Abstract
Rotor shaft position sensors are required to ensure the efficient and reliable control of Permanent Magnet Synchronous Machines (PMSM), which are often applied as traction motors in electrified automotive powertrains. In general, various sensor principles are available, e.g., resolvers and inductive- or magnetoresistive sensors. Each technology is characterized by strengths and weaknesses in terms of measurement accuracy, space demands, disturbing factors and costs, etc. Since the most frequently applied technology, the resolver, shows some weaknesses and is relatively costly, alternative technologies have been introduced during the past years. This paper investigates state-of-the-art position sensor technologies and compares their potentials for use in PMSM in automotive powertrain systems. The corresponding evaluation criteria are defined according to the typical requirements of automotive electric powertrains, and include the provided sensor accuracy under the influence of mechanical tolerances and deviations, integration size, and different electrical- and signal processing-related parameters. The study presents a mapping of the potentials of different rotor position sensor technologies with the target to support the selection of suitable sensor technologies for specified powertrain control applications, addressing both system design and components development.
Highlights
The electrification of vehicles is becoming increasingly widespread in order to reduce greenhouse gas emissions and fulfill the corresponding exhaust emission legislations
Feedback for controlling the electric machine, which is delivered by a rotor shaft sensor, can be separated into two signal types: the rotor speed signal when applying an Induction Motors (IM) and the rotor position information when utilizing a Permanent Magnet Synchronous Machines (PMSM)
14 rotor position sensor types have been analyzed by the specified measurement series on the sensor test bench: six resolver, seven inductive-/eddy current- and one Anisotropic Magnetoresistive (AMR)-position sensor
Summary
The electrification of vehicles is becoming increasingly widespread in order to reduce greenhouse gas emissions and fulfill the corresponding exhaust emission legislations. Feedback for controlling the electric machine, which is delivered by a rotor shaft sensor, can be separated into two signal types: the rotor speed signal when applying an IM and the rotor position information when utilizing a PMSM. Sensorless control, as it is often found in the literature [2,3], is not used in automotive powertrains due to high demands on control reliability and is not discussed further in detail here. This enables the best motor efficiency, resulting in increased driving ranges, increased comfort (by reducing torque ripple) and maintaining Functional Safety (FUSA)-relevant issues, e.g., according to the ISO 26262 [4,5,6]
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