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Abstract— Brushless DC (BLDC) motor are now a days control scheme is discussed in section VI, and experimental
becoming popular in battery operated vehicles, fuel pumps, results in section VII.
medical equipments, printers and in many other domestic,
industrial and aerospace applications because of its light weight, II. MODELLING OF BLDC MOTOR
high operating speed and excellent speed-torque characteristics. The modeling of BLDC motor drive system is based on
However, BLDC motor requires complex and expensive high- the following assumptions.
speed driver and converter circuits to perform electronic All the stator phase windings have equal resistance per
commutation and suitable control circuits for implementing
phase and constant self and mutual inductances.
control techniques. This paper presents a compact, economical
high-speed driver and converter circuits and a pulse width
1. Power semiconductor devices are ideal.
modulation (PWM) control strategy implemented in a versatile 2. Iron losses are negligible.
Aduc812 micro controller for achieving better performance. 3. The motor is unsaturated.
The results presented shows that this experimental set up will Based on the above assumptions, the three phase input
yield better performance. voltages [2] are expressed as follows.
dia
Keywords-BLDC drive; high performance; low cost; PWM va = Ria + L + ea (1)
dt
I. INTRODUCTION di b
v b = Ri b + L + eb
Brushless DC motors used in variety of applications dt (2)
require low-cost, compact, high performance drive system
for smooth operation over a wide speed range. The BLDC di
motor is preferred now days for many applications because v c = Ri c + L c + ec
of its reduced size, weight, excellent speed-torque
dt (3)
characteristics, less maintenance and spark less operation. The Electro magnetic torque is expressed as
But the BLDC motor requires expensive built-in position 1
sensors to sense the position of the rotor and generate gating Te = ( e a i a + e b ib + e c i c ) (4)
signals for the semiconductor switches in the converter in ω
order to perform electronic commutation by decoding the The electromagnetic torque can also be expressed as
position sensor signals with the complex decoder and driver 2 EI
circuits [1], [3], [4]. The conventional drive circuits are Te = (5)
expensive, bulky and more complex. This paper proposes a ω
low-cost, compact, high performance BLDC drive system
employing hybrid power IC and low cost microcontroller Where E = ea = eb = ec and I = i a = ib = i c
and sensor circuits. This paper is organized as follows.
Modeling of BLDC is described in section II, experimental The electromagnetic torque can be expressed in terms of
set up is discussed in section III, features of ADUC812 mechanical parameters as
digital controller is discussed in section IV, PWM control dω
technique is discussed in section V, implementation of speed Te = TL + J + Bω (6)
dt
978-0-7695-3845-7/09 $26.00
$25.00 © 2009 IEEE 456
DOI 10.1109/ARTCom.2009.66
where va, vb, and vc are the stator phase winding IV. ADUC812 DIGITAL CONTROLLER
voltages of phase a, b and c respectively, ea, eb , and ec are The die-size, low-cost Aduc812 microcontroller [5], [11]
the back-emfs of phase a, b and c respectively, ia, ib, and ic has a fully integrated 12-bit data acquisition system
are the phase currents of phase a, b and c respectively, TL is incorporating multi-channel ADC, dual DAC and
the load torque, J is inertia, ω is angular speed, B is viscous programmable 8-bit microcontroller control unit on a single
damping coefficient. chip. The programmable 8051-compatible core is supported
III. EXPERIMENTAL SET UP by 8K bytes Flash / EE program memory, 640 bytes Flash /
EE data memory and 256 bytes data SRAM on-chip. The
The experimental set up shown in Fig. 1 consists of 8051-Compatible core with an internal clock source of 12
motor-generator set up, speed, current and voltage measuring MHz has three 16-Bit Timer/Counters, 32 Programmable I/O
sensor circuits, power converter and digital buffers to lines out of which port 3 has high Current Drive Capability
interface digital controller with power circuit. High-speed and Nine Interrupt Sources. The functions of the
opto-coupler MOC 7811 and disk with equally spaced slots microcontroller include determining the rotor position from
near the outer periphery attached to the shaft of the motor, is the hall sensor signals so as to switch ON the required power
used to generate pulses of accurate width for the semiconductor devices at the appropriate rotor positions to
measurement of speed. The pulse generated is applied as an produce a continuous unidirectional torque, generation of
external clock for the counter so as to accurately measure the PWM signal, measurement of speed, line currents and phase
speed. The low-cost, reliable power hybrid IC voltages. The microcontroller not only reduces the cost and
IRAMA20UP60B is integrated with high speed driver and size of the circuit but also it performs computation at greater
IGBT inverter with thermal overload and short-circuits speed due to its high internal clock frequency and
current limit protection circuits. The hybrid power module architecture design.
IC replaces the conventional bulky and expensive IGBT
inverter and associated isolation and driver circuits. This IC V. PWM CONTROL TECHNIQUE
requires low voltage nearly 3V and 0V to turn OFF and turn In the proposed pulse width modulation control technique
ON respectively. Moreover the effects of electromagnetic [12], the duty cycle of the 20 KHz generated by the
interference and noise signal are completely eliminated. The microcontroller is varied to control the current and average
high-speed digital buffer IC 74HCT244 is used to interface voltage in the windings and hence the torque produced by
microcontroller with hybrid power module IC and hall the motor. The motor if connected to load initially has to be
sensor circuit. The hall sensor signals are applied as input to started with maximum duty cycle in order to produce
the microcontroller through buffer IC and the gating signals sufficient starting torque by allowing sufficient starting
generated by the microcontroller for the IGBT switches are current in the windings. The choice of 20 KHz PWM signal
also applied through buffer IC. Since Port 3 of is made because of the absence of acoustic noise during the
microcontroller has high output driving capability, pins P3.0 motor operation. The expression for average voltage applied
to P3.5 are used for the generation of gating signals. The hall across the winding is given by equation 8. The timer
sensor signals are applied to input port 1 pins P1.0 to P1.2 continuously generates PWM signal while the
through buffer IC. The PWM signal is generated at pin 3.6 microcontroller is executing the main program. The main
using timer1. Counter 0 is used for accurate measurement of advantage of PWM control over resistive power controller is
speed. The program is written for microcontroller using Keil that variable power can be supplied to the motor by varying
software and the output hex file generated is downloaded the duty-cycle without much power loss. Therefore, the
from personal computer to microcontroller. system efficiency is high, while delivering average current in
IGBT Power Hybrid Inverter
the form of pulses to the motor.
+
t on
T1 T3 T5 Motor Generator Set
% Dutycycle = *100 (7)
DC Input Voltage
A
B
T
C Vo ( avg ) = Dutycycle * Vdc (8)
T4 T6 T2 Signal Conditioning Hall Sensor & Speed
_ and Filter Circuits Sensor Signals Where ton is turn on time, T is total time period of PWM
signal, Vdc is the dc input voltage applied to the bridge and
Back Emfs
Gate Driver (Ea, Eb, Ec) Vo (avg) is the average dc voltage applied across the
& winding.
Phase Currents
(Ia, Ib, Ic)
VI. DESCRIPTION OF SPEED CONTROL OF BLDC DRIVE
The flowchart shown in Fig. 2 and Fig. 3 describes the
Personal ADUC812 algorithm implemented in the digital controller for
Computer Microcontroller
controlling the speed of BLDC motor. Initially, initialize the
Figure 1. Experimental set up port1 of microcontroller as input port to identify the rotor
position by reading hall senor signals and port 3 as output
457
port for generating control signals for the IGBTs and a pulse Timer 0 interrupt
width modulated signal. The control signals are given to subroutine
Ib
Measure the Actual Speed and compute
the error signal = set speed – actual speed
Ic
T
T5,T6 T6,T1 T1,T2 T2,T3 T3,T4 T4,T5 T5,T6 T6,T1 T1,T2 T2,T3 T3,T4 T4,T5
Decrease the -ve Check whether +ve Increase the 0o 30o 60o 90o 120o 150o 180o 210o 240o 270o 300o 330o 360o
error is +ve, -ve duty-cycle
duty-cycle
or within the Figure 4. Ideal back-emfs and phase currents of a 3 phase BLDC motor [
top to bottom: Phase Voltages (Ea, Eb, and Ec), Line Currents (Ia, Ib, and
Ic) and Torque (T)]
No change in the duty-cycle The step change in the input reference speed from 700 to
1600 rpm and the corresponding output speed response is
shown in Fig. 12 -Fig.13. The output speed response reveals
that there is no overshoot, output responds faster to the
change in the reference speed, zero steady state error and the
Figure 2. Flowchart for the implementation of speed control
system does not require conventional controllers. The
photograph of the hardware set up is shown in Fig. 14.
458
H1
5 V/div Voltage
H2
H3
Hall Sensor
Current
Signals Conducting Ia
Rotor Position
H1 H2 H3 Devices
5 A/div
60o- 90o 240o- 270o 0 0 1 T1, T2
Ic
90o- 120o 270o- 300o 1 0 1 T2, T3
150 - 180 o o o
330 - 360 o
1 1 0 T4, T5 4 ms/div time
H1 Ea
Voltage
2 V/div
H2 Eb
H3
36 V/div
Ec
2 ms/div time
Figure 6. Hall Sensor Signals [ top to bottom: H1, H2, and H3] 4 ms/div time
Ea
Figure 10. Phase Voltages with PWM [top to bottom: Phase a, b,and c]
36 V/div
Eb
Current
Ec
5A/div
459
APPENDIX
Parameters Of BLDC Motor
Rated Voltage 36V
Speed
Rated Current 5A
No. of Poles 4
No. of Phases 3
Rated Speed 4000 RPM
Rated Torque 0.42 Nm
time (ms) Torque Constant 0.082 Nm/A
Figure 12. Step change in the input reference speed from 700 to 1600 rpm Mass 1.25 KG
with 50% load Inertia 23 KGM2 * 10-6
Terminal Resistance 0.38 Ω
Line-Line Inductance 1 mH
ACKNOWLEDGMENT
Speed
460