Sliding Mode Observer-Based Sensorless Control Strategy for PMSM Drives in Air Compressor Applications

This paper presents a sensorless control strategy for permanent magnet synchronous motor (PMSM) drives in industrial and automotive air compressor applications. The strategy utilizes an adaptive-gain sliding mode observer integrated with a refined back-EMF model to suppress chattering and improve convergence. The proposed approach achieves precise rotor position and speed estimation across a wide operational range without mechanical sensors. It directly addresses the critical needs of reliability, compactness, and resilience in automotive environments. Unlike conventional observers, its originality lies in the enhanced gain structure, enabling accurate and robust sensorless control validated through both simulation and hardware tests. Comprehensive simulation results demonstrate effective performance from 2000 to 8500 rpm, with steady-state speed tracking errors maintained below 0.4% at 2000 rpm and 0.035% at 8500 rpm under rated load. The control methodology exhibits excellent disturbance rejection capabilities, maintaining speed regulation within ±5 rpm under an 80% load disturbance at 8500 rpm while limiting q-axis current ripple to 2.5% of rated values. Experimental validation on a 2.2 kW PMSM-driven compressor test platform confirms stable operation at 4000 rpm with speed fluctuations constrained to 20 rpm (0.5% error) and precise current regulation, maintaining the d-axis current within ±0.07 A. The system demonstrates rapid dynamic response, achieving acceleration from 1320 rpm to 2365 rpm within one second during testing. The results confirm the method’s practical viability for enhancing reliability and reducing maintenance in industrial and automotive compressors systems.