Abstract

This study proposes an integrated self-aligning-torque energy recovery and DC-bus voltage stabilization strategy for a permanent-magnet synchronous motor (PMSM)-driven steer-by-wire system in new energy vehicles. During the front-wheel return-to-center process, self-aligning torque may provide excess mechanical energy to the steering actuator. Instead of dissipating this energy through a braking resistor, the proposed strategy converts part of the self-aligning-torque-induced mechanical energy into electrical energy and feeds it back to the low-voltage DC bus. To avoid ambiguity in the operating-mode description, this paper distinguishes the standard PMSM torque–speed quadrants from the mechanical stages of the steering process. Regenerative operation is defined according to the condition (Teωm<0), corresponding to the second or fourth quadrant of the PMSM torque–speed plane, whereas the return-to-center regenerative stage refers to the self-aligning-torque-dominated stage of the steer-by-wire motion. Based on this definition, an electromechanical energy-flow model is established to describe the transfer path from self-aligning torque to the PMSM and then to the DC bus. Considering that regenerative energy injection may cause DC-bus voltage fluctuation or braking-resistor activation, a single-loop bus-voltage stabilization method based on active disturbance rejection control is developed. A third-order linear extended state observer is adopted to estimate the lumped disturbance caused by self-aligning-torque variation, current coupling, load variation, parameter uncertainty, and inverter loss. The observer bandwidth, controller gains, current limitation, and overvoltage protection mechanisms are further discussed to improve the practical implementability of the proposed control strategy. In addition, an energy-accounting method is introduced to distinguish total steering energy consumption, available self-aligning-torque mechanical energy, gross recovered electrical energy, system losses, net recovered energy, and recovery efficiency. Simulation and experimental results show that the proposed strategy can suppress DC-bus voltage rise, reduce braking-resistor energy dissipation, and achieve measurable steering-actuator-level energy recovery during repeated return-to-center maneuvers. The results verify the feasibility of using self-aligning-torque-induced regenerative energy in PMSM-driven steer-by-wire systems, while the actual vehicle-level energy benefit depends on the driving cycle, low-voltage load demand, battery charging acceptance, and converter efficiency.

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