Rotor Speed Detection Method For An Ultra-High-Speed InductionMotor Utilizing Slot Harmonics

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SAE TECHNICAL
PAPER SERIES 2007-01-0410
Rotor Speed Detection Method for an Ultra High

Speed Induction Motor Utilizing Slot Harmonics
Takashi Masuzawa, Nobumasa Isogai and Masami Fujitsuna
Denso Corporation
Reprinted From: Vehicle Sensors and Actuators, 2007

(SP-2124)
2007 World Congress

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2007-01-0410
Rotor Speed Detection Method for an Ultra High Speed

Induction Motor Utilizing Slot Harmonics
Takashi Masuzawa, Nobumasa Isogai and Masami Fujitsuna
Denso Corporation
Copyright © 2007 SAE International
ABSTRACT reasons, we adopted the IM for our ultra high speed

application.
Recently many automotive components have become
electrified and an ultra high speed drive (over 150,000 A speed sensor is required to control the IM, but it can
rpm) is now expected in applications such as a cause problems concerning cost, space and reliability.
turbocharger. In these applications, a robust induction Therefore, a sensorless speed detection method is
motor (IM) with a rectangular wave drive is generally required. General sensorless methods apply a motor-
adopted. A speed sensor is required to control the IM, equivalent circuit based on a sinusoidal wave drive.
but it can cause problems concerning cost, space and However, a rectangular wave drive should be applied to
reliability. Thus, a sensorless speed detection method is an ultra high speed drive because of the limitation of
required. Because general sensorless methods based switching frequency. Therefore, general methods based
on a sinusoidal wave drive are not applicable to a on motor-equivalent circuits are not applicable here.
rectangular wave drive, we propose a method utilizing
slot harmonics that are generated by the mechanical Another method that could be used employs slot
structure of the IM. Signal-to-noise (S/N) ratio of slot harmonics [2]. Since the slot harmonics are generated
harmonics is very small, and hence we suggest three by the mechanical structure of the IM, this method is
techniques: a detection circuit, a digital filter with a applicable to a rectangular wave drive. In addition, this
variable passband, and a detection method to restart the method is robust with regard to variations in motor
motor while rotating. parameters. However, it is difficult to detect accurate
rotor speeds when the S/N ratio of slot harmonics is low.
The proposed method was evaluated with a test vehicle,
and the results show that the rotor speed of IM can be In this paper, a novel speed estimation method using
detected up to 180,000 rpm with error less than 0.5%. slot harmonics is proposed. The structure makes it
possible to acquire accurate speeds in case of low S/N
INTRODUCTION ratio. The features of the proposed method are as
follows:
The number of motors in use on automobiles is
increasing, because many advanced functions and types 1) Detection circuit of slot harmonics using a neutral
of equipment are required on today’s vehicles. The point of motor and a neutral point of Y-connection
recent development of power electronics technology and resistances;
appearance of magnetic materials with very low core
loss have made it possible to realize an ultra high speed 2) A digital filter with a variable passband using fast
drive. These drives are expected in various applications fourier transform (FFT); and
such as a turbocharger.
3) A detection method to restart the motor while
In a prior study, a permanent magnet synchronous rotating using negative phase excitation voltage.
motor (PMSM) was adopted for an ultra high speed
application [1]. However, IMs are more suited for ultra
high speed applications because of their lower
electromotive force. PMSMs require a large input
voltage and a field weakening control owing to the
permanent magnet in the rotor. Moreover, IMs are low in
cost and robust compared with PMSMs. For these
PRINCIPLE OF ROTOR SPEED DETECTION 2. CALCULATING FORMULAS FOR ROTOR SPEED
1. GENERATION MECHANISM OF SLOT HARMONICS Flux of the air gap is described as follows:
Figure 1 shows a cross section of an IM. Slots can be BT , t B0 cosZt T u ^1 k H cos N r Z r t T ` (1)
seen where the secondary conductor is inserted into the
rotor. Because the secondary conductor is made of where
aluminum, the permeability is different between the slot
part and core part, which is made of silicon steel. T: angular position
Variation in air gap reluctance is caused by this Zr: angular speed (both T and Zr are in electrical
difference in permeability. The flux of the air gap is angle scale)
modulated according to the number of slots, as shown in
Z: angular speed of the power supply
Figure 2. The harmonics generated by the modulation is
N r: number of rotor slots per pole pair
defined as slot harmonics. Since slot harmonics are
B0: modules of fundamental component of flux
generated based on the structure of the IM, it contains
k H: ratio of the amplitude between fundamental
information on rotor speed.
harmonic and slot harmonics
stator slot Because the slot harmonics appear in a phase voltage,
T[rad] the phase voltage is described as below.
wBT , t
v(t ) K
wt
ª k
ZB0 «sin Zt T H sin^N r Z r Z t N r 1T `
¬ 2
core º
sin^N r Z r Z t N r 1T ` »
¼
Figure 1: Cross section of the IM
kH
B0 N r Z r >sin^N r Z r Z t N r 1T `
2
sin^N r Z r Z t N r 1T `@
(2)
where K is a proportional constant.
Since slot harmonics are generally a small percentage of

phase voltages, it is necessary to remove the
Figure 2: Flux of the air gap fundamental harmonic from the phase voltages.
Summation of the phase voltages, which is defined as
Table 1: Specs of tested motor slot harmonics voltage vsh, is described as below.
3
Rated power [W] 1400 v sh (t ) ¦ vi (t )
i 1
Rated voltage [V] 30
Speed range [rp m] 5,000 – 170,000 Kk H B0 / 2>( N r Z r Z )^1 2 cos 2( N r 1) S / 3`

Slip 0 – 0.5
u sin^( N r Z r Z )t ( N r 1)T ` ( N r Z r Z )^
Nu mber of poles 2
Nu mber of phases 6 (t wo pairs of three-phase) ^1 2 cos 2( N r 1) S / 3` u sin^( N r Z r Z )t ( N r 1)T `@
(3)
Nu mber of slots (stator) 12
Nu mber of slots (rotor) 16
If Nr is a natural number, formula (3) is obtained as SPEED ESTIMATION METHOD
0 >N r 3 N , N 1,2, @ 1. DETECTION CIRCUIT

°
° As stated in the foregoing section, fr cannot be detected
°° (3Kk H B0 / 2)( N r Z r r Z )
v sh (t ) ® due to the influence of an inverter excitation voltage. In
°u sin^( N r Z r r Z )t ( N r r 1)T ` this section, a newly developed detection circuit is
° proposed. As shown in Figure 4, vsh_dif is acquired as the
° difference between a neutral point voltage of the motor
°¯ >N r 3 N # 1@
(4) and Y-connection resistances. Figure 5 shows vsh_dif with
the developed detection circuit.
Formula (4) shows that if Nr is a natural number other
than a multiple of three, the frequency of the slot Y-connection resistances
harmonics fsh is given by
motor
vU
f sh Nr fr f (5) ~ EU
~
~
where EW EV vW
f: excitation frequency vV
fr: frequency of the rotor
Formula (5) shows that fr can be acquired from vsh, -

because Nr and f are known values.
+ vsh_dif
3. INFLUENCE OF HIGHER HARMONICS
In the foregoing section, it was stated that fr could be

detected from vsh using the formula based on the case of
Figure 4: Developed detection circuit
a sinusoidal phase voltage. Since practical motor drive
systems apply an inverter, the phase voltages contain
0.4
various time harmonics, except for a multiple of three
time harmonics. In this case, vsh contains higher 0.3
0.2
v sh_dif [V]
harmonics, so the formula cannot be applied without

regard to the influence of higher harmonics. 0.1
0
Figure 3 shows a waveform of vsh acquired under an -0.1 0 0.002 0.004 0.006
inverter drive. Because the excitation voltage is much -0.2
larger than the slot harmonics component, it is -0.3
impossible to detect fr from vsh. In the following section,
-0.4
we propose effective solutions to eliminate the time [s]
unnecessary higher harmonics.
(a) Waveform
slot harmonics component
1515 fundamental
0.3
3 harmonic
third harmonic slot harmonic
voltage [V]
1010
2
0.2
vsh [V]
0.1
1
fifth harmonic
55 0
excitation voltage of inverter 0 5000 10000 15000 20000

time [s] frequency [Hz]
0 00 0.001 0.002 (b) Harmonic components

0 0.001 0.002
Figure 5: Acquired vsh_dif with the developed detection
Figure 3: Waveform of vsh under inverter drive circuit (f=1,000 Hz, s=0.06)
(f=1,000 Hz, s=0.06)
Although the inverter excitation voltage is eliminated 2) After changing to frequency domain, higher
considerably from vsh, higher harmonics still remain due harmonics are eliminated from vsh_dif using the
to an unbalance in motor impedance. A digital filter using developed digital filter.
FFT to extract slot harmonics is described in the
following section. 3) The frequency of the largest harmonic component is
detected as slot harmonic frequency fsh.
2. DIGITAL FILTER
4) The current fr is calculated by the formula using the
Number of data points for FFT detected fsh.
Frequency resolution 'f is described as 6f Passband 16f
fs 7f 15f
'f (6)
N fft
Vo ltage
5f slip increasing
where
fs: sampling frequency frequency

Nfft: data points for FFT fifth fsh fsh
harmonic (at s = 0.5) (at s = 0)
Since fs is decided according to the maximum frequency
required in a measurement, 'f is determined by Nfft. Figure 6: Passband of digital filter
Although Nfft should be a high number from the
viewpoint of 'f as shown in formula (6), as Nfft increases exciting frequency f
detection circuit slot harmonic slot harmonic
the time response becomes worse. Thus, an optimal voltage vsh_dif FFT voltage vsh_dif
number of Nfft under the measurement conditions should ~
~ EU 2
time 10.1
~
be considered. EW EV
domain 0 digital
- Ļ filter
+ frequency
As shown in Table 1, the number of slots Nr and the domain
maximum motor speed used in the experiment are 16

exciting frequency f
and 170,000 rpm respectively. In this case, the calculate rotor speed slot harmonic
maximum value of fsh is about 40 kHz, hence fs was acquire fr 30.3
voltage vsh_dif
peak detect
configured to 100 kHz from the sampling theorem. Nfft fr (fsh detect)
2
10.1
fsh 0
was configured to 1,024 from the viewpoint of 1
30.3
fr f sh f 2
acceleration and tolerance of fr. Moreover, the acquired Nr 10.1

0
data overlaps with 512 data points from the previous fsh
calculation to shorten the update time of fr.

Figure 7: System configuration
Passband design
3. DETECTION METHOD TO RESTART MOTOR
The relation between fsh and s is described as below,
where s is the slip. As stated in the foregoing section, fr can be acquired
from vsh by means of the digital filter above. However, in
f sh Nr fr f N r 1 s f f (7) case the motor is restarted while rotating, the excitation
voltage is not applied. Therefore, it is impossible to
As described in Figure 6, fsh varies according to the slip. detect fr. Slot harmonics are also not generated in this
Since the range of motor slip is 0 - 0.5, fsh varies in the case. In this section, a detection method to restart a
range of 7f - 15f. The passband was configured to be 6f motor while rotating is proposed.
- 16f in consideration of interference with the fifth
harmonic and calculation error. Specifically, the Sensing signal to generate slot harmonics
passband changes according to the excitation frequency.
It is obvious that only fsh can be extracted correctly from It is necessary that an excitation voltage be applied to
vsh_dif using this filter. generate slot harmonics. Since the excitation voltage is
required not to have an effect on motor revolution, a very
Figure 7 shows the system configuration. In this system, short-time sensing signal is applied. On the other hand,
rotor speed frequency fr is acquired using the following the frequency of the sensing signal should be higher
procedure. than maximum speed to avoid rapid braking. From these
points of view, the applied time and the frequency of the
1) The slot harmonic voltage vsh_dif is detected with the sensing signal were configured to 40 ms and 3,333 Hz
detection circuit stated above. (200,000 rpm) respectively.
Limit of detectable range 50000 Detectable range of fsh

(1,000 - 200,000rpm)
40000
Formula (5) above shows the relation between fsh and fr.
The formula indicates that fsh decreases as fr decreases 30000
fsh [Hz]
in a case of constant f. As stated above, fsh is extracted
using a digital filter. From past test results, only the 20000
fundamental harmonic of the sensing signal can be 10000
larger than the fsh component. Hence, in a case where f sense
the fundamental frequency of the sensing signal fsense 0
0 500 1000 1500 2000 2500 3000 3500
and fsh overlap, fr cannot be acquired. Figure 8 shows -10000 fr [Hz]
the relation between fr and fsh, where fsense is 3,333 Hz
(200,000 rpm) as stated above. In this case, fsense and fsh
Figure 9: Relation between fr and fsh
overlap at an fr of 433 Hz (26,000 rpm). Therefore, it is
in case of a negative excitation voltage
impossible to detect the rotor speed when fr is less than
26,000 rpm.
TEST RESULTS
50000 Detectable range of fsh
(26,000 - 200,000rpm) It is apparent that the developed method using slot
40000 harmonics can accurately detect rotor speed over the
finj fsh finj fsh entire speed range theoretically as stated above. In this
Voltage
Voltage
30000 section, the proposed method is evaluated with a test

fsh [Hz]
Frequency Frequency
20000 vehicle in order to prove its effectiveness.

433Hz
10000 Table 2 shows the evaluation conditions. In this
f sense
0 evaluation, we adopted an electric motor-assisted
0 500 1000 1500 2000 2500 3000 3500 turbocharger as an application of an ultra high speed
-10000 fr [Hz] drive. Moreover, the whole algorithm is implemented in a
field programmable gate array (FPGA) to accomplish
Figure 8: Relation between fr and fsh rapid calculation.
Method to expand the detectable range Table 2: Evaluation conditions
As for methods to expand the detectable range of fsh, the Passenger car, diesel engine,
relation between fr and fsh should be shifted in the Test vehicle
2000cc, manual transmission
positive direction. There are two ways to shift the Motor output
relation, as follows: 1400 W
(command value)
Applied time of
1) Reverse the rotational direction of the excitation 40 ms
sensing signal
voltage, or
2) Change the number of rotor slots. Figure 10 shows the test results with the test vehicle.
We see from Figure 10 that rotor speed is detected
Since the number of rotor slots is determined by the without any large error caused by frequency resolution
motor design, this would be difficult to change. For this and time response delay. Figure 11 shows an error in
reason, we adopted method 1 above. In the case of a detected rotor speed using the proposed method. The
negative excitation voltage, the relation between fr and maximum error is 300 rpm ( tolerance = ±1,000 rpm).
fsh is described as below.
f sh Nr fr f (8) 100000
100000
Rotor speed nr [rpm]
80000
80000
Figure 9 shows the relation between fr and fsh in case of
a negative excitation voltage. The frequency at which fsh 60000
60000
and fsense overlap is 17 Hz (1,000 rpm). From these
results, it is apparent that this method using a reversed 40000
40000
excitation voltage can cover the whole speed range of sensor
20000
20000 sensorless
the motor.
0
0 1 2 3 4 5
0 1 2 3 4 5
Time t [s]
(a) Initial rotor speed 3,600 rpm
tolerance
1000
100000
100000
800
80000
80000 600
Error of rotor speed [rpm]

400
60000
60000
200
40000
40000 0
sensor
-200 2 5 10 20 50 80 100 120 135 160 180
20000
20000 sensorless Rotor speed [krpm]
-400
0 -600
0 1 2 3 4 5
0 1 2
Time t [s]3 4 5 -800
-1000
tolerance
(b) Initial rotor speed 51,000 rpm
Figure 11: Error of detected rotor speed
140000
140000 CONCLUSION
120000
120000
In this paper, we proposed a rotor speed detection
100000
100000 method utilizing slot harmonics by means of the
80000
80000 following three unique techniques: a detector circuit, a
60000
60000 digital filter with a variable passband, and a detection
40000
40000 sensor method to restart the motor while rotating. Moreover, the
sensorless effectiveness of the developed method was evaluated
20000
20000 with a test vehicle. From the results, we can conclude
0 that a rotor speed detection method applicable to an
0 1 2 3 4 5
0 1 2
Time t [s]3 4 5 ultra high speed induction motor has been established.
As for automotive applications, the proposed method is
suitable for use as a turbocharger. When a turbocharger
(c) Initial rotor speed 100,000 rpm
system using a motor is required in the future, this
method will be an important technique to realize the
system.
REFERENCES
200000
200000
160000
160000 1. B-H Bae, S-K Sul, J-H Lwon, J-S Byeon,
“Implementation of Sensorless Vector Control for
120000
120000 Super-High-Speed PMSM of Turbo-Compressor,”
IEEE Trans. Ind. Appl., Vol. 39, No. 6, p. 811, 2003.
80000
80000 2. M. Ishida, K. Iwata, “A New Slip Frequency Detector
sensor
40000
40000 of an Induction Motor Utilizing Rotor Slot
sensorless
Harmonics,” IEEE Trans. Ind. Appl., Vol. IA-20, No.
0 3, p. 575-582, May/June 1984.
0 1 2 3 4 5
0 1 2 3 4 5
Time t [s]
CONTACT
(d) Initial rotor speed 170,000 rpm Takashi Masuzawa
Figure 10: Test results Corporate R & D Dept., DENSO CORPORATION
1-1 Showa-cho, Kariya City, Aichi 448-8661, JAPAN
E-mail: takashi_masuzawa@denso.co.jp

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Licensed to University of Bath

Rotor Speed Detection Method for an Ultra High

Reprinted From: Vehicle Sensors and Actuators, 2007

2007 World Congress

For permission and licensing requests contact:

For multiple print copies contact:

SAE Customer Service

Rotor Speed Detection Method for an Ultra High Speed

Copyright © 2007 SAE International

ABSTRACT reasons, we adopted the IM for our ultra high speed

PRINCIPLE OF ROTOR SPEED DETECTION 2. CALCULATING FORMULAS FOR ROTOR SPEED

where K is a proportional constant.

Since slot harmonics are generally a small percentage of

Speed range [rp m] 5,000 – 170,000  Kk H B0 / 2 >( N r Z r  Z )^1  2 cos 2( N r  1)  S / 3`

If Nr is a natural number, formula (3) is obtained as SPEED ESTIMATION METHOD

­0 >N r 3 N , N 1,2, @ 1. DETECTION CIRCUIT

Formula (5) shows that fr can be acquired from vsh, -

In the foregoing section, it was stated that fr could be

harmonics, so the formula cannot be applied without

excitation voltage of inverter 0 5000 10000 15000 20000

0 00 0.001 0.002 (b) Harmonic components

Frequency resolution 'f is described as 6f Passband 16f

fs: sampling frequency frequency

maximum motor speed used in the experiment are 16

acceleration and tolerance of fr. Moreover, the acquired Nr 10.1

calculation to shorten the update time of fr.

Limit of detectable range 50000 Detectable range of fsh

30000 section, the proposed method is evaluated with a test

20000 vehicle in order to prove its effectiveness.

Method to expand the detectable range Table 2: Evaluation conditions

(a) Initial rotor speed 3,600 rpm

Error of rotor speed [rpm]

Figure 11: Error of detected rotor speed

(d) Initial rotor speed 170,000 rpm Takashi Masuzawa

Figure 10: Test results Corporate R & D Dept., DENSO CORPORATION

1-1 Showa-cho, Kariya City, Aichi 448-8661, JAPAN

S-ar putea să vă placă și

Speed range [rp m] 5,000 – 170,000 Kk H B0 / 2>( N r Z r Z )^1 2 cos 2( N r 1) S / 3`

0 >N r 3 N , N 1,2, @ 1. DETECTION CIRCUIT