Position From 3-Hall sensors in FOC Motor Control

[engeek]

Dear All,


I am currently working on a 10 kW motor drive for controlling a PMSM in an automotive traction application, utilizing a Field-Oriented Control (FOC) algorithm. I am facing a challenge with position extraction from the motor’s Hall sensors.


The motor is equipped

   

with three Hall sensors spaced 120 electrical degrees apart. However, due to sensor misalignment or misplacement, I am experiencing position jumps at N*60 electrical degrees. This issue appears to stem from the position extraction algorithm. Specifically, the Hall sensors' XOR logic determines position in 60-degree segments of the electrical cycle. To obtain a continuous angle, I interpolate between these segments using speed summation.


I have tested various smoothing methods, including PLL and others, which work well up to around 3000 RPM. Beyond this speed, I observe current spikes leading to torque ripple and an audible buzzing noise from the motor.


I will attach plots of the extracted position and Hall sensor signals for reference.


If anyone has encountered similar issues or has experience with position extraction from Hall sensors in such conditions, I would greatly appreciate your insights or recommendations.


Thank you in advance.

[Hui_Ma]

Hi

Please help to share the motor control system main processor/microcontroller part number.

Or referred NXP motor control reference design name/link. Thanks.

Best regards,

Mike