What we actually do
Field-oriented control on motor-control DSPs, with the current loop fast enough that the outer loops have something stable to sit on. Where an encoder is a recurring field-service cost, sensorless startup replaces it — using initial rotor position detection before torque release rather than ramping through the rollback window.
Wide operating envelopes
Motor characteristics held as profiles and blended at runtime let one firmware image serve several power classes, which removes the per-site commissioning build and the engineer who would otherwise have to fly out to produce it.
Ride and feel
S-curve jerk limiting on the speed reference, and field weakening above base speed to hold torque across the full travel profile. Torque ripple that a pump would tolerate is felt directly in a passenger system, so the acceptance bar is set by the person in the car.
Protection
Gate-drive protection is verified against short-circuit and desaturation events before any load testing, because the first time a fault path is exercised should not be with a machine attached.
