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8, AUGUST 2009
Abstract—Development of advanced motor drives has yielded Replacing these inefficient motors with more efficient brushless
increases in efficiency and reliability. Residential and commercial dc (BLDC) motors will result in substantial energy savings.
appliances such as refrigerators and air conditioning systems use A permanent-magnet synchronous machine has several ad-
conventional motor drive technology. The machines found in these
applications are characterized by low efficiency and high main- vantages over other machine types. Most notably (compared
tenance. A brushless dc (BLDC) motor drive is characterized by to other dc motors), they require lower maintenance due to
higher efficiency, lower maintenance, and higher cost. In a market the elimination of the mechanical commutator. They also have
driven by profit margins, the appliance industry is reluctant to high power density. Compared to induction machines, they have
replace the conventional motor drives with the advanced motor lower inertia, allowing for faster dynamic response to reference
drives (BLDC) due to their higher cost. Therefore, it is necessary
to have a low-cost but effective BLDC motor controller. This paper commands. In addition, they are more efficient due to the
lays the groundwork for the development of a new low-cost IC permanent magnets, which results in significantly lower rotor
for control of BLDC motors. A simple novel digital pulsewidth- losses. The major disadvantage with permanent-magnet motors
modulation control has been implemented for a trapezoidal BLDC is their higher cost and relatively greater degree of complexity
motor drive system. Due to the simplistic nature of this control, introduced by the power electronic converter used to drive them
it has the potential to be implemented in a low-cost application-
specific integrated circuit. The novel controller is modeled and [2], [3].
verified using simulations. Experimental verification is carried Hysteresis current control and pulsewidth modulation
out using field-programmable gate arrays to validate the claims (PWM) control coupled with continuous control theory have
presented. produced the most widely used BLDC motor control techniques
Index Terms—Brushless dc (BLDC) motor drives, converters, [4]. Hysteresis current control is essential toward achieving
field-programmable gate arrays (FPGAs), inverters, motion con- adequate servo performance, namely, instantaneous torque con-
trol, pulsewidth modulation (PWM). trol, yielding faster speed response compared to PWM control.
For most applications, proportional-integral (PI) current and
speed compensators are sufficient to establish a well-regulated
I. I NTRODUCTION
speed/torque controller. In other cases, state feedback control is
the motor winding is constant for 120◦ , before and after which
it changes linearly with rotor angle.
In order to get constant output power and, consequently, con-
stant output torque, current is driven through a motor winding
during the flat portion of the back-EMF waveform. Only two
switches are turned on at a time, one in a high side and the other
in a low side. Thus, for a star-connected motor winding, two
phases are connected in series across the dc bus, while the third
winding is open. The switches in Fig. 1 are operated such that
each phase carries current only during the 120◦ period when
Fig. 2. Back EMF and phase current variation with rotor electrical angle. the back EMF is constant. Thus, there is a commutation event
between phases for every 60◦ electrical, as shown in Fig. 2.
Effectively, it means that there is a current transition every
characteristic equations of a BLDC machine have been used to 60◦ . Appropriate commutation therefore requires knowledge of
derive the design procedure, which involves simple first-order rotor position, which can be directly detected using position
nonhomogenous differential equations. During steady-state op- sensors or estimated in sensorless manner by monitoring back
eration, the design procedure is reduced to a few simple alge- EMF in the open phase [11].
braic equations. Computer simulations and experimental results Unlike a brushed dc motor, the commutation of a BLDC
are presented for proof of concept. motor is controlled electronically [12]. To rotate the BLDC
motor, the stator windings should be energized in a sequence.
It is important to know the rotor position in order to follow
II. B RUSHLESS DC M OTOR D RIVE S TRATEGIES
the proper energizing sequence. For the present system, rotor
For a three-phase BLDC application, the most common position is sensed using Hall effect sensors embedded into the
topology used is a three-phase buck-derived converter or a stator. By reading the Hall effect sensors, a 3-b code can be
three-phase inverter bridge [8], [9]. The typical inverter drive obtained, with values ranging from one to six. Each code value
system for a BLDC motor is shown in Fig. 1. represents a sector in which the rotor is presently located. Each
As shown in Fig. 1, the output stage consists of a three- code value therefore gives us information on which windings
phase inverter composed of switches that could be MOSFETs need to be excited to turn the rotor [13], [14]. State “0” and “7”
or insulated-gate bipolar transistors (IGBTs). If IGBTs are are considered invalid states for Hall effect sensors. A timing
used, antiparallel diodes need to be connected across them for diagram showing the relationship between the sensor outputs
carrying reverse currents, while MOSFETs use body diodes. and the required motor drive voltages is shown in Fig. 3.
MOSFETs give lower turn-off switching loss and usually lower The numbers at the top of Fig. 3 correspond to the current
diode forward drop, but that advantage may be offset by higher phases shown in Fig. 4. It is apparent from Fig. 3 that the
ON -state voltage drop and turn-on switching/diode reverse re- three sensor outputs overlap in such a way as to create six
covery loss than IGBTs. Typical waveforms for a three-phase unique 3-b codes corresponding to each of the drive phases. The
BLDC motor with trapezoidal flux distribution are shown in numbers shown around the periphery of the motor diagram in
Fig. 2 [10]. Approximately, the back EMF induced per phase of Fig. 4 represent the sensor position code. The north pole of the
3042 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 56, NO. 8, AUGUST 2009
TABLE I
CLOCKWISE SENSOR AND DRIVE BITS BY PHASE ORDER
Fig. 5. Conventional PWM current control.
rotor points to the code that is output at that rotor position. The
numbers are the sensor logic levels where the most significant
bit is sensor C and the least significant bit is sensor A [15]. The
input sensor state and the corresponding drive state required for
commutation can be put in the form of a state table as shown in
Table I.
Fig. 8. Block diagram for digital PWM control for a BLDC motor drive
system.
the rated motor current. This is because motors can handle Fig. 9. Gate switching waveforms.
1.5 times the rated current for a short duration of time. The
minimum value of Ilimit decides the steady-state error. For a As long as
value equal to zero, a large steady-state error is observed in
the simulation. The minimum value of Ilimit is defined as the ωactual < ω ∗ − Δω, Ilimit = Ilimit,max . (3)
ratio of a percentage (1%) of the rated torque to the torque
constant. In addition, Ilimit α ωerror
The proportional constant K for a desired speed ripple can
be calculated as follows. In steady state, Δω ≤ |ωerr ∗ 2|. In the Ilimit = K ∗ ωerror . (4)
worst case, Δω = |ωerr ∗ 2|. For the desired speed ripple Δω,
a constant Kset can be defined as By using (1)–(3) in (4), it can be shown that
Δω 2 ∗ Ilimit,max
Kset = . (1) K= . (5)
ωrated Kset ∗ ωrated
Taking the maximum value of the speed ripple In this control strategy, both the high- and low-side switches
are switched simultaneously. Both high- and low-side diodes
ωerr ∗ 2 conduct. The waveforms for this type of switching are shown
Kset = . (2)
ωrated in Fig. 9.
3044 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 56, NO. 8, AUGUST 2009
IV. C ONTROLLER D ESIGN The maximum deviation from the reference speed (ω ∗ ) due
to the application of high duty DH is denoted by ΔωH , and
The value of the duty ratio D can be obtained from the
the maximum deviation from the reference speed due to the
electrical and mechanical equations. The value of D can be
application of a low duty DL is denoted by ΔωL . The speed
expressed as a function of the motor parameters.
response can be expressed as
From the torque equation, we have
Tem − TL ∗ Tem − TL b
dω ω(t) = + ω − e− J t . (12)
Tem = J + bω + TL (6) b b
dt
where Tem , ω(t), b, J, and TL denote developed electromag- From Fig. 10, at time t = t2 + TP
netic torque, rotor angular velocity, viscous friction constant, Tem − TL Tem − TL b
(TL + ωss b) From (18), for a desired speed ripple, the sampling time can
DVdc = R + Ke ωss (10) be calculated. ωNL,max is the maximum speed under no-load
Kt
conditions.
where ωss denotes the steady-state angular velocity.
Therefore, the duty ratio can be expressed in terms of the B. Steady-State Analysis
motor parameters as
For the purpose of analysis, the proposed digital controller
1 (TL + ωss b) was considered equivalent to a proportional controller with high
D= R + Ke ωss . (11)
Vdc Kt gain and saturation. This analysis was aimed at determining if
the actual motor speed reaches the reference speed at steady
A. Speed Ripple Calculation state. The transfer function for a BLDC motor is shown as
Kt
Steady-state error is a function of the speed samples. It is ω(s) JLa
= (19)
therefore necessary to find out the effect of sampling time (TP ) V (s) s2 + (JRa +BLa ) +Kt Ke )
s + (BRaJL
JLa a
on the speed ripple. Fig. 10 shows the speed response at steady
state. where V = DVin , with D being the duty cycle.
SATHYAN et al.: FPGA-BASED NOVEL DIGITAL PWM CONTROL SCHEME FOR BLDC MOTOR DRIVES 3045
TABLE II
DATA SHEET FOR BLDC MOTOR FROM POLY-SCIENTIFIC (BN42-EU-02)
Fig. 11. Closed-loop control of the BLDC motor with the novel digital PWM
controller.
Fig. 15. Experimental results for a reference speed of 2500 r/min under no-
load condition.
Fig. 14. Simulated duty, speed, and current response for a commanded speed
of 2500 r/min for full-load operation.
Fig. 19. Experimental results for a reference speed of 2100 r/min under
full load.
Fig. 17. Experimental results for a reference speed of 1500 r/min under no-
load condition.
Fig. 20. Speed response for change in load torque and for a reference speed
of 2000 r/min.
VII. C ONCLUSION
A new digital control concept for BLDC machines has
been introduced and experimentally verified. The aim of this
paper is to develop a low-cost controller for applications where
inefficient single-phase induction motors are used. Due to the
simplistic nature of this control, it has the potential to be imple-
mented in a low-cost application-specific integrated circuit. The
controller exploits the characteristic of most electromechanical
systems. Since electrical time constants are much faster relative
to the mechanical time constants, speed regulation with an
acceptable amount of ripple is possible by rapid switching of
states. Furthermore, this control strategy does not require a
state observer. Under dynamic load conditions, the proposed
controller was found to be capable of regulating speed without
the use of an observer. This results in a considerable reduction
of size and the cost of the system.
R EFERENCES
[1] A. Emadi, Handbook of Automotive Power Electronics and Motor Drives.
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[15] W. Brown, “Brushless DC control made easy,” Application Notes—
in operating conditions (Figs. 20 and 21). Fig. 20 shows the Microchip. AN857.
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[17] P. Pillay and R. Krishnan, “Modeling, simulation and analysis of
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the speed response was observed to settle within 5% of the Trans. Ind. Appl., vol. 25, no. 2, pp. 274–279, Mar./Apr. 1989.
commanded value. Thus, this simple low-cost stable control [18] M. Tomita, T. Senjyu, S. Doki, and S. Okuma, “New sensorless control for
brushless DC motors using disturbance observers and adaptive velocity
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SATHYAN et al.: FPGA-BASED NOVEL DIGITAL PWM CONTROL SCHEME FOR BLDC MOTOR DRIVES 3049
[19] N. Keskar, M. Batello, A. Guerra, and A. Gorgerino, “Power loss Young-Joo Lee (S’07) received the B.S. degree
estimation in BLDC motor drives using iCalc,” Application Notes— in electrical engineering from Korea University of
International Rectifier. AN-1048. Technology and Education, Cheonan, Korea, in 1996
[20] N. Matsui“Sensorless PM brushless DC motor drives,” IEEE Trans. Ind. and the M.S. degree from Gwang-Woon University,
Electron., vol. 43, no. 2, pp. 300–308, Apr. 1996. Seoul, Korea, in 2003. Since 2006, he has been
[21] Y. Lai, F. Shyu, and Y. Chang, “Novel loss reduction pulse width modu- working toward the Ph.D. degree in the Department
lation technique for brushless dc motor drives fed by MOSFET inverter,” of Electrical and Computer Engineering, Illinois In-
IEEE Trans. Power Electron., vol. 19, no. 6, pp. 1646–1652, Nov. 2004. stitute of Technology, Chicago. His Ph.D. research
[22] Z. Q. Zhu, Y. Liu, and D. Howe, “Comparison of performance of brushless focuses on integrated bidirectional converter for
DC drives under direct torque control and PWM current control,” in Proc. plug-in hybrid electric vehicles.
8th Int. Conf. Elect. Mach. Syst., Sep. 2005, vol. 2, pp. 1486–1491. In 1995, he joined SunStar R&C, Incheon, Korea,
[23] F. Rodriguez, “Advanced digital control techniques for brush-less where he specialized in industrial sewing machines and controllers, and motors
DC (BLDC) motor drives,” Ph.D. dissertation, Illinois Inst. Technol., and controllers for industrial sewing machines. He then joined Genoray Com-
Chicago, Dec. 2006. pany, Ltd., Seongnam, Korea. He has over ten years of industrial experience
and has developed several commercial system controllers for sewing machines
and medical X-ray fluoroscopy equipment, which require control of brushless
dc motors, induction and stepper motors, high-frequency full-bridge converters,
X-ray electron tubes, and other electric–pneumatic actuators.
Anand Sathyan (S’04) received the B.S. degree
(with distinction) in electrical engineering from
Amrita Institute of Technology, Coimbatore, India,
Mahesh Krishnamurthy (S’02–M’08) received the
in 1998, the M.S. degree (with distinction) in electri-
M.S. degree from the University of Missouri, Rolla,
cal engineering from Coimbatore Institute of Tech-
nology, Coimbatore, in 2001, and the Ph.D. degree in 2004 and the Ph.D. degree from the University of
Texas, Arlington, in 2008.
from the Department of Electrical and Computer En-
Since 2008, he has been with the Department of
gineering, Illinois Institute of Technology, Chicago.
Electrical and Computer Engineering, Illinois Insti-
From August 2001 to August 2004, he was a
tute of Technology, Chicago, as an Assistant Profes-
Faculty Member with the Department of Electrical
sor. His current research interests include numerical
Engineering, Amrita Institute of Technology. From
analysis of energy conversion in electric machines;
August 2004 to December 2008, he was a Research Assistant with the Grainger
Power Electronics and Motor Drives Laboratory, Illinois Institute of Technol- design, analysis, and control of power electronics
and drives in renewable energy; and hybrid and plug-
ogy. Since April 2009, he has been with Chrysler Corporation, Detroit, MI,
in hybrid vehicular applications.
working on hybrid and plug-in hybrid vehicles. His research interests include
power electronics, motor drives, and renewable energy systems.