Rapid Prototyping of Digital Twins Control System for IPM Drives Considering Both Saturation and Spatial Harmonics to Achieve Fast Development and Accurate Emulation

A rapid prototyping of digital twins control system for interior permanent magnet (IPM) drives system based-up model-in-the-loop (MIL), software-in-the-loop (SIL), and hardware-in-the-loop (HIL) is proposed in this article. Both motor saturation and spatial harmonics are considered in the proposed digital twins control system to achieve accurate emulation while providing fast prototyping to shorten the cost and development time significantly. First, the motor drives system, including designedmotor, inverter and drives control, is fully verified based upon MIL, SIL and HIL, respectively. Both saturation and spatial harmonics of motor are considered in the MIL by including the 3-D equivalent circuit extraction (ECE) model of ANSYS. Based upon this motor model, the drives control method is developed and verified using SIL. Then the control code generated automatically by SIL to dramatically reduce the error of programming and debug time is downloaded to the digital signal processor (DSP)-based HIL platform. Both motor and inverter models are included in the HIL platform for the verification of designed controllers and control code. Finally, the verified motor drives control code is used to drive the real motor drives system. The proposed rapid prototyping of digital twins control system for IPMdrives systemis validated using a 2 kW IPM drives system for electrical scooter application. The experimental results show very accurate consistence between the proposed system and real system. The maximum deviation in between is 0.99% under half speed and full load condition. These results demonstrate fast prototyping and accurate emulation can be achieved. The proposed rapid prototyping of digital twins control system can be applied to any motor, not limited to the illustrated interior permanent magnet synchronous motors (IPMSM) drives.