Presentation LA4 - BLDC Machine and Two Phase Control 23-24

OWE: AUM4-PT3-EV (Design an electric driveline)
BLDC Machine
and two-phase
control
G. Angelino
edited by M. Rondel
1
L.A.4 BLDC machines and two-phase control
Learning assignment 4) BLDC machines and two-phase control
Introduction
Permanent Magnet Synchronous Machines (PMSM) can be divided into the following two categories BLDC and BLAC. The PMSM
which acts like a BLDC contains a back emf voltage in the shape of a trapezoidal signal, whereas the BLAC has a nice sinusoidal
shape. In most of the literature, they indicate a machine with concentrated stator windings as a BLDC. They have less end windings
and have therefore a smaller length of the machine. These machine are often indicated as pancake or disc-design machines.
Whether this is true or false, you might learn this in the future. In practice, some of the PMSM machines do have a trapezoidal
shape back emf signal. For these type of machine often a switching diagram is used to control two of the three phases. With this
learning assignment the student will learn to obtain such a switching diagram and to understand the response of the machine on
this type of “control”.
Questions:
1. What is the relation between the load torque and the load angle of a BLDC?
2. How can we obtain the switching pattern of a three phase BLDC machine in order to rotate the machine clockwise and
counterclockwise.
3. How can we obtain the stator flux vector based on the switching pattern.
4. What is the direction of the current flow during the on- and off-time of one switching period, during motor and generator
operation?
5. How can we control the amount of motor- and brake power of the BLDC with the uses of PWM control?
Sources:
Besides using the internet, you could study this presentation

Electric machine categories:
EV machines
Electrical
Commutator commutation
(EC)
DC Asynchronous / Synchronous
Induction
(Squirrel) Cage Wound rotor

PM field Wound field rotor Excited Not excited
Synchronous
Separately PM field reluctance
Series Shunt Wound rotor
excited (PMSM) (SR)
Brushless DC machine (BLDC)

Brushless DC machine
Brushless machine
T
Sparks at the brushes
(inductive limitation)
Machine bearings
Overheating
brushes
Crossflow voltage
DC-machine with
brushes
Floating brushes
AC BLDC
distributed windings concentrated windings
sinusoidal voltages trapezium voltages
BLDC rotor position sensor

The rotor position
feedback makes it a
BLDC motor!
Without this feedback it
is a synchronous motor
Rotor position
Load angle
angle  = load angle
A: No torque B: Medium torque C: Maximum torque
This is valid for PMSM. Also for BLDC with sinusoidal flux and voltages, which
is not what is shown here.
BLDC motors
• Trapezium-shaped voltages
• Concentrated windings (BLDC)
• Sinusoidal voltages
• Distributed windings (Synchronous & BLDC)
Inner stator Outer stator
10
Difference in BLDC and Synchronous AC
Flux and voltage
Stator windings sinus trapezium
synchronous
distributed x
BLDC
concentrated BLDC BLDC
11
Load angle depending on the load
Load
Motor operation Generator operation
𝑀𝑒 = −𝑀𝑚𝑎𝑥 sin(𝛿𝑙𝑜𝑎𝑑 ) [Nm]
This is valid for PMSM and for BLDC with sinusoidal flux and voltages
Stator and rotor flux for two-phase control
Rotor flux
Stator flux
30o before and 30o after maximum load angle

How to choose the 600 steps?
600 after maximum load angle vs. 30o before and 30o after
maximum load angle.
𝜽𝑳𝒐𝒂𝒅 𝜽𝑳𝒐𝒂𝒅
Torque ripple 50% Torque ripple 13%
For sinusoidal voltages and fluxdensity only

Switching table clockwise
Six stepper
On/Off pattern 1 2 3 4 5 6 1
transistor T1 (U+) on on off off off off on
transistor T2 (U-) off off off on on off off
transistor T3 (V+) off off on on off off off
transistor T4 (V-) on off off off off on on
transistor T5 (W+) off off off off on on off
transistor T6 (W-) off on on off off off off

Stator and rotor flux clockwise 1a

Stator and rotor flux clockwise 1b













Switching table counter clockwise
1 2 3 4 5 6 1
on/off pattern
transistor T1 (U+) on off off off off on on
transistor T2 (U-) off off on on off off off
transistor T3 (V+) off off off on on off off
transistor T4 (V-) on on off off off off on
transistor T5 (W+) off on on off off off off
transistor T6 (W-) off off off off on on off

Change of direction by changing two-phases

Switching table for counter clockwise
1 2 3 4 5 6 1
on/off volgorde
transistor T1 (U+) on off off off off on on
transistor T2 (U-) off off on on off off off
transistor T3 (V+) off off off on on off off
transistor T4 (V-) on on off off off off on
transistor T5 (W+) off on on off off off off
transistor T6 (W-) off off off off on on off
Switching table V and W changed
on/off volgorde 1 2 3 4 5 6 1
transistor T1 (U+) on on off off off off on
transistor T5 (W+) off off off off on on off
transistor T3 (V+) off off on on off off off
Stator and rotor flux counter clockwise 1







Change of flux in coil U
-60o
rotor angle
-45o
rotor angle
-30o
rotor angle
-15o
rotor angle
0o
rotor angle
15o
rotor angle
30o
rotor angle
45o
rotor angle
60o
rotor angle
75o
rotor angle
90o
rotor angle
105o
rotor angle
120o
rotor angle
Back EMF (theoretically)

Back EMF real (trapezium)

Back EMF
Phase voltage for two-phase control

Phase current (torque) for two-phase control
The torque will also look like this since the back-EMF is constant each 60˚ interval
This torque ripple doesn’t correspond to the EMF and currents.

two-phase control power

Synchronous machine speed
nsynchr
fstator = * N pp [Hz]
60
fstator
nsynchr = * 60 [min -1 ]
N pp
Npp is number of pole pairs

Rotor 2 magnets =
1 pole pair example 1
Step rotation 60o which means 6 steps = 360o

Rotor 4 magnets =
2 pole pairs Example 2
Step rotation 30o which means 12 steps = 360o


Example 3
6 coils
4 magnets = 2 pole pairs
fstator = 100 Hz
nsynchr = 100 / 2 * 60 =
nnsynchr = 3000 min-1

Example 4
12 coils
8 magnets = 4 pole pairs
fstator = 100 Hz
nsynchr = 100 / 4 * 60 =
nnsynchr = 1500 min-1

Example 5
Honda motor
18 coils
12 magnets
6 pole pairs
fstator =100 Hz
nsynchr = 100 / 6 * 60 =
nsynchr = 1000 min-1
Maxon EC 45 brushless 250 W



Equivalent circuit BLDC

BLDC characteristics calculations 1
𝑉𝑇 48
Stall current: 𝐼𝑠𝑡𝑎𝑙𝑙 = = = 45,7 𝐴
𝑅𝑠 1,05
𝑇𝑠𝑡𝑎𝑙𝑙 3220 𝑚𝑁𝑚

Torque constant: 𝐾𝑇 = = = 70,9
𝐼𝑠𝑡𝑎𝑙𝑙 −𝐼𝑜 4537−0,311 𝐴
𝑛𝑜 6460 𝑟𝑝𝑚
Speed constant: 𝐾𝑣 = = = 135,5
𝑉𝑇 −𝐼𝑜 ∙𝑅𝑠 48−0,311∙1,05 𝑉
60 60 𝑚𝑁𝑚
Torque constant: 𝐾𝑇 = = ≈ 70,5
2𝜋∙𝐾𝑣 2𝜋∙135,5 𝐴
BLDC operation calculations 2
ෝ for Is = 5 A :
Speed 𝒏
𝑛ො = 𝐾𝑣 ∙ 𝑉𝑇 − 𝐼𝑠 ∙ 𝑅𝑠 = 135,5 ∙ 48 − 5 ∙ 1,05 = 5793 𝑟𝑝𝑚
Load torque Ta for Is = 5 A :
𝑇෡𝑒 = 𝐾𝑇 ∙ 𝐼𝑠 − 𝐼𝑜 = 70,5 ∙ 5 − 0,311 = 331 𝑚𝑁𝑚

BLDC operation calculations 3
Mechanical power for Is = 5 A :

n 5793
Pa = 2 .M a = 2 0,333 = 201,7 W
60 60
Electric power for Is = 5 A :
Pop = U k .  a = 48 * 5 = 240 W
Efficiency  for Is = 5 A :
Pa 201,7
= .100% = .100% = 84,1 %
Pop 240
Maxon 250W BLDC performance

Current control BLDC
T1 and T4 on
T1 off T4 on
Switching table clockwise

on/off pattern 1 2 3 4 5 6 7
transistor T1 (U+) chop chop off off off off chop
transistor T3 (V+) off off chop chop off off off
transistor T5 (W+) off off off off chop chop off

Phase voltages PWM control clockwise

Phase currents PWM control clockwise
Torque shape not correct, look in previous figures

Regenerative braking BLDC 1
T2 on
T2 off
Switching table regenerative braking clockwise
on/off pattern 1 2 3 4 5 6 7
transistor T1 (U+) off off off off off off off
transistor T2 (U-) chop chop off on on off chop
transistor T3 (V+) off off off off off off off
transistor T4 (V-) on off chop chop off on on
transistor T5 (W+) off off off off off off off
transistor T6 (W-) off on on off chop chop off
Phase voltages PWM control clockwise

Phase currents PWM control clockwise
Torque shape not correct, look in previous figures

The brushless DC-motor (Honda)

Stator Commutation sensors
Rotor
Honda’s BLDC motor

Commutation-
Stator coils (18)
sensors
Rotor with
permanent
magnets (12)
Honda’s BLDC motor
• permanent magnet synchronous

motor (= BLDC)
• Pmax = 18,5kW
• Mmax = 103 Nm
• n = 0 – 6000 rpm
• Stator diameter 250mm
• Rotor diameter 150mm
• Width 70mm!
• Weigth ca 20kg
• 18 stator coils
• 6 rotor pole pairs (12 magnets!)
Inverter connection
•Blue phase on
inverter connection A
•Red phase on
inverter connection C
•Grey phase on
inverter connection B
Step by step
Step by step
Step by step
Step by step
Step by step
Automatically
Automatically
Automatically
Automatically
Automatically
Automatically

Presentation LA4 - BLDC Machine and Two Phase Control 23-24

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OWE: AUM4-PT3-EV (Design an electric driveline)

Learning assignment 4) BLDC machines and two-phase control

Besides using the internet, you could study this presentation

Electric machine categories:

(Squirrel) Cage Wound rotor

Brushless DC machine (BLDC)

BLDC rotor position sensor

A: No torque B: Medium torque C: Maximum torque

Inner stator Outer stator

Flux and voltage

Stator windings sinus trapezium

concentrated BLDC BLDC

Load angle depending on the load

Motor operation Generator operation

𝑀𝑒 = −𝑀𝑚𝑎𝑥 sin(𝛿𝑙𝑜𝑎𝑑 ) [Nm]

Stator and rotor flux for two-phase control

30o before and 30o after maximum load angle

How to choose the 600 steps?

Torque ripple 50% Torque ripple 13%

For sinusoidal voltages and fluxdensity only

Switching table clockwise

transistor T1 (U+) on on off off off off on

transistor T2 (U-) off off off on on off off

transistor T3 (V+) off off on on off off off

transistor T4 (V-) on off off off off on on

transistor T5 (W+) off off off off on on off

transistor T6 (W-) off on on off off off off

Stator and rotor flux clockwise 1a

Stator and rotor flux clockwise 1b

Stator and rotor flux clockwise 2a

Stator and rotor flux clockwise 2b

Stator and rotor flux clockwise 3a

Stator and rotor flux clockwise 3b

Stator and rotor flux clockwise 4a

Stator and rotor flux clockwise 4b

Stator and rotor flux clockwise 5a

Stator and rotor flux clockwise 5b

Stator and rotor flux clockwise 6a

Stator and rotor flux clockwise 6b

Stator and rotor flux clockwise 1a

Stator and rotor flux clockwise 1b

Switching table counter clockwise

transistor T1 (U+) on off off off off on on

transistor T2 (U-) off off on on off off off

transistor T3 (V+) off off off on on off off

transistor T4 (V-) on on off off off off on

transistor T5 (W+) off on on off off off off

transistor T6 (W-) off off off off on on off

Change of direction by changing two-phases

Stator and rotor flux counter clockwise 1

Stator and rotor flux counter clockwise 2

Stator and rotor flux counter clockwise 3

Stator and rotor flux counter clockwise 4

Stator and rotor flux counter clockwise 5

Stator and rotor flux counter clockwise 6

Stator and rotor flux counter clockwise 1

Change of flux in coil U

Change of flux in coil U

Change of flux in coil U

Change of flux in coil U

Change of flux in coil U

Change of flux in coil U

Change of flux in coil U