A

Project Report on

Control of BLDC Motor For Thread Traversing In

Texturising Machine

DEPARTMENT OF ELECTRICAL ENGINEERING

C. K. PITHAWALLA COLLEGE OF ENGINEERING & TECHNOLOGY

SURAT-395007

ACADEMIC YEAR 2015-2016

 Major Project Report on

Control of BLDC Motor For Thread Traversing In

Texturising Machine

BACHLOR OF ENGINEERING

IN

ELECTRICAL ENGINEERING

Submitted By

Adak Ankit SwapanKumar 130093109001

Patel Mukund Kishorbhai 130093109009

Bhalodia Vivek Rasiklal 130093109004

Mistry Chirag Mohanbhai 130093109006

Saraswala Rajat Jawahar 130093109013

DEPARTMENT OF ELECTRICAL ENGINEERING

C. K. PITHAWALLA COLLEGE OF ENGINEERING & TECHNOLOGY

SURAT-395007

JUNE – 2016

ii
 C. K. PITHAWALLA COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF ELECTRICAL ENGINEERING

CERTIFICATE

This is to certify that following students :

Sr. No. Enrollment No. Name of Student

1 130093109001 Adak Ankit SwapanKumar

2 130093109009 Patel Mukund Kishorbhai

3 130093109004 Bhalodia Vivek Rasiklal

4 130093109006 Mistry Chirag Mohanbhai

5 130093109013 Saraswala Rajat Jawahar

of Final year, Seventh semester Electrical Engineering have

successfully completed the Industry Defined Problem (IDP) - identification

report and presented the same as per guidelines of Gujarat Technological

University (GTU) on “Control of BLDC Motor For Thread Traversing In Texturising

Machine”

The work done by them is found satisfactory.

Place : Surat

Date :

............................. ............................. .............................

Guide Jury HOD, EED

iii
 Prof. Dr. N. K. Zaveri

ACKNOWLEDGEMENT

Knowledge in itself is a continuous process. Research is hard but involves great joy as
well. The greatest of joys has been working with the people here at C. K. Pithawalla College
and Technology. An observer might have thought we were working alone but the critical
mass of people here in Electrical Department meant that we could always find the help and
encouragement on all issues.

For achieving success, man is not an independent identity. The guidance and support
of their colleagues, peer and teachers which helps him to find the way of success.

Keeping this in mind, first of all, we are thankful and grateful to our project guides
Prof. Chetan k. Lad & Prof. Amisha H. Kapadia for their immense support and
providing their deep, core knowledge to us regarding to our project work and layout.

My sincere thanks to all faculty members as they spent their valuable time in guiding
us in our project. We would also like to present our gratitude to Department Head, Dr.
Naimish K. Zaveri for providing us all the facilities that would cherish our project.

And last but not least our sincere thanks to all friends who supported us and
inestimable help us in providing us the necessary information and help during the preparation
of our project. Because without their support, the completion of our project was not possible.

Adak Ankit SwapanKumar

Patel Mukund Kishorbhai
Bhalodia Vivek Rasiklal
Mistry Chirag Mohanbhai
Saraswala Rajat Jawahar

iv
 ABSTRACT

We have visited the company named ALIDHRA TEXTILE ENGINEERING

LIMITED.is located at Road No. 6 ,Udhyognagar, Udhna Surat on date 25/07/2015. It is area
production company.

In Alidhra the thread traversing in texturising machine is done by using induction

motor and gear box to achieve the low speed control and for the position control system such
as forward, reverse and locking in different pattern. Now a days in the recent development of
the world the BRUSHLESS DC MOTOR drives are becoming more popular in Industries,
Traction, Automotive, Aerospace, Automation equipment & Instrumentation. Our main
aspect is to use the BLDC motor for thread traversing in texturising machine. This motor has
permanent magnet at rotor & 3-phase winding at stator. Due to the elimination of brushes
BLDC motor has advantages of noiseless operation, high dynamic response, high-efficiency
etc. BLDC motor can operate in four steady states modes of torque-speed plane. In 1st& 3rd
quadrant, the supply voltage is greater than the back emf which is forward & reverse
motoring modes respectively. In 2nd& 4th quadrant the back emf generated by motor should
be greater than the supplied voltage, which are the forward braking and reverse braking
modes of operation. By using the BLDC motor the gear mechanism can be neglected so that
the maintenance reduces, overall cost reduces, and the efficiency increases and the
requirement of high torque is fulfilled. Our project group is going to verify the performance
of BLDC motor with various modes of operation specially forward, reverse and locking in
THREAD TRAVERSING IN TEXTURISING MACHINE and also the simulation using
MATLAB.

v
 CONTENTS

Page
Content
no.
ACKNOWLEDGEMENT iv
ABSTRACT v
CONTENTS vi
LIST OF TABLE vii
LIST OF FIGURE vii
ABBREVIATION x
NOMENCLATURE xi
CHAPTER : 1 INTRODUCTION 1
1.1 Industrial Visit At Alidhra 1
1.2 Operation In Textile Industries 1
1.3 Requirement of Motor Speed Control 2
1.4 Generalized Block Diagram of Bldc Motor Based
2
Thread Traversing In Textile Industry
1.5 Organization of Chapter 3
CONCEPT OF THREAD TRAVERSING IN
CHAPTER : 2 4
TEXTILE INDUSTRY
2.1 Traversing Mechanism Used On Winding Machines 4
CHAPTER : 3 3.1 GENERAL DETAILS OF BLDC 9
3.2 Construction 10
3.3 Four Quadrant Control Operation 14
3.4 Theory of Operation 15
3.5 Torque/Speed Characteristics 18
HARDWARE AND SOFTWARE
CHAPTER : 4 19
IMPLEMENTATIONS
4.1 Simulation Machine Parameter 19
4.2 Simulation Model 20
4.3 Hardware 25
4.4 Testing and speed control of BLDC Motor 33
CHAPTER : 5 CONCLUSION AND FUTURE WORK 40
5.1 Conclusion 40
REFERENCES 41
APPENDIX 42

vi
 LIST OF TABLE

Table no. Table Page no.

1 Parameters of BLDC Motor 19

2 Open Circuit Test Results 27

3 Load Test Results 27

4 Testing results of hardware 39

vii
 LIST OF FIGURES

Fig no. Figure Page no.

1.1 Generalized Block Diagram 2
2.1 Precision Type Winding Mechanism 4
2.2 Traverse Roll 5
2.3 Gear And Shaft Mechanism 5
2.4 Thread Guide Assembly 6
2.5 Traverse Bar Driver 6
2.6 Roll Driver 7
2.7 Traverse Cam 8
3.1 Stator of BLDC Motor 10
3.2 Trapezoidal Back Emf 11
3.3 Sinusoidal Back Emf 11
3.4 Rotor Magnet Cross Section 12
3.5 BLDC Motor Transverse Section 12
(A) Schematic Representation of A Three Branches Hall Sensor
3.6 (B) Three Branches Vertical Hall Device Mounted As Angular 14
Position Sensor For Brushless Motor Control
3.7 Four Quadrants of Operation 15
3.8 Electronically Commutated BLDC Motor Drive 16
3.9 Hall-Sensor Signal,Back Emf,O/P Torque & Phase Current 17
3.10 Torque/Speed Characteristics 18
4.1 Simulink Model of BLDCM 20
4.2 Three-Phase Inverter Circuit 21
4.3 Hall Sensor Pulses 23
4.4 Gate Pulses 23
4.5 Speed And Torque Characteristics 24
4.6 Back Emf And Current Waveforms 24
4.7 Power Supply 25
4.8 Transformer 26
4.9 Testing of Transformer 27
4.10 Bridge Rectifier 28

viii
4.11 Bridge Rectifier With Capacitor Filter 29
4.12 Rectifier Testing (A) Input Voltage (B) Output Voltage 29
4.13 15 Volt Supply 30
4.14 Three-Phase Inverter Card 31
4.15 Micro-Controller Card 31
4.16 Gate pulse g1 and g4 33
4.17 Gate pulse g1 and g3 33
4.18 Current Ia 33
4.19 Hall sensor signal Ha and Hb 34
4.20 Hall sensor signal Hb and Hc 34
4.21 Hall sensor signal Ha and Hc 34
4.22 Gate signal g1 and g4 at 750rpm 35
4.23 Gate signal g1 and g3 at 750rpm 35
4.24 Current Ia at 750rpm with loading 35
4.25 Gate signal g1 and g4 at 950rpm 36
4.26 Gate signal g1 and g3 at 950rpm 36
4.27 Current Ia at 950rpm with loading 36
4.28 Line voltage Vab and Vac 37
4.29 Line voltage Vab and Vac 37
4.30 Gate signal g1-g3, g1 and g3 37
A.1 Block Diagram of P89V51RD2 43
A.2 Pin Diagram of P89V51RD2 44

ix
 ABBREVIATIONS

BLDCM …………………………………………….BRUSHLESS DC MOTOR

RPM ……………………………………….......REVOLUTION PER MINUTE

IM……………………………………………………......INDUCTION MOTOR
EMC………………………………ELECTRO MAGNETIC COMPATIBILITY
SRM……………………………………SWITCHED RELUCTANCE MOTOR
SPM………………………………….......SURFACE PERMANENT MAGNET
IPM………………………………….......INTERIOR PERMANENT MAGNET
EMF……………………………………………….ELECTROMOTIVE FORCE

x
 NOMENCLATURE

Vin……………………………………………………………INPUT VOLTAGE

Vout………………………………………………………..OUTPUT VOLTAGE

Iin…………………………………………………………….INPUT CURRENT

Iout………………………………………………………...OUTPUT CURRENT

Tp………………………………………………………………PEAK TORQUE

Tr……………………………………………………………RATED TORQUE

Vdc………………………………………………………………DC VOLTAGE

xi
 CHAPTER : 1

INTRODUCTION

1.1 Industrial Visit At Alidhra : -

The project group visited the company named ALIDHRA TEXTILE

ENGINEERING LIMITED. Which is located at Road No. 6 Udhyognagar, Udhna Surat. In
alidhra textile industries there is a method of thread traversing used in the texturising
machine. Thread Traversing means the thread is wound up in the bobbin having a lateral
motion in which they are adjusted laterally that is the thread‟s adapted for giving lateral
motion. As they are using conventional induction motor with the VFD CONTROL LOGIC
and they were getting as the high speed and low torque but their requirement was low speed
and high torque which was fulfilled by the gear mechanism connected at the shaft of the
induction motor.

1.2 Operation in Textile Industries : -

There are various basic operations in textile industries. They are as follows:-

1. Carding
2. Spinning
3. Slashing (Sizing)
4. Weaving
5. Knitting
6. Tufting
7. Designing
8. Scouring
9. Wool Carbonizing
10. Filling
11. Bleaching
12. Mercerizing
13. Dyeing
14. Printing
15. Finishing
1.3 Requirement of Motor Speed Control : -

As conventional induction motor has no brush, so no such problem of brush friction

generation arcing and sparking, but its starting torque is small at below base speed, efficiency
is low and speed response is bad. To overcome these drawbacks we recommended them to
use BRUSHLESS DC MOTOR (BLDC) instead of induction motor and gear box combine
to use in texturising machine. BLDC without brush, commutated by electronic control
method, having higher efficiency and speed–torque response. Efficiency is an important
indicator of energy saving and carbon reduction. There are two types of permanent magnet
configuration used in the BLDC motor structure named :

1. SURFACE MOUNTED PERMANENT MAGNET (SPM)

2. INTERNAL EMBEDDED PERMANENT MAGNET (IPM)

SPM BLDC have magnets on the rotor surface, while the IPM BLDC have magnets
inside the rotor. Obviously, due to the high speed requirement, the IPM structure is selected
to be used in the Thread Traversing in the Texturising Machine.

Our main aim of this project is controlling the speed of BRUSHLESS DC MOTOR at
low speed and high torque such that gear box can be removed and also the size will be
reduced.

1.4 Generalized Block Diagram of BLDC Motor Based Thread Traversing

In Textile Industry : -

FIG 1.1 GENERALIZED BLOCK DIAGRAM

2
 As shown in (fig : 1.1) 1-phase AC input is given to the transformer which converts
the 230 volt Ac to the 12volt Ac. Supply. This single phase 12volt Ac supply is given to the
rectifier which convert single Ac supply into equivalent DC output which will be measure
across output terminal of rectifier. A capacitor is connected for the ripple free output dc
voltage. This Dc output voltage is given to the 3-phase inverter circuit which converts dc
voltage into 3-phase ac voltage and this output ac voltage is given to the BLDC motor. In
BLDC motor hall sensors is used which gives control signal which is useful for control
operation in the control circuit. Output of the control circuit is given to the 6-step operation
block. This step operation gives output in the form of pulse. This pulse is given to the 3-phase
inverter circuit. 24 volt supply from rectifier is given to the input of inverter to drive the
inverter circuit. BLDC motor work with the help of this output signal from 3-phase inverter
by proper switching combinations so that BLDC motor rotates in clockwise or anticlockwise
direction.

1.5 Organization of Chapter : -

CH : - 2 Concept of Thread Traversing In Textile Industries

CH : - 3 Basic Concept of IM BLDC Motor

CH : - 4 Implementation and Simulation Results

CH : - 5 Conclusion and Future Work

3
 CHAPTER : 2

CONCEPT OF THREAD TRAVERSING IN TEXTILE

INDUSTRY

2.1 Traversing Mechanism Used on Winding Machines : -

The seven mechanism are used on different types of yarn and coil winding machines.
Their fundamentals, however , may be applicable to other machines which require similar
changes of motion, Except for the lead screw as used, for example on lathes, these seven
represent the principles of all well-known, mechanical types of traversing devices .

2.1.1 Winding Mechanism : -

FIG 2.1 PRECISION TYPE WINDING

As seen in fig 2.1 package is mounted on belt driven shaft on this precision type
winding mechanism. Cam shaft imparts reciprocating motion to traverse bar by means of cam
roll that runs in cam groove. Gears determine speed ratio between cam and package. Thread
guide is attached to traverse bar. Counterweight keeps thread guide against package.

2.1.2 Traverse Roll : -

Package is friction-driven from traverse roll. Yarn is drawn from the supply source by
traverse roll and is transferred to package from the continuous groove in the roll different
winds

4
winds are obtained by varying the groove path .

FIG 2.2 TRAVERSE ROLL

2.1.3 Gear and Shaft Mechanism : -

Reversing bevel gears which are driven by a common bevel gear , drive the shaft
carrying the traverse screw as shown in fig 2.3 . Traverse nut mates with this screw and is
connected to the yarn guide. Guide slides along the reversing rod . When nut reaches end of
its travel , the thread guide compresses the spring that pawl and the reversing lever. this
engages

FIG 2.3 GEAR AND SHAFT MECHANISM

the clutch that rotates the traverse screw in the opposite direction . as indicated by the large
pitch on the screw, this mechanism is limited to low speeds, but permits longer lengths of
traverse than most of the others shown .

5
2.1.4 Thread Guide : -

FIG 2.4 THREAD GUIDE ASSEMBLY

As seen in fig 2.4 drum drives package by friction . pointed cam shoe which pivots in
the bottom side of the thread guide assembly rides in cam grooves and produces reciprocating
motion of the thread guide assembly on the traverse bar . plastic cams have proved quite
satisfactory even with fast traverse speeds interchangeable cams permit a wide variety of
winds.

2.1.5 Traverse Bar Driver Assembly : -

FIG 2.5 TRAVERSE BAR DRIVER

6
 Roll that rides in heart-shaped cam groove engages slot in traverse bar driver which is
attached to the traverse bar shown in fig 2.5. Maximum traverse is obtained when adjusting
guide is perpendicular to the driver . As angle between guide and driver is decreased ,
traverse decreases proportionately . Inertia effects limit this type mechanism to slow speed .

2.1.6 Traverse roll driver : -

FIG 2.6 ROLL DRIVER

Two cam rolls that engages heart shaped cam are attached to the slide . Slide has a
driver roll that engages a slot in the traverse bar driver . Maximum traverse (to capacity of
cam) occurs when adjusting disk is set so slide is parallel to traverse bar . As angle between
traverse bar and slide increases, traverse decreases . At 90 deg traverse is zero .

2.1.7 Traverse Cam : -

Traverse cam ( fig 2.7 ) imparts reciprocating motion to can follower which drives
thread guides on traverse guide rods . Package is friction driven from drum . Yarn is drawn
from the supply source through thread guide and transferred to the drum-driven package .
speed

7
 FIG 2.7 TRAVERSE CAM

of this type of mechanism is determined by the weight of the reciprocating parts .

8
 CHAPTER : 3

BLDC MOTOR

3.1 General Details of BLDC : -

BLDC motor, also called Permanent Magnet DC Synchronous motor, are one of the
motor types that have more rapidly gained popularity, mainly because of their better
characteristics and performance. These motors are used in a great amount of industrial sectors
because their architecture is suitable for any safety critical applications.

The brushless DC motor is a synchronous electric motor that, from a modelling

perspective, looks exactly like a DC motor, having a linear relationship between current and
torque, voltage and rpm. It is an electronically controlled commutation system, instead of
having a mechanical commutation, which is typical of brushed motors. Additionally, the
electromagnets do not move, the permanent magnets rotate and the armature remains static.
This gets around the problem of how to transfer current to a moving armature. In order to do
this, the brush-system/commutator assembly is replaced by an intelligent electronic
controller, which performs the same power distribution as a brushed DC motor. BLDC
motors have many advantages over brushed DC motors and induction motors, such as :

 Better speed versus torque characteristics

 High dynamic response
 High efficiency and reliability
 Long operating life
 Noiseless operation
 Higher speed ranges

In addition, the ratio of delivered torque to the size of the motor is higher, making it
useful in applications where space and weight are critical factors, especially in aerospace
applications.

9
3.2 Construction : -

BLDC motors are a type of synchronous motor. This means the magnetic field
generated by the stator and the magnetic field generated by the rotor rotates at the same
frequency. BLDC motors do not experience the “slip” that is normally seen in induction
motors. BLDC motors come in single-phase, 2-phase and 3-phase configurations.
Corresponding to its type, the stator has the same number of windings. Out of these, 3-phase
motors are the most popular and widely used.

3.2.1 Stator : -

The stator of a BLDC motor consists of stacked steel laminations with windings
placed in the slots that are axially cut along the inner periphery as shown in (Fig 3.1).
Traditionally, the stator resembles that of an induction motor; however, the windings are
distributed in a different manner. Most BLDC motors have three stator windings connected in
star fashion. Each of these windings are constructed with numerous coils interconnected to
form a winding. One or more coils are placed in the slots and they are interconnected to make
a winding. Each of these windings are distributed over the stator periphery to form an even
numbers of poles. There are two types of stator windings variants: trapezoidal and sinusoidal
motors. This differentiation is made on the basis of the interconnection of coils in the stator
windings to give the different types of back Electromotive Force (EMF).

FIG 3.1 STATOR OF BLDC MOTOR

As their names indicate, the trapezoidal motor gives a back EMF in trapezoidal
fashion and the sinusoidal motor‟s back EMF is sinusoidal, as shown in (Fig 3.2) and (Fig
3.3) In addition to the back EMF, the phase current also has trapezoidal and sinusoidal
variations in the respective types of motor. This makes the torque output by a sinusoidal

10
motor smoother than that of a trapezoidal motor. However, this comes with an extra cost, as
the sinusoidal motors take extra winding interconnections because of the coils distribution on
the stator periphery, thereby increasing the copper intake by the stator windings.

FIG 3.2 TRAPEZOIDAL BACK EMF

FIG 3.3 SINUSOIDAL BACK EMF

Depending upon the control power supply capability, the motor with the correct
voltage rating of the stator can be chosen. Forty-eight volts, or less voltage rated motors are
used in automotive, robotics, small arm movements and so on. Motors with 100 volts, or
higher ratings, are used in appliances, automation and in industrial applications.

11
3.2.2 Rotor : -

FIG 3.4 ROTOR MAGNET CROSS SECTION

The rotor is made of permanent magnet and can vary from two to eight pole pairs with
alternate North (N) and South (S) poles. Based on the required magnetic field density in the
rotor, the proper magnetic material is chosen to make the rotor. Ferrite magnets are
traditionally used to make permanent magnets. As the technology advances, rare earth alloy
magnets are gaining popularity. The ferrite magnets are less expensive but they have the
disadvantage of low flux density for a given volume. In contrast, the alloy material has high
magnetic density per volume and enables the rotor to compress further for the same torque.
Also, these alloy magnets improve the size-to-weight ratio and give higher torque for the
same size motor using ferrite magnets. Neodymium (Nd), Samarium Cobalt (SmCo) and the
alloy of Neodymium, Ferrite and Boron (NdFeB) are some examples of rare earth alloy
magnets. Continuous research is going on to improve the flux density to compress the rotor
further. (Fig. 3.4) Shows cross sections of different arrangements of magnets in a rotor.

3.2.3 Hall Sensors : -

FIG 3.5 BLDC MOTOR TRANSVERSE SECTION

12
 Unlike a brushed DC motor, the commutation of a BLDC motor is controlled
electronically. 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 understand which winding will
be energized following the energizing sequence. Rotor position is sensed using Hall Effect
sensors embedded into the stator.

Most BLDC motors have three Hall sensors embedded into the stator on the non-
driving end of the motor. Whenever the rotor magnetic poles pass near the Hall sensors, they
give a high or low signal, indicating the N or S pole is passing near the sensors. Based on the
combination of these three Hall sensor signals, the exact sequence of commutation can be
determined.

(Fig:-3.5) shows a transverse section of a BLDC motor with a rotor that has alternate
N and S permanent magnets. Hall sensors are embedded into the stationary part of the motor.
Embedding the Hall sensors into the stator is a complex process because any misalignment in
these Hall sensors, with respect to the rotor magnets, will generate an error in determination
of the rotor position. To simplify the process of mounting the Hall sensors onto the stator,
some motors may have the Hall sensor magnets on the rotor, in addition to the main rotor
magnets. These are a scaled down replica version of the rotor. Therefore, whenever the rotor
rotates, the Hall sensor magnets give the same effect as the main magnets. The Hall sensors
are normally mounted on a PC board and fixed to the enclosure cap on the non-driving end.
This enables users to adjust the complete assembly of Hall sensors, to align with the rotor
magnets, in order to achieve the best performance. Based on the physical position of the Hall
sensors, there are two versions of output. The Hall sensors may be at 60° or 120° phase shift
to each other. Based on this, the motor manufacturer defines the commutation sequence,
which should be followed when controlling the motor.

Nowadays, because miniaturized brushless motors are introduced in many

applications, new position sensors are being developed, such as a three branches vertical Hall
sensor depicted in (fig:-3.6(a)). The connecting principle between the brushless motor and
this sensor is reminiscent of the miniaturized magnetic angular encoder based on 3-D Hall
sensors. A permanent magnet is fixed at the end of a rotary shaft and the magnetic sensor is
placed below, and the magnet creates a magnetic field parallel to the sensor surface. This
surface corresponds to the sensitive directions of the magnetic sensor. Three-phase brushless
motors need three signals with a phase shift of 120° for control, so a closed-loop regulation

13
may be used to improve the motor performance. Each branch could be interpreted as a half of
a vertical Hall sensor and are rotated by 120° in comparison to the other. Only a half of a
vertical Hall sensor is used since little space is available for the five electrical contacts(two
for the supply voltage and three to extract the Hall voltages). This sensor automatically
creates three signals with a phase shift of 120°, which directly correspond to the motor
driving signals, to simplify the motor control in a closed-loop configuration. A drawing of
this device‟s use as angular position sensor for brushless motor control is given in (fig:-
3.6(b)) A first alignment is between the rotor orientation and the permanent magnet, and a
second alignment is between the stator and the sensor. This alignment will allow the motion
information for the motor and the information about its shaft angular position.

FIG 3.6 (a) SCHEMATIC REPRESENTATION OF A THREE BRANCHES HALL

SENSOR (b) THREE BRANCHES VERTICAL HALL DEVICE MOUNTED AS
ANGULAR POSITION SENSOR FOR BRUSHLESS MOTOR CONTROL

3.3 Four Quadrant Control Operation : -

There are four possible modes or quadrants of operation using a three phase Brushless
DC (BLDC) Motor. In 1st Quadrant positive speed and the torque is positive hence the motor
rotates in the forward direction. In 2nd Quadrant motor is rotating in the forward direction,
but torque is being applied in reverse. Reverse Torque is applied to “brake” the motor, and
the motor is now generating power. In 3rd Quadrant negative speed and negative torque. In
this condition the motor is rotating in reverse direction. In 4th Quadrant exactly the opposite,
the motor rotates in the reverse direction, but the torque is being applied in the forward
direction. Again, torque is being applied to attempt to slow the motor and change its direction
to forward again. Once again, power is being generated by the motor.

14
 FIG 3.7 FOUR QUADRANTS OF OPERATION

The three phase brushless DC (BLDC) motor is initially made to rotate in forward
direction, but when the speed command is given reverse, the control goes into the forward
braking mode hence current flows from motor to battery , in this case the rotor comes to the
standstill position is term named as forward braking or regenerative braking. Instead of
waiting for the absolute standstill position, continuous energization of the main phase is
attempted. This rapidly slows down the rotor to a standstill position. Similarly for when the
motor rotates in the reverse direction, but when the speed command is given positive, the
controller goes into reverse regeneration mode, in this case the current is flows from motor to
source.

3.4 Theory of Operation : -

A BLDC motor is driven by voltage strokes coupled with the rotor position. These
strokes must be properly applied to the active phases of the three-phase winding system so
that the angle between the stator flux and the rotor flux is kept close to 90° to get the

15
maximum generated torque. Therefore, the controller needs some means of determining the
rotor's orientation/position (relative to the stator coils), such as Hall-effect sensors, which are
mounted in or near the machine‟s air gap to detect the magnetic field of the passing rotor
magnets. Each sensor outputs a high level for 180° of an electrical rotation, and a low level
for the other 180°. The three sensors have a 60° relative offset from each other. This divides a
rotation into six phases (3-bit code).

FIG 3.8 ELECTRONICALLY COMMUTATED BLDC MOTOR DRIVE

The process of switching the current to flow through only two phases for every 60
electrical degree rotation of the rotor is called electronic commutation. The motor is supplied
from a three-phase inverter, and the switching actions can be simply triggered by the use of
signals from position sensors that are mounted at appropriate points around the stator. When
mounted at 60 electrical degree intervals and aligned properly with the stator phase windings
these Hall switches deliver digital pulses that can be decoded into the desired three-phase
switching sequence. A BLDC motor drive with a six-step inverter and Hall position sensors is
shown in (Fig:-3.8).

Such a drive usually also has a current loop to regulate the stator current, and an outer
speed loop for speed control. The speed of the motor can be controlled if the voltage across
the motor is changed, which can be achieved easily varying the duty cycle of the PWM signal
used to control the six switches of the three-phase bridge.

16
FIG 3.9 HALL-SENSOR SIGNAL,BACK EMF,O/P TORQUE & PHASE CURRENT

17
 Only two inverter switches, one in the upper inverter bank and one in the lower
inverter bank, are conducting at any instant. These discrete switching events ensure that the
sequence of conducting pairs of stator terminals is maintained. (Fig:-3.8) shows an example
of Hall sensor signals with respect to back-EMF and the phase current. One of the hall
sensors changes the state every 60 electrical degrees of rotation. Given this, it takes six steps
to complete an electrical cycle. However one electrical cycle may not correspond to a
complete a mechanical rotation is determined by the rotor pole pairs. For each rotor pole pair,
one electrical cycle is completed. The number of electrical cycles\rotations equals the rotor
pole pairs. This sequence of conducting pairs is essential to the production of a constant
output torque.

3.5 Torque/Speed Characteristics : -

(Fig:-3.10) shows an example of torque/speed characteristics. There are two torque

parameters used to define a BLDC motor, peak torque (TP) and rated torque (TR).During
continuous operations, the motor can be loaded up to the rated torque. As discussed earlier, in
a BLDC motor, the torque remains constant for a speed range up to the rated speed. The
motor can be run up to the maximum speed, which can be up to 150% of the rated speed, but
the torque starts dropping. Applications that have frequent starts and stops and frequent
reversals of rotation with load on the motor, demand more torque than the rated torque. This
requirement comes for a brief period, especially when the motor starts from a standstill and
during acceleration. During this period, extra torque is required to overcome the inertia of the
load and the rotor itself.

FIG 3.10 TORQUE/SPEED

18
 CHAPTER : 4

HARDWARE AND SOFTWARE IMPLEMENTATIONS

4.1 Simulation Machine Parameter : -

TABLE : 1 PARAMETERS OF BLDC MOTOR

SR
BLDC MOTOR
NO.
1 Back EMF waveform Trapezoidal

2 Mechanical Input Torque Tm

3 Stator phase inductance Ls [h] 8.50E-03

4 Stator phase resistance Rs [ohm] 2.875

5 Back emf flat area [degree] 120 degree

Inertia, friction factor, pole pairs

6 [0.0008 0.001 4]
[j(kg.m^2) F(N.m.s) p()]

Flux linkage established by magnets

7 0.175
(V.s)

8 Voltage constant (V_peak L-L/ krpm) 146.6077

9 Torque constant (N.m/A_peak) 1.4

19
4.2 Simulation Model : -

FIG 4.1 SIMULINK MODEL OF BLDCM

20
 (Fig : 4.1) shows a block diagram of Simulation Model of BLDC motor based Thread
Traversing in textile industry. With the help of this type of connection we performed six-step
operation. In which different block are used like 3-phase Inverter circuit, BLDC motor block,
and Control circuit block.

A 300 Volt DC supply is given to the 3-phase inverter circuit Block. In inverter circuit
6 Ideal switches are used to form 3-phase inverter circuit as shown in (fig : 4.2).

FIG 4.2 THREE-PHASE INVERTER CIRCUIT

In inverter circuit switch S1, S3, S5 are connected in Upper side while switch S4, S6,
S2 are connected in lower side of the circuit. In ideal switch terminal 1 and g are input signal
while terminal 2 and m are output signal. In switch gate pulses (g1, g2, g3, g4, g5, g6) are
applied from the Hall sensor signal of the BLDC motor. Terminal „m‟ of the IDEAL switch is
terminating through Terminator Block.

21
 Output of the inverter is taken from Terminal a, b, c as shown in (fig:-4.2). Output of
this inverter circuit is given to the 3-phase BLDC motor. The parameter of BLDC motor is
given in (table no. 1)

Output of the BLDC motor is given to the Bus selector block which gives output as
Hall effect signal (ha, hb, hc), Back emf (ea, eb, ec) in volt, Current(Ia, Ib, Ic) in ampere,
electromagnetic torque Te (N*m) and rotor speed wm (rad/s).

In Hall sensor, logical operation will be performed and which gives output as gate
pulses. This gate pulses are used to drive 3-phase inverter circuit.

In control circuit step input and repeating sequence are used which gives out control
signal and this signal is given to the switch S1, S2 and S3 of the 3-phase inverter circuit.

This way we get six step output operation of BLDC Motor .

22
4.2.1 Simulink Results : -

1. Hall Sensor Pulses for forward and reverse rotation

Reverse Rotation Waveform After This Intersection

FIG 4.3 HALL SENSOR PULSES

2. Gate Pulses for forward and reverse rotation

Reverse Rotation Waveform After This Intersection

FIG 4.4 GATE PULSES

23
3. Speed and Torque for forward and reverse rotation

Reverse Rotation Waveform After This Intersection

FIG 4.5 SPEED AND TORQUE CHARACTERISTICS

4. Back Emf and Current for forward and reverse rotation

Reverse Rotation Waveform After This Intersection

FIG 4.6 BACK EMF AND CURRENT WAVEFORMS

24
4.3 Hardware : -

4.3.1 24 volt DC supply : -

The power supply is designed to convert high voltage ac mains electricity to a suitable
low voltage supply for electronics circuit and other device the RPS (regulated power supply)
is the power supply with rectification, filtering and regulation being done on the ac mains to
get a regulated power supply for a microcontroller and for the other devices being interfaced
to it.

A power supply can be broken down into a service of blocks, each of which performs
a particular function. A DC power supply which maintains the output voltage constant
respective of ac mains fluctuations or load variations is known as „regulated power supply‟.

(Fig : 4.7) shows a regulated power supply.

FIG 4.7 POWER SUPPLY

4.3.2 Transformer : -

Transformer is an electrical device which is used to convert electrical power from one
electrical circuit to another without change in frequency.

Transformer convert ac electricity from one voltage to another with little loss of
power. Transformers work only with ac and this is one of the reasons why mains electricity is

25
ac. Step up transformer increase in output voltage, most power supplies use a step down
transformer to reduce the dangerously high mains voltage to a safer low voltage. Input coils
called a primary and the output coils is called the secondary. There is a no electrical
connection between the two coils instant they are linked by the alternating magnetic field
crated in the soft iron core of the transformer. The two lines in the middle of the circuit
symbol represent the core. The transformer waste the very little power so power out is equal
to the power in note that as voltage is step down current is stepped up. The ratio of the
number of the turns on each coils called the turns ratio determine the ratio of the voltage. A
stepped down transformer large number of turns on the its primary coil which is connected to
the high voltage main supply, and a less number of turns in secondary(output) coil to give a
low output voltage.

Turns ratio = Vp/Vs = Np/Ns

Power out = power in

Vp = primary (input) voltage

Np = no. of turns on primary coil

Ip = primary (input) current

FIG 4.8 TRANSFORMER

In project transformer are used with rating of 230/24 V and current rating of 10 A. For
testing of transformer two type of test will be performed

 Open Circuit Test

 Load test

26
 FIG 4.9 TESTING OF TRANSFORMER

TABLE : 2 OPEN CIRCUIT TEST RESULTS

INPUT (Volt) OUTPUT (Volt)

235 25.2

TABLE : 3 LOAD TEST RESULTS

Sr No. Vp Vs Is
1 235 24.2 3.25
2 235 24.2 4
3 235 23.8 4.5
4 235 23.6 5.1
5 235 24.1 5.5
6 235 24.2 6.2
7 235 23.6 6.55
8 235 23.5 7
9 235 23.3 7.5
10 235 23.1 8

4.3.3 Rectifier : -

A circuit which is used to convert AC to DC is known as RECTIFIER. The process of

the conversion ac to dc called „rectification‟.

4.3.3.1 Bridge Rectifier : -

A bridge rectifier makes use of four diodes in bridge arrangements to achieve full
wave rectification. This is widely used configuration; both with individual diodes wired as
shown and with single component bridge were the diode bridge is wired internally.

27
 FIG 4.10 BRIDGE RECTIFIER

A bridge rectifier makes use of four diodes in bridge arrangement as shown in (fig :
4.10) to achieve full wave rectification. This is widely used configuration both with
individual diode wired is shown and signal component bridge where the diode bridge is wired
internally.

 Operation : -
 During positive half cycle of secondary, the diode D2 and D3 are forward in biased
while D1 and D4 are in reverse biased as shown in (fig : 4.10) .
 During negative half cycles of secondary voltage, the diodes D1 and D4 are in
forward biased while D2 and D3 are in reverse biased as shown in (fig : 4.10) .
 Capacitor Filter : -
 Capacitive filter is used in this project. It removes the ripples from the output of
rectifier and smoothens the D.C. Output received from this filter is constant until the
mains voltage and load is maintained constant. However, if either of the two is varied,
D.C. voltage received at this point changes. Therefore a regulator is applied at the
output stage.
 The simple capacitor filter is the most basic type of power supply filter. The use of
this filter is very limited. It is sometimes used on extremely high-voltage, low-current
power supplies for cathode-ray and similar electron tubes that require very little load
current from the supply. This filter is also used in circuits where the power-supply
ripple frequency is not critical and can be relatively high. Below figure can show how
the capacitor changes and discharges.

28
 FIG 4.11 BRIDGE RECTIFIER WITH CAPACITOR FILTER

4.3.3.2 Rectifier Testing : -

In our circuit we are using 2200uf hence large value of capacitor is placed to reduce
ripples and to improve the DC component.

In rectifier circuit 35A Range Bridge, 50V, 2200µF Capacitor and transformer with
the rating of 230/24V-10A are used.

(A) (B)

FIG 4.12 RECTIFIER TESTING (A) INPUT VOLTAGE (B) OUTPUT VOLTAGE

29
4.3.4 15 Volt DC supply for Inverter : -

For inverter a 15 volt DC supply is used for its operation. (Fig : 4.13) shows the 15
volt dc supply with 5 volt supply for Hall sensor signal amplification circuit.

FIG 4.13 15 VOLT SUPPLY

4.3.5 Hall Sensor Signal Amplification Circuit : -

BLDC motor has three Hall sensors inside the stator on the non-driving end of the
motor. Whenever the rotor magnetic poles pass near the hall sensors they give a high or low
signal indicating the N or S pole is passing near the sensors. Based on the combination of
these three Hall sensor signals, the exact sequence of commutation can be determined. A 5
volt DC supply is given to Hall-sensor terminals.

4.3.6 3-phase Inverter : -

A three phase inverter consists of three single-phase inverter switches each connected
to one of the three load terminals. For the most basic control scheme, the operation of the
three switches is coordinated so that one switch operates at each 60 degree point of the
fundamental output waveform. This creates a line-to-line output waveform that has six steps.
The six steps waveform has a zero-voltage step between the positive and negative sections of
the square-wave such that the harmonics that are multiples of three are eliminated. When
carrier-based PWM techniques are applied to six-step waveforms, the basic overall shape, or

30
envelop, of the waveform is retained so that the 3rd harmonics and its multiples are
cancelled.

FIG 4.14 THREE-PHASE INVERTER CARD

4.3.7 8051 Micro-Controller : -

A microcontroller unit is a specialized type of digital computer used to provide

automatic sequencing or control of a system.

FIG 4.15 MICRO-CONTROLLER CARD

31
 Microcontroller differ from ordinary digital computers in being very small (typical a
single integrated circuit chip), with several dedicated pins for input and/or output of digital
signals, and limited memory. Instructions programmed into the microcontroller‟s memory tell
it how to react to input conditions, and what types of signals to send to the outputs.

The simplest type of signal understood by a microcontroller is a discrete voltage level:

either “high” or “low” measured at a specified pin on the chip.

4.3.7.1 P89V51RD2 IC : -

The P89V51RD2 is 80C51 microcontroller with 64kB flash and 1024 B of data RAM.
A key feature of P89V51RD2 is its X2 mode option. The design engineer can choose to run
the application with the conventional 80C51 clock rate (12 clocks per machine cycle) or
select the X2 mode (six clocks per machine cycle) to achieve twice the throughout at the
same clock frequency by half, thus dramatically reducing the EMI.
The flash program memory supports both parallel programming and in serial ISP.
Parallel programming mode offers gang-programming at high speed, reducing programming
costs and time to market. ISP allows a device to be reprogrammed in the end product under
software control. The capability to field/update the application possible.
The P89V51RD2 is also capable of IAP, allowing the flash program memory to be
reconfigured even while the application is running.

32
4.4 Testing and speed control of BLDC Motor : -

4.4.1 Six step operation

Fig. 4.16 Gate pulse g1 and g4

Fig. 4.17 Gate pulse g1 and g3

1.1.1.1 Fig. 4.18 Current Ia

33
 Fig. 4.19 Hall sensor signal Ha and Hb

Fig. 4.20 Hall sensor signal Hb and Hc

Fig. 4.21 Hall sensor signal Ha and Hc

34
4.4.2 Speed control by pwm

Fig.4.22 Gate signal g1 and g4 at 750rpm

Fig.4.23 gate signal g1 and g3 at 750rpm

Fig.4.24 current Ia at 750rpm with loading

35
Fig.4.25 gate signal g1 and g4 at 950rpm

Fig.4.26 Gate signal g1 and g3 at 950rpm

Fig.4.27 Current Ia at 950rpm with loading

36
 Fig.4.28 Line voltage Vab and Vac

Fig.4.29 Line voltage Vab and Vac

Fig.4.30 Gate signal g1-g3, g1 and g3

37
4.4.3 Operation with pwm method : -

For the PWM method we used g1, g3, g5 as PWM pulses whereas g2, g4, g6 used as normal
pulses (speed frequency) as input to the inverter.

For the PWM mode we use PCA timer (8-bit) which is shown in fig.3.15 that has five
modules, Modules0, Modules1…., in that we use 3 modules as PWM input that is Modules0,
Modules2, Modules4.

This timer is 8-bit so, range is 0 to FF (0 to 255), for the PCA input we use fosc/12 as internal
clock frequency.

For calculating the frequency f,

= 7.2 KHz

For the connection, Modules0 of the PCA timer is connected to pin P1.3 as g1,

Modules1 is connected with P1.4 as g2

Modules2 is connected with P1.5 as g3

Pin P1.6 is connected as g4

Pin P1.7 is connected as g5

Pin P1.2 is connected as g6

For timer base key scanning 3 pin is used as an Increment, Decrement and Start/Stop.

For Increment pin P2.0 is used.

For Decrement pin P2.1 is used.

For Start/Stop pin P2.2 is used.

For the time variation 10 time we will take so for the 255 time we get 25 time
speed variation is achieved.

Suppose, the position of the key press is already as (1, 1, 1).

38
 So, for the first position of the pin P2 is as 0x07 and when we compare 0x01 with
it that time we get output as 0x01, for the second interval if P2 is compare with
0x02 then it gives out as 0x02, and for third interval if P2 is compare with 0x04
then it gives out as 0x04.

For speed control (change the duty ratio), for increment and decrement we use + or – 10 step
time variation so, we get 0 (minimum) to 250 (maximum) speed control in step wise.

Table shows the testing of hardware

Table 4 Testing results of hardware

DC link voltage: 24V Fs= 7.2 kHz

% Duty Ratio
Sr. Line Voltage Speed N
of
No. Vab (rpm)
PWM
1. 45.8 48 1800
2. 55 50 1925
3. 65 60 2171
4. 80 62 2280
5. 85 65 2430
6. 95 72 2780

39
 CHAPTER : 5
CONCLUSION

5.1 CONCLUSION : -

The simulation is carried out using MATLAB Simulink for six step operation of
BLDC motor and motor simulation results are analyzed for forward and reverse motoring.
Some hardware components like voltage regulator, transformer, rectifier and 3-phase inverter
card have been made. We have use BRUSHLESS DC MOTOR (BLDC) instead of
induction motor and gear box combine to use in texturizing machine. BLDC without brush,
commutated by electronic control method, having higher efficiency and speed–torque
response. Efficiency is an important indicator of energy saving and carbon reduction.

We have finally completed the thread traversing with BLDC motor in the forward ,
reverse and forward-stop-reverse-stop operation.

40
 REFERENCES

[1] AN885, Microchip : AZ , “Brushless DC (BLDC) Motor Fundamentals Application

Note” , USA. 2003.
[2] AN10661, Rev. 01-17 October 2007 .
[3] “3-Phase BLDC Motor Control with Hall Sensors using 56000/E Digital Signal
Controllers Application Note” ; AN1916, Freescale Semiconductor: TX, USA, 2005.
[4] Leonard N. Elevich , “3-Phase BLDC Motor Control With Hall Sensors Using
56800/E Digital Signal Controllers3-Phase BLDC Motor Control With Hall Sensors
Using 56800/E Digital Signal Controllers”.
[5] Dr. Inaam Ibrahim , “AC machine”.
[6] V.U, S.Pola and K. P. Vittal , “Simulation of four quadrant operation & speed control
of BLDC motor on MATLAB/SIMULINK” , ‖ in Proc.IEEE Region 10 Conference ,
2008, pp. 1–6.
[7] Becerra R.C. ; Ehsani M. “High-Speed Torque Control of Brushless Permanent
Magnet Motors” , IEEE Trans. Ind. Electron. 1988, 35, 402-406.
[8] Krishnan R. ; Lee S. “PM Brushless DC Motor Drive with a New Power-Converter
Topology” , IEEE Trans. Ind. Appl. 1997, 33, 973-982.
[9] T.J.E. Miller , “Brushless Permanent Magnet and Reluctance Motor Drives” , (Book),
Clarendon Press Oxford, 1989.

TEXT BOOK : -

[1] BIMAL K. BOSE , “Modern Power Electronics and AC Drives”

41
 APPENDIX

 Features of P89V51RD2 : -
 80C51 CPU
 5 V operating voltage from 0 MHz to 40 MHz
 64kB of on-chip flash user code memory with ISP and IAP
 Supports 12-clock(default) or 6-clock mode selection via software or ISP
 SPI and enhanced UART
 PCA with PWM and capture/compare functions
 Four 8-bit I/O ports with three high-current port 1 pins (16 mA each)
 Three 16-bit timers/counters
 Programmable watchlog timer
 Eight interrupt sources with four priority levels
 Second DPTR register
 Low EMI mode (ALE inhibit)
 TTl and CMOS compatible logic levels
 Brownout direction
 Low power modes
 Power-down mode with external interrupt wake-up
 Idle mode
 PDIP40, PLCC44 and TQFP44 packages

42
 BLOCK DIAGRAM : -

FIG A.1 BLOCK DIAGRAM OF P89V51RD2

43
  PIN DIAGRAM : -
(Fig:-A.2 shows the pin diagram of P89V51RD2. It has 40 Pin i.e 1 to 40. Description
of the pin is given to Appendix

FIG A.2 PIN DIAGRAM OF

44