Real-Time Sensorless Speed Control of PMSMs Using a Runge–Kutta Extended Kalman Filter

Permanent magnet synchronous motors (PMSMs) are widely preferred in modern applications due to their high efficiency, high torque-to-inertia ratio, high power factor, and rapid dynamic response. Achieving optimal PMSM performance requires precise control, which depends on accurate estimation of motor speed and rotor position. This information is traditionally obtained through sensors such as encoders; however, these devices increase system cost and introduce size and integration constraints, limiting their use in many PMSM-based applications. To overcome these limitations, sensorless control strategies have gained significant attention. Since PMSMs inherently exhibit nonlinear dynamic behavior, accurate modeling of these nonlinearities is essential for reliable sensorless operation. In this study, a Runge–Kutta Extended Kalman Filter (RKEKF) approach is developed and implemented to enhance estimation accuracy for both rotor position and speed. The developed method utilizes the applied stator voltages and measured phase currents to estimate the motor states. Experimental validation was conducted on the dSPACE DS1104 platform under various operating conditions, including forward and reverse rotation, acceleration, low- and high-speed operation, and loaded operation. Furthermore, the performance of the developed RKEKF under load was compared with the conventional Extended Kalman Filter (EKF), demonstrating its improved estimation capability. The real-time feasibility of the developed RKEKF was experimentally verified through execution-time measurements on the dSPACE DS1104 platform, where the conventional EKF and the RKEKF required 47 µs and 55 µs, respectively, confirming that the proposed approach remains suitable for real-time PMSM control while accommodating the additional computational effort associated with Runge–Kutta integration.