Journal of Textile Research ›› 2025, Vol. 46 ›› Issue (09): 232-241.doi: 10.13475/j.fzxb.20241002501

• Machinery & Equipment • Previous Articles     Next Articles

Position detection method of permanent magnet synchronous motor for weft storage device based on Kalman feedforward fitting observer with Hall sensor

MENG Ziyu1, LU Wenqi2(), ZHANG Song2, MIAO Shenghong2, HUANG Fuhua2, PENG Laihu2   

  1. 1. School of Information Science and Engineering, Zhejiang Sci-Tech University, Hangzhou, Zhejiang 310018, China
    2. School of Mechanical Engineering and Automation, Zhejiang Sci-Tech University, Hangzhou, Zhejiang 310018, China
  • Received:2024-10-14 Revised:2025-04-25 Online:2025-09-15 Published:2025-11-12
  • Contact: LU Wenqi E-mail:luwenqi@zstu.edu.cn

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Abstract:

Objective In order to meet the high-speed and high stability control requirements of the motor driving sulutions for the application of weft storage, and to improve the accuracy of position and speed estimation in the permanent magnet synchronous motor drive system based on Hall sensors so as to enhance the stability of yarn transport in the weft storage device, This paper analyzes in detail the working principle of Hall sensors and proposes a motor rotor position and speed estimation method based on Kalman feedforward fitting state observer to address the problems of discrete position signals and low speed estimation accuracy in the permanent magnet synchronous motor drive system based on Hall sensors.

Method This article provides a detailed analysis of the working principle of Hall sensors and proposes a motor rotor position and velocity estimation method based on Kalman feedforward fitting state observer. First of all, This method uses the Kalman iterative algorithm to filter and fit the discrete Hall signal, eliminating the noise disturbance caused by Hall installation deviation; secondly, a full dimensional state observer is adopted to estimate the rotor position information of the motor, ultimately obtaining continuous rotor position and velocity information of the motor.

Results Compared with conventional algorithms, in the motor drive performance testing section, using the algorithm proposed, running at a given speed of 500 r/min, the startup response time is consistent and the steady-state error is reduced by 15%. At a given speed of 1 500 r/min, the startup time was shortened by 0.2 s and the steady-state error was reduced by 11.5%. At a given speed of 5 000 r/min, the startup time was shortened by 0.8 s and the steady-state error was reduced by 0.8%. In the performance testing of closed-loop yarn conveying in the weft storage device, the algorithm proposed was a dopted to shorten the start-up time by 0.1 s and steady-state error by 7.6% under the condition of external sock machine pulling yarn speed of 100 m/min. Under the condition of external sock machine pulling yarn at a speed of 700 m/min, the startup time was shortened by 0.2 s and the steady-state error was reduced by 13.3%.

Conclusion The experimental results show that compared with conventional algorithms, the proposed energy storage control system based on Kalman feedforward fitted state observer has higher estimation accuracy of motor rotor position and velocity during start-up and steady-state operation, and better motor driving performance; in the process of yarn conveying, the dynamic and steady-state performance of the weft storage control system is better, which better meets the high-performance control requirements of weft storage yarn conveying.

Key words: Hall sensor, permanent magnet synchronous motor, weft storage device, Kalman filtering, full order state observer, vector control

CLC Number: 

  • TM341

Fig.1

Sectional view of bipolar three-phase permanent magnet synchronous motor"

Fig.2

Electrical signal output by Hall sensor"

Fig.3

Estimation results of rotor position and speed based on linear extrapolation algorithm"

Fig.4

Overall principle diagram based on Kalman feedforward fitting state observer Hall position detection method"

Fig.5

Principle block diagram of weft storage control system based on Kalman feedforward fitting state observer Hall position detection method"

Fig.6

Key components of weft stotage, complete machine and sock knitting machine of weft storage device.(a)Stator; (b) Rotor; (c)Controller; (d)Spinning structural components; (e)Completee machine; (f)Automatic hosiery knitting machine"

Tab.1

PMSM parameters"

参数 指标 参数 指标
极对数 2 磁链/wb 0.016 28
线电感/mH 6.11 额定电流/A 0.65
线电阻/Ω 3.63 额定电压/V 57
额定转速/(r·min-1) 5 000 反电动势常数 3.41

Fig.7

Performance test of motor driving at reference speed of 500 r/min. (a) Conventional linear extrapolation algorithm; (b) Improved Kalman feedforward fitting state observer algorithm"

Fig.8

Performance test of motor driving at reference speed of 1 500 r/min. (a) Conventional linear extrapolation algorithm; (b) Improved Kalman feedforward fitting state observer algorithm"

Fig.9

Performance test of motor driving at reference speed of 5 000 r/min. (a) Conventional linear extrapolation algorithm; (b) Improved Kalman feedforward fitting state observer algorithm"

Fig.10

Performance test of weft storage device at yarn speed of 100 m/min. (a)Conventional linear extrapolation algorithm; (b) Improved Kalman feedforward fitting state observer algorithm"

Fig.11

Performance of weft storage device at yarn speed of 700 m/min. (a) Conventional linear extrapolation algorithm; (b) Improved Kalman feedforward fitting state observer algorithm"

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