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Analysis of torque ripple and torsional vibration considering Hall mounting errors in permanent magnet synchronous motors for light EVs

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Abstract

The digital Hall-effect sensors are widely used for the rotor position estimation in permanent magnet synchronous motors (PMSMs) for light electric vehicles. Many scholars have discovered that the inevitable misalignment in the sensor mounting due to technical limitations has a negative impact on motor torque and vibration, but the characteristics of the torque ripple and torsional vibration remain unsolved. The analysis of the torque ripple and torsional vibration considering Hall mounting errors is carried out in this work, which makes the vibration-based diagnosis of Hall mounting errors possible and lays a foundation for improving the torque and vibration quality of electric motors. The harmonic characteristic analysis of PMSMs is firstly carried out, which lays a foundation for analyzing the phase current caused by the rotor position error. Subsequently, the order characteristics of the phase current and motor torque considering the rotor position error are derived. Then, the rotor position error caused by Hall mounting errors is analyzed, and the consequential order characteristics of the phase current and torque ripple are derived. Finally, simulated and experimental results are presented to validate the theoretical analysis. It is found that the rotor position error will induce voltage harmonics in PMSMs, resulting in the corresponding current harmonics and torque ripples. The rotor position error caused by Hall mounting errors contains dc component and even order harmonics, which will mainly produce new even order torque ripple and torsional vibration.

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Acknowledgements

This work was supported by a Grant (Project 51875410) from the National Natural Science Foundation of China.

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  1. School of Automotive Studies, Tongji University, Shanghai, 201804, China

    Shuguang Zuo & Zhiyong Huang

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  1. Shuguang Zuo
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Zhiyong Huang wrote the main manuscript text and Shuguang Zuo prepared the analysis methodology. The authors conducted the experiment.

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Correspondence to Shuguang Zuo.

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Zuo, S., Huang, Z. Analysis of torque ripple and torsional vibration considering Hall mounting errors in permanent magnet synchronous motors for light EVs. Electr Eng 105, 1111–1123 (2023). https://doi.org/10.1007/s00202-022-01719-w

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