>97% Motor efficiency measured. Motor/ controller performance evaluation, test bench setup.

Posted: 5th July 2019 by iulian207 in Projects
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1

Efficiency analysis between an IGBT controller and a mosfet controller

Motor/ Inverter connection diagram. I used the second motor as a generator and to dump the energy i used water heaters seen in a picture below.
I use a state of the art Power Analyzer PA3000 from Tektronix with 0.04% accuracy.


My small setup for testing motors and controllers, I have a very precise torque sensor with 0,1% accuracy
Range is 0-500Nm and up to 8000 RPM



Paul Open source controller test results, using water cooling plate and 400AMP IGBT modules. Encoder angle was fine tuned until i got the best performance.
Advanced angle Id current was adjusted but without any practical improvement.

Orange wave is phase voltage, and green line represents the current.
Using Paul Open source controller

Even at low loads the efficiency parameters matched the simulation parameters in FEMM the software model.
Results using Vesc controller using in sensorless mode.
As we can observe the inverter efficiency is much better since is using mofets instead if the IFBT`s. The drive PWM frequency was set to 20khz.
The motor efficiency is also better because the sinewave generated is much closer to a pure sinewave. The torque per amp constant in this case was better from 0,14Nm/Arms to 0,22Nm/Arms

Open source controller used to run my RED 130 motor in sensorless mode

Vesc open source controller driving the motor in sensorless mode.
The controller has automatically detected all the motor parameters including: Internal resistance, Inductance, Flux Linkage, Kp, Ki and observer gain
Waveforms for all the 3 phases and the currents
Voltage Harmonics. As we can observe due to very careful slot pole design the third and the fifth harmonic are very small, negligible

To be continued…

    1. Freewing RC JET says:
      August 21, 2020 at 08:12

      i like your article, it can help me. thanks

      Reply