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Holistic modelling, control configuration, and design systematics for locally concentrated Multi-Motor Drive Systems - Follow-up application

Subject Area Engineering Design, Machine Elements, Product Development
Automation, Mechatronics, Control Systems, Intelligent Technical Systems, Robotics
Electronic Semiconductors, Components and Circuits, Integrated Systems, Sensor Technology, Theoretical Electrical Engineering
Term from 2017 to 2023
Project identifier Deutsche Forschungsgemeinschaft (DFG) - Project number 389029890
 
Final Report Year 2024

Final Report Abstract

Electric drives are components of modern industrial technology. Asynchronous motors (ASM) are often used due to their cost advantages and robustness. In some applications - for example, where load requirements vary considerably - the use of multi-motor drive systems (MMDS) is more effective than single-motor drive systems (SMDS): In this way, higher efficiencies can be achieved in partial load operation and redundancy can also be realized. In addition, the use of standardized inverters and motors reduces complexity as well as increases availability. In the project, the departments of Design and Drive Technology (KAt) and Power Electronics and Electrical Drives (LEA) at the University of Paderborn jointly investigated both electrotechnical and mechanical engineering aspects of MMDS in more detail. Since the MMDS is often operated in speed-controlled mode, precise torque control is required for the individual SMDS in order to achieve high control quality and efficiency over the entire operating range. From an electrotechnical point of view, a data-driven motor model, which takes into account numerous non-linear electrical and thermal effects, was identified for this purpose. With this motor model, all non-measurable states in online operation are precisely estimated, in particular the magnetic flux in the ASM, thus enabling a highly accurate torque control. Furthermore, the losses of the ASM that can be deduced from this model were used to derive an efficiency-optimal operating strategy for the SMDS or the entire MMDS. This operating strategy was developed as a model-predictive approach, which results in high torque dynamics on the one hand and steady-state, efficiency-optimal operation on the other. The nonlinear motor model requires the phase voltages of the ASM as input variables, which are estimated with the aid of a gray-box inverter model. This developed gray-box inverter model accurately represents the nonlinear switching behavior and was also identified based on test bench measurements. From a mechanical perspective, the presence of torque oscillations in an MMDS was particularly challenging before the start of the project. With an online estimation of these vibrations and a method similar to active noise cancelling, they could be effectively compensated. The concepts investigated were validated on an SMDS and MMDS test bench by means of extensive experimental investigations. With the help of the experimental validations, it was possible to empirically demonstrate the achievement of the main project objectives. In addition, extensive measurement data of the electric drive were published, which researchers can use in the future to develop or validate their own data-based methods.

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