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Closed loop speed control of a BLDC Motor drive prototype using position
sensor.
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Abstract—This paper presents steps and procedures of de- motors (rectangular waveforms)[3] is carried out using current
signing a closed loop speed controller for a surface mounted controlled voltage source inverter(VSI). Pulse Width mod-
permanent magnet(SM-PM) brush-less DC machine(BLDC). The ulation(PWM), hysteresis and predictive current controllers
closed- loop speed control technique has been implemented using ([2],[8]-[11]) are used to generate the switching signals to the
Hall-effect position sensor. The BLDC motor control algorithm
has been modelled and simulated first. The same has been devices of the inverter to keep winding currents close to the
thereafter practically implemented on a 0.75 hp, 1500 r.p.m set reference/command currents. Speed control is generally
BLDC motor that was designed and developed as a lab prototype. achieved by using a speed feedback and generating speed
Both the simulation and the experimental results are in excellent command through speed controller which outputs a command
in agreements. signal for torque controller. Position control is implemented
Index Terms—Permanent magnet, Brush-less DC motor,
Closed loop speed control, position sensor, Hysteresis current through position feedback and position command using po-
control, Simulation results, Experiments on BLDC motor. sition controller. The output of the position controller[2]
provides the speed command for the inner speed loop.
I. I NTRODUCTION In this paper, a speed control technique of BLDC motor
Brush-less DC Motor(BLDC)[1] is emerging as an attractive has been designed, analysed and finally implemented on a
alternative to induction motors(IM) in different variable speed laboratory developed 0.75hp BLDC motor prototype. The
drive applications for reasons which are well known - the speed control technique presented here is valid for 4-quadrant
most important ones being high energy density and absence VSD applications ([2], [3]), though implementation has been
of brushed contacts. The use of permanent magnets (PMs) done here for 2-quadrants (i.e. forward motoring and forward
in electrical machines in place of electromagnetic excitation braking) only.
results in many advantages such as elimination of excitation
II. BASICS OF BLDC MOTOR SPEED CONTROL
losses, improved efficiency, fast dynamic performance, lower
maintenance, higher speed ranges and high torque or power A. Modelling of a BLDC motor
density([1], [2], [4]). The BLDC motor can be viewed as a permanent magnet AC
Unlike a brushed DC motor, the commutation of a (PMAC) motor with trapezoidal back emf. The motor is oper-
BLDC motor is controlled electronically in an appropriate ated with 1200 rectangular current pulses(2 phase conducting
sequence[1]. The rotor position may be also sensed by us- at a time), such that its operating characteristics (torque-speed
ing Hall-effect sensors mounted on the stator[2], resolvers, characteristics) are similar to that of a DC shunt motor. To
inductive modular absolute system(IMAS), shaft-mounted in- turn-on and turn-off the switches of the inverter/converter
cremental encoders [3] etc. (shown in Fig.1) in synchronism with the rotor position and
BLDC motors are used for position , speed and torque at the rotational frequency of the rotor, a position sensor is
control[2], [3] for variable speed drive in motion control required to feedback the rotor position signal. The stator (3-
applications. For speed control applications, an outer position phase) windings are placed in slots within 60o e phase belts.
control loop is not required and the set speed serves as Fig.2 shows the ideal phase back-emf pattern and the
the command signal. Torque control is incorporated in high corresponding the phase current wave-shape. It also shows the
performance motion control through closed -loop regulation of converter switching sequences required to achieve the desired
phase currents in synchronization with rotor rotation through current and hence mmf wave-shape for each phase of a BLDC
shaft position feedback. In majority of the BLDC motors, motor.
torque is linearly related to currents and torque command The dynamic machine model ([2], [5]) of BLDC motor can
maps onto current commands through a simple proportionality be described by (1), (2), (3) and (4).
constant. Current regulation in the phase windings of BLDC
⎛ ⎞ ⎛ ⎞⎛ ⎞ ⎛ ⎞⎛ ⎞ ⎛ ⎞
van Rs 0 0 ia L Lm L ia ea
⎝ vbn ⎠ = ⎝ 0 Rs 0 ⎠⎝ ib ⎠ + p⎝ Lm L Lm ⎠⎝ ib ⎠ + ⎝ eb ⎠ (1)
vcn 0 0 Rs ic Lm Lm L ic ec
⎞ ⎛
⎛ ⎞⎛ ⎞ ⎛ ⎞⎛ ⎞ ⎛ ⎞
ia 1 0 0 van Rs 0 0 ia ea
(L − Lm )p⎝ ib ⎠ = ⎝ 0 1 0 ⎠⎝ vbn ⎠ − ⎝ 0 Rs 0 ⎠⎝ ib ⎠ − ⎝ eb ⎠ (2)
ic 0 0 1 vcn 0 0 Rs ic ec
167
Fig. 3. Schematic of closed loop speed control of BLDC motor
Fig. 4. Block diagram of the inner current loop with the BLDC motor model
168
Fig. 6. Simplified model of speed control loop Fig. 7. Position sensor waveforms H1 , H2 and H2 accordingly at 25Hz.
2.33×10−3
TABLE I V/r.p.m. and the transfer function is Hw (s)= 1+0.0165S .
0.75 HP BLDC: PARAMETER DETAILS
The transfer function of the speed loop PI-controller is tuned
−3
Parameter Values through trial and error as (Kp + Ksi ) = (0.061+ 3.052×10
s )=
s
Rs /ph (Ω) 7.4 1+
0.061( 2π × 7.95mHz. ) whose corner frequency is
Ld (mH) 43.75 s
Lq (mH) 43.75 2π × 7.95mHz.
leakage Ll /ph (mH) 16.8 7.95mHz and the gain is chosen 0.061 using phase margin
EMF constant Ke 245 and gain margin (via Bode plots) method. So, the total loop
l−l /1000rpm) gain of the speed-control loop (Fig.4) is given by T(s)=
(E −3
169
Fig. 10. Simulated waveforms of motor speed ωm (blue) and line current
IA (green)
The closed loop control scheme of BLDC motor has been IV. C ONCLUSIONS
tested at 560W load at 1500 rpm. A 0.5 hp, 1500 rpm In this paper the design of a closed loop speed controller for
separately exited DC generator has been mechanically coupled BLDC motor has been presented. Torque rippler eduction has
with the BLDC motor for loading . The closed loop control been achieved both through motor design (earlier [6],[7]) and
algorithm has been simulated first and then implemented on then through closed loop control strategy. The BLDC machine
the the above mentioned system. has been modelled first and then simulated with closed loop
Fig.9(a)shows waveforms motor of the line to line induced speed control algorithm. An appropriate speed control strategy
emf eAB and corresponding phase emf eA in the generating has also been implemented on a 0.75hp, 1500 r.p.m, 400V
mode at 850 rpm while Fig.9(b) shows line to line induced (DC-link) surface mounted BLDC motor in FPGA platform.
emf eAB and position hall sensor pulses H1 of corresponding A 0.5 DC shunt generator coupled with the BLDC motor has
170
Fig. 13. Experimental waveforms of Position sensor output( H1(upper) and
(a) Simulated waveforms of 4 pole BLDC at 1045 rpm line current Iph (lower) at 1200 rpm with 75/[Ch1: Y axis-5V/div; Ch2: Y
with 2A max. current level. axis-100mV/div, current probe gain-10A/V; X axis-5ms/div]
TABLE II [3] Bose B.K., Modern power Electronics and a.c. drives., Pearson Educa-
R EDUCTION OF TORQUE RIPPLE ( RATED TORQUE =3.35 N- M ) tion 2002.
[4] Hendershort J. R. and Miller T. J. E. , Design of Brushless Permanent-
Category Torque Steps Procedure Magnet Motors, Clarendon Press, Oxford, 1994.
[5] O’Kelly D. and Simmons S., ”Generalized Electrical Machine Theory”,
ripple(%) McGRAW HILL, 1968.
From 15 without Rotor skew [6] Mukherjee P., Sengupta M. “Design, Analysis and Fabrication of a
design for cogging torque Brush-less DC Motor”,IEEE conference , PEDES-2014, IIT Bombay.
[7] Mukherjee P., Sengupta M.“Fabrication, Parameter Evaluation and
end 10 with reduction Testing of a surface mounted -Brush-less DC Motor.”, NPEC-2015, IIT
From 20 open loop Current hysteresis Bombay.
Control control with square [8] Tae-Hyung Kim, Hyung-Woo Lee and Mehrdad Ehsani, ”State of the Art
and Future Trends in Position Sensorless Brushless DC Motor/Generator
end 10 closed loop wave current Drives” ,IEEE conference, 2005.
[9] Senjyu T. and Uezato K., ” Adjustable Speed Control of Brush less DC
Motors without Position and Speed Sensors ”, IEEE/IAS Conf. Proc.
been used as loading purpose. The simulated and experimental on Industrial Automation and Control: Emerging Technologies, pp. 160-
164, 1995.
results are presented and the they are found to be in excellent [10] Iizuka K., Uzuhashi H., and Kano M., “Microcomputer control for
mutual agreement. sensorless brushless motor”, IEEE Trans. Ind. Applicat., vol. IA-27,
pp. 595-601, May/June 1985.
V. ACKNOWLEDGEMENTS [11] Ogasawara S. and Akagi H., “An approach to position sensorless drive
for brushless DC motors”, IEEE Trans. Ind. Applicat., vol. 27, pp. 928-
The authors wish to thank the staff of M/S GE motors Pvt. 933, Sept./Oct. 1991.
Ltd, Sheoraphuli and Mr. Kousik Pyne, in particular, for the [12] Jahns T. M., Becerra R. C., and Ehsani M., “Integrated current regula-
tion for a brushless ECM drive”, IEEE Trans. Power Electron., vol. 6,
manufacturing support received in fabricating the BLDC mo- pp. 118-126, Jan. 1991.
tor. The authors also acknowledge the support received from [13] Soong W.L. , Miller T.J.E., “Field -weakening performance of brushless
the DeitY,GoI and the research colleagues at the Advanced synchronous AC motor drives”, IEEE Proc-Electr.Power Appl,. vol. 141,
No-6, Nov. 1994.
Power Electronics Laboratory, Dept. of EE, IIEST, Shibpur [14] Adnanes A.K., , Undeland. T.M. , “Optimum torque performance in
towards this work. PMSM Drives above rated speed”, Proc. of IEEE Industry Applications
Society annual meeting. Oct 1991, pp 169-175.
R EFERENCES [15] Morimoto.S., Takeda Y., Hirasa T., Taniguchi K., “Expansion of oper-
ation limits for operating limits for parmanet magnet motor by current
[1] Venkataratnam K., Special Electrical Machine,University Press, 2008.
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[2] Krishnan R., Permanent Magnet Synchronous And Dc Motor Drives,Crc
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