An electrical direct drive system with controllers, sensors, and actuators is proposed to replace conventional gym equipment. Replacing the heavy, redundant iron box with a light and intelligent direct drive system has become an unstoppable trend. Compared with QDD system, DD system can obtain durable torque output and a more accurate torque control with lower cost by removing the gear box. The proposed DD system includes a) The electro-mechanical system, with a straightskew large torque SPMSM, angle, current and temperature sensors, b) multiple conventional and customized training modes stored in the controllers, c) a fast response current, speed, and angle controller.

A Dead-zone Current Calculation (DCC) method is designed to increase the current controllers’ bandwidth with limited h...[ Read more ]

An electrical direct drive system with controllers, sensors, and actuators is proposed to replace conventional gym equipment. Replacing the heavy, redundant iron box with a light and intelligent direct drive system has become an unstoppable trend. Compared with QDD system, DD system can obtain durable torque output and a more accurate torque control with lower cost by removing the gear box. The proposed DD system includes a) The electro-mechanical system, with a straightskew large torque SPMSM, angle, current and temperature sensors, b) multiple conventional and customized training modes stored in the controllers, c) a fast response current, speed, and angle controller.

A Dead-zone Current Calculation (DCC) method is designed to increase the current controllers’ bandwidth with limited hardware condition. To further increase the torque control accuracy, the cogging torque is analyzed and anti-cogging algorithms such as VCT are applied. A fast response current controller is the basis of a high-performance DD system.