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Abstract -- This paper presents a PFC (Power Factor (Continuous Conduction Mode) or DCM (Discontinuous
Correction) based BL-Luo (Bridgeless-Luo) converter fed Conduction Mode) operation. A CCM offers an advantage of
BLDC (Brushless DC) motor drive. A single voltage sensor is
lower stress on a PFC converter switch, but requires a two
used for the speed control of BLDC motor and PFC at AC
control loop (i.e. voltage and current control loops) for
mains. The voltage follower control is used for a BL-Luo
converter operating in DICM (Discontinuous Inductor Current achieving a DC link voltage control with PFC at AC mains
Mode). The speed of the BLDC motor is controlled by an [9]. This requires three sensors for the operation, which is a
approach of variable DC link voltage, which allows a low costly option, and hence preferred for high power ratings
frequency switching of VSI (Voltage Source Inverter) for (>lkW). Whereas, the converter operating in DCM acts as an
electronic commutation of BLDC motor; thus offers reduced
inherent power factor corrector and hence requires a single
switching losses. The proposed BLDC motor drive is designed to
voltage control loop (i.e. single voltage sensor) for DC link
operate over a wide range of speed control with improved power
quality at AC mains. The power quality indices thus obtained voltage control. But, a higher stress on PFC converter switch
are under the recommended limits of IEC 61000-3-2. The is obtained in it for a PFC converter operating in DICM;
performance of the proposed drive is validated with test results hence this mode is preferred for low power applications [9].
obtained on a developed prototype of the drive. Many configurations of PFC converter feeding a BLDC
motor drive have been reported in the literature [6, 10-12]. A
Index Terms-BL-Luo Converter, BLDC motor, PFC, Power
boost-PFC converter fed BLDC motor drive has been the
Quality.
most widely used configuration but it utilizes a constant DC
I. INTRODUCTION link voltage with PWM (Pulse Width Modulation) based VSI
BLDC (Brushless DC) motors have become increasingly for speed control [10, 11]. A high switching loss on account
popular in the past decade due to the advantages such as high of high switching frequency occurs which drastically reduces
efficiency, high power density, compact size, high the efficiency. Moreover, it requires high number of sensors
ruggedness, lower maintenance requirements and their and complex control for its operation. A concept of variable
immunity to EMI (Electro-Magnetic Interference) problems DC link voltage for speed control of BLDC motor has been
[1-3]. A BLDC motor is a three phase synchronous motor reported in [3]. Gopalarathnam et. al. [12], have proposed a
having torque-speed characteristics of a DC motor [1-3]. It SEPIC (Single Ended Primary Inductance Converter) for
has three phase windings on the stator which are excited by a feeding a BLDC motor drive using the concept of variable
VSI (Voltage Source Inverter) and permanent magnets on the DC link voltage. It uses a bifilar winding which uses a PWM
rotor. It does not require any brushes and commutator based control of VSI and have high switching losses. Singh
assembly; rather an electronic commutation based on the et. at. [6], have proposed a Cuk converter fed BLDC motor
rotor position as sensed by Hall Effect position sensors is drive using the control of variable DC link voltage. This
used [4, 5]. Hence the problems such as sparking, wear and utilizes a Cuk converter operating in CCM; hence requires
tear of brushes, EMI and noise interference are eliminated in three sensors and is preferred for higher power rating.
the BLDC motor. Bridgeless converter configurations have gained
A conventional BLDC motor drive using a front end DBR importance in the past decade due to their high efficiency.
(Diode Bridge Rectifier) and a high value of DC link The front end DBR is eliminated in these configurations
capacitor draws highly distorted peaky current which is rich which reduce the conduction losses associated in them [13-
in harmonics [6]. This leads to a very low power factor of the 16]. The bridgeless buck and boost converters have been
order of 0.7-0.8 and high THD (Total Harmonic Distortion) reported in [13] and [14] respectively. They suffer from a
of supply current at AC mains. Such types of power quality limited voltage conversion ratio 1 for buck and >1 for
indices are not acceptable under the limits of international boost converter) which limits its application for a wide range
power quality standards such as IEC 61000-3-2 [7]. Hence, of speed control by varying DC link voltage. The bridgeless
IPQC's (Improved Power Quality Converters) are used for Cuk and SEPIC converters have also gained popularity due to
improving the power quality at AC mains [8, 9]. a wide voltage conversion ratio [15, 16].
An IPQC may be designed to operate in either of CCM A Luo converter has been widely used due to its inherent
characteristics of voltage lifting [17-21]. Many versions of A. Operation during Positive and Negative Half Cycle of
Luo converter voltage lifting technique such as re-lift [19], Supply Voltage
super-lift [20] and ultra-lift [21] have been reported in the Figs. 2(a) and (b) show the operation of PFC BL-Luo
literature. The use of Luo converter as a PFC has been converter for positive and negative half cycles of supply
explored in [22]. Inheriting the advantages of the Luo voltage respectively. The bridgeless converter is designed
converter, a bridgeless configuration of the Luo converter is such that two different switches operate for a positive and
explored in this paper for feeding a BLDC motor as a low negative half cycles of supply voltages. As shown in Fig.
cost solution for low power applications. 2(a), switch Sw" inductors Li' and Lo' and diodes Dp and Dp'
conduct during the positive half cycle of supply voltage. In a
II. PROPOSED PFC BL-Luo CONVERTER FED BLDC MOTOR similar manner, switch Sw2, inductors Li2 and Lo2 and diodes
DRIVE Dn and Dnl conduct during the negative half cycle of supply
voltage as shown in Fig. 2(b). Fig. 2(c) shows the associated
Fig. 1 shows the proposed PFC based BL-Luo converter
waveforms demonstrating the vanatlOn of different
fed BLDC motor drive. A single-phase supply followed by
parameters such as supply voltage (vs), discontinuous input
filter and a BL-Luo converter is used to feed a VSI driving a inductor currents (iLil and iLi2), output inductor current (iLol
BLDC motor. The BL-Luo converter is designed to operate in and iLo2) and the intermediate capacitor's voltage (Vc, and
DICM (Discontinuous Inductor Current Mode) to act as an VC2) during complete cycle of supply voltage.
inherent power factor pre-regulator. The speed of the BLDC
motor is controlled by adjusting the DC link voltage of VSI
using a single voltage sensor. This allows VSI to operate at
fundamental frequency switching (i.e. electronic
commutation of BLDC motor) and hence has low switching
losses in it; which are considerably high in PWM based VSI
feeding a BLDC motor. The proposed scheme is designed
and its performance is simulated for achieving an improved
power quality at AC mains for a wide range of speed control
and supply voltage variations. Finally, the simulated
performance of the proposed drive is validated with test
results on a developed prototype of the drive.
(a) d max Vc
Cm = C = C =
- =--=- (4)
1 2
- --
2f SRL (I1Vc/2)
where RL is the emulated load resistance, VC is a voltage
appearing across intermediate capacitor (i.e. Yin+Vde) and
11VC is the permitted ripple voltage, which is taken as 50%.
Hence the value of intermediate capacitors (Cl and C2) is
Inductor Discharging Capacitor Charging Capacitor Discharging VC ..-i _+--+
11-_-+---,,..._ obtained as 502nF and their selected value is 440nF.
(b) The relation governing the value of output inductor's (Lol
and L02) is given as [17],
L -L dmaxIo
- ---'-""''--'--
'-
01 - 02 (5)
- 16f:Cin (!,!,jo/2)
where l1io is the permitted ripple current in output inductors
(d) (Lol and L02) which is taken as 10% of Io.
Inductor Discharged Capacitor o;scl/arglng Capacitor Charging Hence value of Lol and L02 obtained is as 1.78mH.
(c) The value of DC link capacitor (Cd) is obtained as [9],
Fig. 3. Operation of the PFC BL-Luo converter during complete switching
10
cycle for positive half cycle of supply voltage -
C d = ---.:::...-
.- (6)
2coL Vdcnom
11
IV. DESIGN OF PFC BL-Luo CONVERTER
where 11Vde is the permitted ripple voltage in DC link
The PFC BL-Luo converter is designed for its operation in capacitor (taken as 2%) and COL is line frequency in rad/sec.
DICM to act as a power factor pre-regulator. The current in Hence a value of Cd obtained is 2211.61lF and its selected
input inductors (iLil and iLi2) becomes discontinuous in a value is 2200IlF.
switching period, whereas the output inductor currents (iLol An input filter (L-C filter) is designed to avoid the
and iL02) and intermediate capacitor's voltage (VCl and VC2) reflection of high current ripple in the supply system. The
remain continuous. A 400W (Po) PFC converter is designed maximum value of filter capacitor (Cmax) is given as [25],
to control the DC link voltage from 50V (Vdemin) to 200V
(Vdemax) with nominal voltage (Vdenom) as 120V. The average lpeak
Cf < Cmax = tan(8) (7)
voltage (Vin) appearing at the input of filter is given as [23],
coLVpeak
2J2V 2J2x220 where Vpeak and Ipeak represent peak value of supply voltage
"in = 5 = ::::: 198V (1) and supply current respectively and e represent displacement
7t 7t
__
Now the required inductor value is calculated by sensors. The conduction states of two switches (Sl and S4)
considering the source impedance (4-5% of base impedance) are shown in Fig. 4. A line current iab is drawn from the DC
of the supply system and is given as, link capacitor which magnitude depends on the applied DC
I
( J( J link voltage (Vde), back emfs (ean and ebn), resistance (Ra and
1 V2
L = -0.05 s (8) Rb) and self and mutual inductance (L., Lb and M) of the
f
_ __
41t2fe 2C Po(OL stator windings. Table-I shows the governing the different
f
where fe is the cut off frequency (fL<fe<fsw) taken as fswllO. switching states of the VSI feeding a BLDC motor based on
Hence a value of filter inductor (Lreq) is selected 3.77mH. the Hall Effect position signals (Ha-He).
A DC filter of 3.77mH and 330nF is required for the
proposed application.
The control of the PFC BL-Luo converter fed BLDC motor vdc
drive is classified into two parts as follows.
The control of the front-end PFC converter generates the Fig. 4. A VSI feeding a BLOC motor.
PWM pulses for the PFC converter switches (Swl and Sw2) for
TABLE I
DC link voltage control with PFC operation. A single voltage
PERFORMANCE OF PFC BL-LUO CONVERTER FED BLOC MOTOR
control loop (voltage follower approach) is utilized for the DRIVE UNDER SPEED CONTROL
PFC BL-Luo converter operating in DICM. A reference DC e(o) Hall Signals Switching States
link voltage (Vde*) is generated as,
Ha Hb He SI S2 S3 S4 S; S6
(9) NA 0 0 0 0 0 0 0 0 0
where kv is motor's voltage constant and (0* is reference 0-60 0 0 I I 0 0 0 0 I
speed. 60-120 0 I 0 0 I I 0 0 0
Reference DC link voltage (Vde*) is compared with 120-180 0 I I 0 0 I 0 0 I
sensed DC link voltage (Vde) to generate voltage error signal 180-240 I 0 0 0 0 0 I I 0
(Ve) given as, 240-300 I 0 I I 0 0 I 0 0
300-360 1 1 0 0 1 0 0 1 0
Ve(k) = Vdc *(k)- Vdc(k) (10)
NA I I I 0 0 0 0 0 0
where k represents the k th sampling instant.
This error voltage signal (Ve) is given to the voltage PI
VI. SIMULATED PERFORMANCE OF PROPOSED PFC BL-Luo
controller to generate a controlled output voltage (Vee) as,
CONVERTER FED BLDC MOTOR DRIVE
Vee (k) = Vee (k -1) + kp {Ve(k) -Ve(k -I)} + kj Ve(k) (11)
A MATLAB/Simulink environment is used to evaluate the
where kp and ki are proportional and integral gains of the performance of proposed PFC BL-Luo converter fed BLDC
voltage PI controller. motor drive for wide range of speed control and supply
Finally, output of voltage controller is compared with a voltage variation using a standard model of BLDC motor [6].
high frequency saw-tooth signal (md) to generate the PWM Performances indices such as supply voltage (vs), supply
pulses as,
current (is), DC link voltage (Vde), speed ((0), electromagnetic
{ if md(t) < vcc (t) then SWI =Sw2 ='ON '
if md(t) Vcc(t) then Swl =Sw2 ='OFF'
} (12)
torque (Te), stator current (ia), inductor currents (iLi!, iLi2' iLol
and iL02), intermediate capacitor's voltage (VCI and VC2) and
PFC converter switch's voltage and current (vsw and isw) are
where Swl and Sw2 represent the switching signals to the
analyzed for determining the performance of proposed BLDC
switches of PFC converter.
motor drive. Power quality indices such as PF (Power
Factor), DPF (Displacement Power Factor), CF (Crest Factor)
B. Control of BLDC Motor: Electronic Commutation and THD (Total Hannonic Distortion) of supply current at
An electronic commutation of the BLDC motor includes AC mains are analyzed for demonstrating the improved
the proper switching of VSI in such a way that a symmetrical power quality at AC mains.
DC current is drawn from the DC link capacitor for 1200 and A. Steady State Performance of Proposed Drive
placed symmetrically at the centre of each phase. A rotor
Figs. 5(a) and (b) show steady state performance of
position on a span of 600 is required for electronic
proposed BLDC motor drive at rated load on BLDC motor
commutation; which is sensed by Hall Effect position
with supply voltage as 220V and DC link voltage as 200V. A
.505 =
180 1710 1 3.48 0.9994 1.609
2i6
200
The performance of proposed BLDC motor drive is also
evaluated for varying supply voltages to demonstrate its
i2 l , ;
1 , I I\/V\] {ITV\]
u uu uu ' uu u u
}
10
i ,u u'ul
Time(s) Time(s)
! u"ul u + J
Funl (50Hz) -2.54SA (peak),
1lID-345%
Fundamental(50Hz) -0 6393A(peak),
1lID-542"/.
J 1000.-
: i 'i . I I
u
50
0.5 0.511 0.52 0.53 ..
0.I54
I0.550.56 . .I
lu 1 ..n .J t."
. .11,1 .I
200 400 600 800 1000 200 400 600 800 1000
Time(s) >
Frequency (Hz) Frequency (Hz)
(a)
0.5 05
. 1 0.52 0.53 0.54 0.55 05. 0.51 05
. 2 05
. 3 0.54 0.55
10 ,..-__-_-_--, 10 ,..-____-_--,
Time(s) Time(s)
$
4 LrCu!.l"uu, :i! 2 :i! 2
(C)
)!
(d)
Fig. 6. Harmonic spectra of supply current of the proposed PFC-Luo
converter fed BLDC motor drive at rated load torque on BLOC motor with
% 10t-.5I--
---'-o01.51-4..
-"""I0.5-
-- 2---;-4
0. 53--....,..:--
0.54--- .55--- 0.56
0.-
200V.
Time(s) >
link voltage from lOOV to 150V. Fig. 7(c) shows TABLE III
PERFORMANCE OF PFC BL-LUO CONVERTER FED BLOC MOTOR
perfonnance during varying supply voltage from 270V to
DRIVE UNDER VARYTNG SUPPL Y VOLT AGE
l70V. A smooth control of DC link voltage is obtained which
Vs THD of Is
shows a satisfactory performance of the closed loop control. (V)
DPF
ls (%)
PF
(A)
CF
The controller gains are given in Appendix.
170 0.9997 3.17 0.9992 2.333 1.414
190 0.9998 3.27 0.9993 2.083 1.414
210 0.9999 3.39 0.9993 1.887 1.414
230 I 3.52 0.9994 1.72 1.414
250 0.9999 3.71 0.9992 1.584 1.414
270 0.9998 3.93 0.999 1.468 1.414
Figs. 8(a) and (b) show the steady state behavior of the
proposed BLDC motor drive at rated torque conditions of
load on BLDC motor with DC link voltage as 70V and 200V.
A sinusoidal supply current in phase supply voltage is
obtained with a near unity power factor at AC mains.
B. Operation of PFC Based BL-Luo Converter
Fig. 8(c) shows the input and output inductor currents (iLil
and iLo1) and intermediate capacitor voltage (VC1) with the
supply voltage. A discontinuous current of the input side
Time(s) --->
inductor is obtained for positive half cycle which
(c) demonstrates the DICM operation of PFC BL-Luo converter.
Fig. 7. Dynamic performance of the proposed PFC-Luo converter fed BLOC
motor drive during (a) Staring of BLDC motor at DC link voltage of 50V,(b)
Step change in DC link voltage from 100V to 150V and (c) Step change in
supply voltage from 270V to 170V.
Figs. 8(d) and (e) show the voltage and current stress on
the PFC converter switches and its enlarged waveforms. A
peak voltage and current stress of S80V126A is obtained
which is in accordance with the simulated results.
D. Dynamic Performance of Proposed Drive
VIII. CONCLUSION
A PFC based BL-Luo converter fed BLDC motor drive
has been proposed for wide range of speeds and supply
voltages. A single voltage sensor based speed control of
BLDC motor using a concept of variable DC link voltage has
been used. The PFC BL-Luo converter has been designed to
operate in DICM and to act as an inherent power factor pre
regulator. An electronic commutation of the BLDC motor has
been used which utilizes a low frequency operation of VSI
for reduced switching losses. The proposed BLDC motor
drive has been designed and its performance is simulated in
MATLAB/Simulink environment for achieving an improved
power quality over wide range of speed control. Finally, the
performance of proposed drive has been verified
experimentally on a developed hardware prototype. A
satisfactory performance of proposed drive has been achieved
and is a recommended solution for low power applications.
ApPENDIX
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