The 3Mh Annual Conference of the IffE Industrial ElectronicsSociety, November 2 - 6,2004, Busan, Korea
Speed Control System of slotless PM Brushless DC Motor
Using 2Hall-ICs
Yong Ho Yoon', Mu Sun Woo2, Seung Jun Lee3,Chung Yuen wOn4,Member, iEEE, You Young Choe5
IDept. Information & Communication Eng., Sungkyunkwan University, Gyeonggi-do, 440-746, Korea
e-mail: dydgh@skku.edu
'#304, Sungsin Techno Park, 509-7, Maetan3-Dong, Yeongtong-gu, Su-won city, Gyeonggi-do, Korea, Kinemotion Co. Ltd
e-mail:wchoe@,kinemotion.com
Absfrm- The high performance drives of the slotless
Permanent Magnet Brushless OC(PM BLDC) Motor can be
achieved by the current control, where the currents flow
according to the rotor position and the current phase is
suitably controlled according to the operation condition. The
inexpensive Hall-ICs are a right choice or the s o s a l e d back
EMF sensorless algorithm can be used for the rotor position
sensing. Generally, to drive and control of the PM BLDC, it is
necessary that the three Hall-ICs evenly be distributed around
the stator circumference and encoder be installed in case of the
3phase motor. So, the Hall-ICs nre set up in this motor to detect
the main flux from the rotor, and the output signal from Hall-
ICs is used to drive P power transistor to control the winding
current. However, instead of using three Hall-ICs and encoder,
we used only two Hall-ICs for the permanent magnet rotor
position and for the speed feedback signals, and also for a
microcontroller of 16-bit type (80C196KC)with the fphase PM
BLDC whose six stator and two rotor designed. Two Hall-ICs
CS1 and CS2 are placed on the endplate at l2Odegree intervals,
and with these elements, we estimated information of tbe
others phase in sequence through a revolving rotor.
I. INTRODUCTION
The emergence of high-energy permanent magnets has
promoted renewed interest in slotlessbrushlessmotor topologies,
since although their power densities maybe lower than for
equivalent slotted machines, they eliminate cogging torque.
Generally, the position sensor represents the important factor
in PM BLDC motor drives.
It drives employ encoders or resolvers mounted on the shaft to
identify the rotor flux position.
But the presence of the encoder or resolver causes several
disadvantages in high-speed motors.
In order to meet the demand of mechanical ruggedness and
stifhess of high-speed motor, the shaft should be as short as
possible. It may be difficult to mount an encoder or a resolver
on shaft.
?rmunenl
I m a g n e t roior
bding
fig. I . Slotless PM BLDC Motor.
Q2004 IEEE
0-7803-8730-9/04/$20.00
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In fact, in order to obtain good petformances and low torque
ripple, hi&-resolution sensor is needed, which is m t l y and
usually needs a special conshution for the machine.(for
example a second shaft end to couple the sensor)[11.
So, the Hall-ICs are set up in this motor to detect the main flux
from the rotor, and the output signal from Hall-ICs is used to
drive a power transistor to control the winding current.
However, instead of using three Wall-ICs and encoder, we
used only two Hall-ICs for the permanent magnet rotor
position and for the speed feedback signals with the 3-phase
slotless PM BLDC motor whose six stator and two rotor
designed.
Fig. 1 shows a cross-sectionof a three-pb, Zpole, radial-gap,
slotless PM BLDC.
Two Hall-ICs, CSl and CS2 are placed on the endplate at
120degree intervals, and with these elements, we estimated
information of the others phase in sequence through a revolving
rotor. Then, hysteresis current conmller is adopted for inverter
to firther reduce switching loss.
Also a digital signal processor, namely XDc196kc is used to
implement the speed controller,
Finally, a prototype is constructed and some experimental
and simulation results are presented.
It is found that for general PM BLDC motor applications, the
proposed slotless PM BLDC motor drive can indeed satisfy the
desired perfommce without using an expensive en& or
ESolVer.
11. MATEEMATICAL
MODEL OF THE P M BLDC MOTOR
Fig. 2 shows the equivalent circuit of the PM BLDC Motor.
The mathematical model for this motor can be described in
Eq. (1) with the assumption that the magnet and stainless steel
retain sleeves has high resistivity and rotor-inducedcurrents be
neglected[3,5].
I ' I t I
Fig. 2. Equivalent circuit of the PM BLDC Mator.
 Using the coupled windmg approach, the voltage equations
of the three phase take the form
where P is the phase number of turns and T is the mean
air-gap flux density.
R,and R, are the inner and outer radii of the toroid
respectively.
Equations (3) to (7) provide the necessary information
required to solve for both the dynamic and steady-state
opemtion of the motor.

P[ii] +

whereR and L are the resistance and self inductance of each

phase and M is the mutual inductance between phases.
The self and mutual inductances are the same for each phase
because of the winding symmetry and the constant air-gap
length.

Since i, + i, + i, =0

+
"herefore M (io ib) = -Mi, (2)
substitutingfrom Eq. (2) in Eq. (1) and rewriting the equations
on state-space form gives: Phase Cuirenl I,. It a
BackEMF .e,. eo, e, O T 0 r ~ u e - T . .Tb, T,

Fig. 3. Back EMF,current, torque waveforms of

the slotless PM BLDC Motor.

The back EMF'S e,, e,, and e, have trapezoidal shapes

P[J - [I!] (3)

and the cments i,, ib, and i, needed to produce a steady
state torque without torque pulsations are shown in Fig. 3.

111. SLOTLESS
PM BLDC MOTOR CONTROL
The back emf is directly proportional to the motor speed,
and the developed torque is almost directly proportional to the
The state-space form of the speed dynamic equation is phase current.
This means that the torque can be maintained constant by a
PW = (T, -Tl - T , ) / J (4) stable supply current. In order to realize this state, one methcd
is to keep the ratio of voltage to k p e n c y a constant.
where w = Pe and e is the angle defining the rotor It is also required along with frequency control to avoid
position. 1; and are the electromagnetic and load saturation of magnetic circuit.
torque respectively. This can be achieved by using a speed and current closed-loop
control as shown in Fig. 4.
TF is the friction torque and can be expressed as The control structure has an innermost current closed-loop
and an outer-speed loop to govem the current.
TF = a + bw (5)

J is the moment of inertia of the motor and connected load.

The electromagnetictorque is derived from

T, =(iaea +i,e, +icec)/w (6)

The emfs e, , e, and e, are trapezoidal in shape and

Fig. 4. Closed-loop control far slatless PM BLEC Motor.
displaced 120" electrical apart, the amplitude of each can
In Fig. 5, hysteresis current control comparing real current
be determined by the expression
gained by feed back with calculated reference value is applied
for variable speed range.
The error between real current obtained from CTiCurrent
Transducer) and reference current of 80c196kc is applied to

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the first OP-Amp’s input and output of the second OP Amp
dwided by Ri and Rz gets into the non-inverting terminal,
making up hysteresis band
Gate signals keep on and off maintaining the steady current
between reference values and real current into the hysteresis
band.
Speed controller regulates the rotor speed by varying the
frequency of the pulse based on signal feedback from the
Hall-ICs. This pulse is to be injected to the inverter to energize
the stator windings.
1
Fig. 5. Hysteresis current controller.
The speed PI feedback loop compares the rotor speed o
with the desired rotor speed ~ l etof produce the command torque
component current
If the speed is faster than desired speed, it will decrease the
frequency of the pulse to be injected to the inverter.
Oppositely, if speed is slower frequency, it will be increased.
Using 2 Hall-ICs, the position and speed estimation is
achieved for speed regulation reference frame transformation.
The position estimator for the slotless PM BLDC motor needs
to detect six positions, which determine the commutation
points.
CS1 slgnal
111
111
Slotless
PM ELOCM
1 T L
Fig. 6. The proposed slotless PM BLLX Motor driving system
To further illustrate the importance of rotor position
estimation, Fig. 6 shows the schematics of the slotless PM
BLDC motor with two Hall-ICs installed.
The two Hall-ICs CSl and CS2 evenly distributed around the
stator circumference.
Generally, to drive and control of the slotIess PM BLDC
motor, it is necessaIy that the three Hall-ICs evenly be
distributed around the stator circumference and encoder
installed in case of the 3-phase motor.
In this paper, a low-resolution position sensor (2Hall- ICs
and the other phase estimation circuit), which has accuracy of
only 60 elecmcal degrees, is used instead of a high-resolution
position sensor.
For example, such low-resolution position information can be
obtained by the processed signals from 2 Hall-ICs (CS 1, CS2)
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and CS3 signal estimation circuit (the other phase estimation
circuit) as shown in Fig, 7.
Two Hall-ICs, CS1 and CS2 are placed on the endplate at
120degree intervals, and with these elements, we estimated
infomtion of the others phase signal (CS3) in sequence through
a revolving rotor.
We extend frequency as six times using logical operation at the
EPLD because the resolution of frequency is low related to
speed at Hall-IC signals.
Therefore, one cycle is divided into six intervals of 60
electrical degrees each by the processed signals CSI, CS2, and
the other phase estimation signal circuit, CS3 as shown Fig. 8.
a11
0 I I i I 1
I 1 I I 1
I
t M M > I I I I
Fig.7. The proposed estimation circuit of the Hall-IC(CS3)
Initially, The Hall-IC signals (CSI, CS2) and estimation
signal(CS3) feedback occurred starting the motor by speed
command.
Logic signals of gate driver are generated using these Hall-IC
signals and estimation signal in the switching logic part,
The speed controller regulates the speed of the rotor by
varying the frequency of the pulse based on the signal
feedback from the Hall-ICs.
Referring to Fig. 8, we assumtng that the motor spends “t”
seconds between two consecutive transitions, then the average
rotor speed in this section can be calculated.
I 6P1sesb-d
Fig. 8. Speed pulse and Hall-IC signals.
So the speed algorithm can be simply implemented by a
microcontroller. Noting that depending on allowed cost and
required performance, 2 Hall-ICs can be used.
Fig. 9 shows a simplified schematic diagram of the rotor
position signal synthesizer.
For the concerned 2-pole slotless PM BLDC motor, the Hat1
ICs provide CS1, CS2 signals and estimated CS3 signal from
rough rotor position information.
 Fig. I I. Estimation Hall-IC signal(CS3).

Fig, 9.The circuit of 6 pulse

Iv. SMULATION RESmTS

Fig. 10 shows the overall block diagram of the developed
model for slotless PM BLDC motor drive system
The simulation is performed using the PSIM software. cs3
the system is composed of slotless PM BLDC motor, six-step .w:
inverter, gate drive of inverter, switching logic, 6 pulse
-.
4,-
"--L-
logic(DLL block of PSIM), and current control block. Estimfion iignanf the CS3"

Fig. 12. Hall-IC signals and estimation signal ofthe CS3.

" CpoLresignal 'I

MAY- 4

Fig. 13. 6 pulse and Hall-IC signals

Fig. IO. Configuration of simulation,

Fig. I 1 shows the estimation signal of CS3 in case of not

using Hall-1C of the CS3.
Firstly, gotten signal of CS1 from Hall-IC of the CSl can
convert to bipolar square of range from + I 5V to -15V by the
OP Amp and with this converted signal, we can get a triangle
wave from the OP A m p ' s integrator output
Furthermore, using the triangle wave and comparator, we
can also get a compared value which can be changed by the
upper limit value and lower limit value of comparator.
At this point, we know that compared value accords with the
genemted signaf from Hall-IC of CS3 in cazx of using of Hall-IC. Fig. 14. Each phase current waveforms. (livdiv. Imddiv)

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 Fig. 12 shows each phase Hall-IC signals and estimation system, which consists of EPLD, a slotless PM BLDC motor,
signal of the CS3 that would be generated from the estimation and the associated circuits.
signal circuit. According to the signal of the position sensor, the switches
Hall-IC signal and estimation signal of CS3 show nearly the state of the inverter (TRI-TR6)can be determined.
same wave of non-phase difference. The dates of switches related to rotor position are stored in
Fig. 13 shows the 6 pulse and estimation signal of the CS3 EPLD in case positive and negative rotation.
are created in case of using two Hall-ICs, CS1 and CS2. Therefore, the switching sequence is accomplished by data
Fig. 14 shows the current of each phase waves at in the EPLD that related to rotor position.
2000Orpm. .......................... ....................
jbyw, ..... E...* .-
BLOC :.- pr"o:?:::"':'*-.
................
w:
~~

v. EXPERIMENTAL
RESULTS
Dl. t l l l ..I .
I m3
The experimental system for investigating the
characteristics of 2 Hall-ICs speed control with slotless PM ... ...................... .....................................
BLDC motor drive is shown in Fig. 15.
The system is composed of slotless PM BLDC motor,
six-step inverter, gate driver of inverter, EPLD (Embedded
Programmable Loge Device), and PI controller.
Switching logic, PWM resolution converter(6pulse), CS3
E?
signal estimation circuits are located w i t h the EPLD.
Fig 16 Block diagram ofEPLD.
WO&

Fig.17. The simulation results of 6 pulse block

Fig. 15. Sfotless PM BLDC motor driving system.
The motor used in this paper is a 2-poles, Y-connected,
slotless PM BLDC motor,
The windings of the motor are arranged in three phases:
Phase-A, Phase-B, and Phase-C.
These three phase windmg are distributed in the stator with a
separation of 120 degrees from one another.
The rotor has 1 pairs of permanent magnets flux,which provide
distributed magnetic flux in the air gap between the stator and
the rotor. The machine parameters and ratings are:
Fig. 17 shows the simulation resuIts of 6 pulse block.
The CS1, CS2 and CS3 represent ofeach phase Hall-IC signal.
The CLOCK takes advantage of oscillator of lOMHz and
PULSE is used for measuring of speed.
In order to veri@ the proposed performance control, the
system is implemented by software of INTEL XOC196KC
m i m n t r o l l e r board,
The 6 pulse and Hall-IC signals of each phase at real speed
20000rpm as shown in Fig. 18 and Fig. 19 respectively.

Stator resistance 0.88 P

9OV -
340Vdc cs1

0.9 KW cs2
Rated curreni 3.6Amps at 28OVdc cs3
No. of poles 2
Rated torque 0.245Nm(2.5kpfCm)
Stator inductance 1SmH Ise signnl
Inertia 15.067X io6kgm'
Torque Const. 0.07433
Fig. 18. HalI-IC signals and pulses.
Fig. 16 shows the block diagram of the experimental (using the three Hall-ICs CS I , CS2 and CS3)

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 Fig. 18 shows each phase Hall-IC signals and 6 pulse per
lcycle using the three Hall-ICs of the CSI, CS2, and CS3.
Generally, using three Hall-ICs easily got the 6 pulse which
has the same interval of one pulse to another one.
Fig. 19 shows estimation signal of the CS3 and 6 pdse per
lcycle created in case of using two Hall-ICs, CSI and CS2.
To get 6 pulse which has same interva1of one pdse to another
one using two Hall-ICs in Fig. 19, it tested same experiment
as simulation.
Fig. 19. Hall-IC signals and estimation signal
of the CS3 and pulse. (using the two Hall-ICs CS I,CS2 )
Fig 20 Each phase current (3000Orpm,2A, 0Sms)
Fig. 20 shows the current of each phase.
To examine the performance of the slotless PM BLDC motor
with the proposedcontrol scheme, it is loaded with an impeller,
rated torque demand in this case is 0.3” and the motor speed
is 30000 rpm.
Experiments show that even under this transient, the time
delay due to the Hall-ICs does not cause any problem to the
proposed circuit.
In order to verify theoretical results of a prototype slotless
PM BLDC motor, Fig. 21 has been realized.
- -.-..-. -... . ...- . ~ ., .
F i g 21. F.ryerimental led Jciup.
1..
VI. CONCLUSION
Using the two Hall-ICs instead of the three Hall-ICs at the
3-phase slotless PM BLDC motor guarantees performance for
the proposed control algorithm of the slotless PM BLDC
motor the same as that achieved with an expensive optical
encoder or resolver.
As a result, the reduction in size achieved by eliminating the
high-resolution rotor position sensor and the encoder may be
critical many applications.
It has the advantage of the low cost and the simple composition
compared with the conventional drive system.
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