High-Precision Sensorless Drive For High-Speed BLDC Motors Based

This article has been accepted for publication in a future issue of this journal, but has not been
fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TPEL.2017.2688478, IEEE
Transactions on Power Electronics
High-precision Sensorless Drive for High-speed BLDC Motors based

on the Virtual 3rd harmonic back-EMF
Xinda Song, Bangcheng Han, Shiqiang Zheng, Jiancheng Fang
Abstract: In order to improve the performance of the according to the bearing [4, 5]. Meanwhile, the load power
high-speed brushless direct current (BLDC) motor of the motor developed for the blower type applications is
drives, a novel high-precision sensorless drive has been increasing with the motor speed [6]. Therefore, precise
developed. It is well known that, the inevitable voltage detecting of the rotor position for the sensorless drive
pulses, which are generated during the commutation scheme is essential to ensure the high efficiency and low
periods, will impact the rotor position detecting loss of the overall system, especially in the high-speed
accuracy, and further impact the performance of the range.
overall sensorless drive, especially in the higher speed It is well known that, for the operation of the inverter in
range or under the heavier load conditions. For this BLDC control system, six discrete rotor position signals in
reason, the active compensation method based on the one rotating cycle are required. Conventionally, the rotor
virtual 3rd harmonic back-EMF (the back position detecting methods can be classified into two
electromotive force) incorporating the SFF-SOGI-PLL categories: the mechanical position sensor-based methods
(synchronic-frequency filter incorporating the and the sensorless methods. The typical sensors include
second-order generalized integrator based the resolver [7], the encoder [8] and the Hall-effect sensor
phase-locked loop) is proposed to precise detect the [9], which are traditionally used in the mechanical position
commutation points for sensorless drive. An sensor-based methods. However, these mechanical sensors
experimental driveline system used for testing the need special arrangements to be mounted as well as
electrical performance of the developed magnetically increasing the cost, which limits the application in the
suspended motor is built. The mathematical analysis high-speed motors. Hence, more and more researches are
and the comparable experimental results have been focused on the sensorless-based methods.
shown to validate the effectiveness of the proposed Numerous of sensorless-based methods have been
sensorless drive algorithm. reported in the pre-researches, which mainly contain the
back-EMFs based method, the 3rd harmonic based method,
Key words—sensorless drive, high-speed BLDC, the integration based method, the phase-locked loop (PLL)
virtual 3rd harmonic back-EMF, phase-locked loop based method, the flux linkage estimation based method
(PLL) and the other sensorless method. Among the sensorless
drive methods, the most popular category is the back-EMF
based method. The back-EMF sensorless method is firstly
I. INTRODUCTION proposed by Kenichi Iizuka through extracting the
back-EMF zero crossing points (ZCPs) of the terminal
In recent years, owning to the advantages of its
voltage [10]. On this basis, many sensorless methods
compactness, maintenance, high efficiency and low cost,
based on the terminal voltage have been developed, and
the brushless direct current (BLDC) motors are getting
obtained good performances in the certain applications
more and more attention in many areas like the blower and
[11-13]. However, since the back-EMF is very small when
compressor, especially in the high-speed applications [1-3].
the motor’s speed is nearly zero, the performance of the
Commonly, the speed of the high-speed motor could reach
sensorless method based on the terminal voltage
up tens of thousands revolutions per minute (r/min)
back-EMF is still not satisfied, especially in the
This work was supported by the Natural Science Foundation of China high-speed motor applications, which the phase resistance
under Grant 61573032 and 61421063, the Fundamental Research Funds and phase inductance are much small. The 3rd harmonic
for the Central Universities under Grant YWF-16-BJ-J-24, and the based methods provide a better solution, in which the
National Major Project for the Development and Application of
Scientific Instrument Equipment of China under Grant 2012YQ040235. commutation points can be extracted from the 3rd
X. Song, S. Zheng and J. Fang are with the School of Instrumentation harmonic of the back-EMF. In [14], Moreira, J.C. pointed
Science and Opto-electronics Engineering, Beihang University, Beijing that the 3rd harmonics of the back-EMF kept a constant
100191, China, X. Song and S. Zheng are with the Beijing Engineering phase relationship with the rotor flux for any motor speed
Research Center of High-Speed Magnetically Suspended Motor
Technology and Application, Beijing 100191, China (e-mail:
and load condition, and a sensorless commutation control
songxinda@buaa.edu.cn; zhengshiqiang@buaa.edu.cn); had been developed in a wide speed range. Francesco
fangjiancheng@buaa.edu.cn. Bonanno used the 3rd harmonic component of the stator
B. Han is the corresponding author and he is also with the School of voltage to estimate the air-gap flux and the torque in the
Instrumentation Science and Opto-electronics Engineering, Beihang
University, Beijing 100191, China, and also with the Beijing
DSC scheme for induction motor drive [15]. An
Engineering Research Center of High-Speed Magnetically Suspended application of 3rd harmonic back-EMF based sensorless
Motor Technology and Application, Beijing 100191, China (e-mail: rotor position estimation has been demonstrated to both
hanbangcheng@buaa.edu.cn). BLDC and BLAC motor in [16], and the proposed method
0885-8993 (c) 2016 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TPEL.2017.2688478, IEEE
is utilized in the flux-weakening mode successfully. In pulse due to the freewheel diode conduction is not
[17], J.M.Liu proposed a rotor position estimator based on discussed deeply. Another popular technical in high-speed
the continuous signal of the 3rd harmonic back-EMF for applications is the PLL-based method, which has the
PMSM (permanent magnet synchronous motor) sensorless advantages as simplicity, robustness and effectiveness. In
control system, and the proposed estimator achieved [27], Shen proposed a sensorless control method based on
accurate rotor position estimation and obtained the PLL and the 3rd harmonic back-EMF integration in an
outstanding dynamic performances. However, the ultrahigh-speed range. The commutation error is
applications of the methods mentioned above are usually significantly reduced by the proposed ASIC-based
in the low-speed motor applications. In addition, the large sensorless controller, whereas the neutral wire is needed to
noise interference limits its application. Another category obtain the 3rd harmonic back-EMF. As a conclusion, to
is the integration based sensorless method. The back-EMF the best of the authors, the proper sensorless control
integration method is used in [18] to extract the rotor method for the wide speed range BLDC motors has not
position by integrating the back-EMF of the unexcited been fully investigated in the previous researches, which
phase. In [19], a Kalman filter is used in a back-EMF meets the requirements of compensating the commutation
integration based sensorless method for reluctance error adaptively, does not need neutral wires, and
machines to smooth the noise. Nevertheless, an error operating in the high-speed range under various load
accumulation problem at low speed range impacts its condition simultaneously.
performance. Moreover, most of above methods need the The main contribution of this paper is that a novel
neutral wire in the sensorless control. However, the neutral high-precision sensorless drive method for BLDC motors
wire is usually not provided to most of the BLDC motors. is proposed. The proposed method can compensate the
In [20], based on the virtual neutral voltage, a sensorless commutation error adaptively in a wide operating range,
rotor position detecting method has been utilized. and does not need the neutral wire at the mean time. In
However, the performance in the high-speed range is not order to catch the accurate commutation points, an
mentioned. Cui proposed a hybrid sensorless drive method SOGI-PLL incorporating the virtual 3rd harmonic
for the high-speed BLDC motor based on the virtual back-EMF scheme is used in the proposed method.
neutral voltage in [21]. Although the proposed sensorless Meanwhile, a synchronic-frequency filter (SFF) is put up
method obtained satisfied performance in a wide speed as a pre-filter to improve the performance of SOGI-PLL.
range, the commutation error resulting from the freewheel Thus, the rest of this paper is organized as follow. In
diode conduction is not discussed. Section II, the control scheme of the high-speed BLDC
On the other hand, the commutation error is one of the motor drive system in the wide speed range is first briefly
most concerning problems in the BLDC motor dive system, introduced. Then, the traditional sensorless drive method
since it has drawbacks of the inaccurate hardware based on the virtual 3rd harmonic back-EMF is shown, as
parameters, different load conditions, and the variable well as the commutation error analysis. Section III
operating temperature, especially in the high-speed presents the main idea of the proposed high-precision
applications. As a result, many efforts have been done to sensorless drive based on the high-precision commutation
limit the commutation errors in the pre-researches. An points detection. The experimental setup is given in
error-compensation circuit is proposed to compensate the Section IV, and the experimental results are illustrated to
commutation error in [22]. But the high-speed validate the effectiveness of the proposed method.
performance is not mentioned. In [23], a fuzzy model Moreover, some important conclusions can be found in
based estimator for the error of the estimated position Section V.
angle and the closed-loop compensation method are
proposed, while the error of the estimated position angle is II. ORIGINAL SENSORLESS DRIVE METHOD OF
decreased to 2%. Yet the estimation algorithm is HIGH-SPEED BLDC MOTORS
complicated for the high-speed motor control scheme. A A. Control Scheme of high-speed BLDC motors
hysteresis comparator is applied to compensate the The typical applications of the high-speed BLDC motor
commutation error in [24]. However, the performance of contain the aeration blower for sewage treatment and the
the compensation method in high-speed range and under air compressor. The feature of the applications is that the
heavier load conditions are not mentioned, although the motor’s load is increased with the rotating speed. On
proposed method presents a good performance in a wider another hand, since the speed range of the high-speed
speed range. In [25], a straightforward method of the motor is always above tens of kr/min, the winding
commutation angle self-compensation based on the inductance and resistance of the high-speed motor are
dc-link current is utilized with a good performance in a always much lower than the traditional low-speed motors.
large speed range. Unfortunately, the mechanical Therefore, a hybrid control scheme is used in this paper,
hall-effect sensors are used in this research and the reliable which combing the PWM (Pulse-Width Modulation)
of the method is limited. In [26], a closed-loop technique and the PAM (Pulse-Amplitude Modulation)
compensation method based on the integration difference technique [29]. The PWM technique is applied in the start
of the virtual neutral voltage is proposed to compensate the stage and the low-speed range to overcome the large phase
commutation errors, and obtained satisfied performance in current. With the speed increasing, the back-EMF is
a wide speed range. However, the impact of the voltage gradually becoming higher. When the value of back-EMF
is large enough, which can counteract the dc-link voltage, In the 6-step inverter operation sequence, each stage
the PAM technique is adopted. Under the PAM control in contains two periods: the commutation period and the
the high-speed range, the 60 degree commutation control normal conduction period. Take the stage of the current
is used and the speed of the rotor is regulated by adjusting transfer from phase C to phase A for instance. During the
the dc-link voltage. The advantage of the hybrid control commutation period, VT2 is switched off and VT4 is
scheme combing PWM and PAM is that the scheme switched on. Because of the phase inductance, the current
guarantees the efficient operation of the high-speed BLDC of the excited phase (phase A) cannot be completed built
motor in the wide speed range. immediately. Then, simultaneously, VT3, VT4 and D5 are
conducted in the commutation period. At the same time,
the terminal-to-ground voltages can be expressed as uAG=0,
uBG=ud and uCG=ud. Combining (2), usp can be written as
usp =1/6ud. In the normal conduction period, only VT3 and
VT4 are conducted, leading to completely current
establishment of the excited phase (phase A). So, uAG=0,
uBG=ud and uCG=eC+uNG. Combining (2), usp can be
expressed as
1 e e 
Hall C
Hall A
Hall B
usp   eC  A B  (3)
3 2 
Since the same situations occur in the other stages, the
Fig. 1. Diagram of the motor drive circuit. frequency of usp is three times as that of the phase
back-EMF, which means that usp has the same zero
B. Sensorless drive method based on the virtual 3rd crossing points as the 3rd harmonic back-EMF. Fig. 2
harmonic phase back-EMF illustrates the relationships between the phase back-EMFs,
The diagram of the motor drive circuit is shown in Fig.1. the 3rd harmonic back-EMF, usp and the commutation
As can be seen in Fig.1, three signals (Hall A, Hall B, Hall points.
C) are needed for the commutation operations of the
3-Phase VSI (Voltage Source Inverter) through the
commutation logic and the drive circuit. In the mechanical
position sensor-based control method, these three signals
are obtained by the hall sensors. In the sensorless drive
methods, these three signals are obtained through the
sensorless detecting method.
As shown in Fig. 1, the three Y-connected resistors are
used to detect the rotor position signal. In the
pre-researches, the most popular technique to obtain the
rotor position signal is to use the voltage between the
neutral point “N” and the virtual neutral point “S” (uSN),
which is the so-called 3rd harmonic back-EMF method.
However, the neutral wire is not provided or expensive to
have access in many applications. Therefore, the virtual
3rd harmonic back-EMF method is discussed in [14],
which the rotor position signal is acquired from the voltage
between the virtual neutral point “S” and the midpoint of
Fig. 2. Relationships between the phase back-EMFs, the 3rd harmonic
the DC-link “P” (uSP). back-EMF, usp and the commutation points.
According to Fig. 1, the phase back-EMFs can be
described as As can be seen in Fig. 2, the frequency and the ZCPs of
usp are the same as that of the 3rd harmonic back-EMF.
eA  2 E cos( t) Contrasting with usn, usp is different with the 3rd harmonic
 back-EMF of the phase back-EMFs because the derivation
eB  2 E cos( t  2 / 3) (1)
contains no 3rd harmonic back-EMF component.

eC  2 E cos( t  2 / 3)
Therefore, for strictly speaking, this sensorless drive
method cannot be called as the 3rd harmonic back-EMF
where E is the back-EMF virtual value. based method. For facility analysis, it can be called as the
By a simple calculation based on the Kirchhoff’s virtual 3rd harmonic back-EMF based method, and usp can
voltage law, usp can be expressed as be called as the virtual voltage difference. Traditionally,
u AG  u BG  uCG ud the zero crossing points of usp can be detected by
usp   (2) commutation signals detection circuits, which are usually
3 2 mainly consisted of a low pass filter and a voltage
where ud is the dc-link voltage. comparator.
C. The analysis of the commutation error

When advanced commutations or lagged commutations
appear, the accuracy of the commutation points detection
will be influenced, which can be seen in Fig. 3(a) and (b).
In order to compensate this kind of commutation error, the
integration based compensation method has been proposed
in prior research[26]. It can be seen that in Fig. 3, in this
kind of compensation scheme, usp is integrated from the
occurrence of the first commutation point to the
occurrence of the second commutation point (Sprior), and (a)
from the occurrence of the second commutation point to
the occurrence of the third commutation point (Safter),
respectively. It can be noted that, the advanced
commutation is reflected by Sprior>Safter, and the legged
commutation is reflected by Sprior<Safter. When the two
integrations are equal (Sprior=Safter), the ZCPs of usp are
regarded as accurate. And then the commutation error is
corrected, which can be seen in Fig. 3(c). A PI adjustor is
always used to control the difference between Sprior and
Safter, and the aim of the PI adjustor is Sprior-Safter =0. (b)
However, usp actually contains pulses during the
commutation period due to the freewheel diode conduction.
The integration of the voltage pulse will be always added
into Safter, which will make Safter always larger than Sprior
when the accurate commutation appears. But the output
value of the PI adjustor will be regulated to achieve
Sprior=Safter. For this reason, Sprior increases and Safter
decreases. As a result, the little advanced commutation
occurs. This problem is not seriously in the low-speed (c)
range because the time of the commutation period (tc) is
short and the advanced degree is small in the low-speed
range, which can be seen in Fig. 3(c). Nevertheless, the
voltage pulse will appear wider in the high-speed range as
shown in Fig. 3(d). According to the analysis in [26], the
time of the commutation period can be written as
1 3 2
(ud  E)
tc   ln 3 2 (4)
1 3 2 (d)
I o R  (ud  E)
3 2 Fig. 3. Performances of the virtual voltage difference (usp). (a) Advanced
where τ=(L-M)/R is the time constant, Io is the initial commutation operation, (b) Lagged commutation operation, (c) Common
commutation operation in low-speed range, (d) Common commutation
current of the conducting phase in the beginning of the operation in high-speed range.
commutation.
It can be noted that from (4), the first reason of tc III. PROPOSED SENSORLESS DRIVE BASED ON
becoming longer in the high-speed range is that the load of HIGH-PRECISION COMMUTATION DETECTION
the motor becoming heavier in the high-speed range. So
the current of the excited phase takes long time to build. According to the analysis above, the virtual voltage
The second reason is that the fundamental cycle is difference (usp) has the same frequency and ZCPs as that of
relatively short in the high-speed range. As a result, in the the 3rd harmonic back-EMF. On this basis, a novel
high-speed range, the voltage pulses will remarkable high-precision sensorless drive method is proposed in this
impact the accuracy of the commutation point detection. section.
Based on the above discussion, the conclusion can be A. Further Discussion of usp
obtained that the performance of the virtual 3rd harmonic It can be noted in Fig. 3(c) and (d) that, in the common
back-EMF based sensorless drive method and the commutation operation, usp is very similar with a
integration based compensation method cannot be triangle-wave. Thus, if neglecting the pulse in usp (since
satisfied for the high-speed BLDC motor applications. the frequency and the ZCPs cannot be changed),
Therefore, a proper sensorless drive and commutation incorporating Fig. 3, usp can be approximately expressed
error compensation method for the high-speed BLDC as
applications should be developed.
 A has been used in the proposed sensorless method.

A  T0
-   t (-  t  0) a. PLL Processing
  2 T0 / 2  2 The PLL technique has been widely used in many
usp (t)   (5) industry applications, and also has the satisfied
-  A  A t  T
(0  t  0 )
performance in high-speed motor drive system. Owing to
  2 T /2  2 the advantages like simple digital implementation, desired
  0  performance under frequency condition and low
where A is the amplitude of the triangle-wave, T0 is the computation burden, the PLL based on SOGI has been
cycle time of the triangle-wave. received much attention recently [30]. So, the
By a Fourier decomposition, (5) can be obtained as single-phase SOGI-PLL technique is used in the proposed
  process, which aims to synchronize the output signal with
 4A 4A n 1  (6) the input signal as well as acquire the rotor position
usp (t)    2 cos 0 t  2 [ cos(2n  1)0 t] 
  
   i 1 (2n  1) 2
 information.
 u (t)  Fig. 5 shows the block diagram of the single-phase PLL
 sp _ 1 u (t) 
sp _ high
based on SOGI. The SOGI-PLL consists of the phase
where usp_1(t) is the fundamental component of usp(t),
detector (PD), the loop filter (LF) and the voltage
usp_high(t) is the sum of the high-order harmonic
controlled oscillator (VCO). The SOGI, which is
components of usp(t).
contained in the PD, is used to generate the orthogonal
signals.
v
v sin(ˆ)
vin
̂
v  (t) ̂ ˆ
0
v
cos(ˆ)
Fig. 4. usp and the fundamental wave of usp
Fig. 5. Block diagram of the single-phase PLL based on SOGI
It is interesting to note that usp is also consisted of the
fundamental wave and high-order harmonics from (6). Fig. By using a simple mathematical calculation, the
4 shows usp and the fundamental wave of usp in one plot characteristic transfer functions of the SOGI can be
(the high-order harmonics are not shown since they are not expressed as
used in the following analysis). Therefore, according to the v ( s ) kˆ s
analysis above, the fundamental wave of usp has the same G ( s )   2 (7)
frequency and ZCPs as the 3rd harmonic back-EMF. It vin ( s ) s  kˆ s  ˆ 2
should be pointed out that the approximation of usp above v ( s ) kˆ 2
will not change the frequency and ZCPs of usp, since the G ( s )   (8)
unconsidered distortion can be considered as the others vin ( s ) s 2  kˆ s  ˆ 2
harmonics of usp, which will not change the frequency and where k is the damping factor (usually a constant term),
ZCPs of usp. In another word, the time of the commutation and ω^ is the estimated frequency (ω0 is the fundamental
period (tc) will not impact the ZCPs of usp_1(t). It is to say
frequency of the input signal ).
that the equivalent ZCPs of usp can be obtained without the
It can be noticed that Gα(s) exhibits as a band-pass filter
impaction of the length of tc. It also should be pointed that,
the usp wave will not change with the selection of the axis. with a center frequency of ω^ from (7). The damping factor
If the 60º point in Fig. 4 is selected as the zero point of the k determines the pass-band of Gα(s). The lower k leads to a
horizontal axis, the minus sign in function (5) and (6) can narrower bandwidth and better filtering capability.
be eliminated. Therefore, in order to simplify the followed Meanwhile, Gβ(s) exhibits a low-pass filtering behavior. If
analysis, the minus sign is eliminated in the followed ^ =ω0, vα(s) will match in amplitude and in phase with the
ω
discuss. fundamental wave of the input signal of PLL (vin(s)). And
B. The Proposed High-precision Commutation Points vβ(s) will match in amplitude but with a phase difference of
Detecting Method 90º with the fundamental wave of the input signal of PLL
Based on the above analysis, if the fundamental wave of (vin(s)) under the same conditions. Assuming that
usp (usp_1(t)) can be exactly extracted, the precise ZCPs of vin=A0cosω0t, and combining (7) and (8), the output signals
usp can be obtained, so as the commutation points. Hence, of the SOGI block (vα(s) and vβ(s)) can be derived as
it attracts the authors to give a suitable process to extract
the precise ZCPs by using the fundamental wave of usp for v ( s )  A0 cos 0 t  A cos(0 1  0.25k 2 t) e 0.5 k0t
the efficient sensorless drive in the wide speed range. At (9)
the meanwhile, the proposed sensorless drive will not be 0.5 k0t
impacted by the voltage pulse in the wide speed range. In v ( s )  A0 sin 0 t  A sin(0 1  0.25k t) e 2
order to achieve this purpose, a hybrid signal processing (10)
where Aα, Aβ are the functions of A0 and k, respectively. (14)

So considering Fig. 5 and combining (9) and (10), the It is noted that x1(t) and x2(t) contains the direct current
output signal of the PD can be expressed as (11) at the components and the AC components. During the integral
bottom of this page. processing, the correlation theorem can be used, which can
In steady state ( ω ^ =ω0), the output signal of the PD filter out the AC components. Thus, combining with (12)
decays to zero (ε(s)=0), which can be calculated from (11). and (13), the ac components contained in x1(t) and x2(t),
Whereas if the input signal of PLL (vin) contains large can be filtered out by using of the integrate processing. So
harmonics like the expression as (6), the output signal of the output signal of the SFF (Xout) can be obtained as
the PD (ε(s)) will contain a harmonic component in steady X out  0.5V0 sin(0t  0 ) (15)
state, which can be written as Compared with (13) and (15), it can be focused that the
n n
h output signal of the SFF (Xout) has the same frequency, the
 high ( s )   Ah sin hht cos ˆ t   Ah sin( hh t  ) sin ˆ t
h2 h2 2 same phase and 0.5 times of the amplitude with the input
(12) signal of the SFF (Xin). In another word, although the
The harmonics components (εhigh(s)) will cause the amplitude of Xout is smaller than Xin, the fundamental wave
bandwidth of the LF to be smaller, which will deteriorate can be extracted by using the SFF, precisely. The
the transient response [28]. Moreover, it becomes severe in amplitude can be easily adjusted by adding a constant gain
the low-speed range. In this case, it is necessary to filter to Xout. The closed-loop transfer function of the SFF can be
out the high-order harmonics of the SOGI-PLL’s input expressed as
signal. In this paper, the input signal of SOGI-PLL is usp. as
From the above discussions, usp contains large odd H (s)  (16)
s  as   02
2
harmonic components. As a result, a novel signal
processing is applied to limit the high-order harmonics. It can be noted that, when s = jω0, the gain of H(s)
b. SFF Processing equals to 1. It indicates that the fundamental wave of Xin
The block diagram of SFF is demonstrated in Fig. 6, can pass the SFF without attenuation. When s = jωh, the
which is used as the pre-filter of SOGI-PLL [31]. In Fig.6, sharpness of the SFF can be adjusted by the factor a. The
Xin and Xout are indicated as the input and output signals of gain of (16) is depended on a, which equals to the inverse
the SFF, respectively. a is the constant gain, sin(^ θ ) and of the quality-factor. In the startup range (nearly zero
speed), the real part of the poles is small (=0.015), which
cos( ^θ ) are the reference signals, which the phase means that the stability margin of the SFF is small in the
difference between them is 90º. The SFF has the character very low-speed range. So it can be considered that the SFF
of precisely extracting the fundamental wave from the is stable in the whole speed range. Additionally, according
input signal (Xin), which is illustrated in the following to (16), the SFF behaves as a low-pass filter when ω0 = 0
analysis. (zero speed), and behaves as a synchronic-frequency filter
Assuming that the input signal (Xin) contains harmonic as long as ω0 ≠ 0, even with very low speed as ω0 = 0.1Hz
components, it can be expressed as (6 r/min for one pole pairs motor). In addition, the
X in  xin (t )  V0 sin(0t  0 )   Vh sin(ht  h ) (13) sharpness of the SFF is growing with the motor speed
     increasing, which means the effectiveness of the SFF is
X1 X high
rising in the high-speed range. As a result, the proposed
sin(ˆ) sin(ˆ)
SFF filter is stable in the whole speed range with satisfied
extraction characteristics of operating frequency.
c. Incorporating SOGI-PLL with SFF
From above discussion, a novel sensorless drive method,
which is based on the single-phase SOGI-PLL
incorporating the SFF, is proposed. The whole block
diagram of the proposed compensation is shown in Fig. 7.
cos(ˆ) cos(ˆ)
As can be seen in Fig. 7, an SFF is located at the
Fig. 6. Block diagram of SFF upstream of the single-phase SOGI-PLL to pre-filter the
harmonic components, which is contained in the input
where V0, ω0 and φ0 are the amplitude, frequency and the
phase of the fundamental component of Xin respectively, signal (usp). The reference signals of the SFF (sin(^
θ ) and
Vh, ωh and φh are the amplitude, frequency and the phase of cos(^θ )) are generated by using the estimated rotor position
the h-order harmonic component of Xin respectively, X1 angle naturally, which is produced from the output signals
and Xhigh are the fundamental and h-order harmonic of the SOGI-PLL. Besides, the reference signals are
components, respectively. returned to the SFF by two feedback paths. The reference
According to Fig. 6, the output signal Xout can be derived frequency for VCO (ω0) is obtained by the conventional
as commutation signals detection circuit, which is explained
X out  sin(ˆ)a  ( X 1  X high ) sin(ˆ)   cos(ˆ) a   ( X 1  X high ) cos(ˆ )  above. There are two reasons to obtain the reference speed
by using the traditional speed acquire technique. Firstly,
 ( s)  v (s) cos ˆ t  v (s)sin ˆ t =A0 sin((0  ˆ ) t)   A cos(0 1  0.25k 2 t) sin ˆ t  A sin(0 1  0.25k 2 t) cos ˆ t  e0.5k t (11) 0
 
since the original usp is processed by the filter processed improve the performance at very low-speed range by using
circuit, the impact of the voltage pulses to the rotor’s the traditional method to generate the reference speed
speed is very limited. Therefore, the obtaining of the motor value. Additionally, because of the existing of the
rotating speed can be seemed as reliable. Secondly, as pre-filter of the SOGI-PLL (the SFF), the damping factor k
analyzed above, the stability margin of the SFF is is chosen as 1.5 for a relative wide bandwidth of SOGI.
relatively small at very low speed range. Therefore, it will
v
sin(ˆ)
sin(ˆ) sin(ˆ) v
̂
v  (t) ̂ ˆ
0
cos(ˆ) cos(ˆ) v
cos(ˆ)
Fig. 7. Proposed active compensation block diagram based on incorporating SOGI-PLL with SFF.
As can be seen in Fig. 7, an SFF is located at the (2  s   2 )

upstream of the single-phase SOGI-PLL to pre-filter the ( s)  (19)
harmonic components, which is contained in the input s2  2 s   2
signal (usp). The reference signals of the SFF (sin(^
θ ) and where is ρ a positive constant. The bandwidth of Ф(s) is
2.48ρ, which can be obtained by a simple calculation.
cos(^θ )) are generated by using the estimated rotor position Therefore, the problem is concentrated on selecting the
angle naturally, which is produced from the output signals value of ρ.
of the SOGI-PLL. Besides, the reference signals are As the harmonics of usp have been pre-filtered by the
returned to the SFF by two feedback paths. The reference SFF, a larger bandwidth of the PLL can be selected
frequency for VCO (ω0) is obtained by the conventional without considering the impact of the high-order harmonic
commutation signals detection circuit, which is explained noises. Furthermore, for the high-speed BLDC motor, the
above. There are two reasons to obtain the reference speed bandwidth should be larger than that of the conventional
by using the traditional speed acquire technique. Firstly, low-speed motors, since the speed range of the high-speed
since the original usp is processed by the filter processed motor is much wider. Therefore, by considering the
circuit, the impact of the voltage pulses to the rotor’s bandwidth of the speed controller and the current
speed is very limited. Therefore, the obtaining of the motor controller, the bandwidth of Ф(s) can be designed, so that
rotating speed can be seemed as reliable. Secondly, as the parameters Kp (= 2ρ) and Ki (= ρ2) can be acquired.
analyzed above, the stability margin of the SFF is d. The Extra Degree Compensation
relatively small at very low speed range. Therefore, it will Although the proposed rotor position detecting method
improve the performance at very low-speed range by using is accurate enough, the rotor position detecting error may
the traditional method to generate the reference speed be appears a few times in the whole speed operating range
value. Additionally, because of the existing of the due to the sampling accuracy of the AD module. For this
pre-filter of the SOGI-PLL (the SFF), the damping factor k reason, an extra rotor position degree compensation link is
is chosen as 1.5 for a relative wide bandwidth of SOGI. used.
According to the above analysis, it can be known that The compensation link consists of a difference
the bandwidth of the LF will be reduced due to the input integration module and a PI adjusting module. The
signal’s harmonic component, which will further impact difference integration module obtained the integration
on the control system’s response. But the problem is from the occurrence of the first commutation point to the
almost disappeared by using the proposed incorporating ZCP of the fundamental wave of usp, and the integration
method, since the fundamental component of the input from the ZCP of the fundamental wave of usp to the second
signal has been extracted by the SFF efficiently. Hence, commutation point, respectively. The PI regular is used to
the key of the discussion is to choose an appropriate control the difference between the two integrations. The
bandwidth of the PLL. aim of the PI regular is that adjusting the difference
The close-loop transfer function of the PLL, which from between the two integrations equals to zero. The working
ε(t) to ^
θ (t) is expressed as principle of the extra degree compensation link is similar
( K p s  K i ) as the traditional integration based compensation scheme,
(s)  (18) which is shown in Fig. 3. Compare to the traditional
s 2  K p s  Ki compensation scheme, the most difference is that the
Setting Kp = 2ρ and Ki = ρ2, another expression of (17) fundamental wave of the usp is used. Since the fundamental
can be expressed as (18), which has equal roots as (17) wave of the usp contains no voltage pulse, the extra degree
[28]. compensation link can further compensate the
commutation error effectively.
IV. EXPERIMENTAL EVALUATION No. of pole pairs, P 1

Because of that the impeller of the developed aeration Rated DC voltage 430V
blower is being processed, an experimental driveline Rated current 70A
system used for testing the electrical performance for the Rated Power 30kW
high-speed magnetically suspended BLDC motor is built. Rated speed, n 48000r/min
The overall high-speed magnetically suspended BLDC Torque constant, Kt 0.0857N.m/A
experimental setup control block based on the proposed Line-to Line back-EMF constant,
sensorless drive scheme is shown in Fig. 8. As illustrated 0.0082V/r/min
Ke-line
in Fig. 8, the magnetically suspended motor is connected Rotational inertia, J 0.0021796kg*m2
with the magnetically generator by a flexible coupling. A Phase resistance, R 35mΩ
variable resistor is taken as load. The PWM method is
Phase inductance, L 195μH
adopted below the switching speed, and the PAM
Mutual inductance, M 40μH
technique is applied when the switching speed is achieved.
A front-end phase-controlled rectifier can provide an A. Experiment 1 – Performance under no-load conditions
adjustable DC-link voltage when the PAM worked, while Fig. 10(a) shows the experimental results (iA, uA, uAB
the back-end VSI achieves the commutation control. The and usp) in the startup stage. The startup stage contains
phase lag angle and the software retarding are three steps: preposition, force synchronous operation and
compensated by using the commutation delay calculation sensorless operation, which is the so-called three-steps
module. The difference integration and the PI module are startup method. There are two reasons to select this startup
used to generate the commutation compensation degree. method: the first one is that the performance in the
Then, the final compensation angle can be obtained. The high-speed range is relatively more important for the
displacement signals (Sm and Sg) and the current signals (im high-speed motor than the transient state in the low-speed
and ig) are sampled to control the magnetically suspended range; the second one is that the three-steps startup method
bearings in the BLDC motors. The specification of the will provide sufficient stability margin, which is relatively
experimental magnetically suspended BLDC motor is small at nearly zero speed according to the analysis above.
shown in Table I. Fig. 9 shows the photograph of the It can be seen in Fig. 10(a), in the force synchronous
experimental platform, which consists of the drive system operation, the current ripple is large due to the inaccurate
and the experimental BLDC motor. commutation. When the sensorless operation is applied,
To test the effectiveness of the proposed method in the the current ripple decreases since the commutation signals
whole speed range, several experimental results are shown is accurate, which is obtained from the proposed method.
in the following. The rotor position angle is detected through the proposed
sensorless method, and it is automatically switched from
the force synchronous operation to the sensorless
operation when the sensorless method provides reliable
position information. The switch speed is usually around
sm sg ig
150 r/min. It can be seen that the proposed method works
im
reliably in the startup stage.
̂
ˆ
0
Fig. 8. Overall high-speed magnetically suspended BLDC experimental

setup control block based on the proposed sensorless drive scheme.
Stator Magnetically
Oscilloscope suspended
Controller
bearing
Current
sensors Rotor
Phase-controlled
rectifier and
trigger board Magnetically Magnetically
suspended motor suspended generator
(a)
Filter reactor Filter capacitor group Flexible coupling
(a) (b)
Fig. 9. Experimental platform. (a) Drive system. (b) Experimental
motors.
TABLE I
TEST PARAMETERS
Variable Value
In order to test the effectiveness of the proposed

sensorless drive method in the high-speed range, the
experimental results in the PWM-PAM switching stage
and 48 000r/min have been shown in Fig. 11. As
mentioned above, the PAM control model will be
triggered when the motor’s speed reaches 5000 r/min. The
performance at the transition process is presented in Fig.
11(a). It can be seen that under PAM control model, the
fluctuations of the phase current (iA) and voltage (uA) are
decreased compared with that under the PWM control
model, since the commutation notches generated at the
(b) frequency of the PWM are vanished. Furthermore, the loss
Fig. 9. Experimental performances of the proposed method in the of the motor will be reduced and the motor efficiency will
low-speed range. (a) Startup stage. (b) 5000 r/min with PWM. be improved because the current ripple decreasing. Also, it
PWM operation PAM operation
can be seen in Fig. 11(b) that the proposed sensorless drive
iA can be effectively operated in the high-speed range. So, the
0 proposed sensorless drive method can be utilized in the
Time (50ms/div) whole speed range.
v v
uA
0
Time (50ms/div)
usp (a)
v v
0
Time (50ms/div)
(a)
(b)
Fig. 11. Experimental performances of signal details of the SOGI-PLL
including the estimated vα and vβ, the FFT analysis and the Lissajou
curves. (a) Performances at 1000 r/min. (b) Performances at 48 000
r/min.
Without compensation
360deg
Estimated rotor
position (deg)
Time(1ms/div)
(a)
(b)
Fig. 10. Experimental performances of the proposed method in the
high-speed range. (a) PWM-PAM switching stage. (b) 48 000r/min with
PAM.
As introduced above, the PWM-PAM combining (b)

control method is adopted. As followed, the switching
speed (from PWM to PAM) is usually around 5000 r/min
(the current ripple is increasing with the speed in the PWM
mode). Therefore, the upper bound speed is set at 5000
r/min. Fig. 10(b) shows the experimental results at the
speed of 5000 r/min, in which the experimental
performance is satisfied. Usually, the satisfied (c)
performance also can be obtained in the conventional Fig. 12. Experimental results of rotor position estimations, the blue
sensorless method, in which the noise is filtered by the curves are the estimated rotor position angle and the red curves are the
precise rotor position angle for comparison. (a) Without compensation.
low-pass filter. However, by using the proposed method, (b) With SOGI-PLL processing (c) With SFF-SOGI-PLL processing.
the accurate commutation signals are gotten from the noisy Fig. 12 shows the details of the signals (vα and vβ)
signal without adding extra hardware (such as the low-pass contained in SOGI-PLL both in the low-speed range and
filters). high-speed range. The experimental performance at 1000
r/min can be seen in Fig. 12(a). It can be noted that vα and
vβ contain no obvious distortion, and quite similar as the

standard sine curve. The FFT analysis of vα has been
shown next, which shows that vα contains very little
high-order harmonic components. Meanwhile, the
Lissajous curve drawn by vα and vβ shows a satisfied phase
cycle, since the high-order harmonic components are
filtered out. The similar experimental performance at 48
000 r/min can be seen in Fig. 12(b).
To verify the effectiveness of the proposed
SFF-SOGI-PLL based rotor position estimation, the
experimental results of the rotor position angle estimations
are shown in Fig. 13. The precise rotor position angle
(a)
curve (the red curve) is given in a same plot for
comparison, which is obtained by an encoder. Fig. 13(a) iA
illustrates the experimental results of the traditional virtual 0 196A
3rd harmonic phase back-EMF based sensorless method Time (1ms/div)
without any compensations under 48 000 r/min, while Fig.

13(b) shows the experimental results with SOGI-PLL uA
processing, followed by the experimental results with 0
SFF-SOGI-PLL processing under same experimental Time (1ms/div)
conditions in Fig. 13(c). It can be noted that in Fig. 13(a),
the estimated rotor position curve fluctuates dramatically, usp With SFF-SOGI-PLL
thus the estimated error occurs. The maximum value of the 0
estimated error is around 10º. The experimental result in Time (1ms/div)
Fig. 13(b) presents a better performance, although it also (b)
contains estimated error obviously. On the contrary, the
Fig. 13. Comparable experimental results at 48 000 r/min with 100% load.
estimated rotor position angle with the proposed
(a) With the traditional compensation method (Sprior=Safter). (b) With the
SFF-SOGI-PLL method processing, which can be seen in proposed sensorless drive method (SFF-SOGI-PLL).
Fig. 13(c), contains little estimated error. The estimated
error is reduced in 1º. In order to show the accuracy of the proposed sensorless
B. Experiment 2 – Performance under load conditions drive method more obviously, Fig. 15 shows the
For further validating the effectiveness of the proposed commutation signals and the FFT analysis, which are
sensorless drive algorithm, the experimental performance under the same conditions as that in Fig. 14. The ideal
under load conditions has been shown in this experiment. commutation signal, usp and the FFT analysis of usp have
Fig. 14 shows the comparison experimental been shown to present the relationship of them. As shown
performance and the relationship among iA, uA and usp at in Fig. 15(a), the advanced degree is 9.64º with the
48 000 r/min with 100% load. As mentioned above, the traditional compensation method. Under the proposed
advanced degree is increasing with the motor speed and sensorless drive method, it can be noted in Fig. 15(b) that
load. Therefore, the advanced degree under the full load the advanced degree is decreased to 0.85º. The residual
conditions at the highest speed is the largest value as well commutation error is mainly caused by the residual
as the reason that the authors choose to show the accuracy harmonics in the estimated signals, although the
performance under the highest speed conditions. Fig. 14(a) performance is satisfied in this paper’s research. The
indicates the performance with the traditional extracted fundamental wave of usp (usp_1) and the FFT
compensation method mentioned above (in Fig. 3, i.e., analysis of usp_1 also have been shown in Fig. 15. As shown,
Sprior=Safter). As can be seen in Fig. 14(a) that, due to the the high-order harmonics have been almost filtered out,
voltage pulse during the commutation period, the which are severely contained in usp.
integration of the voltage pulse has been add to Safter. As a
result, the advanced commutation appears, and the
advanced commutation error cannot be eliminated
according to the above analysis. The waves are distorted
due to the advanced commutation. Fig. 14(b) presents the
performance with the proposed sensorless drive method
(with SFF-SOGI-PLL processing). Obviously, the
accurate commutation appears under the proposed
sensorless drive method, and the distortion has been
further improved.
(a)
Ideal commutation signal Actual commutation signal
0.85º
With SFF-SOGI-PLL
1st 5st 10st 15st 20st 25st 30st 35st 40st

(b)
Fig. 14. Comparable experimental performance of the commutation error,
the commutation signals and the FFT analysis at 48 000 r/min with 100%
load. (a) With the traditional compensation method (Sprior=Safter). (b) With
the proposed sensorless drive method (SFF-SOGI-PLL).
To further show the experimental performance of the
traditional sensorless method and the proposed sensorless
method, a load step experiment has been done at 30 000
r/min as shown in Fig. 16. The load is dramatically (a)
changed from 10% to 90% full load. The load is changed
through switching the load resistance box with different
resistance values. The two results are obtained under same
experimental conditions. It can be noted that the current
ripple is smaller under the proposed sensorless drive
method than that under the traditional sensorless method.
According to the analysis above, it is because the
commutation is more precise than that of the traditional
compensation method. The waves of usp and usp_1 are also
shown in Fig. 16. It can be seen that usp_1 has been
extracted effectively, and the advantage distortion with
Sprior=Safter compensation has been limited effectively in
the proposed method with SFF-SOGI-PLL. It also can be
noted that, when the load is sharply changed from 10%
load to 90% load, the maximum estimated error is 8.7º
under traditional sensorless method, and that under the
proposed sensorless drive method is within 1º. As a
conclusion, the proposed method presents a further
improved performance than the traditional method.
C. Experiment 3 –Efficiency Comparison
In order to evaluate the efficiency performance of the
proposed sensorless method, the experimental results
comparing of the overall efficiency are shown in Fig. 17. (b)
The overall efficiency is defined as the ratio of the Fig. 15. Comparable experimental results with a step load applying. (a)
With the traditional compensation method (Sprior=Safter). (b) With the
generator’s output power to the motor’s input power in this proposed sensorless drive method (SFF-SOGI-PLL).
paper, and the powers are recorded by two power
analyzers (WT1800). It can be noted that in Fig. 17,
resulting from the precise commutation points obtained by
the proposed sensorless drive method, the overall
efficiency is improved compared with that of the
traditional method, especially in the high-speed range.
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[31] X. Song, J. Fang, B. Han and S. Zheng, “Adaptive Compensation
Method for High-Speed Surface PMSM Sensorless Drives of received the B.S. degree from the
EMF-Based Position Estimation Error,” Power Electronics, IEEE Shandong University of Technology
Transactions on, vol. 31, no. 2, pp. 1438-1449, 2016. (now Shandong University), Jinan,
China, in 1983, the M.S. degree from
Xinda Song was born in August 18 Xi’an Jiaotong University, Xi’an, China,
1981. He received the M.S. degree in 1988, and the Ph.D. degree from
from Taiyuan University of Southeast University, Nanjing, China,
Technology, Taiyuan, China, in 2011, in 1996.
and the Ph.D. degree in precision He is the Chinese Academy of Sciences fellow and the
instrument and machinery from the vice-president of the Beijing University of Aeronautics
Beijing University of Aeronautics and and Astronautics, Beijing, China. He has authored or
Astronautics, Beijing, China, in 2016. co-authored over 150 paper and four books. He has been
He is currently a Postdoctoral Research Fellow in the granted 35 Chinese invention patents as the first inventor.
School of Instrumentation Science and Opto-electronics His current research interests include the attitude control
Engineering, Beijing University of Aeronautics and system technology of spacecraft, novel inertial instrument
Astronautics, where he is also a Research Member of the and equipment technology, inertial navigation, and
Key Laboratory of Fundamental Science for National integrated navigation technologies of aerial vehicles.
Defense, Novel Inertial Instrument and Navigation System Prof. Jiancheng has the special appointment professorship
Technology. His research interests include high-speed with the title of Cheung Kong Scholar by the Ministry of
permanent magnet motor control and power electronics. Education of China and the Li Ka Shing Foundation. He is
in the first group of Principal Scientists of the National
Bangcheng Han was born in February
Laboratory for Aeronautics and Astronautics of China. He
1974. He received the M.S. degree from
was a recipient of the first-class National Science and
Jilin University, Changchun, China, in
Technology Progress Award of China as the third
2001, and the Ph.D. degree from
contributor in 2006, the first-class National Invention
Changchun Institute of Optics, Fine
Award of China as the first inventor, and the second-class
Mechanics and Physics, Chinese
National Science and Technology Progress Award of
Academy of Sciences, Changchun,
China as the first contributor in 2007.
China, in 2004. In 2004, he was a
Postdoctoral Research Fellow in the School of
Instrumentation Science and Opto-electronics Engineering,
Beijing University of Aeronautics and Astronautics,
Beijing, China. In 2006, he joined Beijing University of
Aeronautics and Astronautics.

High-Precision Sensorless Drive For High-Speed BLDC Motors Based

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High-Precision Sensorless Drive For High-Speed BLDC Motors Based

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This article has been accepted for publication in a future issue of this journal, but has not been

High-precision Sensorless Drive for High-speed BLDC Motors based

C. The analysis of the commutation error

 A has been used in the proposed sensorless method.

order to achieve this purpose, a hybrid signal processing (10)

where Aα, Aβ are the functions of A0 and k, respectively. (14)

As can be seen in Fig. 7, an SFF is located at the (2  s   2 )

IV. EXPERIMENTAL EVALUATION No. of pole pairs, P 1

Fig. 8. Overall high-speed magnetically suspended BLDC experimental

Filter reactor Filter capacitor group Flexible coupling

In order to test the effectiveness of the proposed

As introduced above, the PWM-PAM combining (b)

vβ contain no obvious distortion, and quite similar as the

illustrates the experimental results of the traditional virtual 0 196A

3rd harmonic phase back-EMF based sensorless method Time (1ms/div)

without any compensations under 48 000 r/min, while Fig.

Ideal commutation signal Actual commutation signal

1st 5st 10st 15st 20st 25st 30st 35st 40st

Transactions on, vol. 62, no. 9, pp. 5700-5708, 2015.

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