Modern Electrical Drives | BEKE 4763

Session: 2022/2023-1
Project : Development of Electronic Speed Controller (ESC) for Brushless DC Motors
Figure 1 shows a three-phase inverter with a gate driver circuit, i.e. (a) PCB photo and (b)
schematic diagram. The inverter circuit consists of 6 power MOSFETs and their switching
operations are driven by their respective gate-source voltages produced from the gate driver
circuit as well as six switching states, i.e. 𝑠1 , 𝑠2 , … and 𝑠6 , produced from a logic control
circuit. The gate driver circuit implements three bootstrap/half bridge driver ICs (Part no.
UCC27710D) and the ICs require an input voltage of +12 V.

(a)

(b)
Figure 1 : Three-phase inverter circuit with gate driver circuit.
Task 1
You are required to design a Printed Circuit Board (PCB) for (a) remote control and (b) logic
control circuits. These circuits are used for adjusting the speed of Brushless DC motor using
PWM technique. Specifically, the design of the circuits must meet the following specifications:

1) Remote Control Circuit

• it requires a single input/supply voltage, Vcc = 5 V or 9 V (supplied by DC voltage
supply or 9 V battery),
• it consists of a generation of PWM signal circuit and a radio frequency transmitter,
• the PWM signal is generated from analogue electronic circuit, e.g. 555 timer IC or
other PWM ICs,
• the frequency of PWM is set to be around 3 kHz,
• the duty cycle of PWM can be varied from 0 to 1.0 using variable resistor (for
adjusting the motor speed),
• the size of the board is 80 mm x 45 mm.
Figure 2 shows the suggested PCB design of remote control circuit, in terms of
arrangement and use of components (a) PCB photo and (b) schematic diagram.

45 mm

(a)
 (b)

Figure 2 : Remote Control (a) PCB photo (b) schematic diagram.

2) Logic Control Circuit
• the circuit board has an input voltage of 12 V. A linear voltage regulator is required
to produce +5V from the input of +12 V. The production of +5 V is required for
supplying voltage to hall sensor of BLDC motor and all logic gate ICs, i.e. NOT
and AND gate ICs. These logic gate ICs are used to implement the logic control of
BLDC motor,
• it rotates the rotor of the motor in clockwise direction,
• it has a 5-pin terminal connection for hall sensor of BLDC motor, i.e. + 5V, GND,
Ha, Hb and Hc,
• it receives a PWM signal generated from remote control via radio frequency
receiver. This signal is used to modify switching states for driving top switches of
the inverter and hence adjust the motor speed,
• the size of the board is 80 mm x 45 mm.
Figures 3 and 4 show the suggested PCB design of logic control circuit, in terms of
arrangement and use of components and schematic diagram, respectively.
 (a)
45 mm

80 mm
(b)

Figure 3 : PCB of logic control circuit (a) 3D view (b) 2D view.

 (refer to datasheet)
Complete the connection

Figure 4 : Schematic diagram of logic control.

Task 2
Completely,
• solder all components/ICs on the PCBs of remote control and logic control circuits.
• connect the BLDC motor and all circuits, i.e. remote control, logic control and three-
phase inverter circuits.

Test the functionality of the circuits,

• adjust the motor speed by adjusting the duty cycle of PWM using the variable resistor,
• observe the direction of rotation and the motor speed, while adjusting the duty cycle,
• record and analyse the experiment results. Use oscilloscope to obtain the experiment
results.

Task 3
Prepare a report not more than 10 pages. The discussion in your report must include the
following sections:
i. Abstract (not more than 150 words)
ii. Specifications of the circuit design
iii. Principle of operation
iv. Photo of PCB design and experimental setup
v. Analysis of some experiment results.
vi. Conclusion
Appendix
List of components
A. Logic Control circuit
Item Quantity Order code/website address
Capacitor, 1206, 0.1 uF,
3228220 (E14)
1 TCC1206X7R104K101FT 6
Resistor, 1206, 1 k,
3226892 (E14)
2 SCR1206FR180 6
NOT Gate, https://www.ti.com/product/SN74LVC1G04
3 SN74LVC1G04DBVRG4, SOT-23 3 /part-details/SN74LVC1G04DBVR
AND GATE, MC74ACT08DG,
2534679 (E14)
4 SOIC14 3
https://www.ti.com/product/SN74LS07/par
Buffer/driver, SN74LS07DR, t-details/SN74LS07D?keyMatch=SN74LS07D
5 SOIC14 1 3119534/303-6276
SMD, 0.33 µF, 50 V, CAP-
2466392 (E14)
6 SMD_BD4.0 / 4SEV33M4X5.5 1
SMD, 1 uF, or 100 nF, 50 V, CAP-
838-7847 (RS)
7 SMD_BD4.0 / 4SEV33M4X5.5 1
8 Linear Voltage Regulator,
1087086 (E14)
L7805ACV, TO-220-3 1
PCB standoff Female M3x6mm 4 Ali Express
Pin header, 2.54, 1 row, 5 pin,
Ali Express
C2504WV-5P 1
Pin header, 2.54, 1 row, 2 pin,
Ali Express
C2504WV-2P 2
Pin header, 2.54, 1 row, 8 pin,
Ali Express
A2543WV-8P 1
Note: Bolded text can be used for searching suitable component footprints.

B. Three-phase inverter and gate driver circuit

Item
half bridge gate driver,
1 UCC27710D
Power MOSFET, N Channel, 55 V,
42 A, 0.011 ohm, TO-252AA,
2 Surface Mount
3 Small signal diode, 1N4148W-7-F
4 SMD, 220 µF, 50 V
5 Capacitor, 1206,2.2 uF
6 Capacitor, 1206, 10 uF
7 Resistor, 1206, 100 R
8 PCB standoff Female M3x6mm
9 Pin header, 2.54, 1 row, 2 pin
10 Pin header, 2.54, 1 row, 8 pin
Quantity Order code/website address
https://www.ti.com/product/UCC27710/par
3 t-details/UCC27710D
2726015 (E14)
6
3 738-4728 (RS)
3 2472024 (E14)
3 3013529 (E14)
3 3013512 (E14)
6 3548903 (E14)
4 Ali Express
1 Ali Express
1 Ali Express