A Controller of Brushless DC Motor for

Electric Vehicle
Wu Hong-xing Cheng Shu-kang Cui Shu-mei
Department of Electrical Engineering Department of Electrical Engineering Department of Electrical Engineering
Harbin Institute of Technology Harbin Institute of Technology Harbin Institute of Technology
Harbin, China Harbin, China Harbin, China
E-mail: whx0422@sina.com E-mail: cskee@hit.edu.cn E-mail: cuism@hit.edu.cn

Abstract—A controller of brushless DC Motor (BLDCM) for transformation is feasible if multiparametric coordinate theory
electric vehicle is developed based on the mathematical model of is used. But it is very complex. The fig.1 shows equivalent
BLDCM and special working condition. The drive and control circuit diagram of BLDCM . Calculation error is great if the
circuit is composed of digital sigal processing and EXB841. The fundamental wave is transformed. By contraries, it is easy and
paper analyses the hardware structure of system in detail. convenience to built the mathematical model [2]-[3] of the
Proportional-Integral-Differential Control strategy is adopted in motor using intrinsic phase variable of motor. The assumption
the system. An arithmetic variable velocity pre-labelled value is is as follows.
presented, in order to solve regulating rotate speed in large range
accurately. The paper also analyzes flux-weakening control in • The stator winding is concentrative winding
high speed and method of energy regenerative braking when the equispaced with 60 degree. It is “Y” connection.
vehicle is decelerating.
• The winding is distributing on the smooth surface of
Keywords- BLDCM, flux-weakening control, DSP stator equably.
• The magnetic saturation is neglected. The loss of
I. INTRODUCTION vortex and magnetic hysteresis are neglected.
People pay more attentions to zero-polluting electrical
• The armature reaction is neglected and the distribution
vehicle with the development of environmental protection
of air gap field is uniform distribution.
consciousness. Dynamical system of electrical vehicle is
composed of storage battery and electromotor. DC motor, AC The voltage equation of three-phase BLDCM is
motor and reluctance motor are usually used in the electric
ua   R 0 0  ia   L M M  ia   ea 
vehicle. The BLDCM has high efficiency and good u  =  0 R 0  i  +  M
performance of timing. It also has some strongpoints of simply  b   b  L M  P  ib  +  eb  (1)
structure, high reliability and convenient maintenance. So it is  uc   0 0 R   ic   M M L   ic   ec 
used widely. Mechanical commutation is replaced electronic
commutation in BLDCM. Electronic commutator is made of ia + ib + ic = 0 (2)
high-power switch transistor. The switch transistors are on or Mia + Mib=-Mic (3)
off according to the position of rotor, so the BLDCM must
combine with driver. The paper introduces a driver of BLDCM ua、ub、uc, phase winding voltage of stator (V);
based on the mathematical model of the motor, and analyses i a、ib、ic, phase winding current of stator (A);
hardware and software of the driver. The core circuit is ea、eb、ec,, phase winding electromotive force of
composed of Digital Signal Processor (DSP) [1]-[2]. The rotate stator;
speed control of BLDCM is inducted a novel control strategy
of variable velocity pre-labelled value, to realize the rotate
L, phase winding inductance (H);
speed accurately in large range. The paper analyses weak-flux M, phase winding mutual inductance (H);
control strategy at high speed for BLDCM. BLDCM P, differential operator P=d/dt.
combining with the drive can work reliably. The controller has
low cost and preferable stability. It can better realize energy
regenerative braking on electric vehicle. ua R L-M ia ea

II. MATHEMATICAL MODEL OF BLDCM eb ec

The characteristic of BLDCM is that the shape of counter-
electromotive force (EMF) is trapezium, which is means that ub R L-M ib
the mutual inductance between stator and rotor is nonsine. It is
difficult to transform the equation of BLDCM to the equation
of d and q axis, because the equation of d and q axis is suitable uc R L-M ic
for the motor which air gap field shape is sine. The

EML 2004 528 0-7803-8290-0/04/$20.00 ©2004 IEEE.

 Figure1. Equivalent circuit diagram of BLDCM Ｋ0 in order to realizing high precision speed control function
So, electromagnet torque is of the system. If |ｅv|>δ and v1≤v≤v2, pre-labelled value of
Timer2 equals to Ｋ1, and so on. The count of timer is
1 optimum matching with speed calculation. Speed precision
T= (ea i a + eb ib + ec ic ) (5)
ω may achieve 0.1%.
K
K0
III. CONTROL STRATEGY OF BLDCM IN EV w
vg +
The motor used in driving system of EV should have the K1 Calculation
following attributes: simply structure, small volume, light vf _
weight, high performance, convenient maintenance, easy K2
control and large torque. The Fig.2 shows the simple structure
of EV. There are some units in the electric vehicle. Most
permanent-magnet machine have sinusoidal flux density in the
air-gap and sine phase current. But the driver system [4] as Figure3. Block diagram of variable velocity ore-labelled value
descried in electric vehicle, the permanent-magnet motor what
has square wave electromotive force is more advantage than
the others. B. PI Control of Speed Loop
Assista The difference value of speed is gained through speed
Display and Input Control nce system feedback value subtracting reference value of speed. It is
calculated new reference current value using a simple PI
arithmetic [5]-[6].
I ref ( k ) = I ref ( k − 1) + K i ⋅ T ⋅ E (k − 1) + K p ( E (k ) − E (k − 1))
Battery Management Unit Battery (6)
Ｉｒｅｆ is output of speed regulator.
Ｋｐ is coefficient of proportionality.
Vehicle Management Unit Controlle Ｋｉ is integratiag coefficient.
Ｔ is sampling period of speed.
The sampling frequency of speed is attained basing
Wheel Gearing Motor practical state. This time the sampling frequency of speed
equal to 62.5μｓ. The following figure shows PI regulation
of speed.
Figure2 Block diagram of electric vehicle struture
The control method of permanent-magnet motor is difficult, Kp
which limits the appliantion of this motor. After using square E(Z) Iref I(Z)
wave motor, the control and driving become easy. Because the
motor of electric vehicle always in the electrodynamic and Ki
decelerating state when vehicle accelerates, brakes, upslopes
and downgrades, the special timing system should be adapted. (1 − Z −1 )
The motor is used as electromotor when vehicle is running,
contrarily it is used as electrical generator to charge storage Figure4. Block diagram of PI regulation of speed
battery when vehicle is decelerating. According to the order of
vehicle management unit, the controller and driver of the motor
control the charging current of battery. C. Control of Current Loop [7]
The process of current regulation is also process of PWM
A. Arithmetic of Variable Velocity Pre-labelled Value signal production. Average value is adjusted
The system calculates speed using variable timer of pre- I e = I ref − I (7)
labelled value, as show in Fig.3. It will improve the precision
of the system response. Speed calculation of the system is duty _ cycle(k + 1) = duty _ cycle(k ) + I e ⋅ k (8)
based on the rotor position signal. Because the alnico of rotor
is symmetrical, timer can calculate speed accurately at some Through adjusting width of PWM signal. The value that
speed range. But, it also produces error in the whole speed reference current subtract from back-check current decides the
range, which is not in favor of PI control of speed loop. width of PWM.
Difference value of speed named ev equals to reference value K is the parameter which connect with motor parameter and
of speed named vｇ and feedback value named vｆ difference. If main voltage. It is a constant when the motor and driver is
|ｅv|>δ and 0≤v≤v1, pre-labelled value of Timer2 equals to shapely.

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 A width PWM signal is formed when I e goes through PID system of equations and equation about of a is derived by Fig
regulator. The value of Ie decides the width of PWM. The 6.
width of PWM is invariable when the value of Ie equal to ωLi
zero. If the value of Ie is very large that means reference α = tag −1 ( ) (9)
current is bigger that practical current, the width of PWM wave K eω + Ri
is the chopping period. The speed increases rapidly. If the
value of Ie is very little (negative), the width of PWM wave
jωLi
will diminish and maybe equal to zero. The speed may jωLi
slowdown in a little time. Fig 5 shows the current U
U RI
regulation used PID control. β RI

id
id
Y
a
I
II δ
iq
iq
Figure5. PID regulation of current loop in the
ll Figure6. Vector diagram of flux-weakening control of
D. Flux-weakening Control of BLDCM
When EMF value of BLDCM reaches the voltage limit T = K t i cos δ
provided by power, the system regulates the direct axis current 
cos γ ⋅ U = e + Ri ⋅ cos δ + ωLi ⋅ sin δ (10)
(id) and quadrature axis current (iq) in order to expanding
sin γ ⋅ U = ωLi ⋅ cos δ − Ri ⋅ sin δ
range of the speed. It is the flux-weakening control method [8] 
of motor. BLDCM which EMF wave is sine increases the
direct axis current realizes the flux-weakening control. In the E. Regenerative Braking for EV
BLDCM system which EMF wave is trapezium, it is unable to Electric vehicle needs regenerative braking when it
control phase position of stator winding current directly. The decelerates or limit speed on the downgrade. At that time, the
equifinal method is to control phase position of stator winding motor rotate speed is under the no-load rating rotate speed.
voltage. The phase position of stator coil current is controlled The paper discusses the line voltage when two phase is in
through controlling phase position of stator winding voltage. It series is bigger than voltage provided by DC power. The
also realizes flux-weakening control of BLDCM. Controlling method is named regenerative braking [9]. In the state, the
lead angle of voltage is the equifinal flux-weakening control only three switch tubes which locate the same half bridge is on
strategy of BLDCM. or off in the inverter circuit, the other is always close. Fig 7
The method is to change phase frequency characteristic of shows the equifinal schematic diagram of controller at
voltage detector, and the phase shift is 90-Y. That means lead regenerative braking.
the triggering angle of BLDCM is Y. As we known that
difference value of voltage on the winding and EMF of
winding decides the current in the winding. At the same time
the amplitude value of EMF is direct ratio to rotate speed of
motor. It can be seen from mathematical model of BLDCM
that the lead angle of BLDCM changes the voltage on the
equivalent resistance and counteracts the induced
electromotive force. In order to meeting the equation of
mathematical model, it makes the rotate speed of motor up
when changing lead angle makes voltage on the equivalent Figure7. Equivalent circuit diagram of regenerative braking
resistance larger. It can realize flux-weakening control. The
The circuit voltage equation is followed:
voltage wave of phase winding shows the superficies of flux-
di
weakening control. Because the voltage of phase winding E a − Eb = 2 Ri + 2(L − M ) + U AB (11)
equal to the induced electromotive force when the switching dt
tube is close and the voltage of phase winding equal to voltage The circuit current equation is followed:
of power when the switching tube is open. The induced
E a − E b − U AB E − E b − U AB −τ / Tm
electromotive force is bigger than voltage of power when the i= + (I − a )e (12)
system implement flux-weakening control. See fig. It is very 2R 2R
useful for electric vehicle in high speed. Fig 6 shows the
vector diagram of flux-weakening control of BLDCM. A Tm is electrical time constant of the circuit.

EML 2004 530 0-7803-8290-0/04/$20.00 ©2004 IEEE.

 The essential of regenerative braking is that kinetic energy of
vehicle will translate into magnetic energy and store in the Start
inductance 2(L-M), when special switch tubes are open. The
kinetic energy of vehicle and the energy stored in the Initialization of EV
inductance translate into electric energy through voltage
boosting of inductance the and store into storage battery. At
the same time, because the direction of current of motor is
contrary to the current of motor working in whole period, it Initialization of system
may hold electromagnet torque. So it will realize regenerative
braking. The energy absorbed by storage battery can express
by equation through fig.
I/O testing
W = ∫ ( E a − E b )idt + ∫ (−U L i )dt (13)

Motor state testing

IV. REALIZATION OF PRACTICAL CIRCUIT
Control circuit utilizes the special purpose chip for control
motor MS320F240. Fig 8 shows the Block diagram of control Control loop
system. The function units are denoted in the dashed line. The
chip may provide high efficiency digital signal processing and
control hardware of high stability. It gathers the high speed Stop
calculation and professional motor control technology. Its
software may instead of the analog component. It can revise
the parameter and control strategy, carry out fault diagnosis, Figure9. Flow chart of system and PID control
communication function and so on. The software flow of the
system is expressed in figure 9-10.
Input parameter

Start
Input SPI SCI Computer

w* Volt- i Current Drive

Inver
Calculate speed Iref
regulator PWM
age circuit ter

Calculate acceleration
Current Limit the error
Capturing Signal
processing A/D
unit Sampling
Limit the error
PID of current
Signal Sensor of stator BLDCM
processing position PI of speed
Refresh the parameter
Figure8. Block diagram of control system of BLDCM
Current loop Y

The rotor position signal of BLDCM is captured through N Output PWM

capture unit. When there are saltus signals at the pins of
capture unit, the count of selected timer is locked in a buffer. Reset timer
DSP will carry out Time-lag and interrupt and initialize logic Return
circuit. The logic circuit decides the polarity of PWM pins
when compare matching takes place. The system uses the full Return
compare unit PWM mode. PWM wave is made of lots of serial
pulse which width is variational. Its period is regulated by the
timer1 repeatedly. The value of period is regulated through the Figure10. Flow chart of PID control interrupt
software. So the width of PWM wave may change through
changing the value of comparator in the current regulator and
the voltage regulator. Then it will control the motor.

EML 2004 531 0-7803-8290-0/04/$20.00 ©2004 IEEE.

 Figure11. Graph of speed response at 1420r/min
Figure12. Graph of brake current at 800r/min
Figure13. Graph of brake current at 1500r/min
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Figure14. Simulate graph of phase current
Figure15. Graph of phase current
Figure16. Graph of phase current
The system of BLDCM has three Hall sensors. The position
of motor rotor can be decteted through line Hall sensors that is
named A3517s. Its power of chip is 5V. Its output is line signal
whose range is 0~5V and its zero point is 2.5V. The output is
the detection signal of three phase positions (Ha, Hb, Hc).
These signals are handled through RC filtering and signal
disposing circuit. The CAP of DSP is connected with the
output of Hall sensors in order to catch rotor position. The Hall
sensors cross 120 degree electrical degree each other. It will
form six signals whose phases are variable through detection
the change of output signal. The system will interrupt because
of the detected signal, and executive interruption program.
The figure 11 shows the correspondence of the motor after
receiving the order from vehicle manage unit. Fig 12-13 show
532 0-7803-8290-0/04/$20.00 ©2004 IEEE.
the graph of the motor when electric vehicle is braking. The
front of wave denotes electric drive. The X axis is the time
axis. The system begins braking at 0.3s. So the total current of
controller is negative value. Fig 14 is the phase current in the
motor at identical conditions. Fig 15 is the graph of phase
current before parameter of PID regulation optimized. Fig 16 is
the graph of phase current after parameter of PID regulation
optimized.
V. CONCLUSION
The driving system of BLDCM used in EV is studied in
this paper. The core of the driving system is the TMS320F240
chip. The driver circuit is consisted of the driver chip EXB841
and peripheral circuits. The intelligent power module is used as
the main power circuit. The system has characteristics of
compact structure, advantageous control and low cost. In the
control strategy, typical PI control and arithmetic of variable
velocity pre-labelled value are applied. The flux-weakening
control and energy regenerative braking control are also
analyzed. The feasibility and high efficiency of the driving
system are approved through experiment.
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