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Synchronous Machine Vector Control System Development and Implementation LAPPEENRANTA UNIVERSITY OF TECHNOLOGY Faculty of Technology Master’s Degree Programme in Energy Technology Synchronous machine vector control system development and implementation Supervisors: Olli Pyrhönen, Pasi Peltoniemi Author: Konstantin Vostrov Lappeenranta 2016 Abstract Author: Konstantin Vostrov Thesis title: Synchronous machine vector control system development and implementation Faculty: Department of Electrical Engineering Major: Industrial Electronics Year of graduation: 2016 Master’s Thesis: Lappeenranta University of Technology 75 pages, 50 figures, 3 tables, 2 appendixes Examiners: Prof. Olli Pyrhönen, D.Sc. Pasi Peltoniemi Keywords: Synchronous motor, Vector control, Field oriented control, PI-controller, Bechoff, TwinCAT, Simulink This Master Thesis describes the vector control system of synchronous motor design and implementation. Theoretical background part includes basic knowledge about synchronous machines, their classification and control methods. Further in the thesis basic principles of Internal Model Control Method (IMC) for tuning PI-controller parameters are described. Application of the IMC for setting the PI controller parameters in relation to the present paper method is also presented. The electrical drive system, including vector control system, was created in Matlab Simulink and PI-controllers parameters were tuned more precisely using sensitivity function analysis tools, provided by Matlab. In the code processing part of the thesis, Simulink-based model was converted into Visual Studio TwinCAT XAE environment. Also some final model and PI-controller parameters tuning, caused by converting, was done. The generated code was downloaded into FPGA- hardware and PC-based control and tested in the laboratory in order to operate with a real 12.5 kVA synchronous motor. Laboratory tests and results are described in respective parts. Acknowledgements First and foremost I want to express my gratitude to my family, people who was waiting for me at home and who worried about me and my studies as well as for themselves. Tatiana, my lovely mom, who was missing me most of all my relatives, thank you for your patience, support and encouraging during this period of my life and for the fact that I became who I am. I want to thank all my friends, both old and newfound during studying in Finland. Without your support and having leisure time together I would lost my mind during the writing of this work. I want to express my deepest gratitude to all the people who were directly involved in this project. My supervisors Prof. Olli Pyrhönen, the person who organized this thesis possible, and D. Sc. Pasi Peltoniemi - people who are easy to work with and who was always happy to share their knowledge and experience. I want to ask forgiveness from everybody for my ridiculous and stupid questions that I was asking you during the time of writing on this thesis. Special thanks to Electrical Drives laboratory staff and particularly to M.Sc. Teemu Sillanpää for his invaluable help and titanic work on the preparation and holding of laboratory tests. Would like to thank all the administrative staff of Electrical Engineering department and LUT at all. My special thanks to D. Sc. Julia Vauterin-Pyrhönen, the person who was taking care of us, newcomers in LUT, from the first days of our studying and who can help you to find a solution in almost any problem situation. Thanks to the administration of Peter the Great Saint-Petersburg Polytechnic University and Lappeenranta University of Technology for collaboration and carrying out the double degree program in Master’s degree. Finally, would like to thank all the Finnish people for this great experience of the wonderful life in this country and people who made my stay in Finland and in Lappeenranta comfortable and enjoyable, thanks to LOAS for providing a nice apartment for all of us (newcomers 2015), thanks to Aalef and of course Sodexo campus restaurants for a tasty meals all these hard studying months, thanks to IT department, library, cleaning and other university and maintenance staff who was doing their job well day by day in order to we, the students, could learn 24 hours a day, fully focusing on the studies and without any problems could have everything we need for a fruitful productive educational process. Lappeenranta, November 2016 List of abbreviations and symbols a phase shift operator AC alternating current DC direct current DIMC Diagonal Internal Model Control method DOL direct online start DTC direct torque control e decoupling term EESM electrically excited synchronous machine f frequency [Hz] FOC field oriented control FPGA field-programmable gate array I electric current [A] i electric current, instantaneous value i(t) [A] IMC Internal Model Control method k phase shift angle between the U-axis and the x-axis Ki integral coeffitient Kp proportional koeffitient L inductance [H] n rotation speed [1/s] p number of pole pairs PI proportional–integral controller R resistance [Ohm] SI International System of Units SM synchronous machine T torque [N m] t time [s] Ti integrator time [s] tr rise time [s] U voltage [V], RMS, depiction of phase u voltage, instantaneous value u(t) [V] V depiction of phase W depiction of phase α bandwidth δ load angle [rad] ψ magnetic flux linkage [V s] ω electrical angular velocity [rad/s], angular frequency [rad/s] Subscripts 0 zero sequence value 1 primary, initial, input value, stator 2 secondary, transformed, output value, rotor cc current control d direct D direct, for damper winding e electromagnetic f field (excitation) load load m magnetizing mech mechanical q quadrature Q Quadrature, for damper winding r reference, rotor ref reference s stator T value responsible for torque control u depiction of phase v depiction of phase w depiction of phase α alpha axis direction β beta axis direction σ flux leakage ψ magnetic flux linkage ω angular speed Superscripts g rotor reference frame s stator reference frame Contents 1. Introduction ......................................................................................................................... 8 1.1. Brief information about different types of machines.......................................................... 8 1.2 Different synchronous machines types ............................................................................. 10 1.3 The design concept of the synchronous machine. ............................................................. 12 Feeding of the field winding. ............................................................................................. 15 1.4 Variable speed motors control.......................................................................................... 16 1.5 Vector control methods .................................................................................................... 18 1.6 Converter technology overview ....................................................................................... 20 2. Drive system modelling and mathematical model description ............................................ 23 2.1. Stator current control ...................................................................................................... 32 2.2. Excitation Current Control .............................................................................................. 33 2.3. Speed Control ................................................................................................................. 35 2.4. Stator Flux Control ......................................................................................................... 40 2.5. Model running ................................................................................................................ 44 3. Hardware description ......................................................................................................... 48 3.1 General structure ............................................................................................................. 48 3.2. Electromechanical part ................................................................................................... 49 3.3. Power converter and its control board ............................................................................. 51 3.4. FPGA ............................................................................................................................. 53 3.5. PC-based Bechoff TwinCAT .......................................................................................... 54 4. Code processing and laboratory tests preparation ............................................................... 55 4.1 General information ......................................................................................................... 55 4.2 Simulink to TwinCAT XAE transferring ......................................................................... 56 4.3 Adjusting the model to real hardware requirements .......................................................... 58 4.4 First test simulation ......................................................................................................... 59 4.5 Second test simulation ..................................................................................................... 61 4.3 Code downloading into hardware ..................................................................................... 63 5. Laboratory tests ..................................................................................................................... 64
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