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INSTASPIN-BLDC: InstaSPIN FOC control behaving weirdly when loaded

Part Number: INSTASPIN-BLDC
Other Parts Discussed in Thread: TMS320F28027, MOTORWARE

Hi,

We are using  TMS320F28027 controller which comes with in built InstaSPIN-FOC module to control a BLDC motor.

We have tuned both the current loop and speed loop using the InstaSPIN labs 5A, 5B with the help of motorware drivers.

But after tuning to a satisfactory performance at no load, when we start loading the line current waveform keeps distorting but when loaded fully the waveform tends to be a pure sine.'

NO-Load line current waveforms 

Medium load huge distorting leading to high current from the dc supply 

Full load and the waveform seems to be better

We have tried adjusting the Kp and Ki parameters for both the speed and current controllers  and still no luck.

We would like to know if there is anything that we are missing or any parameter which could lead this kind of behaviour.

Thanks in Advance