DIRECT TORQUE CONTROL - DT C

John R G Schofield
ABB Industrial Systems Ltd.

The Direct Torque Control System

Direct Torque Confrol (DTC) is the latest, and possibly ultimate, AC motor control method.
The main difference between Direct Torque Control and the traditional AC drive control methods
is that with DTC there is no separate voltage and frequency-controlled PWM modulator.

The Direct Torque Control system comprises three basic functions, namely-
A mofor model which estimates the actual torque, stator flux and shaft speed by means of
measurements of two motor phase currents, the intermediate circuit dc voltage and information
on the state of the power switches. Calculations are performed every 25 micro-seconds and
these include corrections for temperature and saturation effects. The parameters of the motor
model are established by an identification run, which is made during commissioning.
A two level hysteresis controller in which the torque and flux references are compared with the
actual values calculated by the motor model. The magnitude of the stator flux is normally kept
constant and the motor torque is controlled by means of the angle y between the stator and
rotor flux.
Optimal switching logic which translates the controller outputs into the appropriate commands to
the power switching devices. There are six voltage vectors and two different kinds of
zero-voltage vectors available in the two level voltage source inverter and the optimum
switching logic determines the required selection every 25 micro-seconds.

Drive Control

DTC provides only effective torque control and estimates of the motor quantities. In order to
make a practical drive, speed control functions must be added. Typical additional functions
are,-

A. Torque reference chain The input of the torque chain is either the torque referencefrom the
speed controller or an external torque reference. Torque reference is modified in order to keep
the dc intermediate circuit voltage and electrical frequency limited. The inverter is protected
from overload by limiting the torque although short time overloads are allowed. Torque
reference is also limited in order to prevent the motor torque from exceeding the pullout torque.

B. Speed control In many applications, speed control is the most important task of the inverter
drive. Quality parameters of the process often depend on the function of the speed controller.
In a DTC inverter, speed control is not an inner part of the inverter control as in traditional
inverters. Output of the speed control is an external reference to the torque control. This
enables considerationof more process requirements in the speed controller design. The basic
algorithm of the speed controller is PID plus an acceleration compensator. The compensator is
very useful in order to minimise the control deviation in the acceleration and deceleration of
inertia because the PID controller can be tuned to act more as a load compensator. The PID
controller and acceleration compensator are tuned by an automatic tuning method, which is
based on the identification of the mechanical time constant of the drive. The time constant can
be identified during commissioning or normal operation.
C. Flux reference An absolute value of the stator flux can be given as a reference value to the
DTC block. The ability to control and ~~~~ flexibly the absolute value of stator flux reference
provides an easy way to realize many inverter functions. For example, flux reference control is
utilized in flux optimisation, field weakening control, etc,

D.Swifching frequency reference The switching frequency is controlled to match the limitation:
of the power modules (eg 1.5 to 3.5KHz). The method is based on the modification of the
hysteresis parameters as a function of electrical frequency.

Performance of DTC AC Drive

Torque response and linearify, DTC offers extremely fast torque response (typically below 2 rn:
and as a result very fast reversing.
Speed accuracy, the accuracy of shaft speed estimate is very good in the whole speed range.
This enables the use of a DTC inverter in many applications where the tacho-based vector
control is needed.
Special funciional performances, for example, the motor can be started in all eleetromechanica
states almost as fast as it is theoretically possible by DTC. In the case of a rotating shaft, the
position of the stator flux is determined and DTC is synchronised immediately. Flux braking
provides an effective method equal to dc injection braking and during flux braking the inverter i:
fully under control enabling controlled deceleration from one speed to another to be realised
while dissipating the energy in the stator. Of course, full braking torque is avaiilable during
normal operation if the DC link can absorb the energy.

Benefits of DTC

The drive performance described above is realised without tachogenerator or encoder. Hence
the motor is robust , cabling to the motor is reduced and a cost competitive drive is obtained by
obviating the need to provide and fit an encoder.
The performance is superior to that from a DC thyristor drive and it can therefore be used on
those applications previously reserved for DC. The IOW maintenance and robustness of an AC
motor reduces running costs and the AC drive runs at a power factor better than 0.97 at all
speeds and loads and has therefore minimum impact on the supply system.
Harmonic currents are less than those produced by a DC drive. Furthermore harmonic current
can be virtually eliminated by using a second DTC converter as the supply rectifies.
The frequent calculation of optimum switching means that the drive can respond rapidly to
external influences in addition to process requirements. For example riding through a loss of
SUPPlY.
DTC enables the inverter to be switched on to a rotating motor irrespective of the direction of
rotation and motor flux levels; this can be useful for such simple applications as a fan drive.
Noise levels of DTC controlled drives are an improvement compared to conventional PWM; the
noise tends to be ‘white noise”without the noise from the pulse width modulation and
fundamental frequencies which can be intrusive.
A common drive control (CDC) is available for all ABB drives (AC and DC) to provide additiona
programmable features and a high speed interface to an over-riding control system.

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Some of the user benefits are summarised in the following table (I),
Feature Benefit
Fast control 'Servo' performance
available from a standard drive. Better process control.
Tripless drive Process changes will not affect performance. Drive will
not trip.
Flash start Can start into a motor which is running at any speed
without waiting for the flux to decay,
Smooth recovery No process interuptions after short supply outages.
Flux braking Full control during deceleration between speeds.
Reduced need for brake chopper.
Auto tuning Less commissioning time.
Easy retrofit to existing motor.
Low Noise Acoustic noise more acceptable; and easier to screen.
Accurate temperature Improved motor protection.
calculation

Typical performance values compared with other drives are shown in table (2) below
~ ~~~~~~ ~ ~ ~

ACPWM ACPWM DCDrive D T C D T C

Scalar Flux Vector with encoder no encoder with encoder
with encoder
Torque, Linearity +- 12% +- 4% +- 3% +- 5% +- 3%
Torque, Repeatability +-4% +- 1% +- 1.5% +- 1% +- 1%
Torque, Response time 150mS 10-20mS 10-20mS -
1 9mS 1 - 9mS

Speed, Static accuracy +- I-3% +- 0.01% +- 0.01% +-0.1, 0.5% +- 0.01%

Speed, Dynamic accuracy 3%S +- 0.3%S +- 0.3%S +- 0.4%S +- 0.1 %S

Conclusion

Direct Torque Control (DTC) is a new method of induction motor control which provides
excellent performance without tachogenerator feedback. New control features are realised, e.g.
flux braking and fast starting. DTC drives will bring benefits to many drive applications
including those previously reserved for DC and servo drives.

Acknowledgement

This paper is based on one published by Pasi Pohjalainen MSc, Pekka Tiitinen MSc and Jarkko
Lalu MSc of ABB Industry Oy, Power Electronics, Helsinki.

0 1995 The Institution of Electrical Engineers.

Printed and published by the IEE, Savoy Place, London WCPR OBL, UK.

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