Sensorless BLDC motor control

By Vikas Upadhyay Enrolment No. 11AU-1239

Thesis submitted to the Department of Electronics and Communication at University of Allahabad in partial fulfillment for the degree of MASTER OF TECHNOLOGY In Electronics Engineering

Under Guidance of:

Prof. C. K. Dwivedi Department of Electronics and Communication University of Allahabad, Allahabad, May- 2013
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DEPARTMENT OF ELECTRONICS AND COMMUNICATION UNIVERSITY OF ALLAHABAD

CERTIFICATE This is to certify that the thesis entitled Sensorless BLDC Motor Control submitted by Vikas Upadhyay for the degree of Master of Technology in Electronics Engineering is the record of research work carried out by her during the period from January 2013 to May 2013 under the guidance of Prof. C. K. Dwivedi and has not previously formed the basis of any degree, diploma, associateship, fellowship, titles in this or any other university or the other/similar institution of higher learning.

Place: Allahabad Date:

C. K. Dwivedi Professor, Dept. of Electronics & Communication, University of Allahabad

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DEPARTMENT OF ELECTRONICS AND COMMUNICATION UNIVERSITY OF ALLAHABAD

DECLARATION I hereby declare that the work incorporated in the present thesis entitled Sensorless BLDC Motor Control submitted for the degree of Master of Technology in Electronics Engineering is the original research work carried out by me under the guidance of Prof. C. K. Dwivedi. This work (in part or in full) has not previously formed the basis for the award to the candidate of any degree, diploma, associate-ship, fellowship or any other similar title in this or any other university or the similar institution of higher learning.

Place: Allahabad Date:

Vikas Upadhyay M. Tech (Electronics Engineering) 4th Semester

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Acknowledgment

I am greatly indebted and respectful to my guide, Prof. C. K. Dwivedi, for his guidance and support through the last two years. His rigorous attitude to do the research and inspiring thinking to solve problems are invaluable for my professional career. I'd like to express my heartfelt thanks to workshop member for their time and efforts they spent on my project. I am also grateful for the help of Department faculty members.

I am sincerely grateful to Prof. R. R.Tewari, Head of Department (Department of Electronics & Communication), University of Allahabad, for his kind help, assistance and for providing me all the necessary facilities in accomplishing this work. I would like to give special thanks to Priyanka maim for her encouragement during my difficult time of my project. I would like to appreciate my fellow students Govind and Nupur in Department of Electronics & Communication. Last but not least, I would like to thank my parent, for her consistent love, support, understanding, encouragement, both in our good time and hard time.

Vikas Upadhyay

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Table of Content
Chapter I: Introduction

09 09 11

1.1 Background 1.2 Brushless DC (BLDC) Motors and Sensor less Drives

Chapter II: Back EMF Detection for Sensor less BLDC Drives

15 15 21 24 25 27 31

2.1 Conventional Back EMF Detection Schemes 2.2 Proposed Back EMF Detection Scheme 2.3 Hardware Implementation of the Proposed Back EMF Detection Scheme 2.4 Key Experiment Waveforms 2.5 An application Example: Automotive Fuel Pump 2.6 Summary

Chapter III: Improved Circuits for Direct Back EMF Detection

32 33 34 36

3.1 Improved Back EMF Detection Circuits for low cost sensor less control 3.2 Improved Back EMF Detection Circuit for Low speed Applications 3.3 Improved nine step commutation for high initial torque

Chapter IV: Starting the Motor with the Sensor less Scheme

38 38 39 40 43

4.1 Introduction 4.2 Test set-up with open loop start 4.3 Start-up Tuning Procedure and phase delay correction 4.4 Correction of Position Detection Errors

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Chapter V: Conclusions and Future Research 5.1 Conclusions 5.2 Future Research

46 46 48

Reference Appendix Datasheet 89c2051 Datasheet IRF540N & IRF4905P Datasheet LM3111p & IRF 2011 PCB layout Microcontroller 89c2051 coding

49 51 51 53 57 60 61

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Table of Figure

Figure 1.1 Typical sensorless BLDC motor drive `

12

Figure 1.2 Equivalent circuit of the BLDC motor for phase A

13

Figure 2.1 Typical three phase current waveforms in the BLDC motor

15

Figure 2.2 The phase current is in phase with the back EMF in brushless dc motor

16

Figure 2.3 BEMF zero crossing detection scheme with the virtual neutral point

17

Figure 2.4 Back EMF sensing based on virtual neutral point

18

Figure 2.5 BEMF zero crossing and phase current commutation points

20

Figure 2.6 Fundamental wave and third harmonics of back EMF for motor

21

Figure 2.7 The microcontroller-based sensorless BLDC motor driver

23

Figure 2.8 Three phase back EMFs and the zero-crossings of back EMFs

24

Figure 2.9 Sequence of zero crossing of back EMF and phase commutation

25

Figure 2.10 Back EMF and zero crossing at low speed operation

25

Figure 2.11 Shows the system block diagram for the sensorless drive system

27

Figure 2.12 Supply conditioning circuit foe fuel pumps application

28

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Figure 3.1 Back EMF detection during the PWM on time

32

Figure 3.2 Complementary PWM signal

34

Figure 3.3 Results of back EMF zero crossing at low speed

35

Figure 3.4 Three phase pre-conditioning circuit

35

Figure 3.5 Proposed nine step commutations

36

Figure 4.1 Shows provides a window to sense the back EMF

39

Figure 4.2 Shows waveforms of terminal voltages

39

Figure 4.3 Shows a traditional sensorless control scheme

39

Figure 4.4 Shows motor terminal voltages

39

Figure 4.5 Rotor position sensing circuit using only one motor-terminal voltage

41

Figure 4.6 Phase voltages and currents for a BLDC

41

Figure 4.7 Rotor position sensing circuit using a low-pass filter

43

Figure 4.8 Phase delays vs. frequency for a typical low-pass filter design Figure 4.9 Waveforms showing circulating current with a phase-delay < /

43 44

Figure 4.10 Operating waveforms showing delay time correction

45

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Chapter I: Introduction
1.1 Background
Brushless dc (BLDC) motors are desirable for fractional horsepower speed control motors due to their high efficiency, silent operation, compact form, reliability, and low maintenance. However, the control complexity for variable speed control and the high cost of the electric drive hold back the widespread use of brushless dc motor. Over the last decade, continuing technology development in power semiconductors,

microprocessors/logic ICs, adjustable speed drivers (ASDs) the control schemes and permanent-magnet brushless electric motor production have combined to enable reliable, cost-effective solution for a broad range of adjustable speed drive applications.

Home, Medical and Robotics appliances are expected to be one of fastest-growing product market for advance electronic motor drivers (AEMDs) over the next five years. The major appliances include clothe washers, room air-conditioners, refrigerators, vacuum cleaners, freezers, dentist instruments, robotic arm, fuel pump etc. However the applications already using these drives like water heaters, hot-water radiator pumps, power tools, garage door openers and commercial appliances are not included in these figures. These appliances have traditionally relied on historical classic electric motor technologies such as single phase AC induction motor, including split phase, capacitorstart, capacitorrun types, as well as universal motors. These classic motors typically are operated at constant-speed directly from main AC power without regarding

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the efficiency. Consumers now demand for lowering energy costs, better performance, reduced acoustic noise, and more convenience features. Those traditional technologies cannot provide the solutions.

On the other hand, in recent years, the Indian government has proposed new higher energy-efficiency standards for appliance industry. In the near future, those standards will be imposed. Mandatorily these proposals present new challenges and opportunities for appliance manufactures.

At the same time, automotive industry and HVAC (Heating, ventilation, and air conditioning) industry will also see the explosive growth ahead for electronically controlled motor drive system, the majority of which will be of the BLDC type. For example, at present, the fuel pump in a car is driven by a dc brushed motor. A brush type fuel pump motor is designed to last 6,000 hours because of limited lifetime of the brush. In certain fleet vehicles this can be reached in less than 1 year. A BLDC motor life span is typically around 15,000 hours, extending the life of the motor by almost 3 times. The situation is similar for the air-conditioning blower and engine-cooling fan.

It is expected that demands for higher efficiency; better performance will push industries to adopt ASDs with faster pace than ever. The cost effective and high performance BLDC motor drive system will make big contribution for the transition.

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1.2 Brushless DC (BLDC) Motors and Sensor less Drives

In sensorless BLDC motors sensors can be completely eliminated, thus reducing further cost and size of motor assembly, in those applications in which only variable speed control (i.e., no positioning) is required in such cases system dynamics is not to be sensed (i.e., slowly or, at least, predictably varying load). In fact, some control methods, such as back-EMF and current sensing, provide, in most cases, enough information to estimate with sufficient precision for the rotor position and, therefore, it is possible to operate the motor with synchronous phase currents.

A PM brushless drive that does not require position sensors but only electrical measurements is called a sensorless drive.

The BLDC motor provides an attractive contestant for sensorless operation because the nature of its excitation inherently offers a low-cost way to extract rotor position information from motor-terminal voltages. In the excitation of a three-phase BLDC motor, except for the phase-commutation periods, only two of the three phase windings are conducting at a time and the none conducting phase carries the back-EMF information. There are many categories of sensorless control strategies; however, the most popular category is based on back electromotive forces or back-EMFs. Sensing back-EMF of unused phase is the most cost efficient method to obtain the timing for commutation sequence in star wound motors. Since back-EMF is zero at standstill and proportional to speed, the measured terminal voltage that has poor signal-to-noise ratio cannot detect zero crossing at low speeds. That is the reason why in all back-EMF-based sensorless methods the low-speed performance is limited, and an open-loop starting strategy is required. Department of Electronics and Communication Page 11

Generally, a brushless DC motor consists of a permanent magnet synchronous motor that converts electrical energy to mechanical energy, an inverter corresponding to brushes and Commentators, and a shaft position sensor, as shown in Figure 1.1. In this figure, each of the three inverter phases are highlighted by different colors, including the neutral point: red phase A, green phase B, blue phase C, and pink neutral point N. The stator iron of the BLDC motor has a non-linear magnetic saturation characteristic, which is the basis from which it is possible to determine the initial position of the rotor. When the stator winding is energized, applying a DC voltage for a certain time, a magnetic field with a fixed direction will be established. Then, the current responses are different due to the inductance difference, and this variation of the current responses contains the information of the rotor position. Therefore, the inductance of stator winding is a function of the rotor position

Figure 1.1 Typical sensorless BLDC motor drive

Analysis of the circuit depicted in Figure 1.1 is based on the motor model for phase A (highlighted in red color), as illustrated in Figure 1.2. The following assumptions are considered. Department of Electronics and Communication Page 12

1. The motor is not saturated. 2. Stator resistances of all the windings are equal ( Rs) , self inductances are Constant (Ls) and mutual inductances (M) are zero. 3. Iron losses are negligible

Figure 1.2 Equivalent circuit of the BLDC motor for phase A

Then, the voltage function of the conducting phase winding might be expressed as indicated in Equation (1):

= +

(1)

Where Vdc is the DC-link voltage, Rs and Ls are the equivalent resistance and inductance of Stator phase winding respectively and eA is the trapezoidal shaped backEMF.

Basically, two types of sensorless control technique can be found in the literature direct and indirect back-EMF detection.

A. Direct back-EMF detection methods:

The back-EMF of floating phase is sensed and its zero crossing is detected by comparing it with neutral point voltage. This scheme suffers from high common mode voltage and high frequency noises due to the PWM drive, so it requires low pass filters, and voltage dividers. The methods can be classified as: Department of Electronics and Communication Page 13

1. Back-EMF Zero Crossing Detection (ZCD) or Terminal Voltage Sensing. 2. PWM strategies.

B. Indirect back-EMF detection methods:

Because filtering introduces commutation delay at high speeds and attenuation causes reduction in signal sensitivity at low speeds, the speed range is narrowed in direct backEMF detection methods. In order to reduce switching noise, the indirect back-EMF detection Methods are used. These methods are the following: 1. Back-EMF Integration. 2. Third Harmonic Voltage Integration. 3. Free-wheeling Diode Conduction or Terminal Current Sensing. This thesis is arranged as following. Chapter II briefly analyzes some back EMF detection schemes first. After analyzing problems associated with those schemes, the novel back EMF zero crossing detection is presented. A hardware implementation is introduced using a low cost 8-bit microcontroller 89c2051 as well. Chapter III presents proposed back EMF sensing schemes with nine step commutation, extending the scheme to very low speed applications. Real application examples are also provided in Chapter II and Chapter III respectively. Chapter IV describes the starting algorithm for the sensorless BLDC system, a practical tuning procedure to start the motor with the best starting performance. Finally, Chapter V concludes the thesis and future research works are also suggested.

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Chapter II: Back EMF Detection for Sensorless BLDC Drives

In this chapter, a brief review of the conventional back EMF detection will be given first. Then, the proposed back EMF detection will be described. Experiment results demonstrate the advantages of the back EMF sensing scheme and the sensorless system. Specially, a low microcontroller that is used for sensorless BLDC drives is developed by integrating the detection circuit and motor control peripherals.

2.1 Conventional Back EMF Detection Schemes

For three-phase BLDC motor, typically, it is driven with six-step 120 degree conducting mode. At one time instant, only two out of three phases are conducting current. For example, when phase A and phase B conduct current, phase C is floating. This conducting interval lasts 60 electrical degrees, which is called one step.

Figure 2.1 Typical three phase current waveforms in the BLDC motor.

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A transition from one step to another different step is called commutation. So totally, there are 6 steps in one cycle. As shown in Fig.2.1, the first step is AB, then to AC, to BC, to BA, to CA, to CB and then just repeats this pattern.

Usually, the current is commutated in such way that the current is in phase with the phase back EMF to get the optimal control and maximum torque/ampere. The commutation time is determined by the rotor position. Since the shape of back EMF indicates the rotor position, it is possible to determine the commutation timing if the back EMF is known. In Fig.2.2, the phase current is in phase with the phase back EMF. If the zero crossing of the phase back EMF can be measured, we will know when to commutate the current.

Figure 2.2 The phase current is in phase with the back EMF in brushless dc motor.

As mentioned before, at one time instant, since only two phases are conducting current, the third winding is open. This opens a window to detect the back EMF in the floating winding. The concept detection scheme is shown in Fig.2.3.

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Figure 2.3 back EMF zero crossing detection scheme with the virtual neutral point

The terminal voltage of the floating winding is measured. This scheme needs the motor neutral point voltage to get the zero crossing of the back EMF, since the back EMF voltage is referred to the motor neutral point. The terminal voltage is compared to the neutral point, then the zero crossing of the back EMF can be obtained. In most cases, the motor neutral point is not available. In practice, the most-commonly used method is to build a virtual neutral point that will, in theory, be at the same potential as the center of a Y wound motor and then to sense the difference between the virtual neutral and the voltage at the floating terminal. The virtual neutral point is built by resistors, which is shown in Fig 2.3

This scheme is quite simple. It has been used for a long time since the invention.

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However, this scheme has its drawbacks, Because of the PWM drive, the neutral point is not a standstill point. The potential of this point is jumping up and down. It generates very high common mode voltage and high frequency noise. So we need voltage dividers and low pass filters to reduce the common mode voltage and smooth the high frequency noise, shown in Fig.2.4.

Figure 2.4 Back EMF sensing based on virtual neutral point

For instance, if the dc bus voltage is 12 V, the potential of the neutral point can vary from zero to 12V.The allowable common mode voltage for a comparator is typically a few hundreds of mV, i.e. 200mV.We will know how much attenuation should be. Obviously, the voltage divider will reduce the signal sensitivity at low speed, especially at start-up where it is needed most. On the other hand, the required low pass filter will induce a fixed delay independent of rotor speed. As the rotor speed increases, the percentage contribution of the delay to the overall period increases. This delay will disturb current Department of Electronics and Communication Page 18

alignment with the back EMF and will cause severe problems for commutation at high speed. Consequently, this method tends to have a narrow speed range.

A few other schemes for sensorless BLDC motor control were also reported in the literature. The back EMF integration approach has the advantage of reduced switching noise sensitivity and automatically adjustment of the inverter switching instants to changes in the rotor speed. The back EMF integration still has accuracy problems at low speeds.

The rotor position can be determined based on the stator third harmonic voltage component. The main disadvantage is the relatively low value of the third harmonic voltage at low speed.

In, the rotor position information is determined based on the conducting state of freewheeling diodes in the unexcited phase. The sensing circuit is relatively complicated and low speed operation is still a problem.

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2.2 Proposed Back EMF Detection (Terminal Voltage Sensing)

The zero-crossing approach is one of the simplest methods of back-EMF sensing technique, And is based on detecting the instant at which the back-EMF in the unexcited phase crosses Zero. This zero crossing triggers a timer, so that the next sequential inverter commutation Occurs at the end to this timing interval. For typical operation of a BLDC motor, the phase current and back-EMF should be aligned To generate constant torque. The current commutation point shown in Figure 2.5 can be Estimated by the zero crossing point (ZCP) of back-EMFs and a 30 phase shift, using a sixStep commutation scheme through a three-phase inverter for driving the BLDC motor.

Figure 2.5. Zero crossing points of the back-EMF and phase current commutation points.

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The Conducting interval for each phase is 120 electrical degrees. Therefore, only two phases conduct current at any time, leaving the third phase floating. In order to produce maximum Torque, the inverter should be commutated every 60 by detecting zero crossing of back EMF on the floating coil of the motor, so that current is in phase with the back-EMF. This technique of delaying 30 (electrical degrees) from zero crossing instant of the back-EMF is not affected much by speed changes. To detect the ZCPs, the phase back-EMF should be monitored when the particular phase current is zero and the terminal voltages should be low-pass filtered first. The terminal voltage of the opened or floating phase is given by Equation
+ 2 2

= + = +

(2.1)

As the back-EMF of the two conducting phases (A and B) have the same amplitude but opposite sign the terminal voltage of the floating phase results in Equation (2.2):

= => +
Where = =

= +

+ 2

(2.2)

From the analysis of phase A and phase B assuming a balance three phase System, if we Ignore the third harmonic we have,

+ + = 0 =
So, the terminal voltage ,

(2.3) & (2.4)

= + =
2

(2.5)

From the above equations, it can be seen that the terminal voltage of the floating phase is Directly proportional to the back EMF voltage without any superimposed switching noise. It is also important to note that this terminal voltage is referred to the ground instead of the Department of Electronics and Communication Page 21

Floating neutral point. So, the neutral point voltage information is not needed to detect The back EMF zero crossing, and we dont need to worry about the common mode voltage. Since the true back EMF is extracted from the motor terminal voltage, the zero crossing of the phase back EMF can be detected very precisely. The shapes of back EMF are different from two motors. Nevertheless, the zero crossing of The third harmonics is overlapping with that of fundamental for both motors, which means That the third harmonics will not affect the zero crossing of fundamental wave.

Figure 2.6 Fundamental wave and third harmonics of back EMF for motor

As a summary, several advantages of the proposed back EMF sensing technique over The conventional schemes can be listed as following: 1) It has high sensitivity. It still has good resolution even at low speed operation. Second, the high frequency switching and Synchronous sampling can easily get rid of the Switching noise. Third, because the back EMF is referenced to the ground now, the common Mode voltage is minimized. 2) Fast motor start-up is possible because of precise back EMF zero crossing detection Without attenuation. Department of Electronics and Communication Page 22

2.3 Implementation of the Proposed Back EMF Detection Scheme

The 8-bit microcontroller has been the mainstay of embedded-control systems for nearly 30 Years. The devices are available for a low cost; instruction sets are easy to use. As a result, The back EMF detection circuit is integrated with a 89c2051 microcontroller core to become a low cost dedicated sensorless BLDC microcontroller. Figure 2.7 The microcontroller-based sensorless BLDC motor driver.

89c2051
P1.7

P1.2

The commutation algorithm provides the commutation on each 30 electrical degrees after the back EMF zero crossing. Also it is very convenient to adjust the control parameters. For example, the delay between the zero crossing and Commutation can be easily adjusted by Software. Usually, the delay from phase back EMF Zero crossing to commutation is 30 degree to keep the phase current in phase with phase back EMF. For some high-speed applications, commutation can be done in advance to have the Field weakening effect to expand the speed range. Department of Electronics and Communication Page 23

2.4 Key Experiment Waveforms

The proposed sensorless BLDC drive can be successfully apply to some home appliances for Compressors, air blowers, and vacuum cleaner applications and automotive fuel pump and Robotics applications.

Fig.2.8 shows the three phase terminal voltages, the back EMFs, and the zero crossing Signals. Each toggling edge of zero-crossing signal corresponds to the zero crossing of the Back EMF.

Figure 2.8 Three phase back EMFs and the zero-crossings of back EMFs.

Fig.2.9 shows phase back EMF and the phase current. The sequence from back EMF zero Crossing to commutation is clearly demonstrated. Approximately, 30 electric degree after the Zero crossing of the back EMF, the commutation will happen. Department of Electronics and Communication Page 24

Figure 2.9 Sequence of zero crossing of back EMF and phase commutation.

As described before, this zero crossing detection has very good resolution even at low speed, when the amplitude of back EMF is low. Fig.2.10 shows the waveforms of back EMF and zero crossing signal at low motor speed. The system still can function very well even when the peak of back EMF is less than 1V. Figure 2.10 Back EMF and zero crossing at low speed operation.

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2.5 An application Example: Automotive Fuel Pump

A brush type dc fuel pump motor is typically designed to last 6,000 hours. In certain fleet Vehicles this can be expended in less than 1 year. A brushless dc motor life span is typically around 15,000 hours, extending the life of the motor by almost three times. Once a microcontroller is used to perform the brushless commutation other features can be incorporated into the application. Features such as electronic return less fuel system control, fuel level processing, and fuel tank pressure sensing can be incorporated. These added features simplify the vehicle systems as well as drive overall cost down. Therefore, the fuel pump drive is a very good application for the proposed micro-controller based sensorless BLDC drive scheme [].

The challenges of the automotive fuel pump application include: 1). Wide input operating voltage range from 6v ~24v. The issue is that how to make the system work at 6v input; 2) Fast and very reliable start-up of the motor within 200ms; 3). Interface Compatibility for speed command and communication; 4). Low cost. Thanks to the unique back EMF sensing scheme and the flexibility brought by the Microcontroller, all these issues are solved.

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Figure 2.11 shows the system block diagram for the sensorless drive system

The battery voltage can vary from 6v to 24v. At 6v, the gate driver will not function well. The minimum voltage for the gate driver chip L6387 is around 6.5v. A supply conditioning circuit, which is a simple charge pump circuit, is used to boost the voltage for the gate driver. Fig2.12 shows the supply conditioning circuit. The microcontroller will monitor the dc bus voltage (battery voltage). When the dc voltage is below certain threshold voltage (8v), the charge pump circuit will be activated. This supply conditioning circuit solves the wide voltage range issue.

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Figure 2.12 Supply conditioning circuit foe fuel pumps application.

The second issue is that the motor has to start quickly enough to build up the pressure when the engine is starting. With the conventional sensorless method, it is very difficult to start the motor very quickly. Thanks to the proposed high precision back EMF detection of the ST72141, quick starting of the BLDC motor can be accomplished. When the motor is stop condition, there is no back EMF. Usually, the controller forces the motor to rotate with open loop commutation. The motor will try to accelerate the speed if the commutation frequency is increasing. After the motor generates enough back EMF, it switches to synchronous commutation, which is determined by the back EMF zero crossing.. Since we dont attenuate the back EMF signals, the controller can detect the back EMF zero crossing at lower speed. Therefore, the motor can finish start process sooner than conventional method. Using this novel back EMF detection, it is possible to switch to synchronous commutation when the peak back EMF amplitude is as little as 0.5v.

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The pump can be controlled either by pressure sensor or Power train Control Module (PCM). If it is controlled by pressure sensor, the motor speed will be regulated according to the feedback pressure sensor to maintain the desired fuel pressure. If it is controlled by PCM, the speed command will be PWM pulse train. The motor speed will directly follow the duty cycle of the PWM signal from PCM. The microcontroller can easily identify the control mode and control the motor. The communication is relatively easy when there is a microcontroller in the system. Fuel level, fuel tank pressure, and fuel temperature can be monitored by the microcontroller as well. All these informations can be sent back to Power train Control Module (PCM) through certain protocol. These monitoring functions are integrated in this Fuel Pump Driver Module (FPDM). The integration reduces over all system cost.

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2.6 Summary
A new back EMF sensing technique without physical neutral connection for 3-phase BLDC drives is presented in this chapter. The true back EMF can be detected because terminal voltage of the motor is directly proportional to the back EMF of a phase. This back EMF sensing method is immune to switching noise in case of synchronous sampling. Also, the back EMF information is referred to ground without any common mode noise. Therefore, This unique back EMF sensing method has superior performance to others which rely on neutral to phase voltage information. It can provide much wider motor speed range with low cost.

Even though the back EMF signal may contain high order harmonics, it will not affect the zero crossing detection due to integration of waveform. Furthermore, this back EMF sensing scheme is implemented through a low cost microcontroller. This microcontroller integrates the analog detection circuit and other peripherals for motor control, reducing the total system cost. A typical application of this microcontroller-based sensorless BLDC drive system is described in this chapter. The applications of this sensorless BLDC can include hard disk drive, fans, pumps, blowers, and home and robotics appliances.

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Chapter III: Improved Back EMF Detection Circuits for low cost sensor less control
The back EMF detection method described in chapter II has to have minimum PWM off time. Therefore, it cannot go to 100% duty cycle. For some applications, the dc bus is low, like automotive applications. The bus voltage utilization is very important. An alternate back EMF detection is proposed in the chapter to solve the duty cycle limit problem. For some applications, if the motor speed goes very low, the amplitude of the back EMF can be very low. We find that the zero crossing is not evenly distributed. Theoretically, the zero crossing will happen every 60 electrical degree, so they should be evenly distributed. The inaccurate zero detection can cause wrong commutation, which probably could stall the motor at heavy load. Also bad zero crossing detection will cause bad speed regulation for close loop control because the speed feedback is based on the zero crossing. The major reason is voltage drop across the diode in the inverter, biasing the back EMF signals. Also, the threshold voltage of the zero crossing comparison contributes to the unsymmetrical phenomenon to some extend. In this chapter, the reason causing the unsymmetrical zero crossing is analyzed and an improved circuit is presented.

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3.1 Back EMF Detection During PWM On Time

In chapter II, we describe the direct back EMF detection during PWM off time. A true back EMF signal can be captured during that interval. However, one limitation for that method is that it cannot go to 100% duty cycle since we need minimum off time to have the time window to detect the back EMF. For some applications, it is not desirable. Can we detect the back EMF during PWM on time such that we don't need that minimum off time?

We need to find out the terminal voltage signal during PWM on time for the floating phase. If phase A and B are conducting current, phase C is floating. The terminal voltage Vc is detected.

Figure 3. 1 Back EMF detection during the PWM on time

From phase A, we have, Department of Electronics and Communication Page 32

 = From phase B, we have,

(3.1)

= + +

(3.2)

Where Vd is the forward voltage drop of the diode, Vmos is the voltage drop on MOSFET.

From equation (3.1) & (3.2),

2 + 2

(3.3)

Also from the balance three-phase system, ignoring high order harmonics, we have,

+ + = 0
From (3.3) and (3.4), = So, the terminal voltage Vc,
2

(3.4)

(3.5)

= + = +
2

(3.6)

at low speed and low voltage, the Back EMF itself is very small, the second term will play a significant role here. For low voltage MOSFET, Rds on is very low, Vmos can be ignored, so (3.6) can be rewritten as,
3 2 2

= + =

(3.7)

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Therefore, the voltage drop on the diode will bias the terminal voltage. When the back EMF ec is high enough at high speed, the impact of the second term of (3.7) is minimum, and can be neglect. At low speed, we need to consider the effect.

3.2 Improved Back EMF Detection Circuit for Low speed Applications
Complementary PWM
The first method to correct the offset voltage of the back EMF signal is to use complementary PWM. When PWM is off, the current will freewheel through the body diode of bottom switch. The voltage drop across the diode causes biasing back EMF signal. If the complementary PWM is applied, the freewheeling current will flow through the MOSFET instead of the body diode. Both motor terminal windings are tied to ground by MOSFETs, therefore, the offset voltage caused by body diode is eliminated. The PWM algorithm is shown in Fig3.2. Figure 3.2 Complementary PWM signal

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Figure 3.3 Results of back EMF zero crossing at low speed

To eliminate the effect of diode voltage drop, we can also add a compensating t voltage to compensate the effect of the diode before the back EMF signal is sent to the comparator This improved circuit further extends the application of the sensorless BLDC drives. For proposed back EMF detection scheme without the pre-conditioning circuit, the speed range can be up

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to 10:1. The speed range can be extended to at least 50:1, if the pre-conditioning circuit is used. Fig3.4 shows the three-phase pre-conditioning circuit.

Figure.3.4 Three phase pre-conditioning circuit

3.3 Improved nine step commutation for high initial torque

To the construction point of view BLDC motors are simplest one. There are no brushes and have only motor binding and permanent magnets. The nature of its excitation inherently offers six step commutations for BLDC motors which are existing scenario. the combination of three pair inverter connection provide six commutation sequences each of 60 degree.

Figure 3.5 Proposed nine step commutations

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It is found that the problem of back EMF sensing at initial time spam due to dependency of back EMF on initial speed or torque which is quite low initially. Hence to improve the initial torque we proposed new commutation sequences of nine-step commutation each of 40 degree now as shown in fig.3.5.

During study of motor winding and air gap field we measure that current entering inside the winding create South Pole in the air gap while outgoing current create north pole in air gap. the position of permanent magnet is at fixed angle hence by proper analyzing the air gap field Department of Electronics and Communication Page 37

and produced torque we found this nine step commutation provides twice the initial torque compared to six step commutation. Finally, the motor speed can be greatly expanded For example, if a 12 V motor is used, the speed operation range can be from 10 rpm to 10,000 rpm.

The figure 3.5 shown above, offers first zero crossing detection at initial time spam and second smooth speed control [40 degree step].

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Chapter IV: Starting the Motor with the Sensorless Scheme

4.1 Introduction

The sensorless schemes are not self-starting. In order to sense the back EMF, the motor must be first started and brought up to a certain speed where the back EMF voltage can be detected. In practice, open-loop [] starting the motor is accomplished by providing a rotating stator field with a certain increasing frequency profile. Once the rotor field begins to become attracted to the stator field enough to overcome friction and inertia, the rotor will turn. After the speed reaches a threshold voltage value, the back EMF can be detected, providing the position information, the system switches to synchronous commutation mode and the motor acts as a permanent magnet synchronous machine. If there is no specific requirement for start-up, like fans application, this open loop start-up can be satisfactory. However, for some applications, i.e., automotive fuel pump, the start-up has to be finished with 200ms to build up the pressure. It is very difficult to tune the start-up using the open-loop starting algorithm. On the other hand, if the starting torque is medium or high, usually it is difficult to start the motor with the open-loop algorithm.

4.2 Test set-up with open loop start

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This arrangement shown in fig 4.1 provides a window to sense the back EMF, and this window rotates among the three phases as the stator current commutates from one phase to another. Therefore, each of the motor terminal voltages contains the back EMF information that can be used to derive the commutation instants.

Fig.4.2 shows waveforms of terminal voltages, va, vb and vc, referred to the neutral point of a three-phase resistor network of star connection attached to the motor terminals. The clean segments on the voltage waveforms correspond to the back EMFs. Fig. 4.3 shows a traditional sensorless control scheme for a BLDC motor, where upper one show a block diagram of the position detection circuit based on sensing all three motor terminal voltages and lower fig. illustrates ideal operating waveforms for extracting the phase commutation timing information. Fig. 4.4 shows motor terminal voltages, va, vb and vc, is fed into an integrator through a voltage divider integrator in each phase introduces a phase shift of /2 from the zero-crossings of the back EMFs. Detecting the zero-crossing instants of the integrator output generates the required phase-commutation timing signals.

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4.3 Start-up Tuning Procedure and phase delay correction

When the motor stops, the controller doesnt know the rotor initial position. The first step is to align the motor to a known position by exciting two phases of the motor. For instance, we can choose phase A and phase B to be excited to set the initial position. After the rotor is in the initial position, a preset exciting pattern will be sent out. If three phases are alternately excited, the motor will start to accelerate. Table 4.1 and 4.2 show the exciting pattern for forward /backward rotation. The motor is driven with 6-step mode, and the exciting phase just repeats the same pattern after one cycle (6 steps). Table 4.1 Phase exciting pattern for forward rotation

Table 4.2 Phase exciting pattern for backwards rotation

The question is how to set the right time for each step. If we know the instant motor speed, we set the time for each step so that the motor speed keeps accelerating. We can get the instant motor speed from calculating the frequency of rotation by just calculating the inverse the time between two zero crossing along same phase

It is apparent from the previous conversation that sensing each terminal voltage can provide two commutation instants. Based on measuring the time between these two instants, it is Department of Electronics and Communication Page 41

possible to interpolate the other four commutation instants, assuming motor speed does not change significantly over consecutive electrical cycles. The circuit for sensing the other two terminal voltages can therefore be eliminated, leading to a 66% reduction in sensing components. Fig.4.1 illustrates the proposed low-cost sensorless control scheme for BLDC motors, where Fig.4.5 shows a block diagram of the position detection circuit based on sensing only one motor-terminal voltage.

Figure 4.5 Rotor position sensing circuit using only one motor-terminal voltage

Figure 4.6 Phase voltages and currents for a BLDC

Fig 4.6 illustrates ideal operating waveforms for extracting the phase commutation timing information. Phase voltage, va, is fed into an integrator for filtering and introducing the necessary phase delay. Detecting the zero crossing of the integrator output, va, produces two Department of Electronics and Communication Page 42

commutation instants per fundamental cycle. This information is then fed into a microcontroller. The microcontroller measures the elapsed time, Tk, between these two instants and generates the other two commutation instants apart from the last sensed instant by Tk/3 and 2Tk/3, respectively. Because of the use of interpolation, this scheme works best for applications that do not require frequent, rapid acceleration or deceleration, usually encountered in BLDC motor applications.

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4.4 Correction of Position Detection Errors

As mentioned before, an ideal integrator cannot be used in practice. Instead, a low-pass filter is employed to extract the phase information from the back EMF as shown in Fig 4.7

Figure 4.7 Rotor position sensing circuit using a low-pass filter

The phase delay introduced by the filter varies with the back EMF frequency, such that, the motor speed, and is always less than /2. This speed-dependent phase-delay characteristic, if not corrected, will produce incorrect phase-commutation timing.

Figure 4.8 Phase delays vs. frequency for a typical low-pass filter design

The graph shown in Fig 4.8 plots the phase delay versus frequency for a typical filter design. The phase shift is close to the required 90 degrees at the rated frequency of 50 Hz but drops as the frequency is reduced. Fig 4.9 shows simulated current waveforms at 20 Hz with a phase delay less than 90 degrees. Department of Electronics and Communication Page 44

Figure 4.9 waveforms showing circulating current with a phase-delay < /

The insufficient phase delay of the filter causes three major problems at low speed. The first is a decrease in the torque-per-ampere capability because stator currents are not provided throughout the entire time that the phase back EMFs are at peak level. This leads to the second problem, torque ripple. The third is the additional copper loss produced by a circulating current flowing in the supposedly opened phase. This circulating current result from the shorting of the corresponding two phase-back-EMFs through the switch that is turned on and the diode associated with the switch that is turned off in the process of phase commutation between the lower switches. Take for instance the commutation from phase-c to phase-a and refer to Fig 4.1. At the beginning of each negative half-cycle of ia when the motor current is commutated by switching off S6 and switching on S4 while S2 is conducting, the diode of S6 is positively biased because back EMF, ea, is greater than ec. Therefore, the two back EMFs are shorted through the diode and S4, and consequently a circulating current is produced. Notice that commutations between the upper switches will not produce a circulating current because of the PWM switching operation.

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To satisfactorily operate a motor at low speeds, the phase errors need be corrected. Once the filter is designed, the resulting phase delay at a given frequency can be calculated. This can be done online or offline to construct a look-up table.

Figure 4.10 Operating waveforms showing delay time correction

Fig 3.10 shows operating waveforms with phase-error correction. The correction is based on measuring the elapsed time, Tk, between the last two zero-crossing instants and converting it to frequency according to fm=1/(2Tk). With this frequency information, the delay time correction, k, can then be determined.

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Chapter V: Conclusions and Future Research

5.1 Conclusions
The applications of brushless DC (BLDC) motors and drives have grown significantly in recent years in the appliance industry and the automotive industry. Sensorless BLDC drive are very preferable for compact, low cost, low maintenance, and high reliability system. The conventional sensorless method based on neutral motor point has limited its application since it has relative speed range, suffering from high common mode voltage noise and high frequency switching noise. In this thesis, a indirect back EMF sensing technique, without motor neutral voltage for BLDC drives is proposed, analyzed, and extended, overcoming the drawbacks of the conventional scheme. The indirect back EMF sensing scheme avoids the motor neutral point as the reference for the back EMF zero crossing detection. In this scheme, the PWM is applied to high side switches of the inverter, the back EMF is measured during the PWM off time in the floating winding. It is proved that the terminal voltage of the floating winding is directly proportional to the back EMF of that phase.

An improved version of the direct back EMF sensing, detecting the back EMF signal during PWM on time, is presented. Since the original method detects back EMF signal during PWM off time, it can't go to 100% duty cycle. The improved method will overcome the duty cycle limit. The complementary PWM algorithm can eliminate the offset voltage in the back EMF signal caused by the voltage drop of the diode, and also increase the system efficiency by reducing the conduction loss. The pre-conditioning circuit not only compensates the offset

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voltage, but also amplifies the back EMF signal to be stronger. This extends the sensorless BLDC motor drive system to much wider speed range.

As explained briefly in the previous sections, BLDC motors find many applications in every segment of the market, so their control techniques are very important. Automotive, appliance, industrial controls, automation, aviation and so on have applications for BLDC motors. The applications of BLDC motor control can be categorized into three major fields: constant loads, varying loads, and positioning applications

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5.2 Future Research

Control of nonlinear dynamic systems: artificial neural network
A neural network or artificial neural network (ANN) is the interconnection of artificial neurons that tends to simulate the nervous system of a human brain. Each signal coming into a neuron along a dendrite passes through a synaptic junction. The adjustment of the impedance or conductance of the synaptic gap leads to memory or learning process in the case of brain, which is similarly required in ANN. The model of an artificial neuron that closely matches a biological neuron is given by an op-amp summer-like configuration.

In recent years, the use of artificial neural networks for identification and control of nonlinear dynamic systems in power electronics and motor drives have been extended, as they are capable of approximating wide range of nonlinear functions to a high degree of accuracy. If a motor drive is considered, where the essential sensor signals relating to the state of the system are fed to a neural network, the network output can interpret the health of the system for monitoring purposes and control. ANNs can be also used for realization of current-regulated PWM inverters, in which the network receives the phase current error signals and generates the PWM logic signals for driving the inverter devices. Referring to motors, ANNs can be used to estimate rotor flux, unit vector, and torque in vector-controlled drives. The network has to be trained with a very large number of simulation data sets, so DSP-based estimators and ANN-based estimators perform comparably.

New machine design also is an alternate solution to sensorless operation. Some research is going on to add the special sensing winding to the machine to indicate the rotor position. There are no Hall-type sensors; therefore, the system is robust. Department of Electronics and Communication Page 49

References
[1] D. M. Erdman, H. B. Harms, J. L. Oldenkamp, Electronically Commutated dc Motors for the Appliance Industry, Conf. Rec. 1984 IEEE Ind. Applicat. Soc. Ann. Mtg., pp. 1339-1345. [2] T. Endo, F. Tajima, H. Okuda, K. Iizuka, Y. Kawaguchi, H. Uzuhashi , Y. Okada, Microcomputer Controlled Brushless Motor without a Shaft-Mounted Position Sensor, IPEC-Tokyo83 Conf. Record, pp. 1477-1488, March 1983. [3] K. Iizuka, H. Uzuhashi, M. Kano, T. Endo, and K. Morhri, Microprocessor Control for Sensorless Motor, IEEE Trans. Ind. Applicat. Vol. IA-21, pp. 595-601, Aug. 1985. [4]Shen, J.X.; Iwasaki, S. Sensorless Control of Ultrahigh-Speed PM Brushless Motor using PLL and Third Harmonic Back EMF. IEEE Trans. Ind. Electron. 2006, 53, 421-428. [5]Bonfe, M.; Bergo, M. A Brushless Motor Drive with Sensorless Control for Commercial Vehicle Hydraulic Pumps. In Proceedings of the IEEE International Symposium on Industrial Electronics (ISIE 2008), Cambridge, England, July 2008; pp. 612-617. [6]Damodharan, P.; Vasudevan, K. Indirect Back-EMF Zero Crossing Detection for Sensorless BLDC Motor Operation. In Proceedings of the International Conference on Power Electronics and Drives Systems (PEDS 2005), Kuala Lumpur, Malaysia, November 2008; pp. 1107-1111. [7] Low-Cost Sensorless Control of Brushless dc Motors with Improved Speed Range Gui-Jia Su and John W. McKeever Oak Ridge National Laboratory National Transportation Research Center 2360 Cherahala Blvd. Knoxville, Tennessee 37932 Email: sugj@ornl.gov [8] Lin, M.; Gu, W.; Zhang, W.; Li, Q. Design of Position Detection Circuit for Sensorless Brushless DC Motor Drives. In Proceedings of the IEEE International Electric Machines and Drives Conference (IEMDC 2007), Antalya, Turkey, May 2007; pp. 225-228. [9]Barut, M. Bi Input-Extended Kalman Filter Based Estimation Technique for Speed-Sensorless Control of Induction Motors. Energy Convers. Manage. 2010, 51, 2032-2040. [10] Terzic, B.; Jadric, M. Design and Implementation of the Extended Kalman Filter for the Speed and Rotor Position Estimation of Brushless DC Motor. IEEE Trans. Ind. Electron. 2001, 48, 1065-1073. [11] Kojabadi, H.M. Active Power and MRAS Based Rotor Resistance Identification of an IM Drive. Simulat. Pract. Theory 2009, 17, 376-389. [12] Maiti, S.; Chakraborty, C. A New Instantaneous Reactive Power Based MRAS for Sensorless Induction Motor Drive. Simulat. Pract. Theory 2010, In Press. [13] Maes, J.; Melkebeek, J.A. Speed-Sensorless Direct Torque Control of Induction Motors using an Adaptive Flux Observer. IEEE Trans. Ind. Appl. 2000, 36, 778-785. [14]Bose, B.K. Fuzzy Logic and Neural Networks in Power Electronics and Drives. IEEE Ind. Appl. Mag. 2000, 6, 57-63. [15] Bose, B.K. Expert System, Fuzzy Logic, and Neural Network Applications in Power Electronics and Motion Control. Proc. IEEE 1994, 82, 1303-1323.

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[16]Integrated Current Regulation for a Brushless ECM Drive Thomas M. Jahns, Member, IEEE, Roger C . Becerra, and M. Ehsani, Senior Member, IEEE [17] An Approach to Position Sensorless Drive for Brushless dc Motors Satoshi Ogasawara and Hirofumi Akagi [18] A New Stator Voltage Third Harmonic Based Direct Field Oriented Control Scheme A. Testa A. Coosoli M. Coco Department of Electric Electronic and Systems Engineering University of Catania Viale Andrea Doria 6 - 95 125 Catania Italy [19] On the Feasibility of Four-Switch Three-Phase BLDC Motor Drives for Low Cost Commercial Applications: Topology and Control Byoung-Kuk Lee, Member, IEEE, Tae-Hyung Kim, Student Member, IEEE, and Mehrdad Ehsani, Fellow, IEEE

[20] R.Krishnan and R. Ghosh, Starting Algorithm and Performance of a PM DC Brushless Motor Drive System with No Position Sensor, IEEE PSEC 1989,
[21] N.Mastui, Sensorless PM Brushless DC Motor Drives, IEEE Trans. On Industrial Electronics, Vol. 43, April 1996. [22] D.E.Hesmondhalgh, D. Tipping, and M.Amrani, Performance and Design of an Electromagnetic Sensor for Brushless DC Motors, IEE Proc. Vol.137, May 1990. [23] J.Shao, D.Nolan, T.Hopkins, A Novel Microcontroller -based Sensorless Brushless DC (BLDC) Motor Drive for Automotive Fuel Pumps, Industry Applications Annual Meeting IAS2002. [24] J.Shao, D.Nolan, T.Hopkins, A Direct Back EMF Detection for Sensorless Brushless DC (BLDC) Motor Drive and the Start-up Tuning, Power Electronics Technology Conference (Formerly PCIM) 2002.

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Appendix:
Datasheet 89c2051

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Datasheet IRF540N

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Datasheet IRF4905P

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Datasheet IRF 2011

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Printed circuit board layout

GATE DRIVERS ZERO CROSSING DETECTOR

MICRONTROLLER STAGE

INVERTER DRIVER

THREE PHASE SENSORLEE BLDC MOTOR CONTROL

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Microcontroller 89c2051 coding

Basically there will be three mode of BLDC motors operation

1. Constant speed with fix load and varying load 2. Increasing speed with fix load and varying load 3. Decreasing speed with fix load and varying load

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1. Constant speed algorithm (No Load/ Fix load)

**************************Define Directive***************************** S1 EQU 0097H Switch1 = Port 1.7

S4 EQU 0096H Swich4 = Port 1.6 S2 EQU 0095H Swich2 = Port 1.5 S5 EQU 0094H Swich5 = Port 1.4 S3 EQU 0093H Swich3 = Port 1.3 S6 EQU 0092H Swich6 = Port 1.2 ORG 0040H ***********************Open Loop six step Commutation********************** SJMP HOME1 HOME1: CLR S1 SETB S2 SETB S3 CLR S4 SETB S5 CLR S6 ACALL DELAY CLR S5 CPL S6 ACALL DELAY CPL S1 CLR S2 ACALL DELAY CPL S4

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CPL S6 ACALL DELAY CPL S2 CPL S3 ACALL DELAY CPL S4 CPL S5 ACALL DELAY AJMP HOME1 *************************0.5 Sec. Delay Subroutine********************** DELAY: MOV R0,#08H LOOP3: MOV R1,#0F9H LOOP2: MOV R2,#0F8H LOOP1: DJNZ R2,LOOP1 DJNZ R1,LOOP2 DJNZ R0,LOOP3 RET END

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2. Constant speed algorithm (variable load)

****************************************Define Directive************************************ S1 EQU 0097H Switch1 = Port 1.7

S4 EQU 0096H Swich4 = Port 1.6 S2 EQU 0095H Swich2 = Port 1.5 S5 EQU 0094H Swich5 = Port 1.4 S3 EQU 0093H Swich3 = Port 1.3 S6 EQU 0092H Swich6 = Port 1.2 ORG 0040H **********************************Open Loop six step Commutation**************************** SJMP HOME1 HOME1: CLR S1 SETB S2 SETB S3 CLR S4 SETB S5 CLR S6 ACALL DELAY CLR S5 CPL S6 ACALL DELAY CPL S1 CLR S2 ACALL DELAY CPL S4 CPL S6

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ACALL DELAY CPL S2 CPL S3 ACALL DELAY CPL S4 CPL S5 ACALL DELAY AJMP HOME1 ***************************Zero crossing time calculation************************************* START: SETB TR0 JNB ZC,STOP2 STOP2: JNB TF0,STOP2 CLR TR0 MOV A,TR0 MOV B,#06H DIV AB **********************Close loop start with zero crossing************************************** HOME2: MOV R3,A H1: DJNZ R3,H1 CLR S5 CPL S6 H2: DJNZ R3,H2 CPL S1 CLR S2 H3: DJNZ R3,H3 CPL S4

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CPL S6 H4: DJNZ R3,H4 CPL S2 CPL S3 H5: DJNZ R3,H5 CPL S4 CPL S5 H6: DJNZ R3,H6 AJMP HOME2 *******************************0.5 Sec. Delay Subroutine************************************** DELAY: MOV TMOD,#01H MOV R0,#08H LOOP3: MOV R1,#0F8H LOOP2: MOV R2,#0F8H LOOP1: JNB ZC,START DJNZ R2,LOOP1 DJNZ R1,LOOP2 DJNZ R0,LOOP3 RET END

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