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A study on Different PFC Topologies for Permanent Magnet Brushless DC Drives


Richa Dubey #1 , Kaumil B Shah#2 P.G Student , M.E 3rd Sem, Sankalchand Patel College Of Engg, Visnagar. #2 Asst. Prof. Electrical Dept, Sankalchand Patel College Of Engg, Visnagar.
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AbstractThis paper deals with various widely used configurations, control schemes of single-phase power factor controller (PFC) topologies for Permanent magnet brushless DC motor (PMBLDCM) drives and provides a basis for selection of a appropriate PFC topology for a particular application. Half bridge , Cuk , isolated Zeta converters are used as single-stage power factor correction(PFC) for PMBLDCM fed through a diode bridge from a single-phase ac mains and connected to voltage source inverter (VSI) feeding the PMBLDCM. The proposed converters used in PMBLDCM drive are controlled to have the variable speed operation of the compressor for efficiency improvement of the air conditioning system. An improved power quality is observed with almost unity power factor and improved efficiency of the drive in a wide range of the speed and an AC input voltage.
Index TermsPFC, PMBLDCM, converter , isolated zeta converter. Half-bridge converter, cuk

I.

INTRODUCTION

In the recent years, permanent magnet brushless (PMBL) DC motors (PMBLDCMs) have evolved as a rugged, efficient and dynamic for low-power applications. Usually, the low-power adjustable speed drives (ASDs) are powered from single-phase AC mains through a diode bridge rectifier (DBR) with smoothening DC capacitor and voltage source inverter (VSI)[1]. Improved power quality (PQ) converters are mostly required for many applications involving power converters. The permanent magnet brushless DC motors (PMBLDCMs) are suitable for many low power applications due to high efficiency and wide speed control [2]. Increasing concern of PQ problems in the international power communities has prompted the use of power factor correction (PFC) converters with a PMBLDCM. Since, these PMBLDCMs are fed from a single-phase AC mains through a diode bridge rectifier (DBR) and a smoothening DC link capacitor, which results in a pulsed current from AC mains having various power quality (PQ) disturbances such as poor power factor (PF), increased total harmonic distortion (THD) and high crest factor (CF) of
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P.G Student , M.E 3rd Sem, Sankalchand Patel College Of Engg, Visnagar. (email: richa.elec@gmail.com) #2 Asst. Prof. Electrical Dept, Sankalchand Patel College Of Engg, Visnagar. (email: kbshah.ee@spcevng.ac.in)

current [2]. Moreover, various international PQ standards for low power applications such as IEC 61000-3-2 [3], emphasize on low THD of AC mains current and near unity power factor. Therefore, use of a PFC converter topology for a PMBLDCM drive amongst available topologies is essential. The air-conditioning (Air-Con) is an energy intensive application which normally uses single phase induction motors for driving its compressor and fans. The efficiency of these motors is between 70-80% in the low power range which can be improved by replacing them with PMBLDCMs. Moreover the on-off control employed for the temperature control is not energy efficient and introduces many disturbances in the distribution system along with increased wear and tear of the motor. The use of PMBLDCM for driving the compressor results in energy efficiency improvement of the Air-Con. Moreover, the temperature in the air-conditioned zone can be maintained at the set reference smoothly while operating the Air-Con under speed control [2]. A PMBLDCM is a kind of three phase synchronous motor with a trapezoidal back EMF waveform, having permanent magnets on the rotor and replacing the mechanical commutator and brushes. For air-conditioning systems, the PMBLDC motor is operated at constant torque (i.e. rated torque) and a variable speed to achieve the improved efficiency. The PMBLDCM requires three-phase rectangular current blocks of 120 duration, in phase with the back emf waveform timed to coincide with the intervals of constant phase current to maintain constant torque. Moreover, it needs rotor-position information only at the commutation points, e.g., every 60electrical in the three-phase, therefore, a simple controller is required for commutation [4]. At present, the air conditioning system mostly uses a single phase induction motor to drive the compressor. The single phase induction motor achieves maximum efficiency near rated load only; therefore, it is operated at either full load (compressor on) or not at all (compressor off) to regulate the temperature of the air conditioned zone in a hysteresis band. The frequent on/off operation results in increased losses and wear-tear of the motor, thereby poor efficiency and reduced life of the motor. Alternately, the temperature is maintained constant at the set reference by using a PMBLDCM with the speed control to drive the compressor of the air conditioner. It results in reduced electrical energy consumption and efficiently maintains the room temperature at set reference while delivering desired cooling capacity. Based on the literature review, the proposed widely used three PFC topologies are described below:

II. PFC HALF-BRIDGE BOOST CONVERTER Half-bridge boost converter topology is selected for PFC due to its features of high-voltage conversion ratio, low input current ripple and low conduction loss of switches. The PFC half bridge boost converter operating in continuous conduction mode (CCM) results in low conducted electromagnetic interference (EMI) compared to other PFC converters therefore it is preferred for medium and high power (400W to a few kilowatts) application.

reference voltage(V*dc). The resultant modulating current signal from voltage controller is multiplied with a unit template of input AC voltage and compared with DC current sensed after the DBR resulting in a current error. This current error is amplified and compared with sawtooth carrier wave of fixed frequency (fs) to generate the PWM pulse for the devices of the half-bridge boost DC-DC converter. In a halfbridge boost converter, the switches are operated alternatively with shorting of inductor in between through both switches for boost action. The duty ratio (D) and the value of boost inductor (Li) control its DC link voltage. A high switching frequency (fs) is used for fast control and reduced size of inductors and transformers; however, the switching frequency is limited by the factors such as switching devices used, switching losses of the device, operating voltage and power level. 3)Metal oxide field effect transistors (MOSFETs) are used as the switching device for high switching frequency in the proposed converter. However, insulated gate bipolar transistors (IGBTs) are used in VSI bridge feeding PMBLDCM, as it operates at lower frequency compared to PFC switches thereby the switching stresses are reduced.

Fig.1 Control schematic of Proposed Half-bridge PFC converter fed PMBLDCM drive A PFC half-bridge boost converter based PMBLDCM drive has been employed for a compressor load of an air conditioner. The PFC feature of the half-bridge boost converter has ensured PF close to unity in wide range of the speed and an input AC voltage. Fig. 1 shows detailed diagram of a half-bridge boost PFC converter based PMBLDCM drive for an air conditioner where the control loops along with necessary control signals are mentioned[4]. 1) It has two control loops, namely speed control loop and voltage control loop.A proportional-integral (PI) controller is used for the speed control of the PMBLDCM along with PWM current control through a VSI.The speed control loop begins with comparison of reference speed with speed signal derived from signals of Hall effect position sensors mounted on the PMBLDCM.The resulting speed error is passed through a PI speed controller to get the required torque which is converted to an equivalent current using motors torque constant. 2)This current signal is multiplied with a rectangular unit template in phase with motors back EMF to generate reference three-phase currents of the motor.These reference motor currents are compared with the sensed motor currents to get current error which is amplified and compared with triangular carrier wave to generate the PWM pulses for the VSI switches. The voltage control loop uses an inner loop for current control employing current multiplier approach.The half-bridge boost converter is operated in CCM with an average current control scheme to maintain a constant DC link voltage (Vdc) with PFC action.The voltage controller is a PI controller which processes the voltage error generated after comparision of the sensed DC link voltage (Vdc) with a

4)The PFC converter is constituted by a DC link voltage controller, a reference input current generator and a PWM current controller. The DC link voltage controller is a PI controller which closely tracks the reference voltage and gives control signal (Ic) to minimize voltage error.At kth instant of time, the voltage error Ve(k) is calculated from reference DC link voltage V*dc(k) and sensed DC link voltage Vdc(k) as, Ve(k) (1) The output of the controller Ic(k) at kth instant is given as, Ic (k) = Ic (k-1) + Kpv{Ve(k) Ve(k-1)} + KivVe(k) (2) where Kpv and Kiv are the proportional and integral gains of the voltage controller. 5)Referance input current generator: The reference input current of the half-bridge boost converter (i*dc) is given as, i*dc = Ic (k) uvs (3) =V*dc(k)-Vdc(k)

where uvs is the unit template of the voltage at input AC mains, calculated as, uVs = vd/Vsm; vd = |vs|; vs= Vsm sin t (4)

6) PWM Current Controller: The reference input current of the half-bridge boost converter (i*dc) is compared with the current (idc) sensed after the DBR which results in a current error idc=( i*dc - idc). This current error is amplified by gain kdc and compared with fixed frequency(fs). The PFC feature of the half-bridge boost converter has ensured PF close to unity in wide range of the speed and an input AC voltage. The proposed drive has been found as a

promising candidate for a variable speed compressor of an air conditioner. III. PFC CUK CONVERTER Cuk dcdc converter as a single-stage power-factorcorrection converter for a permanent magnet (PM) brushless dc motor (PMBLDCM) fed through a diode bridge rectifier from a single-phase ac mains. A Cuk dcdc converter is used as a PFC converter because of its continuous input and output currents, small output filter, and wide output voltage range as compared to other single switch converters.

Fig 2:Control scheme of the proposed Cuk PFC converter-fed VSI-based PMBLDCMD.

A Cuk dcdc converter is used as a PFC converter because of its continuous input and output currents, small output filter, and wide output voltage range as compared to other single switch converters. Moreover, apart from PQ improvement at ac mains, it controls the voltage at dc link for the desired speed of the Air-Con. Fig 2. shows the proposed speed control scheme which is based on the control of the dc link voltage reference as an equivalent to the reference speed. However, the rotor position signals acquired by Hall-effect sensors are used by an electronic commutator to generate switching sequence for the VSI feeding only at the commutation points. The Cuk dcdc converter controls the dc link voltage using capacitive energy transfer which results in non pulsating input and output currents . The proposed PFC converter is operated at a high switching frequency for fast and effective control with additional advantage of a small size filter. For high-frequency operation, a metaloxidesemiconductor fieldeffect transistor (MOSFET) is used in the proposed PFC converter, whereas insulated gate bipolar transistors (IGBTs) are used in the VSI bridge feeding the PMBLDCM because of its operation at lower frequency compared to the PFC converter. The PFC control scheme uses a current multiplier approach with a current control loop inside the speed control loop for continuous-conduction-mode operation of the converter. The control loop begins with the processing of voltage error (Ve), obtained after the comparison of sensed dc link voltage (Vdc) and a voltage (Vdc) equivalent to the reference speed, through a proportionalintegral (PI) controller to give the modulating control signal ( Ic). This

signal (Ic) is multiplied with a unit template of input ac voltage to get the reference dc current (Id) and compared with the dc current (Id) sensed after the DBR. The resultant current error (Ie) is amplified and compared with a sawtooth carrier wave of fixed frequency ( fs) to generate the pulsewidth modulation (PWM) pulse for the Cuk converter. Its duty ratio (D) at a switching frequency ( fs) controls the dc link voltage at the desired value. For the control of current to PMBLDCM through VSI during the step change of the reference voltage due to the change in the reference speed,a rate limiter is introduced, which limits the stator current of the PMBLDCM within the specified value which is considered as double the rated current in this work. Circuit shows the proposed speed control scheme which is based on the control of the dc link voltage reference as an equivalent to the reference speed. However, the rotor position signals acquired by Hall-effect sensors are used by an electronic commutator to generate switching sequence for the VSI feeding only at the commutation points. The proposed PMBLDCMD has been found as a promising variable speed drive for the Air-Con system. Moreover, it may also be used in the fans with PMBLDC motor drives on the trains recently introduced in Indian Railways. These PMBLDC motor drive based fans have similar PQ problems as they use a simple single-phase diode rectifier and no speed control. These fans also have inrush current problems. All these PQ problems of poor PF, inrush current, and speed control in these fans on the trains in Indian Railways may be mitigated by the proposed voltage-controlled PFC Cuk converter-based PMBLDCMD. IV. ISOLATED ZETA PFC CONVERTER The two stage PFC converters result in high cost and complexity which can be avoided by using a single stage isolated Zeta buck-boost converter. This converter can tolerate the variation of input voltage in a wide range while maintaining the desired DC link voltage. Many variations of Zeta converter topology with zero voltage or zero current switching.

Fig. 1. Proposed Zeta PFC converter fed PMBLDCM drive.

Fig. 3 shows the proposed PFC drive, which uses control of the reference DC link voltage as an equivalent reference speed.

Since the back emf in a PMBLDCM is proportional to the motor speed and the developed torque is proportional to the phase current, therefore, a stable winding current results in a constant torque and the speed is controlled by the terminal voltage of the PMBLDCM. The rotor position signals are required only for electronic commutation of PMBLDCM using switching of voltage source inverter (VSI). The proposed PFC Zeta converter maintains the desired PQ at input AC mains while controlling the DC link voltage at set reference, by controlling its duty ratio (D). For a fast control with reduced size of magnetics, a high switching frequency is used and a Metal oxide field effect transistor (MOSFET) is employed as the switching device in the PFC Zeta converter. The insulated gate bipolar transistors (IGBTs) are used in VSI feeding PMBLDCM to reduce the switching stress, as it operates at low switching frequency compared to PFC switch. The high frequency transformer (HFT) is used for providing isolation between the input and output stages. Moreover it also provides flexibility for use of large voltage ratio to cope up variation of voltages at input AC mains. A current control loop inside the voltage control loop is used with the current multiplier approach in average current control for the operation of PFC converter in continuous conduction mode (CCM). The control loop processes voltage error (Ve) obtained between sensed DC link voltage (Vdc) and reference DC voltage (Vdc*) equivalent to the reference speed, through a proportional-integral (PI) controller. The PI controller outputs a modulating control signal (Ic), which is multiplied with a unit template of input AC voltage to generate reference DC current (Id*) and compared with sensed DC current (Id). The resultant current error (Ie) is amplified and compared with saw-tooth carrier wave of fixed frequency (fs) to generate the PWM pulse for the MOSFET switch of the proposed Zeta PFC converter. A rate limiter is introduced for the control of PMBLDCM current through VSI during step change of the reference voltage due to the change in the reference speed. The rate limiter maintains the stator current of the PMBLDCM within the specified value. PFC CONVERTER: The PFC converter consists of a voltage reference generator, a rate limiter, a voltage controller, a reference current generator and a PWM controller. 1) Voltage reference Generator : To generate a reference DC link voltage equivalent to reference speed of PMBLDCM, the voltage reference generator is used. It uses the PMBLDCM Back EMF data obtained from tests while operating it at various speeds while driving it using another motor connected to its shaft. The accuracy of the speed control depends upon this equivalent DC link voltage reference. 2) Rate Limiter: A rate limiter is introduced in the reference voltage to control the PMBLDCM current. It is designed to maintain a constant voltage error (Ve) at DC link during transient states so that the motor current (Idc) rises within the specified limits. The incremental rise of the motor current Idc depends upon the equivalent resistance (Req) of the PMBLDC motor and incremental voltage rise Ve at DC link.

Therefore the design of rate limiter controls these incremental voltage and current rise according to various PMBLDCM parameters such as rated terminal voltage (VT), winding resistance per phase (Ra), maximum allowable motor current (Idcmax), and mechanical time constant (m) as given in Table-III. 3) Voltage Controller: A PI controller is used as a voltage controller to generate a control signal Ic, depending upon error voltage between reference and sensed DC link voltage. 4)Reference Current Generator: The reference input current of the Zeta converter (id*) is generated using the unit template of AC mains voltage and output of the PI controller. 5) PWM Current controller :The reference current (id*) and sensed current (id) of the isolated Zeta PFC converter are compared to get a current error which is compared after amplification, with a fixed frequency (fs) saw-tooth waveform md(t) to generate PWM signals for MOSFET switch of the PFC converter.
Table no.1 : Modeling equations of proposed PFC controller.

A single stage isolated Zeta PFC converter has been recommended for speed control of a PMBLDCM driven air conditioner using the reference speed as an equivalent voltage at DC link. The speed of PMBLDCM has been found proportional to the DC link voltage, thereby a smooth speed control is observed while controlling the DC link voltage. An effective control of motor current within the desired limits during the transient conditions has been achieved by using a rate limiter in the reference DC link voltage. The PFC Zeta converter has ensured nearly unity PF in wide range of the speed and the input AC voltage. The proposed PMBLDCM drive has been found as a promising variable speed drive for the Air-Con system in low power range. V. CONCLUSION All the PQ problems of poor power factor, inrush current, and speed control can be removed by using PFC cuk, half bridge, and isolated Zeta PFC converters, also they are reliable and widely used. The above discussed PFC topologies has ensured near unity PF in a wide range of the speed and the input ac voltage. Moreover, PQ indices of the proposed PFC drive are in conformity to the International Standard IEC 61000-3-2.

REFERANCES
[1] B.Singh, S.Singh , Single-phase power factor controller topologies for permanent magnet brushless DC motor drives, IET Power Electron., 2010, Vol. 3, Iss. 2, pp. 147175. [2] ] B.Singh, S.Singh , A Voltage-Controlled PFC Cuk converter based PMBLDCM Drive for Air conditioners, IEEE,2012.

[3]Limits for Harmonics current Emission(Equipment input current< 16 A per phase) INT. Std, IEC 61000-3-2,2000. [4] B.Singh, S.Singh, Half Bridge Boost Converter for Power Quality Improvement in
PMBLDCM Drive. Second ICETET,2009,pp 753-758.

[5] B.Singh, S.Singh,A Voltage-Controlled PFC Cuk Converter-Based PMBLDCM Drive for
Air-Conditioners, IEEE transactions on industry applications, VOL. 48, NO. 2, MARCH/APRIL 2012.

[6] T. Kenjo and S. Nagamori, Permanent Magnet Brushless DC Motors,Clarendon Press, oxford, 1985. [7] J. R. Hendershort and T. J. E. Miller, Design of Brushless PermanentMagnet Motors. Oxford, U.K.: Clarendon, 1994 [8] B. Singh, B. N. Singh, A. Chandra, K. Al-Haddad, A. Pandey and D. P. Kothari, A review of single-phase improved power quality AC-DC converters, IEEE Trans. Ind. Electron., vol. 50, no. 5, pp. 962 981,Oct. 2003.

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