Accurate Angle Representation From Misplaced Hall-Effect Switch Sensors for Low-Cost Electric Vehicle Applications

This article presents an accurate method to determine the mandatory rotor position to control a permanent magnet synchronous machine from misplaced Hall-effect switch sensors. The main feature of this technique is the estimated speed from two consecutive edge transitions in the same phase to dodge the inaccurate information. Besides, when a new electrical cycle starts, a gradual compensation algorithm corrects the initial speed estimation to cancel the electrical angle error in order to prevent current distortions. Furthermore, a first-order Taylor series approximation estimates the rotor position from the compensated speed calculation, reducing the possible torque ripple and noise due to an inaccurate control strategy. The proposed method has been compared with other state-of-the-art approaches through simulation and experimental results obtained from a low-voltage powertrain, showing more straightforward implementation and delivering the best balance performance during steady-state and transient operation.