Motion Control Engineering: Author: Tran Cau

MOTION CONTROL ENGINEERING
Author: Tran Cau
https://www.youtube.com/watch?v=y7fVuVfTPmU
AET - HUST
Contents
• Introduce for BLDC motor
• Modelling BLDC motor
• Modelling Inverter
• Introduce the current sensor and position sensors.
• Design the speed and torque controller.
• Practice on Simulink - Matlab
01/29/2022 2
AET - HUST
Overview of BLDC Motor or PMSM
1. Configuration of BLDC motor
Replace brush and commutator

of DC motor with magnetic sensor and
electronic switch
 Brush and commutator do not exist
• Back EMF: Trapezoidal

Stator: Concentrated winding
Rotor: Uniformly magnetized
permanent magnet (PM)
2-phase excitation, 120° conduction,
square wave current
Low cost
Produce torque ripple due to
commutation
AETPower Electronics
– AUTOMATION Laboratory
ENGINEER TRAINING
1. Commutating a BLDC Motor
• We turn on two coils at the same

time in such a way that if one coil
has positive current, the other
energized coil has negative current.
• We pull one coil high, we pull

another coil low
• The 6-step switching

pattern to the right will result
in a full 360 degree rotation
of the rotor. In each state,
two coils are on and one coil
is off
ENGINEER TRAINING
• Each coil has positive current for

120 degrees, turns off for 60
degrees, negative current for
another 120 degrees, and then off
again for 60 degrees. Also, the
switching pattern for each phase
is offset from the other phases by
120 degrees.
• The problem is knowing WHEN to

switch the currents.
ENGINEER TRAINING

Three hall-effect devices
This will result in 6 unique hall-effect

states for every 180 degrees of motor
rotation.
At the end of each state, the controller commutates the current out of
one coil and into another coil.
ENGINEER TRAINING
ENGINEER TRAINING
2. Modelling the BLDC
The voltage equations of BLDC motor are:
ENGINEER TRAINING

The electromagnetic torque equation
P T  e r
P e i a a
 e bi b  e ci c
The equation of motion:
ENGINEER TRAINING
The trapezoidal back-EMF wave forms are modeled as a function of rotor position so
that rotor position can be actively calculated according to the operation speed. The
back EMF’s are expressed as a function of rotor position:
The trapezoidal shape functions with limit values between +1 and -1:
ENGINEER TRAINING
Model of BLDC motor

There are three models:
• Electrical model
• Torque model
• Motion model
ENGINEER TRAINING
• Electrical model
ENGINEER TRAINING
• Torque model
• Motion model
ENGINEER TRAINING

Model one phase of BLDC
Assume that phase A, B is conducted
In other way, we have:
ENGINEER TRAINING

From previous slide, we have the equation:
Using the Laplace method:
Like the DC motor model
ENGINEER TRAINING

Measure R and L:
• Digital multi meter

• RLC meter
ENGINEER TRAINING
• Back-EMF constant
One-phase measurement: Measure the

generated phase voltage (between one phase
terminal and neutral point of the motor).
Usually the neutral point is not accessible;
then measure the line-to-line voltage
Three-phase measurement: If the neutral point is not accessible, it’s possible to create the artificial neutral
point from all three voltage probe clips connected together
Single phase measurement (line-to-line voltage measurement):
Three-phase measurement (phase voltage measurement):
ENGINEER TRAINING
• Back-EMF constant
ENGINEER TRAINING
Design one phase of BLDC
ENGINEER TRAINING
Design Control for BLDC Motor
1. Design one phase of BLDC
Dynamic equation:
Assuming that:
1
k
J
ENGINEER TRAINING
Design speed control for one phase of BLDC
ENGINEER TRAINING
Choosing 𝜀 = 1,
Response time :
ENGINEER TRAINING
PI controllers make a larger overshoot or undershoot during the transition than IP

controllers. This fact is observed when we compare the controller outputs: The PI
controller produces a higher current command, i∗, than an IP controller for the
step input.
ENGINEER TRAINING
The feedback speed
ENGINEER TRAINING

• 3-phase Voltage Source Inverter
• Consists of 6 power switches and 6 free-wheeling diodes
• 6 switches: Transfer energy to motor
• 6 free-wheeling diodes: Provide free-wheeling path for inductor current
under deceleration or braking condition
ENGINEER TRAINING

ENGINEER TRAINING

ENGINEER TRAINING

ENGINEER TRAINING
3. Design control for BLDC

The BLDC motor rotation is controlled by a six-step commutation technique
(sometimes called 60, 120 degree control)
The six-step technique creates the voltage system with six vectors over one
electronic rotation
The applied voltage needs to have amplitude and phase aligned with the back EMF
• Control the applied amplitude
• Synchronize the six-step commutation with the rotor position
ENGINEER TRAINING
Hysteresis Controller
PI controller
Advantages:
• Only one current at a time needs to be controlled.
• Only one current sensor is necessary (or none for speed loop only, as detailed in the
next sections).
• The positioning of the current sensor allows the use of low cost sensors as a shunt
ENGINEER TRAINING
• Hysteresis-type current regulator
The power transistors are switched off and on according to whether the current is
greater or less than a reference current.
The error is used directly to control the states of the power transistors.
The hysteresis controller is used to limit the phase current within a preset
hysteresis band.
Hysteresis controller
ENGINEER TRAINING
• Hysteresis-type current regulator
This method is more commonly implemented in drives where motor speed and load
do not vary too much, so that the variation in switching frequency is small.
ENGINEER TRAINING
Current Control Loop
ENGINEER TRAINING
ENGINEER TRAINING
Phase current of BLDC motor
ENGINEER TRAINING
Control structure of BLDC motor
Hall Sensors A, B and C are connected to IC1, IC2 and IC3, respectively, on the
Input Capture (IC) module
ENGINEER TRAINING
SEQUENCE FOR ROTATING THE MOTOR IN CLOCKWISE DIRECTION
SEQUENCE FOR ROTATING THE MOTOR IN COUNTERCLOCKWISE DIRECTION
ENGINEER TRAINING
Design the state machine for high level design.

INIT STATE
5 state machine for system:
• Initialize state STANDBY STATE
• Standby state
• Run state
• Error state
• Stop state
RUN STATE ERROR STATE
STOP STATE
ENGINEER TRAINING
For control BLDC motor:

• Initialize state
Implement: PWM, ADC, ECAP, …
Control variables
Calibration to get zero offset of currents.
• Standby state
Wait to RUN command
• RUN state
Implement control algorithm: Speed control, current control
• ERROR state
Disable pwm module, report error codes,
Error code contains: overcurrent, over voltage, under voltage, temperate, short
circuit
• STOP state
Disable pwm module
ENGINEER TRAINING
In the reality, at measured point always have the offset voltage. Therefore, we
need to measured this offset. This action is called by calibration function.
At the beginning of the program, Calibration action will be implemented.
Example, we will measure 512 times or 1024 times and calculate the average value
of these offset.
adc _ reality  adc _ measured  offset _ value
ENGINEER TRAINING
ENGINEER TRAINING
Increment for adc value

ENGINEER TRAINING
Capture for Hall signal
ENGINEER TRAINING
ENGINEER TRAINING
Pseudo-vector Control- An Alternative Approach for Brushless DC Motor Drives
• Pseudo-Vector Control" (PVC) to reduce torque ripple in Square-wave

PM Motors (BLDC motor)
ENGINEER TRAINING
Principle of pseudo-vector control
In the conventional square-wave phase current control
• The reference currents depend only on Hall-sensor signal
Pseudo-vector control
• Using back-EMFs into account in calculation of reference currents
if the currents and EMF do not match each other, torque ripple occurs
ENGINEER TRAINING
Principle of pseudo-vector control
If the reference currents are followed by back-emf, there would be no torque ripple
ENGINEER TRAINING
Clark Transformation
The Clark transform is a set of mathematical

relationships that allow you to represent a three-phase
system as a two phase system
Three sinewaves u(t), v(t), and w(t), as shown below, which are applied to the C, A,
and B stator windings respectively of a three-phase machine.
Each winding in the motor is separated spatially from the other windings by 120
degrees
ENGINEER TRAINING
Clark Transformation
For any resultant vector (not just the one

shown), we can represent it as the vector addition of an α
vector and a β vector, which are at 90 degrees with
respect to each other
ENGINEER TRAINING
Park Transformation
the Park transform is a reference frame translation process that allows you
to change from a stationary reference frame to a rotating reference frame
Assume that we want to create a

stator current vector that has a
constant magnitude, and rotates at
a fixed angle with respect to the d-
axis
ENGINEER TRAINING
Park Transformation
ENGINEER TRAINING
The power equation can be rewritten in d-q frame:
Balancing the power for system
If we can a priori select the reference current Id*

we can calculate the reference current Iq, for a given speed and desired torque Te.
ENGINEER TRAINING
At the regular method, we should set Id*= 0

• Id represents to flux
• Iq represents to torque
ENGINEER TRAINING
ENGINEER TRAINING
ENGINEER TRAINING
ENGINEER TRAINING
ENGINEER TRAINING
ENGINEER TRAINING
Calculation of tA and tB
ENGINEER TRAINING
Space Vector PWM - Alternative Method by Using Stationary dq

variables
Determine the sector
ENGINEER TRAINING
Duty Computation
ENGINEER TRAINING
Results for simulation
Three phase currents
Speed
ENGINEER TRAINING
ENGINEER TRAINING

Motion Control Engineering: Author: Tran Cau

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MOTION CONTROL ENGINEERING

Author: Tran Cau

1. Configuration of BLDC motor

Replace brush and commutator

• Back EMF: Trapezoidal

• We turn on two coils at the same

• We pull one coil high, we pull

• The 6-step switching

• Each coil has positive current for

• The problem is knowing WHEN to

1. Commutating a BLDC Motor

This will result in 6 unique hall-effect

1. Commutating a BLDC Motor

2. Modelling the BLDC

The voltage equations of BLDC motor are:

2. Modelling the BLDC

The equation of motion:

2. Modelling the BLDC

2. Modelling the BLDC

Model of BLDC motor

2. Modelling the BLDC

2. Modelling the BLDC

2. Modelling the BLDC

Assume that phase A, B is conducted

In other way, we have:

2. Modelling the BLDC

Using the Laplace method:

Like the DC motor model

2. Modelling the BLDC

• Digital multi meter

2. Modelling the BLDC

One-phase measurement: Measure the

Single phase measurement (line-to-line voltage measurement):

Three-phase measurement (phase voltage measurement):

2. Modelling the BLDC

Design one phase of BLDC

1. Design one phase of BLDC

PI controllers make a larger overshoot or undershoot during the transition than IP

The feedback speed

2. Modelling the BLDC

2. Modelling the BLDC

2. Modelling the BLDC

2. Modelling the BLDC

3. Design control for BLDC

3. Design control for BLDC

Current Control Loop

3. Design control for BLDC

Phase current of BLDC motor

Control structure of BLDC motor

SEQUENCE FOR ROTATING THE MOTOR IN CLOCKWISE DIRECTION

SEQUENCE FOR ROTATING THE MOTOR IN COUNTERCLOCKWISE DIRECTION

Design the state machine for high level design.

5 state machine for system:

• Initialize state STANDBY STATE

For control BLDC motor:

At the beginning of the program, Calibration action will be implemented.

Increment for adc value

Capture for Hall signal

• Pseudo-Vector Control" (PVC) to reduce torque ripple in Square-wave

• The reference currents depend only on Hall-sensor signal

• Using back-EMFs into account in calculation of reference currents

The Clark transform is a set of mathematical