Permanent Magnet Synchronous Motor Driver For Winding System

Three-phase torque motor has been widely used as power source in the winding system of the traditional plastic knitting industry.Three phase torque motor is a special asynchronous motor.Its mechanical characteristics are similar to the winding characteristics in a certain range,so it is also called winding motor.The winding performance is not satisfactory because of the difference between its winding characteristics and ideal characteristics.Due to the special structural parameters,the copper loss of three-phase torque motor is serious and the efficiency is low.This paper designs a winding system based on permanent magnet synchronous motor(PMSM)to replace the original winding system with three-phase torque motor for better winding performance and energy-saving effect.Firstly,the kinematic and mechanical model of the winding system was established.By analyzing of the wire movement process and the stress state,the relationship between wire tension and motor torque is obtained.According to the mathematical model of the permanent magnet synchronous motor,the relationship between the input and output power of the motor and the wire tension is deduced,and then a constant power control method is proposed.Secondly,in order to reduce the complexity and hardware cost of the system,a currentless loop control method is adopted in the inner loop of the constant power control system.To solve the problem of small torque/current under the detailed sixbeat voltage vector control,a detailed six-beat voltage vector control with advanced angle correction is proposed.This method can ensure that the motor runs well in the maximum torque/current ratio without a current loop.Then,the constant power simulation model verifies this method.For the output power fluctuation phenomenon,a power feed forward compensation is added to eliminate the fluctuations.After that,considering the cost requirements of the system,the winding system selects low resolution Hall as a position sensor of PMSM.Based on the relationships between the Hall signal and the magnetic field,between the magnetic field and the back-EMF,between the back-EMF and the rotor position,the correspondence between the Hall signal at different installation positions and the rotor position of the motor is analyzed for position estimation and correction in the later period.In order to extract continuous position information from discrete Hall signals,zero-order algorithm and first-order algorithm are used to estimate the position information.Based on the estimation principle,a simulation model is built to compare the estimated performance of the two algorithms under different given conditions.Finally,based on the proposed control scheme,the hardware circuit and software algorithm of the winding system are designed and each sub-module is described in detail.The accuracy of the proposed constant power control method with power compensation,the detailed six-shot voltage vector control method,the zero-order algorithm and the first-order algorithm proposed was verified by the built platform.The analysis is based on the input and output power data of the permanent magnet synchronous motor and the three-phase torque motor winding system to compares the winding performance and the energy-saving effect of the two systems.