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07 / Electric drives / constrained numerical modeling

PMAC Drive Modeling.

A motor can only deliver the torque that its current and voltage allow. This study uses a second calculation to check a detailed simulation, then extends the analysis into an explicit operating envelope.

ContextApril 2023 · numerical extension October 2026
My role / teamIndividual simulation study; later numerical implementation
Evidence statusHistorical switching simulation and a verified averaged numerical model
Original PMAC torque-response simulation, with positive and negative torque commands
Camden Boston · April 2023. Original simulation output; no physical motor measurements. Open image at full size ↗

Select current from the torque constraint

I modeled a permanent-magnet AC drive in MATLAB/Simulink, generated d- and q-axis current lookup tables, and compared the switching simulation with steady-state torque and power calculations. The machine uses eight poles, with a fixed mechanical speed of 500 rpm in the historical study. At the ±400 N·m reference point, the steady calculation requires about 222.35 A phase peak.

Resolve what the original check leaves open

The saved optimizer minimizes current under torque equality, but does not enforce the declared current maximum or an inverter voltage limit. The reported switching simulation reaches approximately ±394.3 N·m for ±400 N·m requests. A later analytical check shows that the displayed proportional current regulator predicts that offset with finite stator resistance; it is not evidence of measured motor losses.

Define the achievable operating envelope

The separate 2026 model adds explicit current and voltage constraints, a complete speed–torque map, and a guarded lookup interface. With the same illustrative motor values, a 400 V bus, a 225 A phase-peak limit, and 5% steady voltage reserve, +400 N·m is feasible at 500 rpm. At 2000 rpm, the positive torque limit falls to about 171.80 N·m. Infeasible requests return a bounded target with a saturation status.

Check the model and its limits

The new averaged model is checked against exhaustive current searches, a separate voltage-boundary calculation, phase and power identities, time-step refinement, and parameter sensitivity. Its slew-limited PI current controller follows the 0 → +400 → −400 N·m sequence at 500 rpm while staying within the stated current and voltage limits. These are reproducible numerical results. Switching ripple, battery dynamics, thermal behavior, firmware, and physical validation remain outside this model.

2026 calculated operating envelope

New numerical torque limits versus mechanical speed, showing a current-limited plateau and decreasing voltage-limited capability
New averaged dq calculation using the historical illustrative motor parameters. A 400 V stiff bus, 225 A phase-peak limit and 5% steady voltage reserve define this model envelope; these are not measured motor ratings. Open image at full size ↗

2026 averaged current-control response

New averaged PI current-control simulation following zero, positive 400 and negative 400 newton-metre requests with a defined current-reference slew
Separate PI simulation at 500 rpm with a 20 kA/s current-reference slew. It includes current, voltage and energy checks; it does not reproduce the historical switching waveform or establish hardware response. Open image at full size ↗

Project context

Camden Boston's individual April 2023 simulation study used supplied model material and numerical methods. The 2026 implementation is a separate numerical extension. No motor hardware measurements are claimed.

Historical photographs, footage, and plots retain their original dates. Later digital reconstructions are identified separately; their numerical checks do not establish hardware performance.