approximated polynomials instead of the computational tables permits to minimize the complexity of
the control.
                                                                                                                                                                                                                                                                                               Iq table
                                                        0                                                                                                                           180
                                                                                                                                                                                                                                                                                               Iq polynomial
                                                                                                                                         Id table
                                                                                                                                         Id polynomial                              160


                                                    -5                                                                                                                              140


                                                                                                                                                                                    120




                                                                                                                                                                 Iq optimum (A)
                                                   -10
                                  Id optimum (A)




                                                                                                                                                                                    100


                                                                                                                                                                                            80

                                                   -15
                                                                                                                                                                                            60


                                                                                                                                                                                            40
                                                   -20
                                                                                                                                                                                            20


                                                                                                                                                                                                   0
                                                                                                                                                                                                       0       50         100       150     200     250     300       350    400     450         500
                                                   -25
                                                            0          50       100    150   200     250     300       350         400       450     500                                                                                       Tem reference (Nm)
                                                                                                Tem reference (Nm)

      Fig. 4: Optimal id and iq currents depending on the demanding torque for low saliency machine.
                                                                                                                                                                                                                                                                                                Iq table
                                                   10
                                                                                                                                              Id table                            150                                                                                                           Iq polynomial
                                                                                                                                              Id polynomial

                                                   0



                                               -10
                                                                                                                                                                                  100
                                                                                                                                                               Iq optimum (A)
                        Id optimum (A)




                                               -20



                                               -30

                                                                                                                                                                                          50
                                               -40



                                               -50


                                                                                                                                                                                                   0
                                               -60                                                                                                                                                     0       50         100       150     200     250     300       350    400     450         500
                                                        0             50    100       150    200     250     300       350         400       450     500                                                                                       Tem reference (Nm)
                                                                                                Tem reference (Nm)


   Fig. 5: Optimal id and iq currents depending on the demanding torque for high saliency machine.
3.2                                                 Comparison between both control strategies and different saliency machines
Simulations have been carried out in the constant torque zone at a constant speed, 1000rpm, demanding
the nominal torque 500Nm. Therefore, a mecanical power around 50kW is demanded to the motor.
Next figure shows the torque variation (from 0Nm to 500Nm) and the DC bus voltage for the analyzed
four cases: both control strategies with low and high saliency IPMSMs. Left-side of Figure 6 (a and c)
shows zero d-current control strategy for both, low and high saliency machines and right-side of Figure
6 (b and d) shows MTPA control strategy for both, low and high saliency, machines. As it can be seen,
the four curves are almost equal and no differences can be identified. Thus, the same torque is obtained
whatever the control and the machine saliency is.
                                                                                                     Torque                                                                                                                                                Torque

                       600                                                                                                                                                                         600


                       400                                                                                                                                                                         400
      Tem(Nm)




                                                                                                                                                                                  Tem(Nm)




                                                                                                                                                         Tem ref                                                                                                                                             Tem ref
                                                                                                                                                         Tem                                                                                                                                                 Tem
                       200                                                                                                                                                                         200


                              0                                                                                                                                                                            0

                                     1                          1.5         2         2.5     3         3.5        4         4.5         5         5.5                6                                    1        1.5         2         2.5       3         3.5        4     4.5         5           5.5             6
                                                                                                     time (s)                                                                                                                                              time (s)

                                                                                                  DC Bus Voltage                                                                                                                                        DC Bus Voltage
                       800                                                                                                                                                                         800

                       780                                                                                                                                                                         780
                                                                                                                                                                                  Bus Voltage(V)
      Bus Voltage(V)




                       760                                                                                                                                                                         760

                       740                                                                                                                                                                         740

                       720                                                                                                                                                                         720


                       700                                                                                                                                                                         700
                          1                                     1.5         2         2.5     3         3.5        4         4.5         5         5.5                6                               1             1.5         2         2.5       3         3.5        4     4.5         5           5.5             6
                                                                                                      time(s)                                                                                                                                               time(s)

                                                                                                         (a)                                                                                                                                        (b)

                                                                                                                                                                                                                                                                                                                           5
EPE 2011 - Birmingham                                                                                                                         ISBN: 9789075815153                                                                                                                                                          P.5
Stator current and power factor optimization in an IPMSM for railway traction                                                                                                                                                                   LOPEZ DE HEREDIA Amaia
application



                                                                                     Torque
                                                                                                                                                                                                                                Torque
                               600
                                                                                                                                                                 600

                               400
              Tem(Nm)

                                                                                                                                                                 400




                                                                                                                                                Tem(Nm)
                                                                                                                                 Tem ref
                                                                                                                                                                                                                                                                                            Tem ref
                                                                                                                                 Tem
                               200                                                                                                                                                                                                                                                          Tem
                                                                                                                                                                 200

                                   0
                                                                                                                                                                          0
                                       1     1.5           2     2.5       3            3.5         4    4.5       5       5.5              6
                                                                                                                                                                              1       1.5     2       2.5          3               3.5          4           4.5           5           5.5             6
                                                                                     time (s)                                                                                                                                   time (s)

                                                                                DC Bus Voltage                                                                                                                             DC Bus Voltage
                               800                                                                                                                               800

                               780                                                                                                                               780
              Bus Voltage(V)




                                                                                                                                                Bus Voltage(V)
                               760                                                                                                                               760

                               740                                                                                                                               740

                               720                                                                                                                               720

                               700                                                                                                                               700
                                  1          1.5           2     2.5       3           3.5          4    4.5       5       5.5              6                       1                 1.5     2       2.5          3              3.5           4           4.5           5           5.5             6
                                                                                     time(s)                                                                                                                                    time(s)

                                                                                          (c)                                                                                                                     (d)
 Fig. 6. Torque and DC bus voltage for: (a) zero d-current control low saliency, (b) MTPA control low
    saliency, (c) zero d-current control high saliency and (d) MTPA control high saliency machines.
Figure 7 shows d and q axis currents and the stator flux module for the analyzed four cases: both control
strategies with low and high saliency IPMSMs. Left-side of Figure 7 (a and c) shows zero d-current
control strategy for both, low and high saliency machines (note the negligible value of d current). Right-
side of Figure 7 (b and d) shows MTPA control strategy for both, low and high saliency machines. In
this case, a negative d-current is applied to the machine in order to obtain the same torque that in the
previous case but with a lower current (with the low saliency machine id=-19A and with high saliency
machine id=-43A). These values roughly match with the ones obtained in the analytical analysis (see
Figure 4 and 5). As it can be seen, the flux module is decreased in MTPA control, comparing with the
zero-d-current control, as the term Ld .id + ϕ PM is smaller (see equation 3). Besides, in high saliency
machines the flux module increases as the term Lq .iq is bigger (see equation 3).
                                                                                     Id                                                                                                                                             Id
                                                                                                                                                                                                                                                                                                    Id
                    50                                                                                                                                             50                                                                                                                               Id filt
                                                                                                                                            Id(A)
  Id(A)




                               0                                                                                                                                          0

               -50                                                                                                                Id                              -50
                                                                                                                                  Id filt
           -100                                                                                                                                           -100
               1                           1.5     2           2.5     3             3.5        4       4.5    5         5.5            6                     1                       1.5     2       2.5              3            3.5             4         4.5             5             5.5              6
                                                                                  time (s)                                                                                                                                       time (s)
                                                                                     Iq                                                                                                                                             Iq
              200                                                                                                                                                200
              150                                                                                                                                                150
              100                                                                                                                                                100
                                                                                                                                               Iq(A)
   Iq(A)




                                                                                                                                  Iq                                                                                                                                                               Iq
                    50                                                                                                            Iq filt                          50                                                                                                                              Iq filt
                               0                                                                                                                                          0
               -50                                                                                                                                                -50
                  1                        1.5     2           2.5     3           3.5        4         4.5    5         5.5            6                            1                1.5     2       2.5              3           3.5        4               4.5             5             5.5              6
                                                                                time (s)                                                                                                                                        time (s)
                                                                           Stator flux module                                                                                                                              Stator flux module
                0.8                                                                                                                                               0.8
                                                                                                                          Fs mod                                                                                                                                                            Fs mod
                                                                                                                          Fs mod filt                             0.7                                                                                                                       Fs mod filt
                0.7
                                                                                                                                                Fs(Wb)
     Fs(Wb)




                0.6                                                                                                                                               0.6

                0.5                                                                                                                                               0.5
                               1           1.5     2           2.5     3             3.5        4       4.5    5         5.5            6                                 1           1.5     2       2.5              3            3.5             4         4.5             5             5.5              6
                                                                                  time (s)                                                                                                                                       time (s)
                                                                                       (a)                                                                                                                  (b)
                                                                                       Id                                                                                                                                                  Id
                                                                                                                                                                                                                                                                                                             Id
                           50                                                                                                                                             50
                                                                                                                                                                                                                                                                                                             Id filt
                                                                                                                                                      Id(A)
    Id(A)




                               0                                                                                                                                              0

                      -50                                                                                                                                                 -50
                                                                                                                                     Id
                                                                                                                                     Id filt                         -100
              -100
                  1                         1.5        2        2.5        3           3.5          4    4.5       5       5.5             6                             1              1.5       2         2.5             3           3.5             4           4.5           5               5.5              6
                                                                                    time (s)                                                                                                                                         time (s)
                                                                                       Iq                                                                                                                                               Iq
                   200                                                                                                                                                    200
                   150                                                                                                                                                    150
                   100                                                                                                               Iq                                   100
                                                                                                                                                            Iq(A)
      Iq(A)




                                                                                                                                                                                                                                                                                                             Iq
                                                                                                                                     Iq filt
                           50                                                                                                                                             50                                                                                                                                 Iq filt
                               0                                                                                                                                              0
                      -50                                                                                                                                                 -50
                         1                  1.5        2        2.5        3           3.5        4      4.5       5       5.5              6                                1          1.5       2         2.5             3           3.5        4                4.5           5               5.5              6
                                                                                    time (s)                                                                                                                                         time (s)
                                                                               Stator flux module                                                                                                                               Stator flux module
                       0.8                                                                                                                                                0.8                                                                                                                     Fs mod
                                                                                                                                                                                                                                                                                                  Fs mod filt
                       0.7                                                                                                                                                0.7
          Fs(Wb)




                                                                                                                                                                 Fs(Wb)




                       0.6                                                                                                 Fs mod                                         0.6
                                                                                                                           Fs mod filt
                       0.5                                                                                                                                                0.5
                                   1        1.5        2        2.5        3           3.5          4    4.5       5       5.5              6                                     1     1.5       2         2.5             3           3.5             4           4.5           5               5.5              6
                                                                                    time (s)                                                                                                                                         time (s)
                                                                                       (c)                                                                                                            (d)
  Fig. 7. d and q axis currents and stator flux module for: (a) zero d-current control low saliency, (b)
 MTPA control low saliency, (c) zero d-current control high saliency, (d) MTPA control high saliency.

                                                                                                                                                                                                                                                                                                                  6
EPE 2011 - Birmingham                                                                                                  ISBN: 9789075815153                                                                                                                                                                       P.6
Stator current and power factor optimization in an IPMSM for railway traction                                                                                                                 LOPEZ DE HEREDIA Amaia
    application




Figure 8 illustrates the u phase stator current of the IPMSMs. With the low saliency IPMSM, stator
current module decreases, but only slightly (from 162A to 159.1A). However, in the simulations carried
out with the high saliency IPMSM, the MTPA strategy improves considerably the stator current as it
allows a decrease of %11.85, from 162A to 142.8A. Therefore, it can be concluded that depending on
the level of saliency of the IPMSM, the current optimization achieved with MTPA control strategy is
more or less important.
                                                                         Stator current: u phase                                                                             Stator current: u phase
                                        200                                                                                                        200



                                        150                                                                                                        150



                                        100                                                                                                        100



                                         50                                                                                                         50
                    Stator current(A)




                                                                                                                             Stator current(A)
                                             0                                                                                                       0



                                         -50                                                                                                        -50



                                        -100                                                                                                       -100



                                        -150                                                                                                       -150



                                        -200                                                                                                       -200
                                            1      1.5       2    2.5    3         3.5        4     4.5   5     5.5      6                             1   1.5   2   2.5      3          3.5       4       4.5     5       5.5     6
                                                                                time (s)                                                                                              time (s)

                                                                                      (a)                                                                              (b)
                                                                        Stator current: u phase                                                                               Stator current: u phase
                            200                                                                                                                     200



                            150                                                                                                                     150



                            100                                                                                                                     100



                                        50                                                                                                           50
Stator current(A)




                                                                                                                               Stator current(A)




                                        0                                                                                                             0



                                 -50                                                                                                                -50



                      -100                                                                                                                         -100



                      -150                                                                                                                         -150



                      -200                                                                                                                         -200
                          1                      1.5     2       2.5    3         3.5        4     4.5    5     5.5      6                             1   1.5   2    2.5         3       3.5          4     4.5       5     5.5       6
                                                                               time (s)                                                                                                time (s)

                                         (c)                                         (d)
          Fig. 8. Stator currents for: (a) zero d-current control low saliency, (b) MTPA control low saliency, (c)
                          zero d-current control high saliency and (d) MTPA control high saliency.
Other aspect that is worth analyzing is the machine power factor. Table II shows the obtained power
factor for the simulated four cases. The table shows that with both types of machines (with low and high
saliency) the power factor is improved considerably when the MTPA control strategy is used.
Moreover, in a IPMSM with high saliency it does not make sense to use zero d-current strategy as the
machine power factor is very low (as the high reluctant torque is not used).
                                                                                                                      TABLE II.
                                                                                                   POWER FACTOR OF DIFFERENT SIMULATIONS

                                                                                           Type of control                                            Saliency             Cos phi
                                                                                           Zero d-current                                              Low                  0.92
                                                                                             MTPA                                                      Low                  0.96
                                                                                           Zero d-current                                              High                 0.75
                                                                                             MTPA                                                     High                  0.93

4.                                               Experimental results
The experimental tests have been carried out using a prototype composed of a traction inverter
(developed by IKERLAN-IK4 and TRAINELEC S.L) and a 100kW Leroy Somer commercial IPMSM
(see Figure 9).

                                                                                                                                                                                                                                       7
    EPE 2011 - Birmingham                                                                                     ISBN: 9789075815153                                                                                                      P.7
Stator current and power factor optimization in an IPMSM for railway traction                                                                               LOPEZ DE HEREDIA Amaia
             application




                                                                   Fig. 9. Traction inverter and IPMSM test bench.
Experimental tests have been accomplished using a whole traction conversion chain: A DC source,
emulating the 750 DC catenary, a three phase inverter, a 100kW IPMSM and an induction machine
connected to a three phase inverter as a load (see Figure 10).




                                              Fig. 10. Block diagram of the whole traction conversion chain.
Due to power limitation of the DC source, experimental tests have been carried out at 1000rpm and
500Nm, around 50kW are demanded to the IPMSM (the same main characteristics and conditions as in
simulation). Table III shows the IPMSM main parameters, as it can be seen, the machine used for the
experimental tests has low saliency.
                                                                                         TABLE III.
                                                                                      IPMSM MAIN PARAMETERS

                                                                                 Parameter                                              Value
                                                                                 Power (P)                                             100kW
                                                                                Torque (T)                                             500Nm
                                                                                 Speed (ω)                                            2300rpm
                                                                               PM Flux( ϕ PM )                                        0.514Wb
                                                                                 IPMSM                                                Lq=1.4*Ld
Next figure shows the torque variation (from 0Nm to 500Nm) and the DC bus voltage in traction
application for both control strategies: on the left-side the zero d-current control and on the right-side
the MTPA control. As it has been proved in the simulation study, both curves are roughly equal. In the
experimental test, the DC bus voltage decreases during the torque transient response due to the low
capacity of the DC source.
                                                      Torque                                                                                            Torque
                   600                                                                                               600


                   500                                                                                               500


                   400                                                                                               400
                                                                                                  Tem(Nm)




                   300                                                                                               300
Tem(Nm)




                   200                                                                                               200


                   100                                                                                               100


                     0                                                                                                 0


                   -100                                                                                              -100
                          1   1.5   2   2.5   3         3.5         4    4.5      5    5.5    6                             1   1.5   2   2.5   3         3.5        4     4.5   5   5.5   6
                                                     time (s)                                                                                          time (s)




                                                  DC Bus Voltage                                                                                    DC Bus Voltage
                   800                                                                                               800

                   780                                                                                               780

                   760                                                                                               760
                                                                                                    Bus Voltage(V)




                   740                                                                                               740
  Bus Voltage(V)




                   720                                                                                               720

                   700                                                                                               700

                   680                                                                                               680

                   660                                                                                               660

                   640                                                                                               640
                          1   1.5   2   2.5   3         3.5         4    4.5      5    5.5    6                             1   1.5   2   2.5   3         3.5        4     4.5   5   5.5   6
                                                    tiempo (s)                                                                                        tiempo (s)



      Fig. 11. Experimental tests: Torque and DC bus voltage with zero d-current control (left-side) and with
                             MTPA control (right-side) with a low saliency IPMSM.

                                                                                                                                                                                               8
             EPE 2011 - Birmingham                                                      ISBN: 9789075815153                                                                                    P.8
Stator current and power factor optimization in an IPMSM for railway traction                                                                                                                                                                   LOPEZ DE HEREDIA Amaia
                    application




Figure 12 shows d and q axis currents and stator flux module for both control strategies (on the left-side
the zero d-current control and on the right-side the MTPA control). In this case, although the machine
has low saliency, differences can be identified between the curves: in MTPA control id current is equal
to -20A, while in zero d-current control id is equal to zero. In the iq current, the difference is very small
(iq current is decreased from 160A to 157A), and therefore the difference is negligleable. In MTPA
control, the stator flux module is also slighlty reduced, from 0.563Wb to 0.544Wb.
                                                                   Stator current: d axis                                                                                                                                                  Stator current: d axis
                                                                                                                                          Is d
                      80                                                                                                                                                                     80
                                                                                                                                          Is d filt                                                                                                                                        Is d
                      60                                                                                                                                                                     60
                                                                                                                                                                                                                                                                                           Is d filt
                      40                                                                                                                                                                     40
                      20                                                                                                                                                                     20
             Id(A)




                                                                                                                                                                               Id(A)
                       0                                                                                                                                                                     0
                      -20                                                                                                                                                                -20
                      -40                                                                                                                                                                -40
                      -60                                                                                                                                                                -60
                      -80                                                                                                                                                                -80
                            1      1.5       2    2.5       3                3.5                4           4.5       5         5.5                   6                                           1       1.5       2    2.5         3               3.5             4   4.5   5   5.5                 6
                                                                          time (s)                                                                                                                                                                time (s)

                                                                   Stator current: q axis                                                                                                                                                  Stator current: q axis
                     200                                                                                                                                                                200

                     150                                                                                                                                                                150

                     100                                                                                                                                                                100
        Iq(A)




                                                                                                                                                                             Iq(A)
                      50                                                                                                                                                                     50

                       0                                                                                                                                                                     0


                      -50                                                                                                                                                                -50
                            1      1.5       2    2.5       3                3.5                4           4.5       5         5.5                   6                                           1       1.5       2    2.5         3               3.5             4   4.5   5   5.5                 6
                                                                          time (s)                                                                                                                                                                time (s)

                                                                     Stator flux module                                               Fs mod                                                                                                Stator flux module
                     0.65                                                                                                             Fs mod filt                                       0.65
                                                                                                                                                                                                                                                                                         Fs mod
                                                                                                                                                                                                                                                                                         Fs mod filt
                      0.6                                                                                                                                                                0.6




                                                                                                                                                                          Fs mod(Wb)
  Fs mod(Wb)




                     0.55                                                                                                                                                               0.55


                      0.5                                                                                                                                                                0.5


                     0.45                                                                                                                                                               0.45
                            1      1.5       2    2.5       3                3.5                4           4.5       5         5.5                   6                                           1       1.5       2    2.5         3               3.5             4   4.5   5   5.5                 6
                                                                          time (s)                                                                                                                                                                time (s)




                           Fig. 12. Experimental tests: d and q axis currents and stator flux module with zero d-current control
                                       (left-side) and with MTPA control (right-side) with a low saliency IPMSM.
Finally, Figure 13 shows the u phase stator current for both control strategies: left-side, zero d-current
control, and right-side, MTPA control. As the machine has low saliency, both curves are quite similar.
                                                                Stator current: u phase                                                                                                                                                  Stator current: u phase
                     200                                                                                                                                                         200




                     150                                                                                                                                                         150




                     100                                                                                                                                                         100




                      50                                                                                                                                                               50
Stator current(A)




                                                                                                                                                      Stator current(A)




                       0                                                                                                                                                                0




                     -50                                                                                                                                                               -50




                    -100                                                                                                                                                      -100




                    -150                                                                                                                                                      -150




                    -200                                                                                                                                                      -200
                           1       1.5   2       2.5    3                 3.5               4         4.5         5       5.5              6                                                 1          1.5     2       2.5      3                 3.5               4   4.5   5   5.5                 6
                                                                       time (s)
                                                                                                                                                                                                                                                time (s)



                                Fig. 13. Experimental tests: U phase stator current with zero d-current control (left-side) and with
                                                    MTPA control (right-side) with a low saliency IPMSM.
Table IV shows the power factor obtained with both control strategies. As it is shown in the simulation
study, power factor is improved considerably using MTPA control strategy.
                                                                                                                          TABLE IV.
                                                                                                    POWER FACTOR OF DIFFERENT EXPERIMENTAL TESTS

                                                                                            Type of control                                                                                           Saliency                 Cos phi
                                                                                            Zero d-current                                                                                              Low                     0.91
                                                                                               MTPA                                                                                                     Low                     0.95

Experimental tests have confirmed the results obtained in simulation. In low saliency machines,
although the MTPA control strategy only optimizes slightly stator currents, it improves considerably the
machine power factor.




                                                                                                                                                                                                                                                                                                       9
                    EPE 2011 - Birmingham                                                                                 ISBN: 9789075815153                                                                                                                                                     P.9
Stator current and power factor optimization in an IPMSM for railway traction           LOPEZ DE HEREDIA Amaia
application




5.      Conclusions
In this paper two different control strategies, Most Torque Per Amp (MTPA) and zero d-current, are
compared from the point of view of Interior PMSM stator current and power factor optimization on a
railway traction application.
A simulation study has been carried out to compare both control strategies in the constant torque
operation zone. As a case study a tram application has been considered, with a 750V DC bus voltage, a
traction inverter and a 100kW IPMSM. Two different IPMSMs have been analyzed. The first one with
low saliency and the second one with high saliency. The simulation study has concluded that with a low
saliency IPMSM the advantage of using MTPA techniques is limited to the power factor improvement.
However, with high saliency IPMSM, not only power factor but also stator currents are optimized.
The experimental tests have been carried out using a prototype composed of a traction inverter and a
100kW commercial IPMSM. This IPMSM has low saliency, and therefore the simulation study carried
out with the low saliency machine has been validated experimentally, showing the improvement on the
power factor.

6.      References
[1] A. Jöckel and H.-J Knaak, “Intra Ice-A Novel Direct Drive System for Future High Speed Trains”, ICEM
Conference 2002.
[2] S. Belin, M. Scrooby, J. E. Masselus, T. Jobard and S. Courtine, “A PMSM based control for traction
applications”. EPE Conference 2003.
[3] K. Kondo, H. Hata, K. Uruga and N. Terauchi, ‘Development of a traction system for the gauge changing
train’, IAS 2004, Vol. 4, page(s): 2722-2727.
[4] Z. Peroutka, K. Zeman, F. Krus and F. Kosta, ‘New generation of full low-floor trams: Control of wheel drives
with permanent magnet synchronous motors’, ECCE Conference 2009, page(s): 1833–1840.
[5] R. H. Staunton, S. C. Nelson, P. J. Otaduy, J. W. McKeever, S. Das, and R. L. Smith, "PM Motor Parametric
Design Analyses for a Hybrid Electric Vehicle Traction Drive Application." Report of Oak Ridge National
Laboratory, ORNL/TM-2004/217, 2004.
[6] D. Uzel and Z. Peroutka, ‘Control and design considerations for wheel mounted drive of tram: Interesting
features offered by IPMSM technology’, Power electronics and motion control conference, page(s): T9-52 - T9-
58, 2010
[7] K. Kondou and K. Matsuoka. “Permanent Magnet Synchronous Motor Control System for Railway Vehicle
Traction and Its Advantages”. IEEE PCC Conference 1997.
[8] C. Chen and X. Xiao. “Torque Ripple Minimization in Permanent Magnet Synchoronous Motor Magnet
Demagnetization” IEEE EUROCON Conference 2009, 843-848.
[9] S. Chi, ‘Position - sensorless control of permanent magnet synchronous machine over a wide speed range’,
Master’s thesis, Graduate School of The Ohio State University, 2007.
[10] C. Kwon and S.D. Sudhoff, ‘An adaptive maximum torque per amp control strategy’, IEEE International
Conference on Electric Machines and Drives 2005, page(s): 783-788.
[11] P. Vaclavek and P. Blaha, ‘Interior permanent magnet synchronous machine field weakening control strategy
– the analytical solution’, SICE Conference 2008
[12] A. Consoli, G. Scarcella, G. Scelba and M. Cacciato. « Range Extended Efficiency Optimization Technique
for Scalar IPMSM Drives ». EPE-PEMC Conference 2010.
[13] M. S. D. Acampa, A. Del Pizzo and R. Rizzo. “A control Algorithm of AC-Brushless Drives for Railways
Traction Application, ACEMP Conference 2007, page(s): 453-458.
[14] F. Kondo and M. Kondo. “Design of the parameters of permanent magnet synchronous motors for railway
vehicle traction”. Power Electronics and Drive Systems, PEDS Conference 2003.




                                                                                                              10
EPE 2011 - Birmingham                                ISBN: 9789075815153                                      P.10

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16 pf-st.current opt.ipmsm traction (1)

  • 1. Stator current and power factor optimization in an IPMSM for railway traction LOPEZ DE HEREDIA Amaia application Stator current and power factor optimization in an IPMSM for railway traction application A. Lopez-de-Heredia, C. Calleja, A. Lertxundi, A. Aranburu, T. Nieva IKERLAN-IK4 TRAINELEC S. L. Pº. J. M. Arizmendiarrieta, 2 - 20500 Poligono Katategi, 3 bis nº 1 - 20271 Arrasate-Mondragón, Spain Irura, Spain Tel.: +34 / 943 71 24 00 Tel.: +34 / 943 69 08 70 Fax: +34 / 943 79 69 44 Fax: +34 / 943 69 09 12 alopezheredia@ikerlan.es, alerchundi@trainelec.com http://www.ikerlan.es http://www.trainelec.com/ Aknowledgments The authors gratefully acknowledge the support of the Centre for the Development of Industrial Technology (CDTI) of the Spanish Ministry of Science, through the Strategic Consortium for Technology Research, CENIT, called ECOTRANS. Keywords Traction Application, Permanent magnet motor, Rail vehicle, Control of drive Abstract The objective of this paper is to compare two control strategies aimed at optimizing stator current and power factor in the constant torque operation zone on railway traction applications when interior permanent magnet synchronous machines (IPMSM) are used. Both control strategies are the classical “zero d-current”, which is used in most of industrial applications, and the Most Torque per Amp (MTPA) technique, which optimizes the torque with the lowest current. A simulation study has been carried out with different saliency interior permanent magnet syncronous machines, in order to demonstrate that MTPA control strategy allows stator current and power factor optimization, specially if high saliency IPMSM are used. Finally, experimental results with a full-scale 100kW prototype have been carried out, confirming the study fulfilled in simulation. 1. Introduction At present, the squirrel cage induction machine is the preferred solution for railway traction applications as it is considered a very robust and well-established technology. However, the cost reduction of permanent magnets and the new quality and environmental requirements have made industry evolve towards permanent magnet synchronous machines (PMSMs) and more and more train manufactures are developing new traction units based on PMSMs [1] [2] [3] [4]. PMSMs provide high power density, high efficiency and small torque ripple. Besides, they are smaller and lighter. Nevertheless, they also have some disadvantages: only one motor can be connected to an inverter (which increases the final global cost value, even if their power is smaller) and additional contactors are needed in order to isolate the induced voltage created by the rotating magnets from the inverter in case of failure. As it is well-known, radial PMSMs can be divided in two groups depending on the way the magnets are buried. On the one hand, if permanent magnets are buried on the surface of the rotor, the machine is called Surface PMSM (SPMSM). In this case, the machine has no saliency, so Ld=Lq (where Ld and Lq are the longitudinal and transversal inductances respectively). On the other hand, if magnets are buried inside the rotor, the machine is called Interior PMSM (IPMSM) and has a saliency effect, so Ld≠Lq. In this case Lq is bigger than Ld. If the difference between the inductances is important (Lq-Ld), it is said that the machine has big saliency. However, if the difference is small, the machine has low saliency. 1 EPE 2011 - Birmingham ISBN: 9789075815153 P.1
  • 2. Stator current and power factor optimization in an IPMSM for railway traction LOPEZ DE HEREDIA Amaia application In the IPMSM, besides the electromagnetic torque, the machine presents a reluctant torque effect, which allows a higher torque. In addition, as magnets are inside the rotor, they are better protected against demagnetization. As it is well-known, the torque/speed diagram defines the working area of a drive. This characteristic can be associated with the power/speed curve. As it is shown in Figure 1, in the first zone, the drive works with constant torque and flux and the voltage increases with the rotating speed. Once a specific speed is attained (base speed), the second zone starts reducing the torque value while power remains constant due to the energy source voltage limitations. This second zone is called constant power operation zone, where the magnetic field is reduced by injecting a flux component in opposite direction to the magnet flux, maintaning a constant power value. TO RQ U E Fig. 1: Torque/speed and power/speed curves. Railway traction application most important requirements are: field weakening possibility to operate at high speed, capability to cope with high catenary voltage variation, limitations on the converter switching frequency in order to limit power looses and the wide range of possible existing applications: trams, subways, suburban trains, high-speed trains, etc. Because of these characteristics, it is often said that IPMSM is better suited for traction applications, where field weakening is required over a wide speed range [5] [6]. However, the use of IPMSMs not only improves constant power operation zone, but also constant torque operation zone if an appropriate control structure is used [6]. In the constant torque zone, although most of industrial drives use the classical zero d-current control strategy [7] [8], the Most Torque per Amp (MTPA) strategy is also often proposed as an alternative for IPMSM [9] [10]. The objective of this paper is to compare these two control strategies, zero d-current and MTPA, in the constant torque operation zone for a railway application IPMSM. After a short explanation of both control strategies, a simulation study has been carried out with different saliency interior permanent magnet syncronous machines, in order to demonstrate that MTPA control strategy allows stator current and power factor optimization, specially if high saliency IPMSM are used. Finally, experimental results with a a full-scale 100kW prototype have been carried out, confirming the study fulfilled in simulation. 2. PMSM Control Strategy The electric equations of stator voltage on a PMSM (d-q reference frame) are expressed as: ⎧ di d ⎪ V d = R s i d + L d dt − ω L q i q ⎪ ⎨ , (eq. 1) ⎪ V = R i + L di q + ωϕ ⎪ q s q q PM + ω L d i d ⎩ dt where Vd and Vq are the d and q axis stator voltages, id and iq are the d and q axis stator currents, Ld and Lq are the d and q axis inductances, ω is the electrical speed and ϕ PM the permanent magnet flux. Stator flux module ( ϕ S ) and electromagnetic torque (T) on a PMSM (d-q reference frame) can be represented by the following mathematical equations: 2 EPE 2011 - Birmingham ISBN: 9789075815153 P.2
  • 3. Stator current and power factor optimization in an IPMSM for railway traction LOPEZ DE HEREDIA Amaia application 3 (eq. 2) T = . p .[ϕ PM .i q − ( L q − L d ).i d .i q ] 2 ϕS = ( L d .i d + ϕ PM ) 2 + ( L q .i q ) 2 (eq. 3) where p are the pole pairs. As it can be seen, the electromagnetic torque expression is composed of two terms: a magnetic component and a reluctant component. Figure 2 shows the vector representation of a PMSM. Fig. 2: Vector diagram of a PMSM. where Is is the stator current module, the Vs is the stator voltage module and E is the electromotive force (j ϕ PM ω). Regarding the PMSMs control strategy, as it is typical in the constant torque operation zone in PMSM traction applications [2] [3], a Field-Oriented Control (FOC) with space vector modulation is used (see Figure 3). Fig. 3: Block diagram of FOC control strategy in PMSM. In the literature several authors highlight the advantages of controlling the drive with optimal values, in other words, with the optimum stator current depending on the maximum torque (MTPA) [9] on the constant torque operation zone or with Maximum Torque per Flux (MTPF) [11] or Maximum Torque per Voltage (MTPV) [12] in the constant power operation zone. The most widespread technique is Maximum torque per Ampere (MTPA), which permits to obtain the maximum torque with the minimum available current, causing less heating on the drive and consequently, a better global efficiency. In the following lines the classical zero-d current and the MTPA techniques are introduced. 2.1. Zero d-current control strategy This control strategy is based on the principle that in the constant torque zone, and as the permanent magnet flux is constant, id is made equal to zero and therefore torque is just proportional to iq, simplifying the system (eliminating the reluctant torque, see equations 4 and 5) and reducing the computational cost. 3 EPE 2011 - Birmingham ISBN: 9789075815153 P.3
  • 4. Stator current and power factor optimization in an IPMSM for railway traction LOPEZ DE HEREDIA Amaia application 3 T = . p .ϕ PM .i q (eq. 4) 2 ϕ S = ϕ PM 2 + ( L q .i q ) 2 (eq. 5) This technique is very used in industry, because of its simplicity. The main disadvantage of this control strategy is that with interior PMSM, the obtained torque is not optimized, as the reluctant torque is not used. 2.2 MTPA control strategy With the maximum torque per ampere (MTPA) control strategy, the maximum torque with the minimum total current is obtained. This current minimization improves the inverter operation, as there are less power losses, and optimizes the machine efficiency [10]. In this case, d-axe current, id, is not zero, and it has a negative value. Equations 6 to 9 present the mathematical representation of the torque based on the stator current amplitude (Is) and the δ angle of the vector current so as to obtain the position of the current vector that generates the maximum torque [9]. ⎧ i d = − I s . sin δ (eq. 6) ⎨ ⎩ i q = I s . cos δ 3 1 2 T = . p.[ϕ PM .I s . cos δ − .( Lq − Ld ).I s . sin 2δ ] (eq. 7) 2 2 The next step is to calculate the ‘sinβ’ value that gives the maximum torque for a specific current value. Deriving the torque with respect to the δ angle and making it equal to 0, the required ‘sinδ’ is obtained. This variable is positive so that id<0. dT 2 2 (eq. 8) = 0 = ( Lq − Ld ).I s − ϕ PM .I s . sin δ + 2( Lq − Ld ).I s . sin 2 δ dδ With: 2 2 − ϕ PM + ϕ PM + 8 ( L q − L d ) 2 .I s sin δ = (eq. 9) 4 ( L q − L d ). I s 3. Simulation analysis A simulation study has been carried out to compare both control strategies, zero d-current and MTPA, for IPMSMs in the constant torque operation zone. As a case study a tram application has been considered, with a 750V DC bus voltage, a traction inverter and a 100kW IPMSM. Two different IPMSMs have been analyzed. The first one with low saliency, Lq=1.4*Ld, and the second one with high saliency, Lq=2.8*Ld (see Table I). These values can be considered as typical for railway traction applications [13] [14]. TABLE I. SIMULATIONS MAIN PARAMETERS Parameter Value DC bus voltage 750V Power (P) 100kW Torque (T) 500Nm Speed (ω) 2300rpm PM Flux( ϕ PM ) 0.514Wb IPMSM Lq=1.4*Ld IPMSM 2 Lq=2.8*Ld 3.1. Calcul of MTPA current values In MTPA control strategy, id and iq must be calculated in order to obtain the optimized stator current. Using equation 7 and equation 9, the optimal current (in d and q axis is calculated. In order to avoid the implementation of the complete table of calculations, which is quite hard from the computational load 4 EPE 2011 - Birmingham ISBN: 9789075815153 P.4
  • 5. Stator current and power factor optimization in an IPMSM for railway traction LOPEZ DE HEREDIA Amaia application point of view, an approximation to a thirth order polynomial is used. Figure 4 and 5 show how both values (calculations and approximations) fix well for both low saliency machine (see Figure 4) and high saliency machine (see Figure 5). The implementation of the MTPA control carried out with approximated polynomials instead of the computational tables permits to minimize the complexity of the control. Iq table 0 180 Iq polynomial Id table Id polynomial 160 -5 140 120 Iq optimum (A) -10 Id optimum (A) 100 80 -15 60 40 -20 20 0 0 50 100 150 200 250 300 350 400 450 500 -25 0 50 100 150 200 250 300 350 400 450 500 Tem reference (Nm) Tem reference (Nm) Fig. 4: Optimal id and iq currents depending on the demanding torque for low saliency machine. Iq table 10 Id table 150 Iq polynomial Id polynomial 0 -10 100 Iq optimum (A) Id optimum (A) -20 -30 50 -40 -50 0 -60 0 50 100 150 200 250 300 350 400 450 500 0 50 100 150 200 250 300 350 400 450 500 Tem reference (Nm) Tem reference (Nm) Fig. 5: Optimal id and iq currents depending on the demanding torque for high saliency machine. 3.2 Comparison between both control strategies and different saliency machines Simulations have been carried out in the constant torque zone at a constant speed, 1000rpm, demanding the nominal torque 500Nm. Therefore, a mecanical power around 50kW is demanded to the motor. Next figure shows the torque variation (from 0Nm to 500Nm) and the DC bus voltage for the analyzed four cases: both control strategies with low and high saliency IPMSMs. Left-side of Figure 6 (a and c) shows zero d-current control strategy for both, low and high saliency machines and right-side of Figure 6 (b and d) shows MTPA control strategy for both, low and high saliency, machines. As it can be seen, the four curves are almost equal and no differences can be identified. Thus, the same torque is obtained whatever the control and the machine saliency is. Torque Torque 600 600 400 400 Tem(Nm) Tem(Nm) Tem ref Tem ref Tem Tem 200 200 0 0 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) DC Bus Voltage DC Bus Voltage 800 800 780 780 Bus Voltage(V) Bus Voltage(V) 760 760 740 740 720 720 700 700 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time(s) time(s) (a) (b) 5 EPE 2011 - Birmingham ISBN: 9789075815153 P.5
  • 6. Stator current and power factor optimization in an IPMSM for railway traction LOPEZ DE HEREDIA Amaia application Torque Torque 600 600 400 Tem(Nm) 400 Tem(Nm) Tem ref Tem ref Tem 200 Tem 200 0 0 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) DC Bus Voltage DC Bus Voltage 800 800 780 780 Bus Voltage(V) Bus Voltage(V) 760 760 740 740 720 720 700 700 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time(s) time(s) (c) (d) Fig. 6. Torque and DC bus voltage for: (a) zero d-current control low saliency, (b) MTPA control low saliency, (c) zero d-current control high saliency and (d) MTPA control high saliency machines. Figure 7 shows d and q axis currents and the stator flux module for the analyzed four cases: both control strategies with low and high saliency IPMSMs. Left-side of Figure 7 (a and c) shows zero d-current control strategy for both, low and high saliency machines (note the negligible value of d current). Right- side of Figure 7 (b and d) shows MTPA control strategy for both, low and high saliency machines. In this case, a negative d-current is applied to the machine in order to obtain the same torque that in the previous case but with a lower current (with the low saliency machine id=-19A and with high saliency machine id=-43A). These values roughly match with the ones obtained in the analytical analysis (see Figure 4 and 5). As it can be seen, the flux module is decreased in MTPA control, comparing with the zero-d-current control, as the term Ld .id + ϕ PM is smaller (see equation 3). Besides, in high saliency machines the flux module increases as the term Lq .iq is bigger (see equation 3). Id Id Id 50 50 Id filt Id(A) Id(A) 0 0 -50 Id -50 Id filt -100 -100 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) Iq Iq 200 200 150 150 100 100 Iq(A) Iq(A) Iq Iq 50 Iq filt 50 Iq filt 0 0 -50 -50 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) Stator flux module Stator flux module 0.8 0.8 Fs mod Fs mod Fs mod filt 0.7 Fs mod filt 0.7 Fs(Wb) Fs(Wb) 0.6 0.6 0.5 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) (a) (b) Id Id Id 50 50 Id filt Id(A) Id(A) 0 0 -50 -50 Id Id filt -100 -100 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) Iq Iq 200 200 150 150 100 Iq 100 Iq(A) Iq(A) Iq Iq filt 50 50 Iq filt 0 0 -50 -50 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) Stator flux module Stator flux module 0.8 0.8 Fs mod Fs mod filt 0.7 0.7 Fs(Wb) Fs(Wb) 0.6 Fs mod 0.6 Fs mod filt 0.5 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) (c) (d) Fig. 7. d and q axis currents and stator flux module for: (a) zero d-current control low saliency, (b) MTPA control low saliency, (c) zero d-current control high saliency, (d) MTPA control high saliency. 6 EPE 2011 - Birmingham ISBN: 9789075815153 P.6
  • 7. Stator current and power factor optimization in an IPMSM for railway traction LOPEZ DE HEREDIA Amaia application Figure 8 illustrates the u phase stator current of the IPMSMs. With the low saliency IPMSM, stator current module decreases, but only slightly (from 162A to 159.1A). However, in the simulations carried out with the high saliency IPMSM, the MTPA strategy improves considerably the stator current as it allows a decrease of %11.85, from 162A to 142.8A. Therefore, it can be concluded that depending on the level of saliency of the IPMSM, the current optimization achieved with MTPA control strategy is more or less important. Stator current: u phase Stator current: u phase 200 200 150 150 100 100 50 50 Stator current(A) Stator current(A) 0 0 -50 -50 -100 -100 -150 -150 -200 -200 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) (a) (b) Stator current: u phase Stator current: u phase 200 200 150 150 100 100 50 50 Stator current(A) Stator current(A) 0 0 -50 -50 -100 -100 -150 -150 -200 -200 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) (c) (d) Fig. 8. Stator currents for: (a) zero d-current control low saliency, (b) MTPA control low saliency, (c) zero d-current control high saliency and (d) MTPA control high saliency. Other aspect that is worth analyzing is the machine power factor. Table II shows the obtained power factor for the simulated four cases. The table shows that with both types of machines (with low and high saliency) the power factor is improved considerably when the MTPA control strategy is used. Moreover, in a IPMSM with high saliency it does not make sense to use zero d-current strategy as the machine power factor is very low (as the high reluctant torque is not used). TABLE II. POWER FACTOR OF DIFFERENT SIMULATIONS Type of control Saliency Cos phi Zero d-current Low 0.92 MTPA Low 0.96 Zero d-current High 0.75 MTPA High 0.93 4. Experimental results The experimental tests have been carried out using a prototype composed of a traction inverter (developed by IKERLAN-IK4 and TRAINELEC S.L) and a 100kW Leroy Somer commercial IPMSM (see Figure 9). 7 EPE 2011 - Birmingham ISBN: 9789075815153 P.7
  • 8. Stator current and power factor optimization in an IPMSM for railway traction LOPEZ DE HEREDIA Amaia application Fig. 9. Traction inverter and IPMSM test bench. Experimental tests have been accomplished using a whole traction conversion chain: A DC source, emulating the 750 DC catenary, a three phase inverter, a 100kW IPMSM and an induction machine connected to a three phase inverter as a load (see Figure 10). Fig. 10. Block diagram of the whole traction conversion chain. Due to power limitation of the DC source, experimental tests have been carried out at 1000rpm and 500Nm, around 50kW are demanded to the IPMSM (the same main characteristics and conditions as in simulation). Table III shows the IPMSM main parameters, as it can be seen, the machine used for the experimental tests has low saliency. TABLE III. IPMSM MAIN PARAMETERS Parameter Value Power (P) 100kW Torque (T) 500Nm Speed (ω) 2300rpm PM Flux( ϕ PM ) 0.514Wb IPMSM Lq=1.4*Ld Next figure shows the torque variation (from 0Nm to 500Nm) and the DC bus voltage in traction application for both control strategies: on the left-side the zero d-current control and on the right-side the MTPA control. As it has been proved in the simulation study, both curves are roughly equal. In the experimental test, the DC bus voltage decreases during the torque transient response due to the low capacity of the DC source. Torque Torque 600 600 500 500 400 400 Tem(Nm) 300 300 Tem(Nm) 200 200 100 100 0 0 -100 -100 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) DC Bus Voltage DC Bus Voltage 800 800 780 780 760 760 Bus Voltage(V) 740 740 Bus Voltage(V) 720 720 700 700 680 680 660 660 640 640 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 tiempo (s) tiempo (s) Fig. 11. Experimental tests: Torque and DC bus voltage with zero d-current control (left-side) and with MTPA control (right-side) with a low saliency IPMSM. 8 EPE 2011 - Birmingham ISBN: 9789075815153 P.8
  • 9. Stator current and power factor optimization in an IPMSM for railway traction LOPEZ DE HEREDIA Amaia application Figure 12 shows d and q axis currents and stator flux module for both control strategies (on the left-side the zero d-current control and on the right-side the MTPA control). In this case, although the machine has low saliency, differences can be identified between the curves: in MTPA control id current is equal to -20A, while in zero d-current control id is equal to zero. In the iq current, the difference is very small (iq current is decreased from 160A to 157A), and therefore the difference is negligleable. In MTPA control, the stator flux module is also slighlty reduced, from 0.563Wb to 0.544Wb. Stator current: d axis Stator current: d axis Is d 80 80 Is d filt Is d 60 60 Is d filt 40 40 20 20 Id(A) Id(A) 0 0 -20 -20 -40 -40 -60 -60 -80 -80 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) Stator current: q axis Stator current: q axis 200 200 150 150 100 100 Iq(A) Iq(A) 50 50 0 0 -50 -50 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) Stator flux module Fs mod Stator flux module 0.65 Fs mod filt 0.65 Fs mod Fs mod filt 0.6 0.6 Fs mod(Wb) Fs mod(Wb) 0.55 0.55 0.5 0.5 0.45 0.45 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) Fig. 12. Experimental tests: d and q axis currents and stator flux module with zero d-current control (left-side) and with MTPA control (right-side) with a low saliency IPMSM. Finally, Figure 13 shows the u phase stator current for both control strategies: left-side, zero d-current control, and right-side, MTPA control. As the machine has low saliency, both curves are quite similar. Stator current: u phase Stator current: u phase 200 200 150 150 100 100 50 50 Stator current(A) Stator current(A) 0 0 -50 -50 -100 -100 -150 -150 -200 -200 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 time (s) time (s) Fig. 13. Experimental tests: U phase stator current with zero d-current control (left-side) and with MTPA control (right-side) with a low saliency IPMSM. Table IV shows the power factor obtained with both control strategies. As it is shown in the simulation study, power factor is improved considerably using MTPA control strategy. TABLE IV. POWER FACTOR OF DIFFERENT EXPERIMENTAL TESTS Type of control Saliency Cos phi Zero d-current Low 0.91 MTPA Low 0.95 Experimental tests have confirmed the results obtained in simulation. In low saliency machines, although the MTPA control strategy only optimizes slightly stator currents, it improves considerably the machine power factor. 9 EPE 2011 - Birmingham ISBN: 9789075815153 P.9
  • 10. Stator current and power factor optimization in an IPMSM for railway traction LOPEZ DE HEREDIA Amaia application 5. Conclusions In this paper two different control strategies, Most Torque Per Amp (MTPA) and zero d-current, are compared from the point of view of Interior PMSM stator current and power factor optimization on a railway traction application. A simulation study has been carried out to compare both control strategies in the constant torque operation zone. As a case study a tram application has been considered, with a 750V DC bus voltage, a traction inverter and a 100kW IPMSM. Two different IPMSMs have been analyzed. The first one with low saliency and the second one with high saliency. The simulation study has concluded that with a low saliency IPMSM the advantage of using MTPA techniques is limited to the power factor improvement. However, with high saliency IPMSM, not only power factor but also stator currents are optimized. The experimental tests have been carried out using a prototype composed of a traction inverter and a 100kW commercial IPMSM. This IPMSM has low saliency, and therefore the simulation study carried out with the low saliency machine has been validated experimentally, showing the improvement on the power factor. 6. References [1] A. Jöckel and H.-J Knaak, “Intra Ice-A Novel Direct Drive System for Future High Speed Trains”, ICEM Conference 2002. [2] S. Belin, M. Scrooby, J. E. Masselus, T. Jobard and S. Courtine, “A PMSM based control for traction applications”. EPE Conference 2003. [3] K. Kondo, H. Hata, K. Uruga and N. Terauchi, ‘Development of a traction system for the gauge changing train’, IAS 2004, Vol. 4, page(s): 2722-2727. [4] Z. Peroutka, K. Zeman, F. Krus and F. Kosta, ‘New generation of full low-floor trams: Control of wheel drives with permanent magnet synchronous motors’, ECCE Conference 2009, page(s): 1833–1840. [5] R. H. Staunton, S. C. Nelson, P. J. Otaduy, J. W. McKeever, S. Das, and R. L. Smith, "PM Motor Parametric Design Analyses for a Hybrid Electric Vehicle Traction Drive Application." Report of Oak Ridge National Laboratory, ORNL/TM-2004/217, 2004. [6] D. Uzel and Z. Peroutka, ‘Control and design considerations for wheel mounted drive of tram: Interesting features offered by IPMSM technology’, Power electronics and motion control conference, page(s): T9-52 - T9- 58, 2010 [7] K. Kondou and K. Matsuoka. “Permanent Magnet Synchronous Motor Control System for Railway Vehicle Traction and Its Advantages”. IEEE PCC Conference 1997. [8] C. Chen and X. Xiao. “Torque Ripple Minimization in Permanent Magnet Synchoronous Motor Magnet Demagnetization” IEEE EUROCON Conference 2009, 843-848. [9] S. Chi, ‘Position - sensorless control of permanent magnet synchronous machine over a wide speed range’, Master’s thesis, Graduate School of The Ohio State University, 2007. [10] C. Kwon and S.D. Sudhoff, ‘An adaptive maximum torque per amp control strategy’, IEEE International Conference on Electric Machines and Drives 2005, page(s): 783-788. [11] P. Vaclavek and P. Blaha, ‘Interior permanent magnet synchronous machine field weakening control strategy – the analytical solution’, SICE Conference 2008 [12] A. Consoli, G. Scarcella, G. Scelba and M. Cacciato. « Range Extended Efficiency Optimization Technique for Scalar IPMSM Drives ». EPE-PEMC Conference 2010. [13] M. S. D. Acampa, A. Del Pizzo and R. Rizzo. “A control Algorithm of AC-Brushless Drives for Railways Traction Application, ACEMP Conference 2007, page(s): 453-458. [14] F. Kondo and M. Kondo. “Design of the parameters of permanent magnet synchronous motors for railway vehicle traction”. Power Electronics and Drive Systems, PEDS Conference 2003. 10 EPE 2011 - Birmingham ISBN: 9789075815153 P.10