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Review of Sensorless Methods for Brushless DC

James P. Johnson M. Ehsani Yilcan Giizelgiinler


Member, E E E Fellow, IEEE Member, IEEE

Power Electronics Laboratory


Texas A&M University
College Station, Texas

Abstract [1,2,21,26,34,40,49,64]. The voltage equation of the


machine,
This paper provides a review of the lireratiire addressing d
sensorless operation of brushless Dc machines. Methods V=Rl+-v
dt
explained ore stare-of-thenrr, including rhose I . using measured
currents, voltages.findomental machine equations. and algebraic
where,
manipulations. 2. using observers, 3. using back-emf methods, 4. V i s the voltage vector,
sensorless starting rechniqices, and 5. with novel techniques not in I is the current vector,
the previous categories. R is the resistance matrix, and
Y is the flux linkage vector.
1. Introduction This equation is then manipulated to obtain,
t
The purpose of this paper is to provide a review of . v = I( V - R I ) dt.
sensorless methods of BLDC. This paper will focus on the 0
analytical and qualitative basis of these methods. Knowing the initial position, machine parameters,
and the relationship of flux linkage to rotor position, the rotor
2. Sensorless Review position is estimated. Determining the rate of change of the
flux linkage from the integration results, the speed is
Many reviews of sensorless operation of AC drives determined [34]. A variation includes using the previous
have been seen in the literature [1,18,27,32,53]. Of position data and polynomial fitting, extrapolating to obtain
publications presently available in IEEEi and TEE conference the next step position prediction [21]. An advantage of the
proceedings and transactions, past sensorless techniques have flux-calculating method, as shown in [34] is that line-line
been grouped into 5 categories: voltages may be used in the calculations and thus no motor
neutral is required. Others, have combined the flux-
1 . those using measured currents, voltages, fundamental calculating method with advanced control strategies such as a
machine equations, and algebraic manipulations, state observer to compute the speed feedback signal [Z], an
2. those using observers, adaptive control [26], and H2 and H? controls [40].
3 . those using back-emf methods, The second sub-type was published primarily by one
4. sensorless starting techniques, and author, N. Matsui, in [17,20,39,45,70]. Using a d-q model of
5. those with novel techniques not falling into the previous the machine, the actual dq transformed currents and voltages,
four categories. and those on a hypothetical axis offset from the dq axis by a
small angle Ae, the output voltages of the model, on the
2.1. Methods Using Measrirahles arid Math hypothetical axis, and those on the actual dq axis were
compared. The differences between the calculated voltages of
The first type above consists of three sub-types, 1. the hypothetical axis considering A9 = 0, and the actual dq
those using the voltages and currents to calculate flux axis voltages on the hypothetical axis,
linkages, 2. those using the difference between a model’s
prediction of a voltage or current and the actual value, and 3. AV= Vdq - VhYpoh&al-dq = KEesin(A6).
those using the machine equations, measurables, known yielded 88, the actual change in rotor position from the
machine parameters, and algebraic manipulations to calculate
previously known position. as with AI3 = 0, A8 = AV.
position and speed. The first sub-type is seen in The third sub-type uses machine parameters and
equations, measurables, and algebra, reference frame theory

0-7803-5589-W99/$10.00 0 1999 IEEE 143


and transformations to calculate position and speed [25]. as would be the actually measured variables as used in a
Initially the measured voltages and currents are transformed to closed-loop system control. Specific rules apply for the
rotor and stator d-q reference frames. Relations between various types of observers. The interested reader is referred
stator and rotor reference frames, denoted with superscripts s to [73]. An example of a single output observer, from [73], is
and r, respectively, are as follows:
Consider the discrete-time state-space form of a single-output
system,

x[k + I]= Ax[k] + B u l k ]


y [kl = C x[ k] + D u[k]
ii = ii sine, - ii coser
which must be completely observable [73].
These relations allow the substitution of stator reference frame Next, a modal matrix must be determined for the system. A
quantities in the rotor reference frame voltage equations. good reference to obtain the knowledge of this procedure is
Once the substitutions are made and the equations relating
[74]. Using the modal matrix, P, the system is transformed
rotor and stator reference frames are totally in terms of stator into an observable form:
variables, in the stator frame, abc frame equivalents are
substituted in these equations, which are then manipulated to
yield rotor angle. Knowing that the machine is non-salient, x[k]= F'x'[k]= Q-lx'[k] ~

the equivalent rotor flux, and manipulating the same x'[k] = P-'x[k] = Qx[k]
equations, the rotor speed is also determined. The final
equations for position and speed are as follows:
x'[k + 11= A'x'[k] + B'u[k]

1
d . y[k]=ctTx'[k]+DTu[k]
v b - v y c - R ( i b -i,)-Ld .-(th - i C ) - & m ( L q - L d ) i ,
Br = ta,,i' dt
- Ria - Ld -dld- i., ) + a ( L q - I d ) ( & -ic)
where
A'=QAQ-'
B = QB
c' T = cT Q -1
Next, the full-order observer is designed using the designers
choice of eigenvalues. The eigenvalues are usually chosen to
as defined in [ZO]. Variations of this are found in
[20,23,3 1,42,43]. be slightly faster (of a larger negative value) than those of the
actual system so the state estimate error approaches zero as
time approaches infinity. If the observer eigenvalues are
2.2. Methods Using Ohsmws
chosen to be an order of magnitude larger, or more, than the
actual system's, then the estimated values will converge to the
The second type listed above determine rotor actual values within a sufficiently short time [24]. The
position and/or speed using observers. The Kalman filter is observer takes the form
used as a position estimator in [12,13,14,28,46,50]. One of
the earliest of these was by M. Schroedl in 1988. Utilizing c'[k + I] = F'<'[k]+g'y[k]+Hu[k]
various methods of measuring system voltages and currents
where
rough estimates of the angular rotor position were produced.
Kalman filtering added refinement to the first estimates of F1=A'-g'cCT
position and speed. For additional information on Kalman H'= B-g'dT
filtering see [73], and those papers listed. Other observer-
based systems include those using non-linear [29.36,41]. full- with the observer output equation
order [2,33,38], disturbance [ 1,5,39], reduced-order [24,41].
and sliding-mode observers [3,16,47,48]. Observer theory w[k] = Pc[k] = Q-'Y,[k]
can be found in many texts and papers. The fundamental idea
of the basic full-order state observer was developed by David which allows the transformations
Luenberger of Stanford University in 1964 [73]. Observers
take as inputs the outputs and inputs of the actual system.
Typically, the state of the system is produced as the output.
The observer-produced state is then fed back into the system

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trapezoidal BLDC), X consists of the d-q transformed stator
currents, speed, and position, i.e. [id , 4 , 0,8 1, or just the
currents, as previously stated. The state observer takes the
same form with the addition of a term containing the sign of
which gives the estimation errors:

<[k + 11 = FC[k]+gy[k]+ Hu[k] X = f ( k , u ) - K .sgn(s),


where
g=Q-'d where
F=Q- IFQ=Q- 1R Q - Q - ~ ~ ~ T Q = A - & the hat symbol denotes estimated values,
K is the variable gain matrix,
H=Q+= Q-'B&dT =B-gT

which is a full-order observer in x[k], meaning that <[k]


converges to x[k].
Disturbance observers implemented in the cited
papers, were reduced-order observers used with system states S is the vector of state estimation errors, i.e.
which were assumed quasi-static (fast sampling and
calculating times). The slight variations of the state variables [ i ,-x1,?* - x 2 ; . . , i n -Xn]T.

from one sampling to the next is termed a disturbance, which n is the observer order, and
results in observations of small changes in rotor position the superscript T denotes a transpose operation. In
angles. Reduced-order observers depend on some of the order for the observer to operate in the sliding-mode, the
system outputs being linear transforhiations of the system following condition must be met:
states. By coupling some of the system states to the output of
the observers through linear transformations (or actual I d
--s T s<o
measurements if the states are readily available for
2 dt
measurement), only the states of interest need be estimated by
the lower-order observer. This reduces the computational Defining X - X = e, where e is the state estimation error, the
burden of the observer [41]. In [1,5,24], reduced-order general error model and dynamics are described by
observers estimate the back-emfwhich is used to obtain rotor L = f'(e,U)+K.sgn(e)
position and speed. In [41], the rotor position and speed are
where
estimated, as the outputs of a non-linear reduced-order
f ' is the system representing the difference
observer. Sliding-mode observers, offspring of sliding-mode
control, utilize a valying switching function in order to confme f ( k , L J - f ( X , U ) , and disturbances due to parameter
the state estimation error to move toward zero on a phase- variations have been neglected. Now, in order for
plane sliding surface [3]. In [16] and [47], the sliding-mode convergence, K must be continuously selected to insure that
observers were based on the observation of d-q transformed e T e < O , a s -I- Sd T S = e T e
stator currents. From the resulting current estimations, the 2 dt
back-emfs were estimated, producing speed and position
estimates. In [48], the full-order system model was utilized 2.3. Methods Usiiig Back-Emf Sensing
and a reduced-order sliding-mode observer designed. In [3], a
full-order sliding-mode observer was described, and 2.3.1. Terminal Voltage Sensing
modifications were made in order to overcome chattering
problems, inherent in sliding-mode systems. In general, the
In field-oriented operation of the BLDC, phase hack-
sliding mode system starts with the state-space system
emf is aligned with phase current. Switching instants of the
[3,16,47,48]
converter can be obtained by knowing the zero-crossing of the
back-emf and a speed-dependent period of time delay [75].
x = f(X,U), The BLDC motor has a trapezoidal flux density distribution in
Y=cx the air-gap, and thus the induced back-emf in the stator
windings is trapezoidal. Monitoring the phase hack-emf when
where the usual definitions are made. In BLDC systems the particular phase current is zero (the silent phase), the zero
(usually considering the PMSM or the fundamental of the crossing is detected. Low pass filters are used to eliminate

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higher harmonics in the terminal voltages. The zero-crossing The summed terminal voltages contains only the third and the
instants are decoded and appropriately time-shifted to produce multiples of the third harmonic due to the fact that only zero
switching patterns. sequence current components can flow through the motor
Since back-emf is zero at rest and proportional to neutral. This voltage is dominated by the third harmonic,
speed, the terminal voltage sensing method is not possible at which does not necessitate much filtering. To obtain
low speeds. As the speed increases, the average terminal switching instants, the filtered voltage signal which provides
voltage increases, and the frequency of excitation increases. the third harmonic voltage component is integrated to find the
Capacitive reactance in the filters varies with the frequency of third harmonic flux linkage.
excitation, introducing a speed-dependent delay in switching
instants, which disturbs current alignment with the back-emf h r 3 = jv3dt
and field orientation thus, causes problems at higher speeds.
With this method, a reduced speed operating range is normally The third harmonic flux linkage lags the third harmonic of the
used, typically around 1000-6000 rpm. phase hack-emf voltages by 30 degree. The zero crossings of
Another method which similarly has a narrow speed the third harmonic of the flux linkage corresponds to the
range is a method using phase-locked loop circuitry. The commutation instants of the BLDC motor. To acquire correct
phase-locked loop has a narrow speed range due to the commutation instants, sensing the positive or negative going
capabilities of the phase detector, and is sensitive to switching zero-crossing of the back-emf is essential
noise. This method, provides gating signals much like hall- The third harmonic method provides a wider speed
effect sensor outputs by using a phase-locked loop circuit range (100-6000 rpm) than the zero-crossing method, does
which locks onto the back emf of the inactive phase during not introduce as much phase delay as the zero-crossing
every 60' period. method and requires less filtering.

2.3.2. Third Harmonic Back-emf Sensing 2.3.3. Freewheeling Diode Conduction

The third harmonic of the back-emf can be used in This method uses indirect sensing of the zero-
determination of the switching instants in the wye connected crossing of the phase back-emf to obtain the switching
120 degree current conduction operating mode of the BLDC instants of the BLDC motor [6S]. In the 120 degree
mo:or [37]. This method is not as sensitive to phase delay as conducting wye-connected BLDC motor, one of the phases is
the zero-crossing method, as the frequency to be filtered is always open-circuited. For a short period after opening the
three times as high. The reactance of the filter capacitor in phase, there remains phase current flowing, via a free-
this case dominates the phase angle output of the filter more wheeling diode. This open phase current becomes zero in the
so than with the lower frequency. On the other hand, greater middle of the commutation interval, which corresponds to the
than 213 stator winding pole pitch is required. Provided that point where back-emf of the open phase crosses zero. The
this condition is satisfied, the third harmonic of the rotor flux biggest downfall of this method is the requirement of six
can link the stator winding and induces a third harmonic additional isolated power supplies for the comparator circuitry
voltage component which can be detected between the motor for each free-wheeling diode.
neutral and the negative inverter bus terminal. By this technique, 45-2300 rpm sensorless operation
The terminal voltage equation of the BLDC motor has been achieved. This technique outperforms the previously
for phase a can be expressed as mentioned back-emf methods at low-speeds.

2.3.4. Back-emf Integration

In this method position information is extracted by


Back-emf voltage, ea, is comprised ofmany voltage harmonic integrating the back-emf ofthe unexcited phase [30.52.66,69].
components, The integration is based on the absolute value of the open
phase's back-emf. Integration ofthe back-emf starts when the
e, =E(cosoet+k~cos3w,t+kgcosSw,t+k-jcos7wet+ ...) open phase's back-emf crosses zero. A threshold is set to stop
The third harmonic of the terminal voltages is acquired by the the integration which corresponds to a commutation instant.
summation of the terminal voltages. As the back-emf is assumed to vary linearly from positive to
negative (trapezoidal back-emf assumed), and this linear slope
Vas+Vbs+Vcs =3Ek3CoS3w,t+vhighfreq. is assumed speed-insensitive, the threshold voltage is kept
constant throughout the speed range. If desired. current
V 3 + Vhq$ freq. advance can be implemented by changing the threshold. Once
the integrated value reaches the threshold voltage, a reset

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signal is asserted to zero the integrator output. To prevent 2.4.3. Interrogation Techniques for Starting
the integrator from starting to integrate again, the reset signal
is kept on long enough to insure that the integrator does not Machine interrogation techniques [7,8,35,70] offer
start until the residual current in the open phase has passed a an excellent solution for drives where absolute position
zero-crossing. This type of control algorithm has been information is needed at startup. In these techniques, initial
implemented commercially. The integration approach is less rotational direction is controlled. Saliency of the interrogated
sensitive to switching noise, automatically adjusts to speed machine enhances the ability to detect rotor position. Usually
changes, hut the low speed operation is poor. With this type voltage pulses are imposed on the machine terminals while
of sensorless operation scheme, up to 3600 rpm has been monitoring the current peak or level after a time duration from
reported [69]. the start of the pulse, often a period approximately equa! to
the electrical time constant of the windings. The flux of the
2.1.Starling Techniques permanent magnet, either aids or opposes the flux due to the
pulse and the current level indicates their interaction.
To operate a BLDC without a rotor position sensor, Possibilities include using the sign of the difference in the
requires some method of starting the motor. Published current levels providing a sign vector which is compared to
startup methods have belonged to one of five general types: 1 values in a lookup table to obtain position information
open-loop, 2. with known initial position, 3 using a machine [7,8,32]. Alternatively, interrogation of the phase
interrogation and sibqal processing, 4. using computationally combinations with a salient machine using short (non-
complex methods, and 5. those relying on a winding saturating) and long (saturating) pulses has been reported
inductance which varies with rotor position due to saliency. [35,70].

2.4.1. Open-loop Starting 2.4.4. Control System Techniques for Starting

Open-loop [29,65,69] starting the motor is In [28], ti Kalman filter estimates rotor position from
accomplished by providing a rotating stator field which measured voltages and currents. The machine equations of
increases gradually in magnitude and/or frequency. Once the non-sinusoidal waveforms are in a d-q stator reference frame.
rotor field begins to become attracted to the stator field At zero-speed the voltages and currents are zero and alone the
enough to overcome friction and inertia, the rotor begins to Kalman filter cannot provide rotor position information. By
turn and the motor acts as a permanent magnet synchronous injecting a d-axis current this condition is overcome and
machine. This type of system may be satisfactory in certain position information at standstill is obtained.
applications, i.e. pump and fan drives. The disadvantage of
this method is that the initial rotor movement direction is not 2.4.5. Starting Using Machine Inductance Saliency
predictable. When the stator field becomes just strong
enough, the rotor could move in either direction. If then the
Saliency in permanent magnet machines is usually
speed of the stator field is slow enough, and the load torque
present due to the use of interior permanent magnet (PM)
demanded does not exceed the pull-out torque, the motor will machine design. The interior PM allows a shorter air gap
operate synchronously in the desired direction. Initial
which increases the flux intensity on the stator due to the
direction in certain applications such as disk drives strictly
rotor. A thin bridge which usually separates the magnet from
require unidirectional motion, and thus this method is the gap is often saturated during normal operation, increasing
inadequate. Another problem exists if the stator field is
the reluctance of the radial area where the magnets ( CI = 1 )
rotating at too great a speed when the rotor field picks up.
already exist, This allows a varying inductance profile for the
This causes the rotor to oscillate, requiring the stator field to
motor which depends on rotor position. Sensorless
decrease in frequency to allow starting.
operations utilizing the relationships between voltage pulses,
current amplitudes, rate of current rises, etc. have often been
2.4.2. Starting Methods Using a Known Initial Position
used in switched reluctance and synchronous reluctance motor
drives [54-691 where saliency is inherent, and are applicable in
Methods which require a known position interior PM BLDC drives as well.
[1,48,64,72] to start the motor suffer from an additional
constraint, e.g. a detent in which the rotor always freely stops. 2.4.6. 1.C.s for Sensorless BLDC Control
or a stopping circuit (and initial positioning) which always
provides an initial position for the next movement. A simple
In the past there have been several integrated circuits
way of setting an initial position is to excite one phase to which enabled sensorless operation of the BLDC. These
cause the rotor to shift and lock into position. included Unitrode's UC3646, Microlinear's ML4425, and

147
Silicon Systems, Inc. 32M595. Each of these used back-emf eddy currents to flow (in the aluminum). The flow of eddy
methods and open-loop starting. currents in the aluminum acted to increase the reluctance of
the magnetic circuits creating saliency.
2.5. Unique Sensore'* Techniques Two papers describe sensorless methods which rely
on irregularities in the measurahles [54,67]. These methods
The following sensorless methods are unique. These utilize small deviations, or inherent properties of the shapes of
range from artificial intelligence methods to variations in the the current waveforms to obtain position information or
machine structure. There are few which fall into this class, and enable a control which tends to provide a phase current /
therefore each is briefly discussed phase back-emf alignment. The method in [67] considers the
A hackpropagation neural network (BPN) was shape of the D.C. bus current. The authors show that the
trained to provide a non-linear mapping between measured shape of the D.C. bus current varies depending on the
voltages and currents, and rotor position [6]. This rotor alignment of the phase current and phase back-emf A clear
position was then used with the equations of section 2.1. to difference in the distortion patterns is seen between a leading,
calculate the flux linkage vector. This vector was compared aligned, and lagging operation. The method of control is to
to the estimated flux linkage vector using the equations of count the number of samples on a consecutive rising and
section 2.3.1. and the measured voltages and currents. The falling half-cycle of the 6-pulse D.C. current ripple. When
difference was used as the error which was backpropagated to these are equal, the machine is operating at unity internal
modify the BPN weights. An initial flux linkage vector (initial power factor. When unaligned, the difference in the rising and
rotor position) was required to he known a priori. falling counts is used as a multiplier in the D.C. link voltage
A paper using fuzzy logic [ 8 5 ] , proposed two fuzzy incremental update. The machine is operated a; a
logic sub-systems. Using the conventional equations synchronous machine with this control effort to maintain
consisting of phase voltages and currents, the rotor position phase current / back-emfalignment.
was calculated. With the knowledge of the relationships The second method, in [54], works on the principle
between these measurahles and the rotor position, a fuzzy of machine saliency. In this paper, the crest of the current
Mamdami type system was developed to produce rotor waveform, which is controlled by hysteresis chopping, is the
position estimates. It was noted that this could as easily been medium of rotor position information gathering. The
accomplished with look-up tables, however, for the desired elementary equations of the rise and fall of current in the
resolution the size of the lookup tables becomes hysteresis waveform were examined. In these equations, it is
unmanageahly large. The second fuzzy system used took as easily seen that there is a dependency on the instantaneous
input the estimated rotor position and produced reference inductance, as well as other machine parameters. Utilizing a
current values for two different drive strategies: unity power fast sampling and these equations, while considering the other
factor, and maximum torque per amp. machine and drive parameters constant, and with measured
In [15], a sensorless method was developed using the current and voltages, the instantaneous inductance, and thus
calculation of flux linkage by integrating the back-emf The position is determined. This is possible only if the machine
motor was at the end of a 10 km cable. A difficulty in this has inductance saliency.
sensorless method was that the hack-emf had high-frequency
oscillations superimposed on the voltage waveforms at points 3. Conclusion
of current commutations. This was overcome by integrating
the back-emf over the whole 60' silent phase period which A review of prior work in rotor position sensorless
produced pulses with amplitudes proportional to the speed methods for brushless D.C. has been presented. The basis of
and at positions where the peak of the pulses was 30" prior to these techniques has been presented in an effort to provide a
a commutation instant. reference for utilizing these methods. A new method of
Solutions to sensorless operation of BLDC by means sensorless operation which builds on those presented is
of alterations in machine design were shown in [68,71]. In revealed in another paper in these proceedings,
[68], an additional stator lamination with equally spaced slots
around the periphery was added to the machine. Each of the Acknowledgments
equally spaced slots contained a small sensing coil. The local
magnetic circuit variations for each of the sensing coils is The support of Texas Higher Education Coordinating
effected by the permanent magnet rotor's position. A 20 kHz Board Advanced Technology Program, TRW Electronic Controlled
signal was injected through the coils, and the signal distortions Steering, Bodine Electric Company, General Motors Research
were analyzed at the terminals of the sensing coils. The Laboratories, and Texas Insments Digital Control Systems
Division, for this research is gratefully acknowledged.
second harmonic detected provided position information. h
artificial saliency was created in [71], by attaching small pieces
of aluminum to the surface of the permanent magnets allowing

148
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