Final report encoder

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Aalto University, School of Electrical Engineering
Automation and Electrical Engineering (AEE) Master's Programme
ELEC-E8004 Project work course
Year 2021
Final Report
Project 2-01
Low-voltage three-phase electric drive for
laboratory exercises
Date: 3.6.2021
Suran Roman
Hartikainen Hannu
Kulkarni Shweta
Kyllönen Jaakob

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Information page
Students
Roman Suran
Hannu Hartikainen
Shweta Kulkarni
Jaakob Kyllönen
Project manager
Roman Suran
Official Instructor
Lauri Tiitinen
Starting date
12.1.2021
Completion date
3.6.2021
Approval
The Instructor has accepted the final version of this document
Date: 3.6.2021

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Abstract
The project Low-voltage three-phase electric drive for laboratory exercises gives an insight about
the knowledge right from the design of an electrical machine to the control of the machine using
drives. The combination of both software and hardware aspects of the project and their
implementation proves to be very useful for us master’s students. The main inspiration behind this
project is to build a kit that includes all the necessary components required by a student be it a
bachelor’s student or a PhD student. The elements are namely a system with MATLAB and Simulink
installed in it, a micro-controller board with motor control, an inverter, a motor and a load. The
Simulink models in standard form will be incorporated in the kit such that they can be readily used
or modified for different kinds of motor control methods and various applications of the motor.
A project plan was made by the team with the guidance from the instructor and timeline for each task
was decided. The measurables and deliverables of the project were determined and accordingly the
work started. The starting period had to be remote online meetings because of lockdown restrictions
and the status of each task was updated to streamline the work. Individual responsibilities were
assigned to each team member and progress was being monitored once or twice a week. Based on
various characteristics of the elements in the project, one control method was selected, and respective
Simulink model was built for the same. After optimizing the model as per the measurements obtained,
the model was finalized with successfully running the motor as per desired parameters. The motor
was controlled using a Simulink interface called host model which was responsible for the serial
communication between the software and hardware. The obtained measurements of the various
parameters were a check point to see if the control method was working properly or not. Modifications
were made using the standard Simulink model to implement various motor control methods. Apart
from main deliverables and measurables, all the safety parameters were also taken care of while
designing and operating the motor. We were able to analyze the anticipated the risks and prepare a
mitigation plan for the same.
From this project we were enlightened with different aspects of any project such as its technical and
business aspects. Aspects such as choosing what components to be used for the project to
transforming it into a sellable product were clear to us. Our basic concepts of electrical machines and
electric drives were sharpened because of having hands-on experience. Apart from technical skills,
our behavioral skills were developed too. Getting to work together as a team in the University created
a cheerful and productive environment. Preparing instruction manual, business aspect document and
business idea pitching, introductory video and project report and presentation helped us to impart a
professional touch to our project.
We would like to thank the teachers for giving an opportunity to be able to work on realization of a
project which addresses the real time problems and our instructor for timely guidance and support.

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Table of Contents
1. Introduction .................................................................................................................................. 5
2. Objective ...................................................................................................................................... 6
3. Project plan .................................................................................................................................. 7
4. Simulink model and TI microcontroller ...................................................................................... 8
4.1. Main Simulink model ............................................................................................................ 8
4.1.1. Advantages of TI hardware in the context of MATLAB ............................................... 8
4.1.2. Overview of the main Simulink model .......................................................................... 8
4.1.3. Serial communication .................................................................................................. 10
4.1.4. Hardware Interrupt ....................................................................................................... 11
4.1.5. ADC measurements (current, voltage, how the adc block works) ............................... 12
4.1.6. Encoder ........................................................................................................................ 18
4.1.7. PWM signals generation .............................................................................................. 21
4.1.8. Protection ..................................................................................................................... 24
4.1.9. Initialization file ........................................................................................................... 25
4.2. Host model .......................................................................................................................... 25
5. Volts-per-Hertz open loop control ............................................................................................. 26
5.1. Brief introduction to Volts-per-Hertz control ..................................................................... 26
5.2. Volts-per-Hertz open loop control system .......................................................................... 26
5.3. Simulation results ................................................................................................................ 27
5.3.1. No load simulation ....................................................................................................... 28
5.3.2. Load simulation............................................................................................................ 30
5.4. Measured results .................................................................................................................. 31
5.5. V/f conclusions .................................................................................................................... 33
6. Amps-per-Hertz control in the open loop .................................................................................. 34
6.1. Brief introduction to Amps-per-Hertz control..................................................................... 34
6.2. Amps-per-Hertz open loop control system ......................................................................... 34
6.3. Simulation results ................................................................................................................ 35
6.3.1. No load simulation ....................................................................................................... 35
6.3.2. Load simulation............................................................................................................ 36
6.4. Measured results .................................................................................................................. 39
6.5. Amps-per-Hertz open loop control conclusions .................................................................. 40
7. Vector control ............................................................................................................................ 41
7.1. Brief introduction to vector control ..................................................................................... 41
7.2. Vector control system .......................................................................................................... 41
7.3. Simulation results ................................................................................................................ 42
7.3.1. No load simulation ....................................................................................................... 42
7.3.2. Load simulation............................................................................................................ 44
7.4. Measured results .................................................................................................................. 46
7.5. Vector control conclusions .................................................................................................. 47
8. Final conclusions of selected control methods .......................................................................... 48
9. Reflection of the Project ............................................................................................................ 49
9.1. Achieving objectives ........................................................................................................... 49
9.2. Timetable ............................................................................................................................. 49
9.3. Risk analysis ........................................................................................................................ 50
9.4. Project Meetings .................................................................................................................. 50
9.5. Quality ................................................................................................................................. 51
10. Discussion and Conclusions.................................................................................................... 52
List of Appendixes ............................................................................................................................. 53
References .......................................................................................................................................... 54

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1. Introduction
Control of electric drives and power converters is well-known field in Electrical Engineering, which
becomes more and more popular with the rise of the energy consumption. There is also a significant
industry development in automation and robotics which has an impact on the rise of electric drives.
Customers have specific demands whether it is industry or household, thus different types of
converters are needed. The environmental issues such as global warming force us to reduce carbon
emissions as much as possible. The efficiency of the whole system plays an important role from
economic and ecologic point of view. Hence, electric cars and smart grid system are topics we should
deal with. The motivation in this field is enormous and we have already achieved a significant
progress in decade.
Our project is focused on low-voltage three-phase electric drive, which will be used as a laboratory
exercise for future students. Three-phase electric drive will be used to control motor by methods such
as scalar and vector control. Three-phase synchronous servo motor operates at very low voltage level
and therefore fulfils safety precautions and can be used by laymen without professional competence
in electrical engineering. However, to avoid hardware damage, the instruction manual is highly
recommended to read. The online module including the hardware and Simulink models will impart
the flexibility to the users to choose what kind of motor control they would like to implement. The
hardware can be easily bought online and the software with documentation are provided at wiki aalto
website. A business aspect for the project including the hardware, Simulink models with instruction
manual have been developed and designed to sell the module as a product. The main inspiration
behind the business idea is related to how students can learn online with hands-on experience during
the lockdown due to pandemic.
The aim of the project is therefore to create satisfactory motor control together with the instruction
document suited to the knowledge of the students. Thus, it is a simple yet very knowledgeable project
which will clear the basic concepts of the students by getting hands-on experience with step-by-step
instructions and help from the experts in the field. Similar topology of the final project can be also
used widely for different automation industry purposes.