Application Report

SPRA498

Sensorless Speed Controlled Brushless

DC Drive using the TMS320C242 DSP
Controller
Pierre Voultoury Digital Signal Processoring Solutions

Abstract
The Brushless DC (BLDC) variable-speed drive is widely used because of its particularly high
mechanical power density, simplicity, and cost effectiveness. A software rotor position generation
has been implemented on the DSP Controller family, thus saving the mechanical position sensor
cost. Based on the non-fed phase back electromotive force measurement, this software-
computed rotor position is fully integrated and able to adapt itself to any BLDC drive-inherent
problem.

This application report presents successively the sensorless principle theoretical background, the
implementation of the rotor position determination, the BLDC drive imperfection handling the
operating system, and every necessary experimental result, thus leading to an adaptable simple
and cost-effective drive.

Contents
Introduction ......................................................................................................................................................2
BLDC Drive Presentation .................................................................................................................................2
The Sensorless Rotor Position Getting ............................................................................................................5
Conclusion .....................................................................................................................................................16
References.....................................................................................................................................................16

Figures
Figure 1. TMS320C242-Based Sensorless BLDC Drive .................................................................................4
Figure 2. Exhaustive Sensorless Additional Hardware....................................................................................5
Figure 3. PWM Strategy and Operating System .............................................................................................7
Figure 4. Zero Crossing Results at Different Running Speeds........................................................................9
Figure 5. Computed Commutation Instants vs Hall Effect Sensor Output.....................................................11
Figure 6. Balanced and Unbalanced Phases Use........................................................................................12
Figure 7. Phases Use Imbalance Correction Module ...................................................................................13
Figure 8. Phases Use without and with Imbalance Corrector.......................................................................14

Digital Signal Processing Solutions December 1998

Application Report
SPRA498

Introduction
The trapezoidal control of electronically commuted permanent magnet synchronous drive
(BLDC drive) is widely used because of its particularly high mechanical power density,
simplicity, and cost effectiveness. It is based on a speed regulation and interface
performing CPU, a current regulation and one position sensor to synchronize both stator
and rotor fluxes (commutation signals). To improve the system cost effectiveness, many
solutions exist that remove the necessary and cost-ineffective rotor position sensor.

The new software solution presented here is a Back EMF measurement-based method
for commutation of a BLDC motor requiring no rotor position sensor and no additional
silicon (IC, ASIC, MCU). This speed controlled sensorless BLDC drive thus integrates in
one single chip solution not only the mandatory control processing power but the
software commutation signal generation as well. This is accomplished using only the
Texas Instruments (TI) digital signal processor (DSP) Controller family resource.
Furthermore, this solution uses customizable software to resolve all BLDC drive inherent
problems: the electrical behavior at commutation points, the phases use imbalance self-
correction, and the closed-loop control from zero speed.

The neutral point voltage computation is performed in every current regulation loop
thanks to the versatile DSP Controller ADC unit. The Bemf zero crossing point
determination and the necessary 30 shift between the commutation signal and the
detected zero crossing point are performed in real time thanks to the high DSP core
computational power. The phases use imbalance, mostly due to the non-symmetrical
behavior of the three-phase system, is corrected thanks to software offset (computed as
a function of the actual rotor speed) on the Bemf computation. The highly disturbing
current and voltage commutation glitches are filtered by customizable software so that
they do not disturb the correct operation of the software position computation.

BLDC Drive Presentation

The Brushless DC drive has been used in industrial applications for many years because
of its excellent performance, extreme control simplicity, and high cost effectiveness. The
strategy presented in this report is very close to the existing method and includes the
same control simplicity, performance, and an additional system cost reduction.

The BLDC Motor

The permanent magnet synchronous machine used in this drive is a three-phase, Y-
connected motor. There are no brushes on the rotor and the phases commutation must
be performed electronically. It has one magnetic non-salient pole pair on the rotor. The
stator is made of ironless windings. The stator phase inductance is 0.045mH (measured
at 1kHz) and the phase resistance is 300mW. The maximum permissible current at
5000rpm is 2.9A and the torque constant is equal to 11.8mNm/A. It is considered to have
trapezoidal back electromagnetic force (Bemf) waveform shapes and is supplied with
direct currents. The DC bus voltage is 18V.

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 2
Application Report
SPRA498

The Control Algorithm

A Brushless DC motor speed control requires three control layers to be performed. The
innermost one determines the rotor position to commute correctly the stator flux. Once
the rotor position is known, the magnitude of the stator flux has to be generated and
controlled. Assuming that the stator flux is proportional to the current flowing in the stator
coils, the control of the stator flux magnitude is equivalent to the control of the input
current. The most outer control loop is the speed regulation loop.

Most of the time, mechanical angular position sensors obtain the rotor position. The well-
known incremental encoders and Hall effect sensors represent the most chosen solutions
to obtaining rotor position. Incremental encoders provide a very high angular resolution
as well as an accurate derived speed feedback in any speed range. They are ideally
suited to a highly precise speed and/or position control.

Nevertheless, sensors such as those based on the Hall effect are often preferred to
incremental encoders when the speed range is not too low (above 50rpm), even if they
do not provide performances comparable to the encoders ones. The reasons for this are
the rough position information required by the brushless DC drive and the cost
effectiveness of this drive type.

Even the cheap Hall effect sensors can be removed and replaced by DSP Controller
software with no additional glue logic, resulting in a cost optimized drive. This solution
provides Hall-effect sensors output equivalent position information. The TMS320C242
algorithm presentation shows the high robustness of the software rotor position detection:
handling of the electrical behavior at commutation points, phases use imbalance self-
correction, and closed-loop startup sequence.

Depending on the motor electrical time constant, the current regulation might be
performed either analog, thanks to the Hysteresis-type regulator realized with operational
amplifiers, or digital, thanks to software. The choice of the analog solution is constraining
because it forces the power board to support these regulators. This is fixed by the need
of having a high chopping frequency to maintain a continuous phase current into a motor
with very small electrical time constant. Assuming that the digital solution also supports
these high chopping frequencies, the current regulators might also be numerically
performed. This integration is shown in this report.

Regarding the speed regulation, the digital integration appears once again as an efficient
solution. The speed feedback has to be computed based on the clock signal given by the
software position sensor. Once this feedback is computed, the speed regulation might be
performed according to the speed reference, which can be acquired by sampling the
analog input of the via serial link.

This section showed that complete speed control can be integrated in one single DSP
Controller, thus avoiding the need to wire separate CPU and external silicon performing
features, such as PWM, ADC and position determination. This integration leads to a cost-
optimized board that includes both the single chip controller and the power stage. By
replacing the mechanical position sensor with software and avoiding the need for any
additional integrated circuit (operational amplifiers, comparators, FPGAs), the DSP
Controller family further optimizes the overall drive cost.

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 3
Application Report
SPRA498

The Hardware Platform

Two approaches should be considered when the focus is on the hardware platforms.
These platforms are different, depending on whether the BLDC drive is under
development or about to be sent to production.

During development, the control hardware used was the TMS320F240 Evaluation
Module (EVM) introduced by Texas Instruments. The board contains the following
components:

r TMS320F240 DSP controller and oscillator

r JTAG

r RS232 link

r Four digital-to-analog converters

r Connectors that output any DSP Controller pin.

The EVM board is simply wired to the dedicated power converter of the BLDC motor [5]
[6].

For production, it is possible to integrate on one single board the TMS320C242 DSP
Controller as well as the power electronic elements. The board shown in Figure 1 thus
provides a highly integrated sensorless solution for speed-controlled BLDC drives. Notice
that no glue logic is necessary, other than the mandatory current-sensing amplifier.

Figure 1. TMS320C242-Based Sensorless BLDC Drive

+18V D1

F1 NTC1 10TQ045 R1 +15V

2A R2
560R 220R 0.5W

R3 D2 C1
120R 1.5W 15V 100nF
V1 + C2
Vdc
2200uF C3 + U1
220uF LM7805A
1 3 +5V
R4
220R
2

GND C4 C5
100nF 100nF

TX1 +5V

R6 +5V C6 +5V
R5 1K R7 100nF
330R 10K
U2
TLP721 C8 R8 C7 +15V D3 D4 D5
1

1nF 10K 100nF 10BF40 10BF40 10BF40 Q1 Q2 Q3

IRFIZ24G IRFIZ24G IRFIZ24G
+5V
C9 +
TX0 +5V
2

R12 R13 10K 22uF R9 R10 R11

R15 10R 10R 10R
10K
10K R14
65
66
64
12
53
50

54
55

45

62
42
52
16

63

20
24
34
33
23
21

13
14
15
8

10K U4 C10 C11 C12

1 28 100nF 100nF 100nF
XF/IOPC0
XINT2

SCITXD

Test pin
WDDIS
IOPA2

CLKOUT/IOPD0

IOPA5
IOPA4
IOPA3
Vsso

Vcca
SCIRXD

Vcc Vb1
NMI

Vccdd1
Vccdd2
Vccdd3
Vccdd4
Vccdc1
Vccdc2

VREFLO
BIO*/IOPC1

GNDA

VREFHI

7 2 27
CMP1 6 5 HIN1* HO1 26 U
CMP2 5 3 LIN1* Vs1 16
CMP3 HIN2* LO1 R16
44 4 6
9 Vssdd1 CMP4 3 4 LIN2*
61 Vssdd2 CMP5 2 7 HIN3* 560R R17 C13
43 Vssdd3 CMP6 LIN3* 24 220R 330nF
51 Vssdd4 17 Vb2 23
17 Vssdc1 21 nc HO2 22 V
41 Vssdc2 25 nc Vs2 15
R19 Vssdc3 nc LO2
R18
10K
68
67 IOPB7
IOPB6
TMS320C242 IOPC2
PDPINT
IOPC3
56
1
57
11
8
10
SD
Fault*
FLTCLR* Vb3
20 560R R20 C14
C15 18 12 19 220R 330nF
20pF 19 IOPB5 9 Vss HO3 18 W
47 IOPB4 13 ITRIP Vs3 14
XTAL2 COM LO3
R22
4.9MHz R21
ADCIN07
ADCIN06
ADCIN05
ADCIN04
ADCIN03
ADCIN02
ADCIN01

ADCIN00

G1 5M
IOPC7
IOPC6
IOPC5
IOPC4
TRST*

IR2131 560R R23 C17

EMU1
EMU0
TMS

PMT
TDO

TCK
RS*

46 R24 R25 R26 220R 330nF

TDI

XTAL1 U3 10R 10R 10R

C16 R27
35

49
48
39
37
40
38
60
36

10
11
59
58

22
25
26
28
29
30
31

32

20pF 10K
Q4 Q5 Q6
+5V +5V +15V IRFIZ24G IRFIZ24G IRFIZ24G
C18 R28 R29 R30 R31 C19
10uF 10K 10K 10K 10K 100nF

D6 D7
1N4148 LL4148
8

R32 1K2
+5V + 3
1
- 2 R35
R33 U5A R05
330R TLC277 R34 10K
4

Vdc

R36 100K

This board is single layer with discrete power elements to further increase the system
cost reduction. The board allows an accurate sensorless speed control from 100rpm up
to the maximum permissible motor speed.

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 4
Application Report
SPRA498

Figure 2 details the exhaustive hardware necessary to run the presented sensorless
control. This shows that the system cost saving is highly efficient as the mechanical
position sensor is fully replaced in terms of hardware by extremely low cost resistors.
Notice also that this hardware might be easily and freely modified to fit different motor
characteristics. This makes this sensorless dedicated hardware upgradable and versatile.

Figure 2. Exhaustive Sensorless Additional Hardware

U
R520

560R R521 C520

220R 330nF

R510

560R R511 C510

220R 330nF
W

R500

560R R501 C500

220R 330nF

The resistance bridge is sized so that the maximum bridge output addresses the full ADC
conversion range. So if the ADC reference voltages are set to zero and 5V and the DC
bus voltage is 18V, the bridge ratio should be equal to 0.27. Note that the TMS320C242
DSP Controller ADC Unit requires 260W input impedance on the analog line to run the
conversion unit at full speed. The filtering capacitor should filter only the chopping
frequency. The sensorless algorithm is only based on the three terminal voltage
measurements and thus requires only four ADC input lines.

The Sensorless Rotor Position Getting

This core section presents the software solution able to deliver to the classical BLDC
drive control the necessary rotor position without any help other than the C242 DSP
Controller capabilities (this means no additional Ics, no star connection wired out of the
motor housing). The following section explains the succinct theoretical background and
every practical aspect.

Theoretical Background
In the so-called BLDC control, the phases are commuted once every 60 mechanical
(number of pole pairs equals one) rotation of the rotor and at any time only two phases
are fed with direct currents. Furthermore, an efficient control implies synchronization
between the phase Bemf and the phase supply so that the Bemf crosses zero once
during the non-fed 60 sector.

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 5
Application Report
SPRA498

The formula below depicts the motor terminal model, where L is the phase inductance, R
is the phase resistance, Ex is the back electromagnetic force, Vn is the star connection
voltage referenced to ground and Vx is the phase voltage referenced to ground. Vx
voltages are measured thanks to the DSP controller ADC Unit and via the resistor bridge
depicted above.

dI x
Vx = RI x + L + E x + Vn .
dt
As only two currents flow in the stator windings at the same time, the two phase currents
are opposite and the third one is equal to zero. Furthermore remembering that both the
sum of the three stator currents and the sum of the three Bemf are equal to zero, the
neutral point voltage can be calculated as follows:

1 3
Vn = * Vx .
3 x =1
Regarding the non-fed phase (zero current flowing) the stator terminal voltage can be
rewritten as follows:

1 3
E non fed = Vnonfed - Vn = Vnonfed - * Vx .
3 x =1
As each of the Bemfs crosses zero two times per mechanical revolution, and as the
Bemfs are numerically easy to compute thanks to the DSP Controller, it is possible to get
the six necessary commutation information.

Practical Point of View

This section presents the practical implementation of the above theory. It discusses in
particular the theory limitations and the practical solutions used to overcome them. Each
software module is also addressed.

Neutral Point Voltage Computation

As shown above, the neutral point voltage computation requires knowing the three
instantaneous terminal voltages referenced to ground. Let us explain how the ADC is
managed to perform this real-time task.

Due to the very small phase electrical time constant, the chopping frequency has been
set to 80kHz. The PWM period is then equal to 12.5ms. The current regulation loop period
has been set to 50ms. So four PWM period flags occurs in one current loop period. The
DSP Controller Core acknowledges them all and the corresponding interrupt subroutine
is served. Only if the current PWM period ISR is the first or the second one (among the
four available during one current control loop), a double conversion is started by
software. At the End Of Conversion an interrupt to the core is asked, acknowledged and
served to handle the two results. The following plot depicts the interrupt organization.

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 6
Application Report
SPRA498

Figure 3. PWM Strategy and Operating System

Current Loop Period

PWM Period
End Of Conversion
Interrupt

12.5 25 37.5 50
PWM Interrupt Time in ms
6.6ms

The first conversion gives the phase flowing current and the second phase terminal
voltage information. Once these two results have been handled, the ADC input channels
dedicated to the two other phase terminal voltage measurements are selected. The
second End Of Conversion subroutine handles the two conversion results and the reload
of the current and second terminal voltage channels on one hand and computes the
neutral point voltage according to the above formula on the other hand.

This solution assumes that the variation of the phase terminal voltage is negligible during
one PWM period (12.5ms). Note that this real-time sampling structure fits any chopping
and regulation frequencies: for a motor requiring a 20kHz chopping frequency we can
easily imagine a current regulation loop frequency at 10kHz and still having the three
terminal voltages.

Bemf Zero Crossing Point Computation

Once the neutral point voltage is available it is necessary to get the Bemf of the non-fed
phase. This is realized by subtracting the computed neutral voltage from the non-fed
phase terminal voltage. As interest is focused on the zero crossing of the Bemf it is
possible to look only at the Bemf sign change; this assumes that the Bemf scanning loop
period is much shorter than the mechanical time constant. This function is computed after
three terminal voltage samplings, once every 50ms, and during any ISR during the PWM
duty cycle update.

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 7
Application Report
SPRA498

Electrical Behavior at Commutation Points

At phases commutation instants high dV/dt and dI/dt glitches might occur due to the
direct current level or to the parasitic inductance and capacitor of the power board.
Beyond the electromagnetic interference troubles they might generate, these glitches can
lead to a misunderstanding of the computed neutral voltage. One solution to avoid this
problem is to drastically filter the phase voltages before acquiring them. The major
filtering drawback is that the necessary filter introduces a consequent lag in the Bemf
zero-crossing detection. This leads to a bad phase supply synchronization and then to
poor drive dynamic behavior and power conversion efficiency.

No phase filtering and discarding the first scans of the Bemf once a new phase
commutation occurs solves these electrical behavior troubles at commutation. By
discarding, it should be understood that the neutral voltage is still calculated but the zero-
crossing detection function is disabled, thus avoiding any spurious detection. The discard
duration is fully customizable, as this is a software module. The duration depends on the
power switches, on the power board design, on the phase inductance and on the driven
direct current. This parameter is system dependent and should be set to a large value in
the early development stages. Later on, it is possible to tune very small discard duration
in order to achieve a better control.

Some Bemf Zero Crossing Results

On each scope picture presented below channel #1 represents one phase current,
channel #2 is the corresponding half bridge voltage, channel #3 is the computed neutral
point voltage and channel #4 gives one peak each time the software detects the zero
crossing of the scanned Bemf.

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 8
Application Report
SPRA498

Figure 4. Zero Crossing Results at Different Running Speeds

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 9
Application Report
SPRA498

The different speeds tested here are 600 and 2000rpm, respectively. Notice that the
Bemf zero crossing algorithm has been successfully tested down to 30rpm. The most
interesting information is given by the neutral voltage computation: even if there are very
high commutation glitches and/or measurement noises, the software understands them
as glitches, thus allowing detection of the right Bemf sign change. This is achievable
because of the high frequency of computing the neutral point voltage. This high
frequency can be reached thanks to the autonomous ADC peripheral and to the high
DSP Controller CPU power. The channel #4 spikes (representing the Bemf zero
crossing) are located in the middle of the non-fed sector; this synchronization between
the Bemf and the 60 sector is the primary reason the highest motor performances are
achieved.

Commutation Instants Computation

In efficient sensor control, the Bemf zero crossing events are displaced 30 from the
phases commutation instants. So before running the sensorless BLDC motor with help of
the six zero crossing events it is necessary to compute the 30 commutation instants
shift. In fact according to the different desired speed ranges the angle shift might be any
angle. So a position interpolation function should be realized. In this control software it is
implemented as follows: Let T be the time that the rotor spent to complete the previous
revolution and a be the desired shift angle. By dividing a by 360 and multiplying the
result by T we obtain the amount of time (let us call it shift time) to be spent before
commuting the new phases pair.

A question can be asked regarding the transient response of the system. Assume that
the motor slows down. How does the control react? The computed shift time will be too
short in comparison with the actual necessary shift time; this early coming commutation
instant will tend to accelerate the motor. The controller will have opposite reaction if the
motor accelerates. So a kind of natural robustness due the control algorithm is added to
the speed control loop.

In the presented software, a is fixed to 30. We can imagine an additional software

function giving the shift angle as output and taking the mechanical speed as input. Figure
5 presents two charts showing the commutation instant computation compared to the
three Hall-effect sensor outputs. The top chart shows results at low speed (400rpm) and
the bottom chart the results at high speed (2000 rpm).

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 10
Application Report
SPRA498

Figure 5. Computed Commutation Instants vs Hall Effect Sensor Output

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 11
Application Report
SPRA498

These charts show that very good results can be achieved at low or high speed. A slight
shift between the Hall sensor output and the computed commutation is noticeable; the
phases use imbalance corrector will compensate this.

This commutation instant algorithm is based on the time spent by the rotor to achieve the
previous revolution. For noise or system dynamics troubles it is possible to design some
slightly more complex algorithms: for example, a low pass filter on the speed feedback
could improve the transient behavior. It can be simply implemented by saving the
revolution time at stage k and the revolution time at stage k-1, then the computation of

Tk - Tk -1
2
gives smoother change in the shift time, thus improving the transient behavior. Another
possible algorithm that improves dynamic behavior computes the time spent by the rotor
to achieve one third of a revolution. This last algorithm has a quicker reaction to speed
variation but is much more sensitive to measurement noises.

Phases Use Imbalance Self Correction

Some imbalance in the phases use might be present when we simply apply the above
algorithm (detect the zero crossing point and wait for the shift time to be elapsed before
commuting the phases). By imbalance we understand that instead of having six
equivalent 60 sectors per revolution we may have 40 wide and 80 wide sectors, as
shown in Figure 6.

Figure 6. Balanced and Unbalanced Phases Use

0 0
300 300
60 60 40 80 60

80
60
60 40
240 120 240 120

180 180

This imbalance is created by the non-symmetrical behavior of the three-phase system

and of the terminal voltage measurement resistor bridges. The imbalance is application-
dependent but can be approximated as a linear function of the mechanical speed and
can be corrected thanks to software offset on the Bemf computation. The following
implemented structure shown in Figure 7 solves this trouble.

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 12
Application Report
SPRA498

Figure 7. Phases Use Imbalance Correction Module

Position

K1

...
K6
Va
+ + -
Vb + Corrected
1/3 - +
Vc + Bemf

Imbalance Corrector
Neutral Computation
Bemf Computation

The two scope pictures in Figure 8 show the phases use with (right chart) and without
this additional correction module (left chart).

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 13
Application Report
SPRA498

Figure 8. Phases Use without and with Imbalance Corrector

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 14
Application Report
SPRA498

These charts make the necessity of the Bemf computation correction obvious.

Startup Procedure
The first step to start the sensorless drive is to get the initial rotor position. The position
determination strategy differs depending on whether the motor has reluctance variation
around the air gap or not. If there is significant reluctance variation around the air gap (for
example, salient poles on the rotor) we can measure each phase pair current response to
a voltage pulse applied to each winding for a short and constant period of time. By
evaluating the relative magnitude of the current flow through the phase windings it is
possible to get the initial rotor position and thus to determine the proper starting phase of
the motor.

This solution ensures the start rotation direction. When there is no reluctance variation
around the motor air gap (as is the case with the motor we used in this drive), it might be
impossible to estimate the initial rotor position. So at startup is it necessary to energize
one arbitrary phase pair and wait for the rotor to be aligned with the created stator flux.

Nevertheless, the algorithm must address the following questions: how long should the
algorithm wait for the shaft to stop oscillating prior starting the control loops? Is the
applied torque enough to let the load move? In this application a counter is set so that the
magnetic stall is performed long enough to let the shaft move and stop oscillating. The
current flowing in the supplied phase pair is regulated. To further improve this sensorless
drive, the two above questions might be answered by scanning the non-fed phase and by
interpreting the results as follows: oscillating measured voltages means back and forward
rotor moves, constant measured signal means no rotor move. Such an interpretation
leads to an adaptive startup phase current level and to a time optimized initial rotor
position obtaining function.

The second step consists in accelerating the motor up to thirty rpm, at which point this
sensorless algorithm is able to run closed loop. Here also two solutions are possible
depending on whether the load is unknown or not. If the load characteristics are
unknown, then a shift time value must be set so that it enables the first revolution. This
implies maximum motoring torque and long shift time. At every first revolution Bemf zero
crossing the comparison between time elapsed between commutation and zero-crossing
and shift time gives the software a good model of the system dynamics. The first shift
time might be adapted within the first revolution. An effective improvement of this method
might thus be implemented when the first revolution shift time can be a priori calculated.
This requires knowing the motor torque constant and the braking torque (including friction
losses and load) at startup. The fundamental dynamic principal applied to rotational
systems gives

d 2q
J
dt 2
= Ti
i

where J is the system inertia

q is the angular position
Ti represents torque gives a double integral equation.

To solve this equation one needs to know system torque and inertia. The torque sum
might be considered as constant and known as we control the flowing current and as we
know the torque constant ([Nm/A]). The system inertia can be calculated from the load
characteristics. This equations solution is the time necessary to the motor to perform one
revolution. This first shift time T is then given by the relation:

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 15
Application Report
SPRA498

1 4Jp
T=
2 Ti
i

This calculated value should then be divided by the Bemf scan loop period and the result
should be stored into the software shift time variable.

Once these two first steps have been performed, the initial rotor position adjacent 60
sector is fed with Direct Current and the Bemf zero crossing detection algorithm is
immediately started. After one complete revolution, the computed shift time one replaces
the initial one.

Conclusion
This document discussed the software calculation of the rotor position of a sensorless
Brushless DC drive. This single-chip solution is based on the TMS320x24x DSP
Controller family capabilities: high DSP core CPU power and highly versatile peripherals.
This solution replaces the position sensor cost with software. Furthermore, this solution
increases the drive reliability, as the position information will not be temperature- or
vibration-sensitive any longer. This makes the sensorless solution more cost effective
and more reliable. Assuming that the initial rotor position is detectable and knowing that
this solution runs closed loop from quasi zero speed, this sensorless drive can
advantageously replace the sensor solution in a wide range of speed control applications.

References
1) TMS320C24x DSP Controllers - Reference Set: Vol.1, Texas Instruments Inc, 1997.

2) TMS320C24x DSP Controllers - Reference Set: Vol.2 Texas Instruments Inc, 1997.

3) Implementation of a Sensorless Speed Controlled Brushless DC Drive using

TMS320F240, Texas Instruments Inc., 1997 part #BPRA072.

4) DSP Solutions for BLDC Motors, Texas Instruments Inc.,1997 part #BPRA055.

5) DC 12-24V 30A Three Phase Power Hardware for PMSM or AC Induction Machine,
Texas Instruments Inc.,1997 part #BPRA071.

6) TMS320C24x DSP Controllers Evaluation Module, Texas Instruments Inc., 1997

#SPRU248A.

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 16
Application Report
SPRA498

INTERNET
Europe, Middle East, and Africa Asia (continued)
www.ti.com Phone TI Number -800-800-1450
Register with TI&ME to build custom information Deutsch +49-(0) 8161 80 3311 China 10811
pages and receive new product updates English +44-(0) 1604 66 3399 TI Number -800-800-1450
automatically via email. Francais +33-(0) 1-30 70 11 64 Hong Kong 800-96-1111
Italiano +33-(0) 1-30 70 11 67 TI Number -800-800-1450
TI Semiconductor Home Page Fax +33-(0) 1-30-70 10 32 India 000-117
http://www.ti.com/sc Email epic@ti.com TI Number -800-800-1450
TI Distributors Indonesia 001-801-10
Japan
http://www.ti.com/sc/docs/distmenu.htm Phone TI Number -800-800-1450
Korea 080-551-2804
PRODUCT INFORMATION CENTERS International +81-3-3457-0972
Domestic +0120-81-0026 Malaysia 1-800-800-011
US TMS320 Fax TI Number -800-800-1450
Hotline (281) 274-2320 New Zealand +000-911
International +81-3-3457-1259
Fax (281) 274-2324 TI Number -800-800-1450
Domestic +0120-81-0036
BBS (281) 274-2323 Email pic-japan@ti.com Philippines 105-11
email dsph@ti.com TI Number -800-800-1450
Asia Singapore 800-0111-111
Americas Phone TI Number -800-800-1450
Phone +1(972) 644-5580 International +886-2-3786800 Taiwan 080-006800
Fax +1(972) 480-7800 Domestic Thailand 0019-991-1111
Email sc-infomaster@ti.com Australia 1-800-881-011 TI Number -800-800-1450

IMPORTANT NOTICE
Texas Instruments (TI) reserves the right to make changes to its products or to discontinue any semiconductor product or service without notice, and advises its customers to obtain the latest
version of relevant information to verify, before placing orders, that the information being relied on is current and complete. TI warrants performance of its semiconductor products and related
software to the specifications applicable at the time of sale in accordance with TIs standard warranty. Testing and other quality control techniques are utilized to the extent TI deems necessary to
support this warranty. Specific testing of all parameters of each device is not necessarily performed, except those mandated by government requirements. Certain application using semiconductor
products may involve potential risks of death, personal injury, or severe property or environmental damage (Critical Applications). TI SEMICONDUCTOR PRODUCTS ARE NOT DESIGNED,
INTENDED, AUTHORIZED, OR WARRANTED TO BE SUITABLE FOR USE IN LIFE-SUPPORT APPLICATIONS, DEVICES OR SYSTEMS OR OTHER CRITICAL APPLICATIONS. Inclusion of
TI products in such applications is understood to be fully at the risk of the customer. Use of TI products in such applications requires the written approval of an appropriate TI officer. Questions
concerning potential risk applications should be directed to TI through a local SC sales office. In order to minimize risks associated with the customers applications, adequate design and operating
safeguards should be provided by the customer to minimize inherent or procedural hazards. TI assumes no liability for applications assistance, customer product design, software performance, or
infringement of patents or services described herein. Nor does TI warrant or represent that any license, either express or implied, is granted under any patent right, copyright, mask work right, or
other intellectual property right of TI covering or relating to any combination, machine, or process in which such semiconductor products or services might be or are used.
Copyright 1998, Texas Instruments Incorporated
TI is a trademark of Texas Instruments Incorporated.
Other brands and names are the property of their respective owners.

Sensorless Speed Controlled Brushless DC Drive using the TMS320C242 DSP Controller 17