At PEG, we practice an integrative approach involving simulation in the complete product development cycle. It is important to understand the role of simulation in every phase of the product development cycle. Below is a summary of how simulation can be used in each stage:
Concept Phase:
Also, for majority of the engineers, a process methodology or steps to design must include simulation. Simulation is most effective when the circuit behavior is not well understood and one can construct several what-if scenarios or use simulation to build a repertoire of questions to be answered about the design problem at hand. Simulation effectiveness improves with experience and time. An engineering department must be dedicated to it. As with any other skill, to yield simulation as a potent competitive weapon, one must spend significant time and resources to hone it. A frivolous relationship or experimental tinkering with simulation tools will not yield any fruitful results.
Design Phase:
Prototype Phase:
First Article Phase:
Do not be too ambitious to incorporate a host of models at one time. Also realize that incorporating each component model is never required. One must be quite prudent in incorporating essential component models. Just remember Pareto’s principle – 20% or less determine 80% or more of the outcome. This must always be kept in mind
Pre-Production/Production Phase:
What Is Inertia Matching? Inertia is an object’s resistance to changes in motion (i.e., acceleration or deceleration).In a motor-drive system, you’re dealing with two key inertias: Motor inertia — the rotational inertia of the motor rotor Reflected load inertia — the inertia of the load as seen by the motor through the mechanical transmission (gearbox, pulley, etc.) Jload (reflected)=Jload/Gear Ratio2 Why...
Read MoreWhen sizing a motor for an application, it is crucial to distinguish between horizontal and vertical motion axes, as each involves different load considerations and system dynamics. Here's how you should approach each: Before diving into horizontal vs. vertical, the core factors in motor sizing include: Load inertia (moment of inertia) Required torque and speed Acceleration and deceleration profiles Duty cycle and th...
Read MoreIn rotational systems, peripheral velocity (also known as tangential or linear velocity at the rim of a rotating body) plays a key role in determining the power transmitted. Mathematically: P=F⋅v Where: P = Power F = Force (typically tangential) v = Peripheral velocity Since force is related to torque (T=F⋅r), we also get: P=T⋅ω=F⋅r⋅ω=F⋅v Thus, increasing peripheral velocity enables higher power transm...
Read MoreIn mechanical systems, transmitting power effectively from a prime mover (typically a motor) to a machine or between machines requires a crucial intermediary: the coupling. Couplings not only help tailor the power characteristics to suit specific application needs but also play a central role in ensuring reliability, efficiency, and precision in mechanical systems. The Role of Couplings in Power Transmission A prime mover, ...
Read MoreWhether you're building control software for a brushless DC motor (BLDC), PMSM, or induction machine, efficient motor code development is the cornerstone of robust, responsive, and safe performance. At the heart of real-time motor control lies a tight loop of functions executed every pulse-width modulation (PWM) cycle, typically in the range of 10 to 100 microseconds. Here's a comprehensive breakdown of the core principles of efficient...
Read MoreIn today’s fast-paced world of electrification, motor control development is no longer limited to low-level coding and manual testing. Model-Based Design (MBD) has emerged as a game-changing methodology, enabling rapid prototyping, simulation, control validation, and automatic code generation. Various software tools now cater to different aspects of motor control development, from algorithm design to hardware-in-the-loop (HIL) testin...
Read More⚠️ Lessons Learned: The Hidden Cost of Picking the Wrong MCU Semiconductor companies often excel in marketing, even for their lower-end 8-bit MCUs, making it challenging for developers to determine which MCU is best suited for motor control. It’s easy to be misled by claims that an MCU can do “everything” when, in reality, it may fall short in real-time control, peripheral performance, or toolchain support. ...
Read MoreAbstract This paper presents a sensorless control technique for Permanent Magnet Synchronous Motors (PMSMs) using a BackEMF observer. Eliminating physical position sensors improves system reliability and reduces cost and complexity. The proposed method estimates the back electromotive force (BackEMF) by comparing actual and estimated motor current and processing the error through a Proportional-Integral (PI) controller. This techniq...
Read MoreConverting Motor RPM into a 0-to-360-degree ramp signal Rakesh K Dhawan, Power Electronics Group LLC Converting Motor RPM into a 0 to 360-degree rampDownload 1.0 Abstract This article presents a method to convert motor rotational speed (RPM) into a continuous ramp signal spanning 0 to 360 degrees, utilizing LTspice for simulation and implementation. The approach starts with foundational mathematical equations that translate...
Read MoreLet us assume we have a 5-phase motor we are trying to analyze. This motor has the following characteristics. Figure 1 - 5-Phase Motor with 22 Magnets and 25 Slots. OD of 200mm and Stack of 25mm. Motor Characteristics:Input Voltage = 48VMax Phase Current = 40APhase Resistance = 0.22 OhmsPhase Inductance = 1.5mH The motor's backEMF is shown below at 100 RPM. It is slightly trapezoidal compared to the Sinusoidal representation....
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