Small sized electric motors providing high specific torque and power are required for many mobile applications. Air gap windings technology allows to create innovative lightweight and high-power electric motors that show low phase inductances. Low inductance leads to a small motor time constant, which enables fast current and torque control, but requires a high switching frequency and short sampling time to keep current ripples and losses in an acceptable range. This paper proposes an optimal torque feedforward control method, minimizing either torque ripples or motor losses, combined with a very robust and computation-efficient modal current feedback control. Compared to well-known control methods based on the Clarke-Park Transformations, the proposed strategy reduces torque ripples and motor losses significantly and offers a very fast implementation on standard microcontrollers with high robustness, e.g., against measurement errors of rotor angle. To verify the accuracy of the proposed control method, an experimental setup was used including a wheel hub motor built with a slotless air gap winding of low inductance, a standard microcontroller and GaN (Gallium Nitride) Power Devices allowing for high PWM switching frequencies. The proposed control method was validated first by correlation of simulation and experimental results and second by comparison to conventional field-oriented control.
A Direct Mapped Method for Accurate Modeling and Real-Time Simulation of High Switching Frequency Resonant Converters