Comprehensive High Speed Automotive SM-PMSM Torque Control Stability
Comprehensive High Speed Automotive SM-PMSM Torque Control Stability
Comprehensive High Speed Automotive SM-PMSM Torque Control Stability
a
Institute of Industrial and Control Engineering, Universitat Politècnica de Catalunya, Diagonal, 647, 08028 Barcelona, Spain
b
Department of Electronic Technology, UPV/EHU, C. Rafael Moreno, Pitxitxi, 48080 Bilbao, Spain
c
Tecnalia Research and Innovation, Industry and Transpor Unit, Parque Científico y Tecnológico de Bizkaia, c/ Geldo, Edif. 700, 48160 Derio, Spain
d
Centre for Sensors Instruments and Systems Development, Universitat Politècnica de Catalunya, Rbla. Sant Nebridi, 08222 Terrassa, Spain
Keywords: Permanent magnet synchronous machines (PMSM) are widely used in the automotive industry for electric ve-
Discrete-time vector current control hicle (EV) and hybrid electric vehicle (HEV) propulsion systems, where the trend is to achieve high mechanical
Decoupling speeds. High speeds inevitably imply high current electrical frequencies, which can lead to a lack of controll-
Electric Vehicle (EV) ability when using field oriented control (FOC) due to sampling period constraints. In this work, a compre-
Permanent Magnet Synchronous Machines
hensive discrete-time model is fully developed to assess the stability issues in the widely used FOC. A speed-
(PMSM)
High-speed AC electrical drives
adaptive control structure that overcomes these stability problems and extends the speed operation range of the
PMSM is presented. Also, a numerical methodology from which the maximum operating stable frequency can be
computed in advance of any experimentation, is developed. All contributions are accompanied and supported by
numerical results obtained from an accurate MATLAB/Simulink model.
Corresponding author.
⁎
E-mail addresses: [email protected] (A. Arias), [email protected] (E. Ibarra), [email protected] (E. Trancho),
[email protected] (R. Griñó), [email protected] (I. Kortabarria), [email protected] (J. Caum).
https://doi.org/10.1016/j.ijepes.2019.02.035
Received 19 September 2018; Received in revised form 10 December 2018; Accepted 18 February 2019
0142-0615/ © 2019 Elsevier Ltd. All rights reserved.
A. Arias, et al. Electrical Power and Energy Systems 109 (2019) 423–433
power. In this context, two control aspects must be considered for high where vd, vq, i d and i q are the stator voltages and currents; R, Ld and Lq
speed control of PMSM machines: are the stator resistance and inductances, m is the magnetic flux of the
permanent magnets and is the electrical rotor angular speed
(a) Due to DC-link voltage constraints, field weakening control is re- ( = P m , where P is the PMSM pole-pair number). The electro-
quired at high speeds. This aspect has been thoroughly studied in magnetic torque produced by the PMSM is obtained as:
the scientific literature, providing robust solutions even under 3
parameter uncertainties [12,17–19]. Tem = P{ m iq + ( Ld Lq ) id i q}.
(3)
2
(b) Machine stability issues can occur at high speeds. This can be
challenging from the electric machine torque control algorithm In SM-PMSMs, d- and q-axis stator inductances are equal (Ld = Lq ).
point of view, especially if current insulated gate bipolar transistor As a consequence, the reluctant torque component is zero and only
(IGBT) technologies operating with switching frequencies up to magnetic torque can be produced.
10 kHz are used to constitute the power inverter. Thus, it is im- PMSM drives have voltage and torque production constraints,
portant to understand the limitations of conventional control mainly due to inverter ratings and available DC-link voltage limitations
structures due to their corresponding sample time constraints. [33]. These constraints, which arise at high speeds [17,34,35], can be
represented with the following mathematical expressions:
A variety of PMSM control approaches such as direct torque control
id2 + iq2 Imax , (4)
(DTC) [20–22], predictive control [23] and adaptive structures [24,25],
can be found in the scientific literature and in the industry. However, 2 2
field oriented control (FOC) is by far the most common torque control m Vmax
Ld2 i d + + Lq2 iq2 ,
strategy employed for PMSM drives [12,26–29]. In this paper, the in- Ld (5)
fluence of the speed in the conventional FOC control structure is studied where Imax and Vmax are the maximum allowable stator current and
theoretically and by simulation. In order of extending the speed op- voltage, respectively [17,34,35].
eration range of the machine, a novel adaptive control algorithm is
proposed and its stability analysis, from which the maximum frequency
3. FOC control at high speed operation
can be computed, is reported. Simulation results that validate the
proposed approach are presented.
3.1. Traditional FOC control
It is important to point out that although this article focuses on
machine stability at high speed operation, such stability issue might
When FOC control structure is used, machine stator currents are
potentially appear also in grid connected converters applications with
transformed into the synchronous dq reference frame as illustrated in
dq current controllers [30], such as static compensators (STATCOM)
Fig. 1. In order to achieve the EV target torque, an optimal current set
[31] and voltage oriented controllers (VOC) [32]. Thus, the mathe-
point generator [17] sets the dq current references for a given EV op-
matical tools provided in this paper can be reused for a variety of ap-
eration point, considering both machine efficiency and field weakening
plications.
operation. The reference voltages v UVW are synthesized by modulating
a voltage source inverter (VSI) using a pulse width modulation (PWM)
2. Automotive SM-PMSM fundamentals or Space Vector Modulation (SVM) algorithm. It should be pointed out
that, in EV applications, the speed loop is not controlled by the prime
In general, flux linkage of current automotive axial flux SM-PMSMs mover and, therefore, the speed related variables (inertia and friction)
has a linear behaviour, as magnetic saturation is negligible for such and magnitude (torque disturbance) have no influence in the high
particular machine designs. For this reason, the stator inductances and speed behaviour.
PM flux linkage can be considered constant, with independence of the
operation point (torque/speed) of the machine. Thus, the equations that 3.2. FOC control PI adjustment in z domain
represent the stator voltages of SM-PMSMs in the dq synchronous ro-
tating reference frame are: From (1) and (2) it is concluded that the plant dynamics can be
di simplified to a first-order system formed by a resistance and an in-
vd = Ri d + Ld d Lq i q ,
dt (1) ductance, while the back electromotive force (EMF) acts as a dis-
turbance. Traditionally, FOC current controllers for PMSM are ad-
di q dressed tuning proportional and integral (PI) controllers (Fig. 2).
vq = Ri q + Lq + (Ld i d + m),
dt (2) Although PI tuning in the Laplace domain (s domain) is sufficient in
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A. Arias, et al. Electrical Power and Energy Systems 109 (2019) 423–433
Fig. 1. Conventional FOC structure, including optimal current set point generation algorithm, PI based current regulators and Park transform.
many applications, it is advisable to tune such current PI controllers in If the current closed-loop transfer function had just two poles, the
the z domain and to include a pre-filter (PF) if high accuracy is re- desired closed-loop characteristic equation would correspond to ex-
quired. Hence, the well-known zero-order hold (ZOH) transformation pression (10) and the specifications would be (i) settling time at 2%
method [36] has been used to obtain the plant transfer function in z (Ts,2% ) and (ii) damping factor ( ), which in this application is fixed to
domain according to expression (6). Once in the z domain, the delays, = 1 in order to avoid any overshoot.
which are mainly caused by the time needed by the digital signal
5.8
processor (DSP) to sample the currents and execute the controllers as z2 2e wn T z +e 2w n T , being Ts,2% = .
wn (10)
well as the PWM unit to synthesize the required voltage, can be easily
considered in the model including a delay of one sampling period (z 1) However, due to the inclusion of one sample time delay and the zero
along with the mentioned ZOH transformation method. Actually, the introduced by the PI, actually the closed-loop system is composed by
PWM updating mode has, with the mentioned delays, a great impact at the targeted two poles from (10) plus a third pole and a zero, labelled as
high speed operation. Therefore, it is important to include them in the c and b, respectively in (11). Notice how expression (11) matches with
model. In this work, specifically, the voltages are initially synthesized expression (9) of the actual current closed-loop.
(with the PWM) at the beginning of the following iteration after the
current samples, therefore with a delay of one sample (z 1), and are K
z b
.
finally synthesized at the end of the next iteration, i.e. with a delay of (z 2 2e n Tz +e 2 nT )(z c) (11)
two samples (z 2 ). Fig. 3 shows the general block diagram to properly
tune the PI controller in z domain [37], where the back EMF has been Therefore, the tuning of the PI consists in forcing expression (9) and
omitted for simplicity. (11) to be the same. The additional pole and zero will be cancelled by a
PF, whose expression is indicated in (12) and by doing so, the current
G (z ) = z 1 (1 z 1) Z
G (s )
=z 1 (1 z 1) Z
1/R closed-loop dynamics has to perfectly match the second order system
s s [(L / R) s + 1] given in (10) with its specifications.
1 1 e aT
= , (1 b)(z c)
R z (z e aT ) (6) PF (z ) = .
(1 c )(z b) (12)
where a = R/ L and T is the sampling period.
The PI controller transfer function in expression (7) is derived from Once the pole placement technique is numerically solved, expres-
PI expression in s domain when the backward Euler approximation is sions (13)–(16) are obtained.
used [36]. c=1+e aT 2e wn T , (13)
z (K p + K i T ) z Kp
PI (z ) = Kp + Ki T = . Rce 2wn T
z 1 z 1 (7) Kp = ,
1 e aT (14)
Hence, the current open-loop L (z ) and closed-loop T (z ) transfer
functions can be deduced as indicated in expressions (8) and (9), re- R (e 2w n T + 2e wn T c e aT )
spectively. Ki T = Kp ,
(15)
1 e aT
(K p + K i T ) z Kp 1 1 e aT
L (z ) = ,
z 1 R z (z e aT )
(8)
aT )(z Kp
(Kp + Ki T )(1 e Kp + Ki T
))
T (z ) = 1
.
R (z 3 + z2 ( 1 e aT ) + z (e aT + R
(K p + Ki T )(1 e aT ))
Kp aT ))
(1 e
R Fig. 2. Control scheme with the PI(s) controller, plant transfer function and the
(9) current, voltage and back EMF signals for the direct and quadrature axes.
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When conventional FOC is employed and the PMSM mechanical d-axis phase inductance (Ld ) 0.35 mH
speed exceeds a given threshold, the torque control loop can become q-axis phase inductance (Lq ) 0.35 mH
unstable. Fig. 5 illustrates this phenomenon which takes place before Phase resistance (R s ) 100 m
4800 r/min or 400 Hz for the PMSM under study, regardless the com- PM flux linkage ( PM ) 0.07 Wb
Pole-pair (P) 5 –
manded torque reference. In particular, torque references of 100 N·m, 10 kHz
Switching frequency ( fsw )
50 N·m, 10 N·m and −50 N·m were applied in the simulations shown in Battery voltage (VDC ) 500 V
Fig. 5. Nominal torque (Temnom
) 100 N·m
The reason for this loss of stability cannot be explained from the
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A. Arias, et al. Electrical Power and Energy Systems 109 (2019) 423–433
Fig. 6. Full scheme for both current control loops with the Park transformations
(the PF has been removed for the sake of simplicity).
1 1
Id (z ) = Vd (z )[G (ze jwT ) + G (ze jwT )] + Vq (z ) j [G (ze jwT ) G (ze jwT )].
2 2
(26)
Similarly, final expression of the q current is directly given in (27).
1 1
Iq (z ) = Vd (z ) j [G (ze jwT ) G (ze jwT )] + Vq (z )[G (ze jwT )
2 2
+ G (ze jwT )].
(27)
In order to obtain a compact multi input and multi output (MIMO)
transfer function, direct and coupling transfer functions labelled as
GAC (z ) and GC (z ) , respectively, are:
1 1 e aT 1
GAC (z ) = [G (ze jwT ) + G (ze jwT )] =
2 2R ze jwT (ze jwT e aT )
1 e aT 1
+ jwT (ze jwT aT )
2R ze e
1 e aT z cos(2wT ) e aT cos(wT )
= ,
R z (z 2 ze aT 2cos(wT ) + e 2aT )
(28)
Fig. 4. Torque control results of the studied machine with conventional FOC 1
GC (z ) = [G (ze jwT ) G (ze jwT )]
structure up to 3600 r/min (300 Hz electrical). 2
1 e aT zjsin(2wT ) + e aT j sin(wT )
= .
R z (z 2 ze aT 2cos(wT ) + e 2aT ) (29)
The final MIMO transfer function is given in expression (30) and
illustrated in Fig. 7(a),
Id (z ) GAC (z ) GC (z ) Vd (z )
= ,
Iq (z ) GC (z ) GAC (z ) Vq (z ) (30)
from where the following partial conclusions can be drawn:
Fig. 5. Torque control instability of the studied machine with conventional FOC Fig. 7. PMSM model. (a) MIMO scheme given on Eq. (30). (b) Equivalent MIMO
structure under a variety of torque regulation conditions. scheme.
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A. Arias, et al. Electrical Power and Energy Systems 109 (2019) 423–433
the manuscript have been introduced and, with the help of Matlab, a
minimal realization of the closed-loop matrix transfer function and its
closed-loop poles are computed. The numerical results, which are
printed every 25 Hz from 100 Hz until 600 Hz, are illustrated in Fig. 9,
from which it can be concluded that stability is maintained for electrical
frequencies lower than 521.7 Hz.
Nevertheless, in Fig. 5, the instability already appeared before
400 Hz. The explanation for this lower range of stability must be found
in the inclusion of the feed-forward terms (ff), which is quite a common
practice in general purpose drives [38]. The need of the ffd (35) and ffq
Fig. 8. (a) GAC (z ) and (b) GC (z ) pole-zero maps. (36) terms
ffd = Lq iq , (35)
• The PI approach has limitations, which arise at high frequencies, the
closed-loop system becomes unstable. ffd = (Ld i d + m), (36)
• (z) and G (z ) pole-zero maps are given in Fig. 8 a) and b), re-
G AC C
arises from the analysis of the dq PMSMs representation given in (1)
spectively. Two of the three poles have always a constant magnitude
but its angle depends on the mechanical speed. The GAC (z ) zero and (2) and their inclusion is illustrated in Fig. 1.
moves from e aT up to + , leaving rather quickly the unitary circle. Instead of applying the unitary feedback as previously done in the
Zero values, considering the PMSM data given in Table 1 and for open-loop MIMO transfer function (32), now the following feedback
T = 100 μs, are indicated in Table 2 for several electrical fre- expression must be considered1:
quencies. Lq
e Id Id 1 Id
PI (z )
e Iq = .
3.4. Numerical stability study Iq Ld
1 Iq
PI (z ) (37)
Given the fact that the plant under study is not linear time invariant The numerical analysis has been repeated from 100 Hz to 450 Hz
(LTI) but linear time variant (LTV) or linear parameter variant (LPV), and the results obtained, which are illustrated in Fig. 10, confirm the
since the closed-loop poles are frequency dependent, as stated in (28) reduction of the stability down to 379.8 Hz.
and (29) transfer functions collected in the final MIMO matrix transfer From this numerical study, the following partial conclusions can be
function (30), any attempt to obtain an analytic expression for the derived:
stability margin becomes very difficult. Nevertheless, a full numerical
linear study which brings specific information about the stability limits
of the plant under study is presented. The PI controller expressed in the
• The frequency stability limit can be numerically computed in ad-
vance (for any experimental implementation).
MIMO notation is as follows:
• An excellent match of the computed maximum operating fre-
Vd PI (z ) 0 e Id quencies exists between the time results and the MIMO closed-loop
= e Iq , poles, which confirms the validity of the approach presented in this
Vq 0 PI (z ) (31)
subsection and Section 3.3.
Therefore, connecting in series (31) and (30) as deduced from Fig. 6 • The extended use of feed-forward terms (35) and (36), despite im-
scheme, the open-loop expression becomes: proving the FOC performance at standard speeds, drastically reduces
the stability margin when the speed increases. In this specific sce-
Id GAC (z ) PI (z ) GC (z ) PI (z ) e Id
= nario, the stability limit is reduced from 521.7 Hz down to 379.8 Hz,
Iq e Iq .
GC (z ) PI (z ) GAC (z ) PI (z ) (32) which strongly agrees with the result illustrated in Fig. 5.
Imposing the unitary feedback in (33) into (32) and isolating the
actual currents, the final closed-loop MIMO transfer function (34) is 3.5. Discussion about the limits of the decoupling
obtained.
Decoupling is a common way to reduce any MIMO and coupled
e Id Id 1 0 Id Id Id
= = , system into a SISO. The decoupling may be achieved pre multiplying
e Iq Iq 0 1 Iq Iq Iq (33) expression (30) as indicated in (38), where the decoupling transfer
function D(z) is given in (39). However, the unique pole of such de-
Id coupling controller D(z) will already be outside the unitary circle even
Iq for low values of electrical frequency and therefore will be unstable, as
1 + GAC (z ) PI (z ) GC (z ) PI (z )
1 it in can be deduced from the data given in Table 2.
=
GC (z ) PI (z ) 1 + GAC (z ) PI (z ) Id (z ) Vd (z )
GAC (z ) GC (z ) 1(z ) D (z )
=
GAC (z ) PI (z ) GC (z ) PI (z ) Id Iq (z ) GC (z ) GAC (z ) D (z ) 1 Vq (z )
.
GC (z ) PI (z ) GAC (z ) PI (z ) Iq (34) GAC (z ) + GC (z )2 / GAC (z ) GAC (z ) GC (z )/ GAC (z )
From this point onwards, the numerical values given on Table 1 of = + GC (z )
GAC (z ) GC (z )/ GAC GC (z ) GAC (z ) + GC (z )2 /GAC (z )
Table 2
Vd (z )
GAC (z ) and GC (z ) zero values for several electrical frequencies. .
Vq (z ) (38)
Fe (Hz) 0 500 833 1250
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Fig. 9. Evolution (from 100 Hz up to 600 Hz) of the six closed-loop poles of the whole MIMO system (34). The two closed-loop poles, which crosses the unitary circle
for a frequency equal to 521.7 Hz, are zoomed in and its module growth is also detailed.
Fig. 10. Evolution (from 100 Hz up to 450 Hz) of the six closed-loop poles of the whole MIMO system which includes the feed-forward terms. The two closed-loop
poles, which crosses the unitary circle for a frequency equal to 379.8 Hz, are zoomed in and its module growth is also detailed.
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4.1. Decoupling: from MIMO to SISO n 0 = d12 [4.2602cos(2wT )2 6.5580cos(2wT ) + 3.3530cos(wT ) 2], (47)
The whole decoupling algorithm is presented inside the red dashed n1 = d12 [ 5.1345cos(2wT ) 2 + 6.5580cos(2wT ) 3.3530cos(wT )2],
line of Fig. 11. The proposed solution consists on estimating the current (48)
plant currents i (k + 1) and i (k + 2) for both d and q axes. Such esti-
mation is carried out supplying to the closed-loop transfer function n2 = 0.8825. (49)
T2 (z ) the current reference values, and delaying such reference values
It is clear that four coefficients need to be calculated on line since
two iterations to the actual controller. Assuming perfect decoupling, the
they depend on the electrical angular speed. Nevertheless, considering
equivalent closed-loop transfer function would be as indicated in (42).
that the speed, specially in EV and HEV, has a much slower dynamics
Such delay won’t compromise at all the overall performance since it is
than the current, there is no need to update such coefficients at the
much smaller than the current closed-loop dynamics.
current rate, i.e. every sampling period T; bringing the possibility to
C2 (z ) G2AC (z ) numC2 (z) numG2AC(z) reduce the processor capability.
T2 (z ) = = .
1 + C2 (z ) G2AC (z ) denC2 (z) denG2AC (z) + numC2 (z) numG2AC (z) Finally, in order to just have the four poles in the current closed-
loop specified in (44), a PF, whose transfer function is indicated in (50),
(42)
needs to be introduced to cancel the two zeros from numC2 (z) .
n 0 + n1 + n2
4.2. Speed-adaptive controller design PF2 (z ) = .
n 0 z 2 + n1 z + n2 (50)
Once the equivalent MIMO system is decoupled, the system is ef-
fectively reduced to a SISO system, formed by the plant G2AC (z ) and the
controller C2 (z ) . The handicap is that the new plant has got two poles, 4.3. Numerical stability study
one at the origin, but the second one moving acording to speed (Fig. 12)
as indicated in Eq. (40). Some numerical values of this moving pole are The new MIMO speed-adaptive controller, illustrated in Fig. 11, can
indicated on the third row of Table 2, from where it can be seen that it be expressed as follows:
moves rapidly outside the unitary circle and therefore the stable region
Vd C2 (z ) 0 Id
and takes the value infinity for an electrical frequency equal to 1/8 of =
Vq 0 C2 (z ) Iq
the sampling frequency. Therefore, no compensator will exist to stabi-
lize the plant at that speed value, which constitutes the main limitation z 2PF2 (z ) C2 (z ) T2 (z ) D2 (z ) Id
+ .
of this proposed controller. Another approach, which enlarges further T2 (z ) D2 (z ) z 2PF2 (z ) C2 (z ) Iq (51)
than 1/8 of the sampling frequency, is proposed in [40,41]; however,
this approach is not accurate enough to allow analytical tuning The plant defined in (30) is considered in (51) and, after proper
methods, such as pole placement. It is obvious then, that if the con- matrix manipulation, the closed-loop transfer function matrix becomes:
troller C2 (z ) is meant to keep the closed-loop poles at the same position,
C2 (z ) must be adaptive. Pole placement is the methodology used to
design such controller. The specifications are (i) to include an integrator
to cancel the 0 type error, (ii) guarantee the settling time at 2% (Ts,2% )
and (iii) avoid any overshoot = 1, as it was already mentioned in Eq.
(10). According to general control theory [36], the number of coeffi-
cients required by the controller in order to place the closed-loop where
dictated by the specifications, must be equal to the number of the
closed-loop poles. The three coefficients n2 , n1 and n 0 should be enough;
however, the controller would be non causal. Therefore, a second pole
is added to the controller C2 (z ) as indicated in (43).
Fig. 11. Proposed adaptive control structure for PMSM high speed operation.
n 0 z 2 + n1 z + n2
C2 (z ) = , Inside the red dashed line the decoupling controller. (For interpretation of the
(z 1)(d1 z + d2) (43) references to color in this figure legend, the reader is referred to the web ver-
The two dominant closed-loop poles will be forced to have a settling sion of this article.)
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A. Arias, et al. Electrical Power and Energy Systems 109 (2019) 423–433
Fig. 12. Pole map of C2 (z ) in green, GAC2 (z ) in red and the targeted closed-loop
in black. Notice how the P2 of the GAC2 (z ) and the P2 of the C2(z) move depending
on the speed. (For interpretation of the references to color in this figure legend,
the reader is referred to the web version of this article.)
1 1
Id GAC (z ) GC (z ) C2 (z ) 0
= + ·
Iq GC (z ) GAC (z ) 0 C2 (z )
z 2PF2 (z ) C2 (z ) T2 (z ) D2 (z ) Id
T2 (z ) D2 (z ) z 2PF2 (z ) C2 (z ) Iq (52)
The numerical results of Fig. 14 show the effectiveness of the pro- Fig. 14. Torque control results of the studied machine with proposed control up
posed controller, where the system remains stable up to 1000 Hz. Small to 1000 Hz (electrical).
current ripple in the d and q current waveforms can be spotted, which
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A. Arias, et al. Electrical Power and Energy Systems 109 (2019) 423–433
Table 3 Acknowledgements
Relevant Pole Zero values of the equivalent MIMO for several electrical fre-
quencies. The present work has been supported by the Government of Spain
Fe (Hz) 0 250 500 833 1000 1036 1100 through the Agencia Estatal de Investigación under the Projects DPI2017-
85404-P and DPI2014-53685-C2-2-R, by the Generalitat de Catalunya
e aT cos (wT ) 0.97 1.01 1.14 1.68 2.54 2.91 3.99 through the Project 2017 SGR 872, as well as for the research projects
cos (2wT )
pole P2 C2 (z ) 0.92 0.89 0.76 0.22 −0.64 −1.008 −2.09 ENSOL (KK-2018/00040), SICSOL (KK-2018/00064) and GANICS (KK-
zero 1 C2 (z ) 0.91 0.92 0.97 0.99 0.99 0.99 0.99 2017/00050), within the ELKARTEK program of the Government of the
zero 2 C2 (z ) 0.91 0.89 0.77 0.30 0.08 0.06 0.03 Basque Country. Also, this work has been supported by the Department
of Education, Linguistic Policy and Culture of the Basque Government
within the fund for research groups of the Basque university system
IT978-16.
are due to the existing PWM modulation and power electronics con-
verter both included in the accurate and detailed simulation model. References
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