Peng Ding, Jie Zhang, and Xianqun Qiu
Permanent magnet synchronous motor, model predictive control,lifetime extension, disturbance observer, Arrhenius thermal aging,Coffin–Manson fatigue
Gear grinding spindles driven by permanent magnet synchronous motors demand both high dynamic accuracy and long service life, yet conventional proportional–integral (PI) speed controllers cannot explicitly incorporate device degradation constraints into the control law. This paper proposes a lifetime-oriented model predictive control (MPC) strategy that replaces the PI speed loop within a field- oriented control framework. Two physics-motivated penalty terms are embedded in the MPC cost function: a copper-loss term that penalises the squared q-axis current to reduce winding temperature rise and mitigate Arrhenius-type insulation aging, and a control rate-of-change term that suppresses junction temperature cycling to extend insulated-gate bipolar transistor module fatigue life according to the Coffin–Manson model. A Luenberger disturbance observer estimates the time-varying cutting load torque in real time for load-torque feed-forward in the MPC predictor, while an adaptive weighting mechanism preserves dynamic performance under heavy grinding loads by scaling down the lifetime penalties. Ablation simulations on a representative gear grinding spindle load profile comparing four control schemes demonstrate that the proposed method reduces cumulative copper loss by 3.1% and peak winding temperature by 0.04◦C relative to MPC without lifetime terms, and halves the speed rise time to 10 ms compared with an optimised PI controller.
Important Links:
Go Back
