FEC Motor Driver

Project Design Report

Design Team #2
Brad Johnson
Karl Kerstetter
David Nikkel
Steven Stone
Michael Walsh

Faculty Advisor
Dr. Iqbal Husain

Submitted on
November 23, 2004

Table of contents
List of figures .................................................................................................................... iii
List of Tables ..................................................................................................................... iv
Table of Code Listings ........................................................................................................v
Abstract............................................................................................................................... 1
1. Introduction.................................................................................................................... 2
1.1 Statement of Need................................................................................................................ 2
1.2 Problem Definition .............................................................................................................. 2
1.2.1 Goals .............................................................................................................................................2
1.2.2 Objectives .....................................................................................................................................2
1.2.3 Constraints ....................................................................................................................................2

2. Design Requirements ..................................................................................................... 4

2.1 Requirement Specifications ................................................................................................ 4

3. Alternative Design Analysis........................................................................................... 5

3.1 Motors: ................................................................................................................................. 5
3.2 Switching Topographies: .................................................................................................... 6
3.3 Control System: ................................................................................................................... 6
3.4 Communication: .................................................................................................................. 7

4. Accepted Technical Design............................................................................................ 8

4.1 Hardware Design ................................................................................................................. 8
4.1.1 AC/DC Converter .........................................................................................................................9
4.1.2 DC/DC converter ..........................................................................................................................9
4.1.3 Inverter........................................................................................................................................10
4.1.4 Motor ..........................................................................................................................................11
4.1.5 Transformer ................................................................................................................................11
4.1.6 Power Factor Preregulator ..........................................................................................................11
4.1.7 Linear Regulator .........................................................................................................................12
4.1.8 Digital Signal Processor..............................................................................................................13

4.2 Software Design: ................................................................................................................ 15

4.2.1 Speed/Position Module ...............................................................................................................15
4.2.2 Speed Controller .........................................................................................................................15
4.2.3 Current Controller.......................................................................................................................16
4.2.4 PWM Generator..........................................................................................................................16
4.2.5 Fault Monitoring .........................................................................................................................16

4.3 State Diagram .................................................................................................................... 16

4.3.1 Fault monitoring .........................................................................................................................17
4.3.2 Initialize ......................................................................................................................................17
4.3.3 Stop.............................................................................................................................................18
4.3.4 Startup.........................................................................................................................................18
4.3.5 Normal Operation .......................................................................................................................18
4.3.6 Fault ............................................................................................................................................18

4.4 Software Implementation.................................................................................................. 19

4.5 PC Diagnostics ................................................................................................................... 22

5. Testing Procedures....................................................................................................... 24
5.1 Initial System Checks/No Load Testing........................................................................... 24
5.1.1 Input Power Phase-Rectifier/DC-DC converter..........................................................................24
5.1.2 PWM signals from the DSP........................................................................................................24
5.1.3 Inverter switching outputs...........................................................................................................24
5.1.4 No load testing ............................................................................................................................24

5.2 FEC Motor Drive Specifications ...................................................................................... 24

5.3 Drive System Testing Procedures .................................................................................... 25
5.3.1 Output Power ..............................................................................................................................25
5.3.2 Torque.........................................................................................................................................25
5.3.3 Efficiency....................................................................................................................................25
5.3.4 Power Factor ...............................................................................................................................25
5.3.5 Speed Control .............................................................................................................................25
5.3.6 Acoustic Noise............................................................................................................................25
5.3.7 EMI .............................................................................................................................................26

6. Financial Budget.......................................................................................................... 27
7. Project Schedule........................................................................................................... 28
8. Design Team Information ........................................................................................... 29
9. Conclusions and Recommendations ........................................................................... 30
10. References .................................................................................................................. 31
Appendix A Parts List ................................................................................................... 32
Appendix B Relevant Data Sheet Portions................................................................... 35

ii

List of figures
Figure 1: Hardware block diagram ................................................................................................................8
Figure 2: Power Supply and Power Factor Correction Circuit......................................................................8
Figure 3: Inrush current into the inductor of the boost converter. ...............................................................10
Figure 4: IRAMX16UP60B - Integrated Current Shunt Configuration .......................................................11
Figure 5: Steady-state ripple of the boost Power Factor Correction output ................................................12
Figure 6: Controller Circuit..........................................................................................................................13
Figure 7: RS-232 Circuit...............................................................................................................................14
Figure 8: Software Functional Block Diagram.............................................................................................15
Figure 9: Motor Control State Diagram .......................................................................................................17
Figure 10: PC Application Main Panel ........................................................................................................23
Figure 11: PC Application Graphing Panel .................................................................................................23
Figure 12: Project Gantt Chart.....................................................................................................................28
Figure 13: dsPIC overview ...........................................................................................................................36
Figure 14: dsPIC block diagram...................................................................................................................37
Figure 15: Power Module Data Sheet...........................................................................................................38
Figure 16: Development Board for Power Module.......................................................................................39
Figure 17: LM317 Voltage Regulator (U1, U2)............................................................................................40
Figure 18: Power Factor Correction IC (U3)...............................................................................................41
Figure 19: Reset IC (U3)...............................................................................................................................42
Figure 20: DRC01 Input isolated, output-regulated DC/DC converter (U7) ..............................................43
Figure 21: RS232 Driver IC..........................................................................................................................44
Figure 22: Rectifier Bridge Data Sheet.........................................................................................................45
Figure 23: Bridge Rectifier Data Sheet.........................................................................................................46
Figure 24: Transistor (Q1)............................................................................................................................47
Figure 25: Capacitors (C1, C2, C5, C35-C43).............................................................................................48
Figure 26: Diode (D6, D7 use 1N4002-T) ....................................................................................................49
Figure 27: Resistors (R2-R8, R13, R14, R22, R30-R39 USE THIS TYPE OF RESISTOR - 1/2W)..............50
Figure 28: Power Switch...............................................................................................................................51
Figure 29: AC input plug with built-in fuse holder .......................................................................................52
Figure 30: BNC speed input connector.........................................................................................................53
Figure 31: Used to connect controller board to RS232 board......................................................................54
Figure 32: DB9 connector to interface with PC ...........................................................................................55
Figure 33: Connector for In-Circuit Debugger ............................................................................................56
Figure 34: Terminal strip to connect motor to controller board ..................................................................57
Figure 35: Encoder connection.....................................................................................................................58

iii

List of Tables
Table 1: Labor costs......................................................................................................................................27
Table 2: Funding Sources .............................................................................................................................27
Table 3: Complete Parts list..........................................................................................................................32

iv

Table of Code Listings

Listing 1:
Listing 2:
Listing 3:
Listing 4:
Listing 5:
Listing 6:
Listing 7:
Listing 8:

Declarations ..........................................................................................................................19
State: Stop..............................................................................................................................20
State: Start.............................................................................................................................20
State: Normal Operation .......................................................................................................20
State: Fault ............................................................................................................................21
Low Priority Interrupts..........................................................................................................21
High Priority Interrupts ........................................................................................................21
Functions ...............................................................................................................................22

Abstract
Many applications exist today for variable speed drives. Both industrial and residential applications
utilize these types of drives for heating and ventilation, automation, and many other applications.
However, the universal motor brush machines currently in widespread use in home appliances are
inefficient, wasting power and resources. The 2005 Future Energy Challenge (FEC) set forth ambitious
goals for a motor drive system to improve on the efficiency and cost for these applications. The following
design intends to meet the requirements of the FEC with a novel, low cost solution to these problems.
The design is based on the permanent magnet brushless DC motor, a technology proven reliable in
industry and ideal for this application due to its efficiency, cost, and power/torque capabilities. The motor
drive is powered from a standard wall socket and controlled by a digital signal processor utilizing pulse
width modulation to control the speed of the motor.
Key Design Features:
Permanent Magnet Brushless DC Motor (PM BLDC)
Digital Signal Processor (DSP) to control inverter
AC/DC rectifier for AC input from wall socket
DC/DC boost converter to attain necessary motor voltage
6-Switch inverter to control motor speed
Power factor pre-regulator

1. Introduction
1.1 Statement of Need
From their introduction into the consumer appliance and recreation market, brushed based electrical
motors have dominated with their ease of control, price/performance ratio, and reliability. The brushless
motor, as a more recent newcomer, has been too expensive to implement for consumer appliance and
recreational applications. However, with the falling prices of power electronic devices and digital control
systems, these motors are now on the verge of becoming a viable, economic replacement for the
antiquated brush based motor. Brushless motors exhibit similar torque and power properties when
compared to similar sized brushed motors. However, brushless motors require more power electronics
and a more complex control system than similar brushed motors. This drawback is easily made up by the
reliability of brushless motors. Brushless motors have no electrical contact points to the rotor, which is a
common failure point for brushed motors. This also leads to less friction and corresponds to higher
efficiency of the drive. With the motor bearings as the only physical failure point, brushless motors are
the king in reliability, especially in todays warranty and price driven consumer market.

1.2 Problem Definition

1.2.1 Goals
The goal of this project is to produce a prototype brushless motor that, when mass produced, will meet an
aggressive budget of forty dollars for the drive, power electronics, and control system. This drive must
meet criteria that will make it cost effective alternative to the industry standard brushed motor. The
prototype will be produced in such a way that all requirements are met with several percentage points
cushion.
A secondary goal is to be competitive in the 2005 International Future Energy Challenge student
competition. Since this competition sets the minimum standards to which the prototype will be built,
exceeding these standards is the primary goal.

1.2.2 Objectives

Produce an efficient, reliable brushless motor that runs off of a standard 120 volt, 60 hertz power
source.
Meet all the FEC competition requirements.
Contain a self-protection system that will react to continuous stall, over temp, and loss of input
without damage to any system.
Be packaged in a way that is easily implemented and serviceable.

1.2.3 Constraints

Produce 500 watts @ 1500 RPM

Draw power from a standard single phase household wall supply
Cost no more than $40 per unit to build based on 1 millions units produce per year
Have a usable operating range of 150 to 5000 RPM
Exhibit an efficiency of at least 70% for 50 to 500 watt loads across the operating range
2

Use no more than 4 liters of space

Weigh no more than 8 kilograms
Produce 3.18 N-M of torque in from 150 to 1500 RPM
Maintain a power factor of 80% and conform to IEC1000-3-2 across the operating range
Have a standard 0 to 10 volt BNC style input to control the motor speed in a linear fashion
Maintain 5% speed accuracy to the control input signal.
Produce less than 50 dB A-weighted at 0.5 meters
Meet FCC Class A regulations for radiated and conducted EMI
Conform to a maximum of NEMA frame size of #48
Be suitable and fully operational in an indoor and outdoor domestic environment.
A mean time to failure of 90,000 hours

2. Design Requirements
2.1 Requirement Specifications
Produce an efficient, reliable brushless motor that runs off of a standard 120 volt, 60 hertz power source.
Many applications such as home heating and ventilation require a 120VAC 60Hz motor. This project will
cater to these applications. The motor will be capable of maintaining speeds from 150 to 5000 RPM and
produce 3.18 N-m of torque from 150 to 1500 RPM.
Meet all the FEC competition requirements. This project is being submitted to the 2005 Future Energy
Challenge. The requirements are listed in section 1.2.3, Constraints. It is the hope of this design team
to produce a successful design while representing the University of Akron during this project.
Contain a self-protection system that will react to continuous stall, over temp, and loss of input without
damage to any system. To increase cost efficiency, every effort has been taken to reduce the possibility of
any system failure which would require unit replacement or maintenance. Component failure will likely
require unit replacement, as well as downtime while a replacement unit is located and installed. This is
both an inconvenience and unnecessary cost to the end user.
Be packaged in a way that is easily implemented and serviceable. The unit should conform to a
maximum frame size of NEMA #48 and weigh less than 8 kilograms. This will allow the unit to be
installed in a variety of locations and allow for easy installation and if necessary, replacement.

3. Alternative Design Analysis

There are many of options available to simply build a motor drive. The goal of the FEC competition,
however, is to construct an efficient, inexpensive, and novel system. With this in mind, several different
configurations have been researched which could feasibly be used to achieve the goals of the FEC
competition. These configurations include alternative classes of motors, Pulse Width Modulation (PWM)
switching topographies, controllers, and communication protocols. This section will explore the pros and
cons for each alternative.

3.1 Motors:
Motor selection is arguably the single most important decision made in this project. Two different styles
of motors exist that meet the requirements, and are discussed in detail below.
Switched-Reluctance motors (SRM) were some of the first electric motors to be used. They have very
low manufacturing costs and produce a high starting torque. Coupled with modern power electronics and
sensor-less designs, they exhibit an astonishing efficiency that can easily go over ninety percent. Also
important is the fact that it is a brushless motor. There are no contact points between the stator and rotor,
except for the bearings, leading to high mean-time-to-failure operation. The lack of permanent magnets
on its rotor also allows ultra high speed operation (>100,000 RPM), and high temperature applications.
However, no design is without drawbacks. SRMs exhibit a high torque ripple during each revolution.
This ripple is coupled with moderate to high vibrations and noise caused by the excitation of each pair of
poles on the stator. Newer designs have tacked these two drawbacks by adding more poles and stiffening
the stator structure, but this comes at higher manufacturing costs. SRMs also require an expensive and
complex control scheme. Sensors are often used to determine the rotor position, which is required
knowledge in order to turn on the proper switches. Sensors add higher costs to control systems along with
reliability issues. Even though SRMs were one of the first electric motors, they are still very uncommon.
Most applications, until recent, were cost prohibitive.
The Permanent-Magnet Brush-Less Direct Current motor (PMBLDC) is a more common motor that has
proven itself over the last twenty years. It is much quieter than the SRMs and has a relatively easy
control algorithm. It is suitable for many applications where moderate torque ripple is acceptable and
efficiency is not the primary concern. High speed and high temperature operations also pose a problem
for this style of motor due to the permanent magnets on the rotors. However, the slightly elevated
manufacturing cost of the PMBLDC, when compared to the SRM, poses only a small obstacle. Often the
development of an algorithm for a SRM poses a more significant engineering cost than the relatively
simple PMBLDC. As more engineers are educated on the workings and control of SRMs, this cost will
decrease.
Either motor would be suitable for this application. Only minor changes need to be made to switching
and power supply topologies to swap between the two. Both are low cost enough to use, but SRMs do
have the cost advantage if their complex algorithms can be dealt with. Unfortunately, the group was
unable to find a commercially available SRM motor that would fit the bill. This pretty much determined
the motor selection.

3.2 Switching Topographies:

There are two categories for the switching schemes. One for a SRM motor and one for a PMBLDC
motor. The choice of motor ultimately decides with category of switching methods will be used.
However, each motor has different switching methods based on the application and needs. Once the
motor is determined, the cost vs. performance of each method will be analyzed to determine the
appropriate switching method.
For a SRM motor, a 4-switch and a 6-switch topography could be used for this application. With the 4switch method, higher efficiency is achieved along with lower cost and simpler control methods.
However, it also only utilizes 2 quadrant operation and hard switching. The 6-switch method is a better
solution as far as operation, as it utilizes 4 quadrant operation and soft switching. However, with the
additional switches comes a decrease in efficiency and an increase in cost.
The possible topographies for a PMBLDC motor are 6-switch, 8-switch, and C-dump. The C-dump is a
highly efficient option, but is not as fault tolerant as other options.
The 6- and 8-switch topographies are very similar to the 4- and 6-switch topographies used for SRM
motors as far as pros and cons. The 6-switch is more efficient and cost effective, but only offers 2
quadrant operation and hard switching. The 8-switch method offers 4 quadrant operation and soft
switching while sacrificing efficiency, cost, and simplicity.
This project will be using a 6-switch topography to control the PMBLDC motor. The motor is only
required to rotate in one direction, eliminating the need for 4-quadrant operation.

3.3 Control System:

In looking at alternative designs for the control system, there are basically four different ways to control a
Brushless Direct Current (BLDC) motor. The four different control schemes to consider are Digital
Signal Processor (DSP), Microprocessor, Field Programmable Gate Array (FPGA), and Application
Specific Integrated Circuit (ASIC).
A DSP is a very good solution for using to control a BLDC motor. DSPs are designed to process data in
real-time, which is good since a motor control cannot tolerate any delay between calculating the current
position of the motor and when the next phase should be energized and current phase de-energized.
DSPs are also designed for intensive mathematical calculations. This is needed for calculating both
position and actual speed. The disadvantages are DSPs usually have less peripherals available and the
cost. DSPs average cost ranges from $10 to $50 US dollars.
A cheaper alternative to a DSP is the microcontroller approach. A microcontroller is a type of
microprocessor, but specifically designed for control applications. The average cost ranges from less than
a $1 to $15 US Dollars. The disadvantage with a microcontroller is they are usually slower in processing
data, because they are designed to have more peripherals, which allows them to be used in many different
types of applications.
Field Programmable Gate Arrays (FPGA) should also be considered since they are able to process data
fast, do to their dedicated logic circuits. The disadvantages are the can be extremely expensive and they
lack an analog-to-digital converter (ADC). The cost of FPGA from Altera is from $20 to $455 US
6

Dollars1. Since an ADC is not onboard, another IC would be needed which also adds to the cost for this
solution.
The final solution to consider is the ASIC approach. The biggest advantage to this solution is everything
has already been designed and no algorithms need to be written, just drop in the IC and it works. The
disadvantages to this approach are the cost and the inability to change any aspects to how the controller
functions. The cost of ASICs range from just under $2 to $18 US. Of course, the $2 ASIC MC33035 has
very few features, and the $18 MC73110 for example has all of the desired features built in, but the cost
takes up almost half of the target budget of $40.
The controller of choice that appears to meet the necessary requirements is a combination of a DSP and a
microcontroller. It is the dsPIC manufactured by Microchip Inc. It gives us both the computational
power of a DSP but also has the peripherals built in that are need, like a UART. The cost of a dsPIC
ranges from $5 to $8 US depending on the size of memory and options needed.

3.4 Communication:
For providing user feedback and the ability to change the operating parameters of the motor, we have
decided to add some type of communication between the control system and a user interface module. The
interface module could be a laptop or possibly an LCD Display, but what ever the case may be there
needs to be some sort of communication protocol between them. The 2 protocols being considered are
RS-232 and USB.
The RS-232 has been the long running standard for serial type communication, and is very easy to
implement. The disadvantage is it is relatively slow when compared to todays speeds of serial
communication. This shouldnt be a very big issue since only a small amount of data will be transmitted
at any given time. The cost to implement is less than $2 US.
USB on the other hand, is both newer and faster than RS-232. It also has better noise immunity built into
the protocol than RS-232. The big advantage USB has over RS-232 is its a Plug-N-Play type
architecture. Also, Manufactures of PCs and Laptops are starting to replace serial ports with USB ports.
The disadvantages of using USB are the cost to implement and the complexity associated with this
protocol. The cost of Silicon Laboratories CP2101 (a USB to UART IC) is $5.70 US.

Arrow Electronics www.arrow.com Stratix part is most expensive and Cyclone part is the least expensive
7

4. Accepted Technical Design

4.1 Hardware Design
The hardware portion of the electric motor drive will function as shown in Figure 1 below:
AC/DC

Inverter
w/ Gate
Driver

DC/DC

Gate
Driver
Source
Power
Factor
Prereg.

Digital
Signal
Processor

DSP
Source

Figure 1: Hardware block diagram

The preceding block diagram, while very general, provides the basic overall design of the electric motor
drive. Each block will be discussed in depth in the discussion to follow. The complete hardware design
is shown in Figure 2, at the end of this section.
1

POWER SUPPLY AND POWER FACTOR CORRECTION CIRCUIT

+15V REGULATOR

VBUS
+22V
3
1

+22V
D1
20ETF06

VSENSE

R10

D2
4

.25 35W
3

VAC

R11

V+
AC

R12
R18
910k

0.1uF
+

C10
100uF

C12
0.1uF

C7
10uF
C

D4
1N5817

R15
3.9k

Iac

J1
PLUG AC MALE

SW1
20A SPST

R19

VRMS

+5V REGULATOR

VBUS

91k
C14
0.1uF

R20
20k

C24
0.560uF

Q1
IRF460

R22

+22V
3
1

U2
IN OUT
ADJ
LM317T(3)

10

2
D7
1N4002

R23
1k

D9
1N5820

C9
C11
62pF

620pF

PK_LIMIT

D10
1N5343

MUL_OUT
Iac
VRMS

1
2
3
4
5
6
7
8

GND
PK LMT
C/A OUT
I SENS
MUL OUT
I AC
V/A OUT
V RMS

GT DRV
VCC
CT
SS
R SET
V SENS
ENA
V REF

16
15
14
13
12
11
10
9

+22V

C26 .0012uF
C6

VSENSE

R26
84.5k

C2
1uF
B

C8
10uF

0.51uF
10k 1/4W
PK_LIMIT

10k
R27
150k

C25
0.164uF

C5
1uF

D5
1N5817

C27
100pF

R29
1.82k

A
PC INTERFACE

Controller

PC INTERFACE.Sch

Controller.Sch

Iac
VSENSE

R28
R3

UC3854

R25
1.91k

R24
2.49k

U3

R21
20k

620k

GBPB2506W
C13
+22V

D8
1N4748

C1
1uF

+22V

30k 5W
1

R17
4.12k

MUL_OUT
KBPC801

1uF

.25 35W

D3

100

R9

D6
1N4002

R16
392

R13

+22V

C4

470uF

R2
10k

LM317T(3)

R14
8.2M

T1

C3

C45
470uF

IN OUT
ADJ

R1
511k

U1

Figure 2: Power Supply and Power Factor Correction Circuit

8

4.1.1 AC/DC Converter

First and foremost, the AC/DC converter is a necessary component of the design and an obvious starting
point. Direct current devices require a rectified voltage to operate, and that rectified voltage must
eventually come from an AC source.
The AC/DC converter is a full wave rectifier that will provide approximately 108 VDC. This output is
achieved by utilizing four diodes in a bridge configuration. This output is derived from the following
expression which relates the output of a full wave rectifier to the peak voltage of a sinusoidal input:

V DC =

2VRMS

2 2 * VMAX

In order to achieve the AC/DC conversion, a single phase full wave rectifier IC, IR25XB04H,
manufactured by International Rectifier, was utilized based upon the diode blocking voltage capabilities,
cost, and current handling capabilities. The peak forward diode voltage is 0.975V, providing little power
loss. A 450F capacitor is placed across the output to filter the AC components in the output and improve
the DC quality of the output.
This rectified voltage supplies the remainder of the drive. It directly feeds to the DC/DC converter
supplying the motor, as well as a step down transformer that supplies the lower voltage level required by
the remaining components.

4.1.2 DC/DC converter

The DC/DC converter is necessary to boost the rectified voltage of 108 VDC to 400 VDC, the voltage
required by the motor. This converter utilizes the inductance from the high side of a step-down
transformer, which will be discussed later, as the input inductance. The 400 VDC output of this DC/DC
converter supplies inverter the voltage it needs to run the motor.
In order to derive the duty ratio necessary to achieve a 400V output, the following relation, which applies
to boost converters, is used:
Vo
1
=
Vin 1 D

With Vin = 108 V and a desired Vo = 400 V, the required duty ratio is D = 0.73. The period (T) of
switching will be controlled by the power factor preregulator, discussed later.
Immediately following the DC/DC converter is a simple voltage divider network parallel to the output
capacitor. The network consists of two large resistors in series, 511 k on the high side and 9.76 K on
the low side. This results in a voltage of 7.497 V at the node between the two, which will provide the
required 7.5 V reference output voltage for the power factor preregulator.
Because of the high inrush current when the converter is first powered up, an additional divider network is
placed parallel with the output capacitor. This network will supply the required 5V signal to the enable
pin of the power factor preregulator. However, this signal will only reach 5V when the capacitor voltage
reaches 100V. This effectively turns on different stages at different times to minimize the inrush current
due to charging capacitors. Figure 3 shows the inrush current resulting from a simulation run of the
circuit.
9

Figure 3: Inrush current into the inductor of the boost converter.

4.1.3 Inverter
The inverter consists of six Insulated Gate Bipolar Transistors in a high/low configuration. The IGBTs
are arranged such that the phases of the motor can be turned on and off with the correct polarity based
upon inputs from the Digital Signal Processor. They utilize a three high/three low configuration, as
shown below in Figure 4.
The DSP itself can not source sufficient current to control the IGBTs. This issue is resolved by utilizing
six gate drivers. These gate drivers provide the necessary voltage and current to drive the IGBTs.
An integrated power module, manufactured by International Rectifier, was selected as the inverter for this
application. It integrates six IGBTs with bootstrap diodes and a driver IC capable of utilizing the output
signal from the DSP. It also has the capability for temperature monitoring and overcurrent protection.
The IGBTs are rated for a maximum blocking voltage of 600 V and RMS phase current of 6 A at 25 oC.
The only drawback is that an additional power supply is required to provide the 15 V necessary for the
gate driver IC. This will be provided via linear regulator, discussed later.

10

Figure 4: IRAMX16UP60B - Integrated Current Shunt Configuration2

4.1.4 Motor
For the intended application, a Permanent Magnet BrushLess DC motor is ideal. It is a quiet motor based
on proven technology. It is also relatively easy to control when compared to other motors suitable for this
application. Furthermore, the fact that it is brushless decreases the required maintenance and increases
the longevity of the motor.
The motor expected to be used is manufactured by Pacific Scientific, model PMA42N. It is a six pole PM
BLDC motor. It provides a rated power of 1441 watts and maximum speed of 5450 RPM at an operating
voltage of 400 V. The maximum rated winding voltage is 480 V. The back EMF constant is 67 VRMS/kRPM. The DC line-to-line resistance is 5.1 and the line-to-line inductance is 14.5 mH. It meets
the size requirements set forth for the FEC Electric Motor Drive competition.

4.1.5 Transformer
The transformer mentioned earlier is a linear transformer with a turns ratio of 55:13. This provides 22 V
to supply the remaining components of the circuit. The output of the low side of this transformer is
rectified due to the switching current on the high side. This is achieved utilizing a full bridge rectifier IC.
The IC chosen for this application is a KBPC3 series rectifier bridge manufactured by International
Rectifier. The output of this rectifier feeds the remaining components in the circuit. It directly powers the
power factor preregulator as well as two linear regulators.

4.1.6 Power Factor Preregulator

The power factor preregulator serves two purposes in this applicator. First, it controls the MOSFet used
in the DC/DC converter to provide the correct output voltage to the inverter. Second, it controls the
2

Taken from International Rectifier product website.

11

frequency of the switching to maximize the power factor. This is achieved by adjusting the switching
period so that the current drawn by the DC/DC converter resembles is a half-sinusoidal waveform. This
will minimize the current distortion and maximize the power factor. Figure 5 is a simulation output of the
steady-state ripple of the boost power factor correction output.
For this application, the UC3854 manufactured by Unitrode was chosen. It is supplied with a 22 V power
supply from the step down transformer and a 7.5 V reference, as discussed in the DC/DC converter
portion of this report. It also provides the gate driver for the MOSFet used in the DC/DC converter.

4.1.7 Linear Regulator

Two linear regulators, both LM317K manufactured by National Semiconductor, provide the necessary
voltage to both the gate driver IC portion of the inverter module and the DSP. The gate driver IC requires
15 V. The DSP requires 5 V.
By adjusting R1 and R2, the appropriate output voltage can be achieved. The linear regulator forces a
voltage of 1.25 V across the terminals VOUT and ADJ. This voltage is thus forced upon R1. Since the
voltage across R1 is constant, it forces a constant current through it, where IR1=1.25/R1. This also forces
that current to flow through R2 as it is in series with R1.

Figure 5: Steady-state ripple of the boost Power Factor Correction output

12

The resulting voltage is determined by the following equation:

R
VOUT = 1.251 + 2
R1

Note that there is an additional current coming from ADJ of approximately 50 to 100 A. However, this
has a minimal impact on the output (<2% in the case of the 15V supply).
In the case of the 15 V supply, R1 and R2 were found to be 392 and 4.12 k, respectively. For the 5 V
supplying the DSP, R1 and R2 were chosen to be 1k and 2.49 k, respectively.

4.1.8 Digital Signal Processor

The actual control of the motor is going to be implemented in a Digital Signal Processor (DSP). This
system is designed around the Microchip dsPIC30F series. With a 17 x 17-bit high speed multiplier, 40bit ALU, and 15 working registers, this device provides sufficient arithmetic ability for this application.
Figure 6 shows the controller circuitry.
1

QUADRATUREENCODER INTERFACE

+5V
R4

10k

Vdd

RST

+5V

1
CURRENT 2
3
SPEED
4
TEMP
5
INDEX
6
QEI A
7
QEI B
8
9
10
TX
11
12
RX
13
14

Y1

+5V

14.7456MHz

C28
16pF

R31

28
27
26
25
24
23
22
21
20
19
18
17
16
15

AVdd
AVss
PWM1L
PWM1H
PWM2L
PWM2H
PWM3L
PWM3H
Vdd
Vss
PGC
PGD
FLTA
INT1/RD0

L PWM1
H PWM1
L PWM2
H PWM2
L PWM3
H PWM3

R32

QEI B

470

0.1uF
R33
33k

R34
33k

C30

R35
33k

0.1uF

C31
0.1uF

C32
0.1uF

+5V
C17
0.1uF
C

EMUC

R36 470

FAULT

DSPIC30F2010

C16
0.1uF

C29
16pF

MCLR
AN0
AN1
AN2
INDEX
QEA
QEB
Vss
OSC1
OSC2
UTX
URX
Vdd
INT2/RD1

QEI A

470

C15
QIB

U5

INDEX

470
QIA

Vss

R30

INDEX INPUT

DSP CONTROLLER

U4
MCP100

R37

470

EMUD

SPEED INPUT CONNECTION

J2

2
1

INTEGRATED POWER MODULE & 3-PHASE BRUSHLESS DC MOTOR

B
+15V

C33
10uF

VBUS

C18
0.1uF
H PWM1
L PWM1

14

H PWM2
L PWM2

16
19

H PWM3
L PWM3

17
20

FAULT
CURRENT
TEMP

21
22
13

15
18

23

U6
Vdd
H INPUT1
L INPUT1
H INPUT2
L INPUT2
H INPUT3
L INPUT3
FAULT
ITRIP/SENSE
VTH_TEMP
Vss
IRAMS10UP60B

V+ BUS
V- BUS
VB1
U VS1
VB2
V VS2
VB3
W VS3

10
12

2
3

C35
22uF

C19
0.1uF

4
+

C36
22uF

M1

C20
0.1uF

4
5
6
7
8

PHASE A
SPEED

PHASE B
PHASE C

R6
10k

+5V
INDEX INPUT
QIA
QIB

R5
10k

BANANA PLUGS

+5V
INDEX
Q ENCDR A
Q ENCDR B
GND
PM BLDC

1
2

A
+

C37
22uF

C21
0.1uF

Figure 6: Controller Circuit

Critical to the success of this design is the generation of PWM signals to control the current feeding into
the motor. The dsPIC30F provides hardware support for up to six signals, with three duty cycle generators
and six output pins. Three 16-bit special function registers are used to specify the duty cycle values for the
PWM module. All the software will have to do is fill these registers with the appropriate values.

13

Position and speed feedback from the motor is being implemented using an encoder mounted on the
motor. This will produce 1024 signal transitions per revolution. The dsPIC has a Quadrature Encoder
Interface, or QEI, that will take care of much of the logic involved here. The encoder provides three
signals: phase A, phase B, and an index pulse. The index pulse is triggered once every revolution,
providing absolute position information from which to reference the encoder count. The QEI will
determine the direction of the motor by analyzing the order in which the phase changes come in. A 16-bit
counter then contains the actual count of signal transitions on the phase lines. This counter can be set to
reset every time an index pulse is received, and so transforming the counter into an absolute position
reference.
For monitoring fault conditions, the dsPIC provides an Input Change Notification Module. The
International Rectifier inverter chip being used has an overcurrent/ overtemperature signal. The processor
can be configured to generate an interrupt in response to a change on these pins. This removes the need to
constantly poll the fault input.
Also integrated on-chip is a 10-bit high speed analog-to-digital converter, with a maximum sampling rate
of 500ksps. The converter has 16 inputs multiplexed into 4 sample and hold registers. The current design
calls for two A/D conversions, which is well within the capacity of this processor.
The motor driver will be communicating with a PC for diagnostics and troubleshooting. To take care of
this, the dsPIC30F is equipped with a Universal Asynchronous Receiver Transmitter (UART) module.
This capability will be used to establish communication using the RS-232 protocol. Figure 7 shows a
complete block diagram for the dsPIC.
1

CONNECTION FROM CONTROLLER BOARD TO RS232 BOARD

J3

J6

J4

+5V
4
3
2
1

ICD PROGRAMMER & DEBUGGER CONNECTION

TX
RX

6
5
4
3
2
1

1
2
3
4

RX
TX
+5V

CON4

CON4

EMUC
EMUD
+5V

Vpp

RJ11

RS232 DRIVER
ISO +5V
C38
1uF

C39
1uF

C22
0.1uF

C40
1uF

2
6
16

ISOLATED +5V VOLTAGE REGULATOR

+5V

18

V OUT

INPUT GND

ERROR
V REC

SYNC

ENABLE
OUTPUT GND

ISO +5V

9
12

R7

C23
0.1uF

10k

PC TX
TX

C34
10uF

7
11

R8
10k

C42
1uF

13
8
11
10
1
3

R1 IN
R2 IN
T1 IN
T2 IN
C1+
C1 -

GND

V INPUT

R1 OUT
R2 OUT
T1 OUT
T2 OUT
C2+
C2 -

MAX232ACPE(16)

12
9
14
7
4
5

RX
PC RX
B
+

C43
1uF

15

C44
2.2uF 17

U7

V+
VVCC

U8
1

C41
1uF

TO PC COM PORT

DCR01

J5
PC RX
PC TX

1
6
2
7
3
8
4
9
5

A
DB9

Figure 7: RS-232 Circuit

14

4.2 Software Design:

Figure 8 shows a block diagram of the software design. Each block in the diagram represents a separate
module to be implemented. The hardware support described in the previous section makes this design
much simpler. A discussion of each piece follows.
PWM Signals to
Power Stage

imeasured

A
D
C

command

A
D
C

iactual

error

Speed
Controller

idesired

ierror

Current
Controller

ioutput

PWM
Generator
Rotor
position

actual
Temperature
Overcurrent

Speed / Position
Module
Encoder
input

Fault
monitoring

Figure 8: Software Functional Block Diagram

4.2.1 Speed/Position Module

The speed/position module takes in the signals from the encoder on the motor, and translates these into
speed (actual) and position information. The quadrature encoder interface on the dsPIC contains the logic
to translate the encoder inputs into direction and position information.
The current speed of the motor is determined by the simple calculation t , where is distance
traveled between interrupts, and t is the time elapsed between interrupts. The distance, , is a measurable
constant determined by the physical placement of the sensors on the motor.

4.2.2 Speed Controller

The speed controller takes in the actual and compares it to the speed command (command) coming from the
outside world. command is a 0 10V analog signal referenced to the motor case that determines the speed
at which the motor is running. The motor is required to stay within 5% of the command, or
2V/1000RPM. The difference of the two signals (error) is run through a PID controller to determine the
desired current (idesired).

15

4.2.3 Current Controller

The current controller takes the desired current (idesired) calculated in the speed controller and compares it
to the measured current in the return leg of the inverter. The difference of the two signals (ierror) is fed into
a second PID controller, to produce the output current (iout).

4.2.4 PWM Generator

The PWM Generator block, as the name implies, creates the PWM signals needed to control the circuit in
the power stage. The duty cycle of the signals will be directly related to the output current (iout) from the
current controller. Also feeding into this block is the position information from the speed/position
controller. This is used to determine which switches to turn in the power phase.

4.2.5 Fault Monitoring

The IR25XB04H inverter chip being used provides both overcurrent and overtemperature signals to the
DSP. These signals will be monitored periodically to detect possible fault conditions. The actual speed of
the motor is also compared with the speed command input to determine if there is a stall occurring.

4.3 State Diagram

The controller is being implemented using a state diagram approach. Figure 9 contains the diagram. The
individual states are discussed in detail in the following sections.

16

Initialize

Stop

speedCmd > START_LIMIT

speedCmd > STOP_LIMIT

FAULT_CLEARED

FAULT_DETECTED
Startup

Fault
speedCmd <
STOP LIMIT

FAULT_DETECTED
FAULT_DETECTED

Normal
Operation

actualSpeed >
NORMAL_OP_LIMIT

Figure 9: Motor Control State Diagram

4.3.1 Fault monitoring

The fault monitoring block in the system diagram will be executed during all of the states in our machine,
and used to produce the FAULT_DETECTED signal. There are three possible faults: overcurrent,
overtemperature, and a stall condition. Any one of these will set the FAULT_DETECTED bit. Regardless
of the current state when this occurs, control will be sent to the FAULT state.

4.3.2 Initialize
In the initialization state, all of the relevant registers and ports on the processor will be set to a known,
stable state. Interrupts and timers will also get configured in this state. There is a RESET command (not
shown on the diagram to avoid clutter) that will send the processor to this state from any other state.
When the initialization code is done, the state will change to STOP.

17

4.3.3 Stop
The processor will await a starting command in the STOP state. Inside this state, it will convert the
command input into a digital representation (speedCmd). As long as this does not rise above a preset limit
(START_LIMIT), the controller will remain in the STOP state. When this condition is met, the
STARTUP state will be reached. As mentioned previously, a RESET command will send the machine to
the INITIALIZE state, and a FAULT_DETECTED will send it to the FAULT state.

4.3.4 Startup
Starting operation of the motor will require a different algorithm than that of normal operation. When the
actual speed of the motor, calculated from the motor encoder, reaches NORMAL_OP_LIMIT, the
processor will enter its NORMAL OPERATION state, and implement the primary speed control
algorithm. If the motor fails to attain the required threshold, control will go to the FAULT state.

4.3.5 Normal Operation

In normal operation, speed and current control loops will be operating as described in the block diagram
section of this report. The processor will respond to any changes in the command input and produce the
required PWM outputs to the inverter. This will continue until the speedCmd drops below STOP_LIMIT,
a pre-determined threshold. At this point, the STOP state will be entered again.

4.3.6 Fault
The FAULT state is accessed when an error condition is detected. In this state the processor will attempt
to recover from the fault, and if it is possible, then return to the STOP state. By always going to the STOP
state, unexpected startups of the motor are avoided. It will take a new command to get the motor going
again.

18

4.4 Software Implementation

Listing 1: Declarations
//value above which the motor is turned on
#define START_LIMIT
//TBD
//distance traveled between transitions
#define ENCODER_DISTANCE
//TBD
#define COUNTS_PER_SECOND
//TBD
//value below which the motor is turned off
#define STOP_LIMIT
//TBD
//point where motor leaves startup mode and enters normal operation
#define NORMAL_OP_LIMIT
//TBD
//attempts processor will make to recover from a fault condition
#define MAX_RECOVERY_ATTEMPTS //TBD
//enumeration containing fault values. Will be contained in a single
//int, all logically ORed together
//lower byte contains hard faults, upper byte contains possible fault
enum faultCondition
{ fOk
= 0x00;
fOverCurrent
= 0x01;
fOverTemp
= 0x02;
fStallCond
= 0x04;
fPossibleStall = 0x10;}
faultCondition faultCond = fOk; //contains any fault conditions
//possible device states
enum deviceState
{ sInitialize
= 0x01;
sStop
= 0x02;
sStartup
= 0x04;
sNormalOp
= 0x08;
sFault
= 0x80;}
deviceState dState = sInitialize;
//switch states
enum switchState
{ wAllOff
= 0x00;
wPhase1Upper
= 0x01;
wPhase1Lower
= 0x02;
wPhase2Upper
= 0x04;
wPhase2Lower
= 0x08;
wPhase3Upper
= 0x10;
wPhase3Lower
= 0x20;}
switchState switchesOn = wAllOff;
int
int
int
int
int

speedCmd = 0;
actualSpeed = 0;
actualCurrent = 0;
recoveryAttempts;
desiredCurrent = 0;

//start with all switches off

//result of ADC on external speed signal

//speed determined from encoder signals
//result of AD conversion on current
//keeps track of attempted recovery from fault
//output of speed controller loop

19

Listing 2:

State: Stop

while (dState == sStop)

{
CheckForFaults(&faultCond); //verify everything is working properly
if (faultCond != fOk)
dState = sFault;
//go to fault state
else
{
GetCurrentSpeedCmd(speedCmd); //do AD conversion, get input
if (speedCmd > START_LIMIT)
dState = sStart; //go to start state
//make sure switches are off
switchesOn = wAllOff;
}
}

Listing 3:

State: Start

while (dState == sStart)

{
CheckForFaults(&faultCond); //verify everything is working properly
if (faultCond != fOk)
dState = sFault;
//go to fault state
else
{
while (actualSpeed < NORMAL_OP_LIMIT)
{
//verify speed command is still above threshold
GetCurrentSpeedCmd(speedCmd);
if (speedCmd < STOP_LIMIT)
dState = sStop;
/*
Use open loop control to get the motor spinning. Control the switches based simply on
timing information stored in a lookup table. Meanwhile, monitor the actualSpeed to
make sure the motor is not stalled.
*/
}
//speed is above the threshold to switch over
dState = sNormalOperation
enableCurrentTimer();
//start monitoring current
}
}

Listing 4:

State: Normal Operation

while (dState == sNormalOp)

{
//Processing here is done by interrupts
//Current loop is processed on a timer interrupt,
//and speed loop is processed on encoder interrupts
}
20

Listing 5:

State: Fault

//only leave state if all faults are cleared

//only go to STOP state
while (dState == sFault)
{
CheckForFaults(&faultCond); //update fault status
if (faultCond == fOk)
{
dState = sStop;
}
}

Listing 6:

Low Priority Interrupts

if (interrupt == currentTimer)
{
//Fault check
CheckForFaults(&faultCond); //verify everything is working properly
if ( (faultCond & 0x0f) != fOk)
dState = sFault;
//go to fault state
EnableInterrupts();
//allow other interrupts
DoCurrentADC(actualCurrent);
//Get measured current
//run current controller loop
outCurrent = CurrentController(actualCurrent, desiredCurrent);
PWMController (outCurrent); //update PWM signal
}
else if (interrupt == EncoderTransition)
{
int elapsedTime = timer value;
reset timer;
//get value of up/down counter in QEI, indicating distance from
//index pulse
GetEncoderCount(presentEncoderCount);
//convert position into speed and switches command
SpeedPosition(presentEncoderCount, &actualSpeed, &switchesOn, elapsedTime);
//run speed controller with external speed command and measured speed
GetSpeedCmd(speedCmd)
if (speedCmd < STOP_LIMIT)
dState = sStop;
//go to stopped state
else
desiredCurrent = SpeedController(actualSpeed, speedCmd);
//Diagnostic message to PC
SendMessage(actualSpeed, actualCurrent, faultCond);
}

Listing 7:

High Priority Interrupts

if (interrupt == RESET)
21

{
StopMotor();
//stop motor before resetting
dState = sInit;
}

Listing 8:

Functions

CheckForFaults(faultCondition* faultCond)
{
faultCond = fOk;
if (temperature)
faultCond |= fOverTemp;
if (overCurrent)
faultCond |= fOverCurrent;
// Stall condition
if ( actual speed is much smaller than speedCmd)
{
if ( faultCond & fPossibleStall)
faultCond |= fStallCond;
else
faultCond |= fPossibleStall;
}
};
SpeedPosition (short int presentEncoderCount, int* actualSpeed, int *switchesOn, int
elapsedCount)
{
//set switchesOn parameter to match the encoder count range
switchesOn = encoderCountRange(presentEncoderCount);//lookup table
elapsedTime = elapsedCount/COUNTS_PER_SECOND;
actualSpeed = (ENCODER_DISTANCE/elapsedTime);

};

4.5 PC Diagnostics
A PC application is being written to provide user feedback of how the motor is performing. The
application is developed in National Instruments LabWindows to provide an easy to use windows based
application. The information that will be displayed to the user is speed, temperature, and a graphical
representation of phase current over time. The user will also be able to change the desired speed of the
motor. The motor will still be able to run independently, by providing a DC voltage from 0 to 10 volts.
Figure 10 shows the main panel with temperature and current speed, and the dial to change the desired
speed. Figure 11 shows what the graphical representation of the phase current over time will look like.

22

Figure 10: PC Application Main Panel

Figure 11: PC Application Graphing Panel

23

5. Testing Procedures
5.1 Initial System Checks/No Load Testing
Since the motor drive and motor system involves moving parts at high speeds, it is critical for safety to
inspect key sections of the drive individually before implementing them in the designed system. This will
involve several steps which will verify the successful operation of:

5.1.1 Input Power Phase-Rectifier/DC-DC converter

The input power phase will be connected to the 120Vac/1Phase/60Hz supply. Expected results will be an
output of 400Vdc from the DC-DC converter, 5Vdc, for the DSP, 15Vdc for the switching inverter chip,
and 7.5Vdc for the power factor preregulator.

5.1.2 PWM signals from the DSP

Once the input power phase is verified, power will be applied to the DSP. Using an oscilloscope the
PWM outputs of the DSP will be tested to verify that the calculated PWM scheme is created by the DSP.

5.1.3 Inverter switching outputs

After the DSP PWM scheme is operational, the inverter chip will be connected to the outputs of the DSP.
The outputs of the inverter will be connected to the oscilloscope and tested to verify that the proper output
signals are produced to effectively drive the PM BLDC motor.

5.1.4 No load testing

After the critical sections of the drive system are successfully tested individually, the motor will be
connected to the outputs of the inverter chip and run without a load. A 0-10V analog input will be applied
to the system and the speed of the shaft with no load measured. If the speed is in the ballpark of the 5V =
2500 RPM, and 10V = 5000RPM (values are from the FEC competition specifications), then the system is
essentially working and ready to be assembled as a unit.

5.2 FEC Motor Drive Specifications

Once the initial system checks and no-load testing is successfully completed, the system will be tested to
verify it meets the FEC competition specifications. The FEC competition provides a detailed list of
specifications that the prototype motor and motor drive developed by the team must adhere to. Testing of
these system requirements will be accomplished through several steps outlined below. The specifications
include:

500W continuous shaft output power from 1500-5000 RPM.

Continuous output torque of 3.18 N-m from 150-1500 RPM.
70% efficiency for 50W-500W shaft loads from 150-5000 RPM.
80% power factor for 500W shaft load at 1500 RPM.
Speed controlled by a 0-10V analog input for 0-5000 RPM range. Actual speed must be within 50
RPM or 5% of commanded input voltage (2V/RPM).
Less than 50 dBA sound measured 0.5m from unit in operation.
Meet FCC class A requirements for radiated EMI. (Average EMI = 60 dBV for f> 1MHz).
24

5.3 Drive System Testing Procedures

All of the requirements listed above will be discussed individually, providing explanation of the method
chosen to verify that the system meets the respective specification. The specifications for the FEC
competition are well defined. The nature of the specifications such as output power, torque, and efficiency
are quantified and straightforward to measure. As a result our prototype can be efficiently tested and its
performance to the specs verified.

5.3.1 Output Power

Testing that the system provides continuous output power of 500W from the speed range of 1500-5000
RPM will be accomplished by attaching a load of 500W to the shaft. This will be accomplished by setting
up a testing stand in the energy conversions lab. This will consist of an external motor present in the lab,
coupled to the shaft of the PM BLDC motor with whatever brackets are necessary. The external motor
will provide the load. The PM BLDC motor will then be operated at speeds varying from the minimum to
the maximum of the specified range. If the motor achieves the desired speeds at 500W shaft load, then the
system meets the spec.

5.3.2 Torque
Torque will be determined from the test stand and external motor load. Using this system the output
torque of the motor will be measured. The speed of the motor will be varied from 150-1500 RPM as
specified in the FEC requirements, and if the system provides a continuous output torque of 3.18N-m then
the specification is met.

5.3.3 Efficiency
Efficiency of the system can be measured by the following relation
= Pout / Pin
Therefore, by measuring input power from the 120Vrms/60Hz/ 1-phase supply,
i.e. the current and voltage and comparing with the power used by the motor, efficiency can be
determined. The system will meet the specifications if its efficiency is measured to be at least 70% over
the specified range of shaft loads and speeds.

5.3.4 Power Factor

Power factor will be measured with a Fluke 41B multimeter found in the in the energy conversions lab.
This meter will be connected to the input of the system and will display the power factor. If the value is
greater or equal to 0.8 the specification is met.

5.3.5 Speed Control

The speed control signal will be tested by varying the command signal from 0-10V, then measuring the
resulting speed in RPM of the motor. If the speed is within 5% of the commanded voltage (2V/1000rpm)
or 50 RPM then the specification is met

5.3.6 Acoustic Noise

Acoustic noise of the motor will be measured with some kind of sound detection device (i.e. microphone).
If the motor emits a sound level less than 50dBA 0.5m from the unit over the motor speed range 150-5000
RPM, then the specification is met.

25

5.3.7 EMI
EMI emitted by the motor over the required speed range will be measured with a spectrum analyzer probe
and measurement equipment. If the average of the radiated EMI is less than 60dBV over the distance
specified in the FCC class A industrial standard, then the specification is met.

26

6. Financial Budget
The budget for this project is made up of labor and parts costs. Labor costs, as shown in Table 1, were
calculated at $10.00 per hour for each team member.
Table 1: Labor costs
Team Member
Johnson, Brad
Kerstetter, Karl
Nikkel, David
Stone, Stone
Walsh, Michael

Hours/Wk
10
10
10
10
10

Weeks
30
30
30
30
30

Hourly Rate
$
10.00
$
10.00
$
10.00
$
10.00
$
10.00
Total:

Estimated Cost
$
3,000.00
$
3,000.00
$
3,000.00
$
3,000.00
$
3,000.00
$

15,000.00

Looking at the projected parts cost, per Table 3 in Appendix A, yields a project cost of $2,939.02. This is
not including the team labor costs, which are being donated. This is well above the standard $75.00
available per team member provided by for the Senior Design. The remaining funds are being provided by
the College of Engineering. Table 2 shows the total funds available to the FEC Motor Drive group. This
shows that the project is within its operating budget.
Table 2: Funding Sources

Source

Senior Design Budget

Department of Electrical and Computer Engineering
College of Engineering

27

Amount
$375.00
$1500.00
$1500.00
$3375.00

7. Project Schedule
The Gantt chart below in Figure 12 shows the project schedule for the spring semester. The schedule
extends beyond the end of the semester to fulfill the FEC requirements.

Figure 12: Project Gantt Chart

28

8. Design Team Information

The FEC Motor Driver team is made up of five engineering undergraduate students.

Brad Johnson, Electrical Engineer

Karl Kerstetter, Electrical Engineer, Team Leader

David Nikkel, Computer Engineer

Steve Stone, Computer Engineer

Michael Walsh, Electrical Engineer

29

9. Conclusions and Recommendations

The team is confident that the design set forth here will meet all the requirements listed in the opening
sections of this report. The component choices and control topology will fulfill all the needs of the FEC
competition.
It is possible to create an even more cost effective solution by completely removing any position sensors
on the motor. This is possible by measuring the back emf on the different phases of the motor, and
relating this to the position. This raises the level of complexity of the project greatly, however. After
completing all the objectives and requirements listed in the opening sections of this report, the group will
attempt a sensorless solution.

30

10. References
dsPIC30F Datasheet, Motor Control and Power Conversion Family. (2004). Microchip Technology, Inc.
Shiyoung Lee, Effects of Input Power Factor Correction on Variable Speed Drive Systems, Dissertation
submitted to the Faculty of the Virginia Polytechnic Institute, Feb. 17th, 1999.
John Bottrill, AC Requirement for Power Factor Correction Circuits, Texas Instruments, SLUA263,
Copyright 2002.
Philip C. Todd, UC3854 Controlled Power Factor Correction Circuit Design, Texas Instruments,
Unitrode U-134, Copyright 1999.
Unitrode, High Power Factor Preregulator, Texas Instruments, UC3854 Properties Page, Copyright
1999.

31

Appendix A Parts List

Table 3: Complete Parts list
Qty.

Refdes

Part Num.

Description

??

??

CONNECTOR FOR PMBLDC MOTOR

10

C?

08052R471K9B20D

CAP 470PF 50V CERAMIC X7R 0805

10

C1, C2, C5,

C38 - C43

ECE-A1HKA010

1.0UF 50V MINI ALUM ELECT (KA)

C10

ECA-1HM101

CAP 100UF 50V ALUM LYTIC RADIAL

10

C11

GRM1885C2A620JA01D

CAP CER 62PF 100V 5% C0G 0603

20

C12, C15 C23, C30 C32

08052R104K9B20D

CAP .10UF 50V CERAMIC X7R 0805

C13

B81141C1104M

CAP 0.1UF 440VAC EMI SUPPRESSN

C14

2222 418 41204

CAP FILM MKP .12UF 250VDC 2%

C24

2222 418 75604

CAP FILM MKP .56UF 250VDC 2%

C25

2222 417 41604

CAP FILM MKP .16UF 160VDC 2%

C26

2222 419 41202

CAP FILM MKP .0012UF 400VDC 2%

10

C27

GRM2165C1H101JA01D

CAP CER 100PF 50V 5% C0G 0805

10

C28, C29

GRM1885C1H160JA01D

CAP CER 16PF 50V 5% C0G 0603

C3, C45

EET-ED2W471EA

CAP 470UF 450V ELECT TS-ED

C35 - C37

ECE-A1VKA220

22UF 35V MINI ALUM ELECT (KA)

C4

UVR2W010MPD

CAP 1UF 450V ELECT VR RADIAL

10

C44

GRM219R61E225KA12D

CAP CER 2.2UF 25V 10% X5R 0805

10

C6

2222 416 75104

CAP FILM MKP .51UF 63VDC 2%

C7, C8, C33,

C34

ECA-1EM100

CAP 10UF 25V ALUM LYTIC RADIAL

10

C9

GRM2165C1H621JA01D

CAP CER 620PF 50V 5% C0G 0805

D1

20ETF06FP

DIODE FAST REC 600V 20A TO-220AC

D10

1N5343B

ZENER DIODE 7.5V 5% 5.0W T-18

D2

GBPB2506W

BRIDGE SGL PHASE 600V 25A D-34

D3

8GBU01

BRIDGE SGL PHASE 100V 8A GBU

D4, D5

1N5817-T

DIODE SCHOTTKY 20V 1A DO-41

D6, D7

1N4002-T

RECTIFIER GPP 100V 1A DO-41

32

Cost

Total
Cost

$
$
0.06
$
0.14
$
0.29
$
0.06

$
$
0.64
$
1.40
$
0.87
$
0.59

$
0.09

$
1.82

$
1.77
$
0.65
$
1.13
$
0.61
$
0.30
$
0.07
$
0.07
$
9.34
$
0.15
$
0.31
$
0.50
$
0.80
$
0.15
$
0.17
$
1.69
$
1.20
$
4.50
$
1.79
$
0.68
$
0.26

$
1.77
$
0.65
$
1.13
$
0.61
$
0.30
$
0.74
$
0.72
$
18.68
$
0.45
$
0.31
$
4.99
$
8.00
$
0.45
$
1.73
$
1.69
$
1.20
$
4.50
$
1.79
$
1.36
$
0.52

D8

1N4748ADO41

ZENER DIODE 22V 5% 1.0W DO-41

D9

1N5820-T

DIODE SCHOTTKY 20V 3A DO-201AD

Development
Board

DM300020

BOARD DEV DSPICDEM MC1

MOTORCTRL

Development
Board

IRADK10

KIT DESIGN 3-PH 115-230ACV MOTOR

J1

719W-00/02

CONN RCPT 5X20 FUSEHOLDER SCREW

J2

226978-3

CONN JACK BNC RT/ANG 50OHM AU

J3, J4

TM2REA-0604

JACK-PC MOUNT 6-4

J5

747844-5

AMP HD-20 PCB Right Angle Connectors

RECP FRNT MTL SHL 9P

J6

RJ11-6N-B

CONN MOD RJ11 W/FERRITE BLOCK

M1

PMA42N-00112-00

PM BLDC motor (Price: TBD)

M1

38720-6205

CONN BARRIER STRIP 5POS .375"

M1

38660-7803

CONN TRI-BARRIER STRIP 3POS.500"

Q1

IRF460

500V Single N-Channel Hi-Rel MOSFET

(DC/DC converter transistor)

R?

5063JD9K760F12AF5BC

RES 9.76K OHM METALFILM .40W 1%

R?

B0207C20K00F5TBC

RES 24K OHM 1/2W 5% CARBON FILM

R?, R?

15FR025

RES CURRENT SENSE .025 OHM 5W

R1

5063JD511K0F12AF5BC

RES 511K OHM METAL FILM .40W 1%

R11

286-30K

Xicon 5W Small Metal Oxide Resistors

10

R12

ERO-S2PHF6203

RES METAL FILM 620K OHM 1/4W 1%

R13

CFR-50JB-100R

RES 100 OHM 1/2W 5% CARBON FILM

R14

CFR-50JB-8M2

RES 8.2M OHM 1/2W 5% CARBON FILM

R15

5073NW3K900J12AFXBC

RES 3.9K OHM METAL FILM 1W 5%

R16

MFR-25FBF-392R

RES 392 OHM 1/4W 1% METAL FILM

R17

MFR-25FBF-4K12

RES 4.12K OHM 1/4W 1% METAL FILM

R18

5043ED910K0F12AF5BC

RES 910K OHM METAL FILM .40W 1%

R19

5063JD91K00F12AF5BC

RES 91.0K OHM METAL FILM .40W 1%

10

R2 - R8

CFR-50JB-10K

RES 10K OHM 1/2W 5% CARBON FILM

R20, R21

5043ED20K00F12AF5BC

RES 20.00K OHM METALFILM .40W 1%

R22

CFR-50JB-10R

RES 10 OHM 1/2W 5% CARBON FILM

R23

MFR-25FBF-1K00

RES 1.00K OHM 1/4W 1% METAL FILM

33

$
0.25
$
0.68
$
300.00

$
0.75
$
0.68
$
300.00

$
349.00
$
2.42
$
7.10
$
3.12
$
1.40
$
2.87

$
349.00
$
2.42
$
7.10
$
6.24
$
1.40
$
2.87

$1,200.00
$
3.48
$
7.55
$
13.80
$
0.39
$
0.33
$
1.79
$
0.39
$
0.49
$
0.17
$
0.05
$
0.05
$
0.16
$
0.11
$
0.11
$
0.19
$
0.39
$
0.05
$
0.19
$
0.05
$
0.11

$1,200.00
$
3.48
$
7.55
$
13.80
$
1.95
$
1.66
$
3.58
$
1.95
$
1.47
$
1.71
$
0.27
$
0.27
$
0.80
$
0.54
$
0.54
$
0.95
$
1.95
$
0.54
$
0.95
$
0.27
$
0.54

R24

MFR-25FBF-2K49

RES 2.49K OHM 1/4W 1% METAL FILM

R25

B0207C1K910F5TBC

RES 1.91K OHM METL FILM .60W 1%

R26

B0207C84K50F5TBC

RES 84.5K OHM METAL FILM .6W 1%

R27

B0207C150K0F5TBC

RES 150K OHM METAL FILM .6W 1%

R28

MFR-25FBF-10K0

RES 10.0K OHM 1/4W 1% METAL FILM

R29

B0207C1K820F5TBC

RES 1.82K OHM METAL FILM .6W 1%

R30 - R32,
R36, R37

CFR-50JB-470R

RES 470 OHM 1/2W 5% CARBON FILM

R33 - R35

CFR-50JB-33K

RES 33K OHM 1/2W 5% CARBON FILM

R9, R10

TDH35PR250J

RESISTOR .25 OHM 35W SMD TO220

SW1

CRE22F2FBRNE

SWITCH ROCKER SPST RED 20A QC TE

T1

U1, U2

LM317KCS

IC VOLT REG POS ADJ 3TERM TO-220

U3

UC3854N

IC ENH HIGH P-F PREREG 16-DIP

U4

MCP100-450HI/TO

IC SUPERVISOR ACTIVE LOW TO-92

U5

DSPIC30F2010-30I/SPG

IC DSPIC MCU/DSP 12K 28DIP

U6

IRAMS10UP60B

Plug n Drive Integrated Power Module

U7

DCR010505P

IC ISO DC/DC CONV 5V TO 5V 18DIP

U8

MAX232N

IC DUAL EIA-232 DRVR/RCVR 16-DIP

Y1

HC49US14.7456MABJ

CRYSTAL 14.7456 MHZ HC49/US

Software

SW006012

C COMPILER FOR DSPIC30F FAMILY

1 mH primary side transformer, secondary

size windings to be adjusted.

$
0.11
$
0.33
$
0.33
$
0.33
$
0.05
$
0.11
$
0.05
$
0.05
$
8.17
$
0.95
$
$
1.36
$
2.45
$
0.33
$
11.35
$
19.30
$
9.91
$
0.78
$
0.88
$
895.00

Total

34

$
0.54
$
1.66
$
1.66
$
1.66
$
0.27
$
0.54
$
0.27
$
0.27
$
16.34
$
0.95
$
$
2.72
$
2.45
$
0.33
$
11.35
$
19.30
$
9.91
$
0.78
$
0.88
$
895.00

$2,939.02

Appendix B Relevant Data Sheet Portions

35

Figure 13: dsPIC overview

36

Figure 14: dsPIC block diagram

37

Figure 15: Power Module Data Sheet

38

Figure 16: Development Board for Power Module

39

Figure 17: LM317 Voltage Regulator (U1, U2)

40

Figure 18: Power Factor Correction IC (U3)

41

Figure 19: Reset IC (U3)

42

Figure 20: DRC01 Input isolated, output-regulated DC/DC converter (U7)

43

Figure 21: RS232 Driver IC

44

Figure 22: Rectifier Bridge Data Sheet

45

Figure 23: Bridge Rectifier Data Sheet

46

Figure 24: Transistor (Q1)

47

Figure 25: Capacitors (C1, C2, C5, C35-C43)

48

Figure 26: Diode (D6, D7 use 1N4002-T)

49

Figure 27: Resistors (R2-R8, R13, R14, R22, R30-R39 USE THIS TYPE OF RESISTOR - 1/2W)
50

Figure 28: Power Switch

51

Figure 29: AC input plug with built-in fuse holder

52

Figure 30: BNC speed input connector

53

Figure 31: Used to connect controller board to RS232 board

54

Figure 32: DB9 connector to interface with PC

55

Figure 33: Connector for In-Circuit Debugger

56

Figure 34: Terminal strip to connect motor to controller board

57

Figure 35: Encoder connection

58