System and computer-implemented method for reducing angle error in electric motors

A computer-implemented method for improving the functioning of a motor controller for reducing an angle error in a type of electric motor, wherein the type of electric motor has a rotor, a stator, a shaft, an encoder mounted on the shaft, and a plurality of windings, the computer-implemented method comprising:

• measuring one or more electrical parameters of a representative electric motor of the type of electric motor;
• finding a true rotor position of the rotor of the representative electric motor;
• generating sensorless gains based on the one or more motor parameters, including determining a sensorless angle;
• gathering data at a plurality of torque levels for at least one speed of the representative electric motor, including for each torque level, trying a plurality of different inductance values, and determining an inductance value that results in an angle error of zero, wherein the angle error is a difference between the true rotor position and the sensorless angle;
• and
• saving the inductance value that results in an angle error of zero for each speed in an electronic memory of the motor controller of each electric motor of a plurality of electric motors of the type of electric motor, wherein the inductance value that results in an angle error of zero for each speed of the at least one speed is used by the motor controller of each electric motor to control operation of each electric motor of the plurality of electric motors.

A computer-implemented method for improving the functioning of a motor controller for reducing an angle error in an estimated position of a rotor over a plurality of loads in a type of electric motor, wherein the type of electric motor has the rotor, a stator, a shaft, an encoder mounted on the shaft, and a plurality of windings, the computer-implemented method comprising:

• measuring one or more electrical parameters of a representative electric motor of the type of electric motor;
• finding a true rotor position of the rotor of the representative electric motor;
• generating sensorless gains based on the one or more motor parameters, including determining a sensorless angle;
• gathering data at a plurality of torque levels for at least one speed of the representative electric motor, including for each torque level, trying a plurality of different inductance values, and determining an inductance value that results in an angle error of zero, wherein the angle error is a difference between the true rotor position and the sensorless angle;
• and
• saving the inductance value that results in an angle error of zero for each speed in an electronic memory of the motor controller of each electric motor of a plurality of electric motors of the type of electric motor, wherein the inductance value that results in an angle error of zero for each speed of the at least one speed is used by the motor controller of each electric motor to control operation of each electric motor of the plurality of electric motors, including synchronizing the rotor and the stator.