Current surge with hall sensor at engine start

[Oli49]

Hello Everybody,

MCSDK : 6.3.2
CubeMX: 6.3.2
Workbench : 6.3.2
Cube IDE : 1.18.1
Hardware : Custom but based on EVLDRIVE101-HPD
Motor : PMSM 28V - 2 pole pairs - Rmp = 14K - rated current = 13A - Primary sensor : Hall, Secondary sensor Observer+PLL (sensor less)

At power up, after a delay, the motor start with hall sensor.
When motor control switch to RUN, there is current surge, limited by my power supply (15A), during 100ms. (PWM > 90%).
Is it to align the rotor ???
If i use FOC as primary sensor, you can limit the current but not if i use Hall sensor as primary sensor.

I have change IQMAX_A, NOMINAL_CURRENT_A and ID_DEMAG_A at different value, but i has no effect.

What can un do to limit this current to 3/4A during this phase ?

After this surge, the motor works well.

(Green : rpm, Yellow : power supply voltage, Blue : Power supply current, Purple : W current)

[STuser2]

Can you try with MCSDK 6.4.1 i think there are some improvements or changes, this is my suggestion.

[Oli49]

MCSDK 6.4.0 and 6.4.1 doesn't work !!

[STuser2]

why what is the reason?

[Oli49]

For example, with 6.3.2 at 3500rpm, the motor current is sinusoidal, the power supply current is 0.15A@28V.
with 6.4.x the motor current is erractic, the power supply current is 4.5A@28V, and the motor is noisy.
I don't know what the problem is, and i don't have time to waste debugging this MC SDK version.

[GMA]

Hello @Oli49,

A test has been conducted on the ST side with MCSDK6.4.1 and Hall without any issues.
Using Primary sensor: Observer + PLL (sensorless) and Secondary sensor: Hall, did you plot both EL_ANGLE signals to verify that they are aligned?