Development of High-Reliability EV and HEV IM Propulsion Drive With Ultra-Low Latency HIL Environment

This paper proposes an improved and robust method of minimizing the error in propulsion-drive line-currents that are reconstructed from a single dc-link current measurement. The proposed algorithm extends and then shortens the relevant phase pulse-widths in order to provide optimal sampling of the dc-link currents in two consecutive pulsewidth modulation (PWM) periods. The proposed PWM pattern control enables an improved sampling method which cancels offset jitter-like waveform errors present in all three reconstructed line-currents, which is due to a specific combination of nonsimultaneously sampled dc-link current and line-current PWM ripple. The improvement in induction motor drive accuracy using a single current-sensor and no shaft sensor (as proposed in this paper), over that of conventional methods, is shown. Thanks to an ultra-low latency hardware-in-the loop (HIL) emulator, the proposed algorithm, its implementation on a DSP processor, code optimization and “laboratory” testing were all merged into one development step. In order to perform final tests of the proposed current-reconstruction algorithm and to verify the usefulness of the developed HIL platform by means of comparison, experimental results obtained on a real hardware setup are provided.