Control of motor drives with output sinewave filter capacitor current compensation using sinewave filter transfer function
09800190 ยท 2017-10-24
Assignee
Inventors
- Semyon Royak (Orange Village, OH, US)
- Jingbo Liu (Grafton, WI, US)
- Jingya Dai (Burnaby, CA)
- Thomas Nondahl (Greenfield, WI, US)
- Ehsan Al-Nabi (Cambridge, CA)
- Peter B. Schmidt (Franklin, WI)
Cpc classification
H02P23/14
ELECTRICITY
International classification
H02M7/72
ELECTRICITY
H02P23/14
ELECTRICITY
Abstract
Disclosed examples include power conversion systems, methods and computer readable mediums to operate an inverter to drive a motor load through an intervening filter, by computing a speed error value according to a speed reference value and a speed feedback value, computing a torque reference value according to the speed error value, computing a motor current reference value according to the torque reference value, compensating the motor current reference value according to capacitor currents of the output filter using a transfer function representing an output current to input current amplitude vs. frequency behavior of the output filter and the motor load, and controlling the inverter according to the inverter output current reference value.
Claims
1. A power conversion system, comprising: an inverter comprising a DC input, an AC output, and a plurality of switching devices coupled between the DC input and the AC output and operative according to inverter switching control signals to convert DC electrical power received at the DC input to provide AC electrical output power at the AC output to drive a motor load through an intervening output filter; and a controller configured to: compute a speed error value according to a speed reference value and a speed feedback value using a summing component; compute a torque reference value according to the speed error value using a first proportional-integral (PI) control component; compute a motor current reference value according to the torque reference value using a lookup table or a parametric equation; compensate the motor current reference value according to capacitor currents of the output filter by computing an inverter output current reference value according to the motor current reference value and an inverter operating frequency using a first transfer function representing an output current to input current amplitude vs. frequency behavior of the output filter and the motor load; and provide the inverter switching control signals to control the inverter according to the inverter output current reference value; wherein the controller is operative to control the inverter according to the inverter output current reference value by: computing an inverter output current value according to the inverter output current reference value and an inverter output current value, and providing the inverter switching control signals to control the inverter according to the inverter output current value; and wherein the controller is operative to estimate the speed feedback value by: computing a motor current value according to the inverter output current value and the inverter operating frequency using the first transfer function, computing a motor torque value according to the motor current value, and computing the speed feedback value according to the motor torque value.
2. The power conversion system of claim 1, wherein the controller is operative to control the inverter according to the inverter output current reference value by: computing an inverter output voltage control value according to the inverter output current reference value and an inverter output current value, and providing the inverter switching control signals to control the inverter according to the inverter output voltage control value.
3. The power conversion system of claim 2, wherein the first transfer function includes parameter values representing impedance components of the output filter and the motor load.
4. The power conversion system of claim 3, wherein the parameter values of the first transfer function are configurable to adapt the power conversion system for different output filters and different motor loads.
5. The power conversion system of claim 1, wherein the first transfer function includes parameter values representing impedance components of the output filter and the motor load.
6. The power conversion system of claim 5, wherein the parameter values of the first transfer function are configurable to adapt the power conversion system for different output filters and different motor loads.
7. A method of operating an inverter to drive a motor load through an intervening filter, the method comprising: using at least one processor implementing a summing component, computing a speed error value according to a speed reference value and a speed feedback value; using the at least one processor implementing a first proportional-integral (PI) control component, computing a torque reference value according to the speed error value; using the at least one processor implementing a lookup table or a parametric equation, computing a motor current reference value according to the torque reference value; using the at least one processor, compensating the motor current reference value according to capacitor currents of the output filter by computing an inverter output current reference value according to the motor current reference value and an inverter operating frequency using a first transfer function representing an output current to input current amplitude vs. frequency behavior of the output filter and the motor load; using the at least one processor, providing inverter switching control signals to control the inverter according to the inverter output current reference value; using the at least one processor, estimating the speed feedback value according to the inverter output current reference value; using the at least one processor, computing an inverter output current value according to the inverter output current reference value and an inverter output current value; using the at least one processor, providing the inverter switching control signals to control the inverter according to the inverter output current value; and using the at least one processor, estimating the speed feedback value by: computing a motor current value according to the inverter output current value and the inverter operating frequency using the first transfer function, computing a motor torque value according to the motor current value, and computing the speed feedback value according to the motor torque value.
8. The method of claim 7, further comprising: using at least one processor, computing an inverter output voltage control value according to the inverter output current reference value and an inverter output current value; and using at least one processor, providing the inverter switching control signals to control the inverter according to the inverter output voltage control value.
9. The method of claim 8, wherein the first transfer function includes parameter values representing impedance components of the output filter and the motor load.
10. The method of claim 9, wherein the parameter values of the first transfer function are configurable to adapt the power conversion system for different output filters and different motor loads.
11. The method of claim 7, wherein the first transfer function includes parameter values representing impedance components of the output filter and the motor load.
12. The method of claim 11, wherein the parameter values of the first transfer function are configurable to adapt the power conversion system for different output filters and different motor loads.
13. A non-transitory computer readable medium, comprising instructions that, when executed by at least one processor, cause the at least one processor to: implement a summing component to compute a speed error value according to a speed reference value and a speed feedback value; implement a first proportional-integral (PI) control component to compute a torque reference value according to the speed error value; implement a lookup table or a parametric equation to compute a motor current reference value according to the torque reference value; compensate the motor current reference value according to capacitor currents of the output filter by computing an inverter output current reference value according to the motor current reference value and an inverter operating frequency using a first transfer function representing an output current to input current amplitude vs. frequency behavior of the output filter and the motor load; provide the inverter switching control signals to control the inverter according to the inverter output current reference value; estimate the speed feedback value according to the inverter output current reference value; compute an inverter output current value according to the inverter output current reference value and an inverter output current value; provide the inverter switching control signals to control the inverter according to the inverter output current value; compute a motor current value according to the inverter output current value and the inverter operating frequency using the first transfer function; compute a motor torque value according to the motor current value; and compute the speed feedback value according to the motor torque value.
14. The non-transitory computer readable medium of claim 13, further comprising instructions that, when executed by at least one processor, cause the at least one processor to: compute an inverter output voltage control value according to the inverter output current reference value and an inverter output current value; provide inverter switching control signals to control the inverter according to the inverter output voltage control value; compute an inverter output current value according to the inverter output voltage control value and the inverter operating frequency using a second transfer function representing an input current to input voltage amplitude vs. frequency behavior of the output filter and the motor load; compute a motor current value according to the inverter output current value and the inverter operating frequency using the first transfer function; compute a motor torque value according to the motor current value; and compute the speed feedback value according to the motor torque value.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
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DETAILED DESCRIPTION
(12) Referring now to the figures, several embodiments or implementations are hereinafter described in conjunction with the drawings, wherein like reference numerals are used to refer to like elements throughout, and wherein the various features are not necessarily drawn to scale.
(13) The presence of the output filter between the power conversion system and the load makes accurate control of the voltages and currents provided to the load more difficult, as the power delivered to the load is different from that delivered to the input of the filter. The output inverter stage may be controlled according to feedback signals measured at the inverter output terminals, but these feedback values generally do not represent the currents or voltages ultimately provided to the load. Feedback sensors can be provided at the load itself for direct measurement of the load parameters, but this increases system cost, and may not be possible in all applications.
(14) Sensorless motor drives are used in a variety of applications, particularly where providing position and/or speed sensors directly at a motor load is difficult or impractical. In certain applications, a step-up transformer is used to boost the motor drive output voltage, allowing use of a low-voltage drive to power a medium voltage induction motor, and/or to reduce I.sup.2R losses and facilitate use of a smaller diameter cable wire for long cable runs between the motor drive and the driven motor. As previously discussed, certain applications also employ output filters between the motor drive inverter output and the transformer primary in order to suppress reflected wave voltage spikes associated with pulse width modulated (PWM) variable frequency drives. Use of sensorless voltage-frequency control techniques, however, may lead to problems, particularly where a transformer and/or sine wave filter is connected between the motor drive and the motor load. Conventional sensorless field-oriented-control (FOC) or other open loop speed control techniques have thus been found generally unsuitable for low-speed motor drive operation where output filters and transformers are used, such as in electric submersible pumps (ESPs), and these difficulties are particularly problematic in driving permanent magnet synchronous motors (PMSMs). Moreover, motors in sensorless speed control applications also suffer from oscillation in rotor velocity about the setpoint speed following load transitions or speed setpoint adjustments, particularly at low speeds. In certain situations, moreover, the driven motor may be unable to successfully start from a stopped condition due to unstable motor speed oscillations.
(15) Presently disclosed embodiments provide power conversion systems 40 and inverter control methods and apparatus 100 to drive a motor load 20 through an intervening filter 30, which can also be used in combination with a transformer 50 and a potentially lengthy cables 60 coupled between the filter output and the driven motor load 20.
(16) The motor drive 40 receives single or multiphase AC input power from a power source 10 and converts this to a DC bus voltage using a rectifier 42 which provides a DC output voltage to a DC link circuit 44 having a capacitor C.sub.1 The rectifier 42 can be a passive rectifier including one or more diode rectifier components, or may be an active front end (AFE) system with one or more rectifier switching devices (e.g., IGBTs, etc.) and an associated rectifier controller (not shown) for converting input AC electrical power to provide the DC bus voltage in the link circuit 44. Other configurations are possible in which the drive 40 receives input DC power from an external source (not shown) to provide an input to the inverter 46, in which case the rectifier 42 may be omitted. The DC link circuit 44 may include a single capacitor C or multiple capacitors connected in any suitable series, parallel and/or series/parallel configuration to provide a DC link capacitance across inverter input terminals 46A. In addition, while the illustrated motor drive 40 is a voltage source converter configuration including one or more capacitive storage elements in the DC link circuit 44, the various concepts of the present disclosure may be implemented in association with current source converter architectures in which a DC link circuit 44 includes one or more inductive storage elements, such as one or more series-connected inductors situated between the source of DC power (e.g., rectifier 42 or external DC source) and the input 46A of the inverter 46. In other possible implementations, the motor drive 40 includes a direct DC input to receive input power from an external source (not shown), and in certain embodiments the rectifier 42 and DC link circuit 44 may both be omitted.
(17) The DC input 46A of the inverter 46 includes first and second (e.g., plus and minus) terminals connected to the DC link circuit 44, as well as a plurality of switching devices S1-S6 coupled between the DC input 46A and the motor drive AC output 46B. In operation, the inverter switching devices S1-S6 are actuated by inverter switching control signals 102 provided by the controller 100 to convert DC electrical power received at the DC input 46A to provide AC electrical output power as inverter output voltages, V.sub.u, V.sub.v, and V.sub.w and inverter output currents i.sub.u, i.sub.v, and i.sub.w at the AC output 46B. The filter circuit 30 receives the AC output from the inverter 46 of the motor drive 40. Although illustrated as driving a permanent magnet synchronous motor 20, the motor drive 40 can be employed in connection with other types of AC motor loads 20 and/or other forms of power converters to drive non-motor loads 20 using an output inverter 46. One or more feedback signals or values may be provided from the motor 20 itself, including a motor (e.g., rotor) position or angle signal .sub.r and a motor speed or velocity signal .sub.r, although not a strict requirement of all embodiments of the present disclosure. The concepts of the present disclosure advantageously facilitate the sensorless speed estimation by the inverter controller 100, and thus direct feedback from the driven motor load 20 is not required in all implementations. In this regard, the motor drive 40 in certain embodiments implements a motor speed and/or position and/or torque control scheme in which the inverter controller 100 selectively provides the switching control signals 102 in a closed and/or open-loop fashion according to one or more setpoint values such as a motor speed setpoint, which can be a signal or value generated by the controller 100, or a fixed setpoint value, or such setpoint value can be received from an external system (not shown). In practice, the motor drive 40 may also receive a torque setpoint and/or a position (e.g., angle) setpoint, and such desired signals or values (setpoint(s)) may be received from a user interface and/or from an external device such as a distributed control system, etc. (not shown). As used herein, a signal can be an analog signal, such as a current or a voltage signal, or a signal can include digital values generated or consumed by the processor 102.
(18) The inverter 46 of the motor drive 40 is connected to the load 20 through the intervening filter circuit 30. In the illustrated example of
(19) The output of the filter circuit 30 provides motor phase currents i.sub.out to control the motor load 20, whereas the filter capacitor currents i.sub.C flow in the filter capacitors C.sub.1 and non-zero voltages v.sub.L (i.e., filter voltages) may develop across one or more of the filter inductors L.sub.r, whereby simple closed-loop control based on measured inverter output current signals or values i.sub.u, i.sub.v, i.sub.w may result in less than optimal operation of the driven load 20. At the same time, however, directly measuring the motor currents i.sub.out and/or motor voltages would require additional hardware and cabling, which may not be economically feasible or technically possible in certain applications. Nevertheless, for those cases where motor currents and/or motor voltages, such as V.sub.u, V.sub.v, V.sub.w, Y.sub.f.sub._.sub.out.sub._.sub.u, Y.sub.f.sub._.sub.out .sub._.sub.v, and V.sub.f.sub._.sub.out.sub._.sub.w in
(20) The controller 100 and the components thereof may be any suitable hardware, processor-executed software, processor-executed firmware, logic, or combinations thereof that are adapted, programmed, or otherwise configured to implement the functions illustrated and described herein. The controller 100 in certain embodiments may be implemented, in whole or in part, as software components executed using one or more processing elements, such as one or more processors 102, and may be implemented as a set of sub-components or objects including computer executable instructions stored in the electronic memory 104 for operation using computer readable data executing on one or more hardware platforms such as one or more computers including one or more processors, data stores, memory, etc. The components of the controller 100 may be executed on the same computer processor or in distributed fashion in two or more processing components that are operatively coupled with one another to provide the functionality and operation described herein.
(21) Referring also to
(22) The controller 100 in certain embodiments is configured by execution in the processor 102 of instructions in the memory 104 to implement the control configuration illustrated in
(23) At 308, the controller 100 compensates the motor current reference value or values Id,q.motor.ref according to capacitor currents i.sub.C of the output filter 30 by computing one or more inverter output current reference values (e.g., d and q axis values Id.inverter.ref and Iq.inverter.ref) according to the motor current reference value(s) Id,q.motor.ref and the operating frequency of the inverter 46 using the first transfer function 112 (1/A.sub.i()) via multiplier components 208 and 210, respectively. In one example, the first transfer function 112 represents the output current to input current amplitude vs. frequency behavior of the output filter 30 and the motor load 20. In certain embodiments, the first transfer function 112 includes parameter values representing impedance components (e.g., resistances, inductances, and/or capacitance) of the output filter 30 and the motor load 20. In other implementations, the transfer function 112 further includes parameters representing impedance components of any intervening transformer 50 and/or of the motor cable 60. In certain embodiments, moreover, the parameter values of the first transfer function 112 are configurable to adapt the power conversion system 40 for different output filters 30 and different motor loads 20. For example, the motor drive 40 and the inverter controller 100 are programmable in certain implementations to accept programming values for the parameters of a given filter 30 and/or motor load 20. This allows a user to adapt the motor drive 40 for use in combination with a variety of different filter and motor combinations.
(24) At 310, the controller 100 provides the inverter switching control signals 102 to control the inverter 46 according to the inverter output current reference value(s) Id,q.inverter.ref, and the controller 100 computes or estimates the speed feedback value Speed.fbk according to any suitable measured or inferred value, such as inverter currents and voltages in one example. In another example, the controller uses sensor information for the speed feedback. In this manner, the current and voltage control of the driven motor 20 is compensated according to the transfer function 112 that characterizes the components of the intervening filter 30. Moreover, the controller 100 in certain embodiments implements sensorless speed control according to the estimated speed feedback value Speed.fbk without requiring speed feedback. In practice, without wishing to be tied to any particular theory, the steady state filter current compensation implemented by the controller 100 advantageously mitigates or avoids unwanted output oscillation in the motor speed and/or torque for sensorless ESP and other applications, thereby facilitating higher frequency operation of the driven motor load 20. This is particularly beneficial for deep well pumping applications where pumping speeds are important and the motor cable 60 may be quite lengthy.
(25) In certain embodiments, the controller 100 implements voltage control. In the example of
(26) In other possible implementations, the controller 100 operates to control the inverter 46 according to the inverter output current reference value Id,q.inverter.ref. In this case, the controller 100 computes the inverter output current value(s) Id,q..sub.in according to the inverter output current reference value Id,q.inverter.ref and the inverter output current value Id,q..sub.in, and provides the inverter switching control signals 102 to control the inverter 46 (e.g., at 310 in
(27) The controller 100 thus implements capacitor current compensation for motor drives and other power conversion systems 40 to drive a motor 20 using an inverter 46 in systems employing and output sine wave filter 30 using filter and plant parameters without knowledge of voltages. The disclosed apparatus and method examples advantageously employ the transfer function 112 for filter capacitor current compensation in view of the impedance parameters of the output filter 30 and the load, including any associated transformer 50 and the driven motor 20 itself. Moreover, the drive 40 and the controller 100 are programmable to adapt to different filter and/or driven motor combinations.
(28) Referring now to
Ai()=Iout/Iin.(1)
(29)
M.sub.u=K.Math.{square root over (L.sub.r.u.Math.L.sub.rc.u)}(1)
0<K1(2),
(30) where K is a coupling coefficient. The single phase equivalent circuit shown in
M=K.Math.L.sub.0(3), and
L.sub.1=L.sub.2=(1K)L.sub.0(4).
(31) The corresponding resonance frequencies (Hz) can be written as follows:
(32)
(33) The damping factor can be written as follows:
(34)
(35) Reorganizing according to equations 3 and 4 yields the reorganized equivalent circuit shown in
(36)
(37) The following equation (9) can be used to calculate the current I.sub.z using equation (8):
(38)
(39) After some manipulation, the current through the impedance Z is given according to the following equation (10):
(40)
(41) The output voltage (e.g.,
(42)
(43) The filter capacitor current I.sub.c1 can be expressed by the following equation (12):
(44)
(45) The input current provided to the filter 30 is given by the following equation (13):
I.sub.in=I.sub.z+I.sub.c1(13)
(46) Substituting equations (10) and (12) into equation (13), gives the following representations of the input current in the voltage V.sub.2:
(47)
(48) Substituting equation (16) into equation (11), yields the following equation (17):
(49)
(50) From equation (15), the input current can be expressed according to the following equation (18):
(51)
(52) The voltage V.sub.2 can then be expressed according to the following equation (19):
V.sub.2=V.sub.inI.sub.in*(R.sub.r+KL.sub.0P)(19)
(53) From equations (15) and (19), the following relationships can be determined:
(54)
(55) Or:
(56)
(57) After some manipulation the input current to input voltage transfer function can be expressed according to the following equation (24):
(58)
(59) Where:
(60)
(61) From equation (17), the following input current formula can be obtained:
(62)
(63) Further manipulation according to equations 25-28 yields the following expression of the filter input current:
(64)
(65) Where:
g.sub.2=C.sub.1L.sub.1(36)
g.sub.1=R.sub.dampC.sub.1(37)
(66) From equations (24) and (35), the following output-to-input voltage transfer functions can be derived:
(67)
(68) Or:
(69)
Where:
(70)
(71) As seen in
(72)
(73) The following output current-to-input voltage equation (44) can be obtained from equations (38) and (43):
(74)
(75) From equations (24) and (44), the first transfer function 112 can be expressed according to the following equation (45) to relate amplitude as a function of frequency for the filter 30 and the plant (load):
(76)
(77) A phase-frequency response can also be obtained for equations (24), (39), (44-45). Substituting j for the operator p in equation (45), gives the following equation (46):
(78)
(79) After some manipulation, the following transfer function equations (47) and (48) can be derived:
(80)
(81) Or:
(82)
(83) Where:
(84)
(85) The amplitude-frequency response A.sub.i() can be represented according to the following equation (51):
(86)
(87) The phase-frequency response .sub.i() can be represented as follows:
.sub.i()=A TAN 2(a.sub.i,b.sub.i)(52)
(88) Again substituting j for the operator p in equation (24) gives the following equation (53):
(89)
(90) After some manipulation the following equation (54) can be derived:
(91)
(92) Where:
(93)
(94) The amplitude-frequency response A.sub.iv() can be represented as follows:
A.sub.iv()={square root over (a.sub.iv.sup.2+b.sub.iv.sup.2)}(57)
(95) The phase-frequency response .sub.iv() can be represented as follows:
.sub.iv()=A TAN 2(a.sub.iv,b.sub.iv)(58)
(96) Again substituting j for the operator p in equation (39), gives the following equation (59):
(97)
(98) After some manipulation, the following output-input voltage relationship (60) can be derived:
(99)
(100) Where:
(101)
(102) Amplitude-frequency response A.sub.v() can be represented as follows:
A.sub.v()={square root over (a.sub.v.sup.2+b.sub.v.sup.2)}(63)
(103) Phase-frequency response .sub.iv() can be represented as follows:
.sub.v()=A TAN 2(a.sub.v,b.sub.v)(64)
(104) Let's substitute j instead of operator p into equation (44), then:
(105)
(106) After some manipulation we can derived:
(107)
(108) Where:
(109)
(110) Amplitude-frequency response A.sub.v() can be represented as follows:
A.sub.i-out,v={square root over (a.sub.i-out,v.sup.2+b.sub.i-out,v.sup.2)}(69)
(111) Phase-frequency response .sub.iv() can be represented as follows:
.sub.i-out,v()=A TAN 2(a.sub.i-out,v,b.sub.i-out,v)(70)
(112) Based on equations (24) and (51), the general dynamic control approach of
(113)
(114) Referring now to
(115)
(116) The damping factor for no load condition can be written as follows:
(117)
(118) In
(119)
(120) Using equation (76), the input current I.sub.in can be expressed according to the following equation (77):
(121)
(122) The input current can be expressed, following some manipulation, according to the following equations (78) and (79):
(123)
(124) Or:
(125)
(126) The output voltage V.sub.out can be expressed according to the following equation (80):
(127)
(128) Following some manipulation, the output voltage can be expressed according to the following equations (81) and (82):
(129)
(130) Or:
(131)
(132) The filter output current I.sub.out (
(133)
(134) Or:
(135)
(136) From equation (79) the following input voltage equation (85) can be obtained:
(137)
(138) From equations (84) and (85) the following output-input current relationship (86) can be obtained:
(139)
(140) If damping resistor is omitted from the filter 30, the following relationships (87)-(90) are found:
(141)
(142) Amplitude-frequency and phase-frequency transfer functions can be obtained for equations (79), (82), (84), and (86). Initially, equation (79) can be rewritten according to the following equation (91):
(143)
(144) Where:
(145)
(146) Substituting j for the operator p in equation (91) and rearranging the terms yields the following input current-input voltage relationship (92):
(147)
(148) For the manipulation yields the following equation (93):
(149)
(150) Where:
(151)
(152) The amplitude-frequency response A.sub.i() can be represented according to the following equation (96):
(153)
(154) The phase-frequency response .sub.i() can be represented as follows:
.sub.i()A TAN 2(a.sub.i,b.sub.i)(97)
(155) Referring now to
(156)
(157) The second transfer function 114 relating the filter input current to the filter input voltage is given by the following equation (99):
(158)
(159) Where,
m.sub.1=(R.sub.2+R.sub.3)C.sub.1+R.sub.1C.sub.1+R.sub.3C.sub.2(100)
m.sub.2=[2(1K)L.sub.0+L.sub.3]C.sub.1+L.sub.3C.sub.2+R.sub.3C.sub.2*(R.sub.1+R.sub.2)C.sub.1(101)
m.sub.3=2(1K)L.sub.0C.sub.1*R.sub.3C.sub.2(102)
(160)
(161) Rearranging yields the following equation (107) for the first transfer function 112:
(162)
(163) The following equation (108) expresses the second transfer function 114.
(164)
(165) As discussed above, the first and second transfer functions 112 (equation (107) and 114 (equation (108) can be implemented by the processor 102 in the drive controller 100 in order to provide steady state filter current compensation to drive a motor load 20 through an intervening filter 30. As seen above, the transfer functions 112 and 114 may be expressed in terms of the impedance components of the output filter 30 and the load (e.g., motor load 20 and any intervening transformer 50, cable 60, etc.), and the parameters of equations (107) and (108) can be configured in the memory 104 of the controller 100 in order to adapt a particular motor drive power conversion system 40 for operation in association with a variety of different filter/load combinations.
(166) In the preceding specification, various embodiments have been described with reference to the accompanying drawings. It will, however, be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense.