Redundant Drive with Direct Torque Control (DTC)

and Dual-Star Synchronous Machine, Simulations and Verification

H.Burzanowska*, P.Sario *, Ch.Stulz*, P.Joerg *

*
ABB Switzerland Ltd
Austrasse, CH–5300
Turgi, Switzerland
Tel.: +41 / (58) – 589 30 75.
Fax: +41 / (58) – 589 29 84.
E-Mail: [email protected], [email protected],
[email protected], [email protected]

Keywords
«Adjustable speed drive», «Control of Drive», «Multiphase drive», «Voltage Source Inverter (VSI)»

Abstract
The performance of a drive and the quality of torque control in DTC depend on the accuracy of the
estimation of flux linkage. For applications with dual-star machine each stator winding is supplied by
its own inverter and the adequate stator fluxes are built. The full redundant drive is the latest
development of ABB drives based on the DTC control platform. In the paper the motor model for a
dual-star synchronous machine is discussed. Based on simulations with the Simulink/Matlab model of
the redundant drive the operation of the drive was confirmed. Further, the concept was verified with a
1 MW motor and two ACS6000 converters in laboratory environment.

Introduction
Most applications require high levels of availability from an electric drive system. Especially in
electric ship propulsion, where availability becomes safety critical. Due to economical reasons,
redundancy by multiplying the number of complete propulsion systems in one vessel is not preferred.
Just adding redundancy to the power part of the frequency converter is no solution either, since the
small increase in reliability is consumed again by additional complexity [11]. The optimal set-up is
composed of one propeller (marine propulsion only as example) with one electric motor, having
several galvanically isolated winding systems, each fed by one converter. Commonly referred to as
"full redundant variable speed drive", this solution has no single point of failure in the electric nor in
the auxiliary systems, while even allowing on-service repair and maintenance.
It consists of:
- two independent frequency converters with their own auxiliary systems (e.g. ACS6000 product)
- two independent control units, both controlling their own converter.
- dual-stator star 3-phase windings synchronous motor construction. Each of the inverters supplies
one of the stator star windings.

The full redundant drive essentially acts like motors with coupled shafts (Figure 1). By placing the
winding systems onto the same stator iron, they start building and using the same flux, while
individual torque control remains the same. The two driving inverters, which are based on standard
products, could get the torque reference from upper control or they are arranged in Master-Follower
configuration, in which the Master drive operates in speed control mode and creates the torque
reference. The Follower drive gets the torque reference from the Master and controls independently its
own inverter. In case of one failure the drive continues operation with only one of the two windings
supplied. The role of Master can be allocated to both drives.
This paper describes the general vector equations for a dual-stator synchronous motor. Based on the
equations the equivalent circuit is drawn. In comparison with 3-phase motor equivalent circuit there is

(C) IEEE - DOI: 10.1109/EPE.2007.4417422

one additional leakage inductance (mutual inductance) which represents the interactions between the
two stator windings. Electromagnetic torque is contributed with the help of two stator currents and
fluxes [7], [8], [9]. As a characteristic of machines with winding systems phase shifted by 30 degrees
against each other, control will have to deal with the fact, that the flux components of k=6*n +/- 1 (n
odd) disappears in the airgap.
The conventional Master/Follower typical application utilises two motors mechanically coupled and
the full redundant solution is applied with the motor YY30 (Figure 1).

Fig. 1. Conventional Master/Follower and Master/Follower for Redundant drive with YY30 motor

Dual-Star Three Phase Synchronous Machine

The knowledge on harmonic behaviour in electrical machines is described by many authors and
machine designers [1], [2], [8], [10]. The classical approach is based on computation using analytical
methods: first the permeance waves are defined, then mmf-waves due to rotor and stator currents are
calculated. The airgap flux density waves are obtained with interactions between permeance
harmonics and stator and rotor mmf-waves. The physics behind the interactions phenomena is rather
complicated and the harmonic content depends on the machine construction. The new tools using
Finite Element Methods (FEM) improve accuracy of analytical methods. The FEM is used to compute
the magnetic field distribution. With Fourier analysis one can compute orders, amplitudes and phases
of the most significant harmonics in the flux density in the air-gap. With the help of combined
analytical and FEM approaches the field harmonics, forces, noise and additional losses can be
calculated [10].
In the article the topic of the space harmonic generation is not discussed. However the effect from
space harmonics cannot be neglected in modeling of dual star synchronous machines with a phase
shift of 30 degree.
The field harmonics from periodic air gap variation can be described by additional voltages in the
stator windings, or by additional fluxes in the rotor oriented frame. The approach used in the
simulations utilizes additional voltage harmonics defined from the back-emf measurements.
The vector diagram of dual-star salient pole synchronous motor with 3-phase windings in the stator is
presented in Figure 2.

( s2 +
(
sσ2 + sσ1_2 sσ1_2 s1

s1 sσ1_2 s2
(
(
s2 sσ1 + sσ1_2 s1

s1 m
q2 q1 s2 mq

d1 d r
dt
d2 md

Fig. 2: Vector diagram-dual star synchronous motor in a rotor oriented reference

frame
The rotor is rotating at angular velocity ω R = dθ R , where θ R is the angle between the rotor and the
dt
stationary reference frame. The load angle δ S is defined between the stator flux and the coordinate
axis d.

Dual-star synchronous motor equivalent circuit

The schematic of dual-star synchronous motor with 3-phase windings in the stator and with 30
electrical degrees phase shift is presented in Figure 3.

b Axis of phase stA Im stA

Im stB

a Axis of phase stB

b Axis of phase stB ib1 Re stB
ia2
ib2 teta

ia1 Re stA
a Axis of phase stA

ic1
ic2
c Axis of phase stA
c Axis of phase stB
Fig. 3: Schematic of the dual-star three phase stator winding with teta=30 degrees phase shift

With the flux and voltage equations of the dual-three phase synchronous machine [5],[7],[9] the
equivalent circuit can be derived for direct and quadrature axis. (Figure 4, 5).

Rs L sσ2 ωΨsq2
i d2
u d2 Rs L sσ1 ωΨsq1 Lsσ1_2 Lkd uf
id1
RD Rf
u d1 Lmd
id1 + id2+ iD + if L Dσ L fσ
iD
if

Fig. 4: Direct axis equivalent circuit of a dual three-phase synchronous motor

Rs L sσ2 ωΨsd2
i q2
u q2 Rs L sσ1 ωΨsd1 L sσ1_2
i q1
RQ
u q1 Lmq
L Qσ
iq1 + i q2+ if iQ

Fig. 5. Quadrature axis equivalent circuit of a dual three-phase synchronous motor

Flux linkage equations:

The flux direct and quadrature matrix (1) can be expressed:
 Ψsd1   xsd 1 xsd 1 _ 2 xmd xmd  id 1  Ψsg1   xsq1
     
xsq1 _ 2 xmq  isq1 
    
 Ψsd 2  =  xsd1 _ 2 xsd 2 xmd xmd  id 2 
* Ψsq 2  =  xsq1 _ 2 xsq 2 xmq  * isq 2  (1)
 ΨD   xmd xmd xD xfD  iD    
      ΨQ   xmq xmq xQ  iQ 
 Ψ f   xmd xmd xfD xf  i f   

The current direct and quadrature matrices (2) could be calculated from inverse of inductance matrices
and flux components.

i d 1  Ψsd 1 
i  Ψ  iq1  Ψsq1 
 d2  =
i D 
[ ]
Ld * Ψ 
−1 sd 2  
iq 2  = [ ]
−1  
Lq * Ψsq 2  (2)

  
D
 i  Ψ 
Q   Q 
i f  Ψ f 

Voltage equations
Stator voltage equations -d-, -q-, components (3), (4):

dΨsd 1 dΨsd 2
u d 1 = Rs i d 1 + − ω r Ψsq1 u d 2 = R s id 2 + − ω r Ψsq 2 (3)
dt dt

dΨsq1 dΨsq 2
u q1 = Rs iq1 + + ω r Ψsd 1 . u q 2 = Rs iq 2 + + ω r Ψsd 2 (4)
dt dt

Damper winding voltage equations (5):

dΨ D dΨQ
u D = 0 = RD i D + u Q = 0 = RQ i Q + (5)
dt dt

Magnetizing voltage equation (6):

dΨ f
u f = Rf if + (6)
dt

Electromechanical torque equation

3
te = p (Ψ sd 1 i q1 − Ψ sq1 i d 1 + Ψ sd 2 i q 2 − Ψ sq 2 i d 2 ) (7)
2
where p is the number of pole pairs

Dual-star synchronous motor equivalent circuit for harmonics of order k=6*n +/-1, (n odd)
The following describes the main reasons for the k=6*n+/-1 (n=1,3,5,…) harmonics in the stator
currents of YY30 motors:
• Effects from the machine construction: non sinusoidal air-gap flux distribution due to stator
and rotor windings in slots and due to the pole shape. These harmonics can be calculated with
FEM or measured from back-emf.
• Effects from the inverter: modulation around full voltage uses voltage vectors with small
contents of 5th and 7th components
Both above reasons for the presence of 6*n+/-1 harmonics in YY30 machines and the fact that the
impedance for those components is low have an influence on the increased amount of 5th and 7th
components in stator currents.
In the ideal case these harmonics do not contribute to the air-gap flux. The approximate circuit for
harmonic current calculation can be simplified to stator resistance and stray inductance since the
magnetizing reactance is much bigger then the leakage reactance (Figure 6).

.
Fig. 6. Equivalent circuit for k=6*n +/-1 harmonic currents (n=1,3,5,…)

Adaptive Motor Model for DTC Drive with Dual-star Synchronous Motor
To be able to perform control on an electric motor, the controller must be able to accurately calculate
or measure the actual values of the stator or rotor magnetic flux and the airgap torque. When these
actual values are known, the controller can control the inverter switches in a way that the reference
values are reached.
The control system demands for an accurate motor model. The adaptive motor model for DTC drives
with dual-star synchronous machines is presented in the Figure 7. It consists of parts related to the own
drive (index 1- called Master) and inputs from the second drive (index 2- called Follower).
The stator flux linkage estimate is calculated with the voltage model. The inputs to the voltage model
are switching positions and the measured intermediate voltages. The flux calculated from the voltage
integration is corrected with resistive losses and integration errors. DTC controls flux within hysteresis
bands [ 4], [6].
The measured or estimated phase currents are transformed to quadrature components. The inputs to
the current model are the measured or estimated rotor angle and the excitation current. In the current
model the damper winding currents are estimated and the inductance parameters are updated based on
the operating point.
The calculation is performed in rotor coordinates. A difference between the stator flux vector of the
voltage model and the stator flux vector of the current model is calculated and the result is used for
flux correction.
For dual-star motors there is an interaction between the two stator windings and both stator currents
contribute to the flux linkage in each of the stator stars. In both inverters the current model calculates
stator flux linkages with the help of both stator currents, rotor position and inductance parameters. The
torque is calculated with the help of the cross product of stator current and stator flux. In each of the
inverters the torque related to half of the motor current is estimated. Both motor windings contribute to
the torque on the motor shaft. (see equation. 7)

Minimizing harmonic components from stator currents with correction

algorithm
With the YY30 connection we will cancel the sixth harmonic torque pulsation, or minimize it in
comparison to a machine with single stator winding. However the disadvantage is that in such a
topology the fifth and seventh harmonic impedances are very small, which causes high fifth and
seventh harmonic components in stator winding currents, even when no or small harmonic
components are present in the voltage.
 MASTER DRIVE VOLTAGE MODEL Ψx1

Ψy1
SWITCH POSITIONS Ux1 Ψxvolt1 Ψxvolt1 Ψ x1
+ STATOR FLUX Te1
∫ dt
STATOR VOLTAGE -
CALCULATION LINKAGE TORQUE
Ψ yvolt1 CORRECTION Ψy1 CALCULATION
DC BUS VOLTAGE Uy1 Ψyvolt1
+
-
ix1

∆Ψx1 iy1
∆Ψy1

STATOR FLUX
ia 1– measured LINKAGE
current ix1 ∆Ux1 ERROR
VOLTAGE LOSS
CURRENT MEASUREMENT
3/2 TRANSFORMATION iy1 X ∆Uy1 CALCULATION
ib1 – measured
current

Rs

MASTER DRIVE CURRENT MODEL

θ1 - rotor angle
Ψdcur1 Ψxcur1
id1 iD
STATOR FLUX
e − jθ 1 iq1 DAMPER WINDING LINKAGE Ψqcur1 e jθ 1 Ψycur1
if - excitation current CURRENT ESTIMATOR CALCULATION
if iQ CURRENT MODEL

FOLLOWER DRIVE INPUTS TO

CURRENT MODEL

ix2 id2
ia2 – measured CURRENT MEASUREMENT iQ
current 3/2 TRANSFORMATION iy2 e − jθ 2 iq2 iD Lmd
ib2 – measured if Lmq
current SATURATED Lss
iq1
INDUCTANCE
id1 Lss1_2
MODELLING
θ2 - rotor angle from second drive id2
iq2

Fig. 7. Adaptive Motor Model for DTC Drive

The approach for minimizing or controlling the harmonics of order k=6*n+/- 1 (n = 1, 3, 5,…)
components in the stator currents is based on modifying the output voltage of the converter in order to
affect these harmonics. In the below example the adaptation algorithm, which has as input the
difference between the stator flux vector of the voltage model and the stator flux vector of the current
model, is used and the correction term is added to the flux reference. The corrected flux reference is an
input to hysteresis control of flux (Figure 8).

- stator flux linkage error is defined in equation (8)

[∆Ψs] = [∆Ψsx ∆Ψsy ] (8)

Flux difference in the estimated x direction is used only - Ψε

∆ψ sx  (9)
Ψε = [1 0] *  
∆ψ sy 

The correction algorithm is based on the knowledge of sixth harmonic in the rotor oriented frame. In
the flux, which is calculated in rotor coordinates, we could observe the sixth harmonic pulsations.
DTC controls flux with hysteresis control, and the reference is a circle. In case of presence of 5th,
7th…harmonic components the real flux in the machine is not a pure circle, but is deformed with 6th
harmonic.
 Ψxvolt1
Ψyvolt1

Ψε Ψref

Ψref _ cor
θ
Ψxcurl
Ψycurl

Fig. 8. Correction algorithm with additions to flux reference

Simulink Model of Drive with Dual - Star Three Phase Synchronous

Machine
In the Matlab/Simulink model each three-level inverter is fed from a constant DC voltage source and
the switching module is modelled as a set of ideal switches, which are controlled by direct torque
control (DTC) algorithm. The implemented control structure includes models of: full modulator, motor
model and motor control main functions. The simulation of the converter model is executed on several
time levels according to the real application (ACS6000), (Figure 9).

Fig. 9. Redundant Drive Simulator

Simulation and Measurement Results
Simulation results
The steady-state operation of the drive was simulated at 10 rpm and 10% of load. Switching
frequency, phase currents and fluxes in both drives are presented in Figures 10a, 10b, where the effect
of parasitic harmonics is the best illustrated.
Number of Switchings InvA InvB, -1s Motor currents a-phase stA, stB
60
150
sw - freqA
50
sw - freqB current - stA

40 current stB+20
-

100 30

20

10

50 0

-10

-20

0 -30
2 2.5 3 3.5 4 4.5 5 2 2.5 3 3.5 4 4.5 5

Fig. 10.a) Switching freq (Hz) in inverters InvA, InvB b) Motor phase currents Is_a1,
Is_a2+20%offset
flux - statorA,flux- cur1,flux -error flux- statorA,flux - cur1,flux- error

1 flux - statorA
1 flux- statorA
flux - cur1
0.8 flux- cur1 0.8
flux - error
0.6 flux- error 0.6

0.4 0.4

0.2 0.2

0 0

-0.2 -0.2

-0.4 -0.4

-0.6 -0.6

-0.8 -0.8

-1 -1

-1 -0.5 0 0.5 1 -1 -0.5 0 0.5 1

Fig. 11.a) speed =10 rpm, flux_statorA, flux_cur1-flux current model, flux_error b)speed=225 rpm
flux_statorA, flux_cur1-flux current model, flux_error

The steady-state operation of the drive was simulated at rated speed with rated load. The currents in
statorA and statorB are presented in Figure 12a without error correction and in Figure 12b with flux
error correction applied to flux reference.
Motor currents a-phase s tA, s tB
100 Motor currents a-phase stA, stB
100
current stA
- current - stA
80
current -stB+20 80
current - stB+20
60
60

40
40

20 20

0 0

-20 -20

-40 -40

-60 -60

-80 -80

-100 -100
4 4.05 4.1 4.15 4.2 4.25 4.3 4 4.05 4.1 4.15 4.2 4.25 4.3

Fig. 12.a) phase current in statorA and statorB+20% offset without flux correction, b) with flux
correction applied to flux reference
Measurement results
The functionality of the redundant drive concept was tested with measurements in laboratory with test
motor (for machine data see Appendix 1).
In Figure 13.a- the operation is presented when both drives were running with speed 10 rpm and 10%
of rated load. The switching frequency, motor phase currents and speed from both drives are
measured. The robust operation of the whole drive was tested when one was tripping (Figure 13.b)

FLUX_TRIP FOLLOWER

60 150
1.5

50

1
40
PHASE CURRENTS (%) SPEED (RPM)

30 100
0.5

SWITCHINGS (Hz)

FLUX (P.U.)
20

0
10 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5

0 50 -0.5
0 0.5 1 1.5 2 2.5 3

-10

-1

-20

-30 0 -1.5
TIME (SEC) TIME (SEC)

Fig. 13.a) Motor phase currents (%), motor speed (rpm), switching frequency (Hz) from both drives
Fig. 13.b) Stator flux real and imaginary components in both drives, when the other drive is tripping,
At time 0.05 s Follower trips (flux trend continue) and Master remains in operation.

1.5 1.5

1 1

0.5 0.5

0 0
-1.5 -1 -0.5 0 0.5 1 1.5 -1.5 -1 -0.5 0 0.5 1 1.5

-0.5 -0.5

-1 -1

-1.5 -1.5

Fig. 14.a) stator flux linkage from current model, b) actual stator flux flx1,fly1 and flux error

Conclusion
In the article a redundant drive system with DTC motor control is presented and the adaptive motor
model with dual-star synchronous machine is discussed. The effects of the flux density and current
harmonics were investigated with the help of simulation models developed in Matlab/Simulink and the
test laboratory. A simple correction algorithm is proposed. The both simulated and measured results
show good agreement. The functionality of the redundant concept and the robust operation of the two
independent drives were confirmed with measurements.
Especially in marine applications full redundant drives are required to assure the safe operation of the
vessel even when one drive is faulted. In case of a failure in one inverter, the other one was able to
continue without interruption.
References
[1] Fischer, R., “Elektrische Maschinen”, 2004,Carl Hanser Verlag, München, (in German)
[2] Alger, P., “The Nature of Induction Machines”, 1965, Gordon and Breach
[3] Jokinen, T., “Sähkököneen Synnyttämä Melu”, lectures 1980., Helsinki University of Technology, (in
Finnish)
[4] Tiitinen, P., Pohjalainen, P., Lalu, J., “Next generation motor control method: Direct torque control (DTC) ”
EPE Journal, vol. 5, No. 1, March 1995. pp. 14-17.
[5] Vas, P., “Vector Control of AC Machines. 1990New York, Oxford University Press. 327p
[6] Kaukonen, J., “Salient Pole Synchronous Machine Modeling in an Industrial Direct Torque Controlled
Drive Application” Acta Universitatis Lappeenranta, 1999, No. 77, Finnland, Dissertation 138p.
[7] Burzanowska, H., Schroderus, P., Stulz, Ch., Lehti, M., “Novel Concept for full Redundant Drive with
Direct Torque Control (DTC) and Dual-star Synchronous Machine” SPRTS-Ship Propulsion and Railway
Traction Systems Conference Bologna, Italy, October 4th – 6th 2005
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Appendix 1

Parameters of the dual three-phase synchronous motor are referred to the stator
Lmd = 0.1823 (H) direct axis magnetizing inductance
LDσ = 0.0139 (H) direct axis damper winding leakage inductance
Lfσ = 0.0177 (H) magnetizing winding leakage inductance
Lkd = 0 damper winding and magnetizing winding leakage inductance (Canay inductance)
Lmq = 0.0816 (H) quadrature axis magnetizing inductance
LQσ =0.0093 (H) quadrature axis damper winding leakage inductance
Lsσ1 = Lsσ2 =0.0174 (H) statorA, statorB leakage inductance
Lsσ1_2 = 0.0047 (H) statorA _statorB mutual leakage inductance
Rs = 0.5274 (Ω) stator resistance
Rf = 0.0421 (Ω) magnetizing winding resistance
RD = 1.1204 (Ω) direct axis damper winding resistance
RQ = 0.7510 (Ω) quadrature axis damper winding resistance
Motor data :
Nominal power = 1000 kW
Nominal voltage = 3300 V
Nominal current = 185 A
Nominal frequency = 15 Hz
Nominal speed = 225 rpm