In the field of sensorless drive of synchronous machines (SMs), many techniques have been proposed that can be applied successfully in most applications. Nevertheless, these techniques rely on the measurement of the phase currents to extract the rotor position information. In the particular case of low-power machines, the application of such techniques is challenging due to the limited bandwidth of the available current sensors. An alternative is offered by those techniques that exploit the star-point voltage rather than phase currents. This work aims at providing a model of the dynamic behavior of the star-point voltage and presenting a technique for extracting the rotor electrical position needed for sensorless operation of SMs. Two different circuitries for measuring the star-point voltage are also presented and then compared. The presented mathematical analysis and the measurement methods are validated both numerically and experimentally on a test machine.

Self-sensing techniques are a commonly used approach for electromagnetic actuators since they allow the removal of position sensors. Thus, costs, space requirements, and system complexity of actuation systems can be reduced. A widely used parameter for self-sensing is the position-dependent incremental inductance. Nevertheless, this parameter is strongly affected by electromagnetic hysteresis, which reduces the performance of self-sensing. This work focuses on the design of a hysteresis-compensated self-sensing algorithm with low computational effort. In particular, the Integrator-Based Direct Inductance Measurement (IDIM) technique is used for the resource-efficient estimation of the incremental inductance. Since the incremental inductance exhibits a hysteresis with butterfly characteristics, it first needs to be transformed into a B-H curve-like hysteresis. Then, a modified Prandtl–Ishlinskii (MPI) approach is used for modeling this hysteretic behavior. By using a lumped magnetic circuit model, the hysteresis of the iron core can be separated from the air gap, thus allowing a hysteresis-compensated estimation of the position. Experimental studies performed on an industrial switching actuator show a significant decrease in the estimation error when the hysteresis model is considered. The chosen MPI model has a low model order and therefore allows a computationally lightweight implementation. Therefore, it is proven that the presented approach increases the accuracy of self-sensing on electromagnetic actuators with remarkable hysteresis while offering low computational effort which is an important aspect for the implementation of the technique in cost-critical applications.

Position estimation techniques for solenoid actuators are successfully used in a wide field of applications requiring monitoring functionality without the need for additional sensors. Most techniques, which also include standstill condition, are based on the identification of the differential inductance, a parameter that exhibits high sensitivity towards position variations. The differential inductance of some actuators shows a non-monotonic dependency over the position. This leads to ambiguities in position estimation. Nevertheless, a unique position estimation in standstill condition without prior knowledge of the actuator state is highly desired. In this work, the eddy current losses inside the actuator are identified in terms of a parallel resistor and are exploited in order to solve the ambiguities in position estimation. Compared to other state-of-the-art techniques, the differential inductance and the parallel resistance are estimated online by approaches requiring low implementation and computation effort. Furthermore, a data fusion algorithm for position estimation based on a neural network is proposed. Experimental results involving a use case scenario of an end-position detection for a switching solenoid actuator prove the uniqueness, the precision and the high signal-to-noise ratio of the obtained position estimate. The proposed approach therefore allows the unique estimation of the actuator position including standstill condition suitable for low-cost applications demanding low implementation effort.

For decades, sensorless position estimation methods gained lots of interest from the research community, especially in the field of electric drives and active magnetic bearings (AMBs). In particular, the direct flux control (DFC) technique promises unique advantages over other sensorless techniques, such as a higher bandwidth, but on the other hand, it requires the coils to be connected in a star topology. Until now, star-point connections are rarely found on active magnetic bearings. In consequence, there is no known publication about the application of the DFC to an AMB to this date. In order to apply the DFC to an AMB, a star-point driving approach for AMBs must be developed beforehand. A star-connected driving approach, capable of driving a four-phase AMB, is proposed and validated against traditional H-bridges in a simulation. Further, the strategy is tested in a physical application and generalised for 4$\ast n$ phases. In terms of current dynamics, the simulation results can be compared to the well-known full H-bridge driving. The experiments on the physical application show that the actual current in the coils follows a reference with satisfactory accuracy. Moreover, the inductance measurements of the coils show a strong dependency on the rotor’s position, which is crucial for sensorless operation. A star-point connection delivers a satisfying response behaviour in an AMB application, which makes sensorless techniques that require a star point, such as the DFC, applicable to active magnetic bearings.

Due to their unique properties, like no mechanical contact and therefore no wear and no lubrication needed, Active Magnetic Bearings (AMBs) have been a dynamic field of research in the past decades. The high non-linearities of AMBs generate many challenges for the control of the otherwise unstable system, thus they need to be addressed to deliver the performance that modern applications require. Integrating the current controller dynamics into the model of a position controller in a cascading control loop helps to improve the performance of the control loop compared to a plain current controlled schema. Further, this nested control loop guarantees the predefined current dynamics of the current controller, tuned according to an industrial criterion. The systems dynamics are modelled and the proposed controller is validated experimentally on a physical test bench. The experimental results show a performant position control with a nested and explicit current controller on an AMB, even with a large air gap and star-connected coils. The trajectory range of the rotor was reduced by 87% to ±20 $\mathsf{\mu }$m, compared to a plain current-controlled model. The proposed control strategy lays the foundation for further research, especially concerning sensorless position estimation techniques since these usually have limited bandwidth and benefit from a predefined current dynamic.

Techniques for estimating the plunger position have successfully proven to support operation and monitoring of electromagnetic actuators without the necessity of additional sensors. Sophisticated techniques in this field make use of an oversampled measurement of the rippled driving current in order to reconstruct the position. However, oversampling algorithms place high demands on AD converters and require significant computational effort which are not desirable in low-cost actuation systems. Moreover, such low-cost actuators are affected by eddy currents and parasitic capacitances, which influence the current ripple significantly. Therefore, in this work, those current ripples are modeled and analyzed extensively taking into account those effects. The Integrator-Based Direct Inductance Measurement (IDIM) technique, used for processing the current ripples, is presented and compared experimentally to an oversampling technique in terms of noise robustness and implementation effort. A practical use case scenario in terms of a sensorless end-position detection for a switching solenoid is discussed and evaluated. The obtained results prove that the IDIM technique outperforms oversampling algorithms under certain conditions in terms of noise robustness, thereby requiring less sampling and calculation effort. The IDIM technique is shown to provide a robust position estimation in low-cost applications as in the presented example involving a end-position detection.