Utilization of MCU and Real-Time Simulator for Identifying Beatless Control for Six-Step Operation of Three-Phase Inverter

In industries dealing with motor drive systems, the use of real-time simulators for validating control codes is becoming increasingly mandatory. This is particularly essential for systems with advanced control codes or complex microcontroller unit (MCU) register configurations, as this validation process helps prevent accidents and shorten development time. This study presents a validation process using a real-time simulator for the beatless control of six-step operation. Six-step operation, when applied to high-speed drives, has a limitation on the number of samples per electrical rotation, which causes voltage errors. A representative of these voltage error phenomena is the beat phenomenon, resulting in torque ripple at the first harmonic and high current ripple. To mitigate this beat phenomenon, a synchronous PWM method is sometimes used. However, in practical industrial systems, it may not be feasible to synchronously adjust the inverter’s switching frequency with the rotation speed. This study proposes a beatless control method to eliminate the voltage errors caused by the beat phenomenon during six-step operation at a fixed switching frequency. The specific implementation of this control method is explained based on MCU timer register settings. While previous studies have only proposed beatless control methods, this paper goes further by implementing the proposed beatless method using the MCU (TMS320F28335) to generate gating signals and validating the implementation through simulation on a permanent magnet synchronous motor using a real-time simulator (Typhoon HIL).