DevLab PMSM Research Platform
Purpose
DevLab is a flexible, simulation-centric research environment exposing ~70% of the internal PMSM control model (torque & speed loops). Developers can rapidly prototype, test, and transition new control strategies from simulation into real hardware.
Key Features
- Transparent Access: Modify and observe 70% of the internal Simulink model, including speed and torque loops.
- Rapid Prototyping: Seamlessly switch between simulation and real hardware using Variant Source/Sink blocks.
- Fast Deployment: Transition from control design to embedded code generation with built-in scripts.
- Flexible Environment: Supports both simulation and code-generation modes.
- Live Testing: Use FreeMASTER for real-time monitoring of currents, speed, and voltage.
- Dual-Motor Testbed: Run back-to-back or independent tests with two PMSMs and synchronized ECUs.
Core Components
- Dual low-voltage PMSM modules in a portable form-factor
- Basic inverter drive with open-loop and closed-loop modes
- Transparent motor casing for mechanical visibility
- Real-time data acquisition interface using FreeMASTER
- Instructor station with guided experiment software
- Emergency stop and safety interlocks
- PMSM Testbench Hardware
- Motor & Inverter: Single PMSM coupled to inverter board, powered by DC supply.
- ECU Board: NXP-based controller for PWM generation and signal processing.
- Sensors: Current and speed sensors integrated on the inverter board.
- Software Environment
- Simulink Model: Pre-built DevLab model using Variant Source/Sink blocks.
- FreeMASTER GUI: Real-time monitoring dashboard.
- Data Dictionary: Shared global variables for parameter tuning without recompilation.
WHY CHOOSE DEVLAB
Key Objectives
Hands-on environment to illustrate PMSM principles and validate advanced control strategies.
- Explore motor dynamics (FOC, sensorless, adaptive controllers)
- Capture high-resolution data for model-based design
- Integrate advanced sensors for comparative control studies
Expected Outcomes
- Validated custom control algorithms
- Data-supported insights into controller stability and performance
- Refined control models and robust prototypes
Typical Workflow
- Model Modification – Edit internal blocks or parameters in DevLab Simulink project.
- Simulation Verification – Run standalone simulations to validate control logic and metrics.
- Code Generation – Generate C code targeted at NXP MPC5744P.
- Hardware Upload & Real-Time Testing – Deploy firmware to ECUs and monitor motors with FreeMASTER.
Suggested Research Modules
| Module | Focus |
|---|---|
| 1. Open-Loop Characterization | Map speed vs. voltage; understand system drift without feedback. |
| 2. Closed-Loop Performance | Step responses; quantify settling time, overshoot, disturbance rejection. |
| 3. Control Tuning & Strategy Comparison | Adjust PI gains; compare default vs. custom tuning; evaluate decoupling effects. |
| 4. Four-Quadrant Operation | Motoring/braking in all quadrants; study power flow in B2B coupling. |
| 5. High-Speed Field Weakening | Inject negative d-axis current; measure torque vs. speed trade-offs. |
| 6. Automated Regression Testing | Script FreeMaster via MATLAB API for repeatable sequences. |
| 7. Efficiency Mapping & MTPA | Generate torque/efficiency contours; derive MTPA curves for optimal currents. |
Learning Outcomes
- In-Depth Control Design: Hands-on with inner-loop current & outer-loop speed regulation algorithms.
- Model-Based Development: Master variant modeling and global data dictionaries.
- Hardware-In-The-Loop Testing: Observe simulated logic on real ECUs under variable load.
- Automation & Validation: Reproducible test benches and scripted regression checks.
DevLab exposes internal control structures and automates the build/test cycle, empowering rapid iteration on PMSM drive strategies beyond a “black-box” kit.