Investigations of Rotor Shaft Position Sensor Signal Processing in Electric Drive Train Systems

An Extended Approach for Validation and Optimization of Position Sensor Signal Processing in Electric Drive Trains

“…Of course, the evaluated system has to be synchronized with the reference sensor system to enable a comparison between both systems (see Section 2.4). For an adequate signal accuracy, all electronic components and measurement systems are shielded to prevent electromagnetic compatibility (EMC) influence [2,3,6,15]. Figure 2 shows an overview and the relevant components of the sensor test bench.…”

“…In this context, the information about rotor position-delivered by the shaft sensor-has to be converted, conditioned (e.g., filtered), processed, and transferred to the motor control algorithm embedded in an electronic control unit (ECU). The motor controller comprises a microcontroller (μC) as an actual control unit and the power electronics (gate drivers) for controlling the electric traction motor [2][3][4][5]. Figure 1 demonstrates a state-of-the-art architecture of an electric drive train and highlights the position sensor, exemplarily represented as a resolver.…”

“…Figure 1. State-of-the-art electric drive train system containing four main components: the powertrain battery (high voltage), an electronic control unit, the three-phase electric motor and the rotor position sensor (e.g., resolver) [2][3][4][5][6][7]. The entire sensor system containing an accurate sensor system, as well as a powerful computation unit, must suit the harsh boundary conditions during the operation of a car.…”

“…Other real-time and offline synchronization methods only rely on clock synchronization of independent working systems, but they do not enable measurand compensation in the same step [11][12][13][14]. , an electronic control unit, the three-phase electric motor and the rotor position sensor (e.g., resolver) [2][3][4][5][6][7]. The entire sensor system containing an accurate sensor system, as well as a powerful computation unit, must suit the harsh boundary conditions during the operation of a car.…”

“…Once all compensation steps are done, the performance capability of the examined sensor system is determined as a result of the evaluation process. This enables a novel sensor system characterization by establishment of the angle error and a statistical error analysis based on design of experiments (DoE) [6,7,15] under consideration of signal processing issues such as system latency [2,3]. Based on the high degree of measurement accuracy, the introduced analysis process allows an enhanced optimization of various types of position and speed sensor systems for electric drive trains.…”