Agenda

Motor Types Overview

BLDC Motor Applications Comparison of DC to Brushless DC Motors Hall Sensors Six-Step Commutation Sensorless Commutation with Back-EMF Vector Motor Control basics Closed-Loop Speed Control Summary
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Motor Types

Brushed DC Motors Review

A winding assembly (armature) within a stationary magnetic field Brushes and Commutators switch current to different windings in correct relation to the outer permanent magnet field.

Pros: Electronic control is simple, no need to commutate in controller Requires only four power transistors Cons: A sensor is required for speed control The brushes and commutator create sparks and wear out Sparks limit peak power Heat in armature is difficult to remove Low power density

Brushless DC Motors
Permanent magnet rotor within stationary windings Pros: No brushes or commutator to wear out No sparks and no extra friction More efficient than DC motor Higher speed than DC motor Higher power density than DC motor Cons: Rotor sensor OR sensorless methods needed to commutate Requires six power transistors
Stator windings

Permanent Magnet Rotor

Brushed DC Commutation
The windings in the armature

are switched to the DC power by the brushes and armature Each winding sees a positive voltage, then a disconnect, + then a negative voltage The field produced in the armature interacts with the stationary magnet, producing torque and rotation
N
+
U -

DC Motor Bridge
The DC motor needs four transistors to operate the DC motor

The combination of transistor is called an H-Bridge, due to the obvious shape

Transistors are switched diagonally to allow DC current to flow in the

motor in either direction The transistors can be Pulse Width Modulated to reduce the average voltage at the motor, useful for controlling current and speed

Three-Phase Bridge to Drive BLDC Motor

The Brushless DC motor is really a DC motor constructed inside-out,

but without the Brushes and Commutators The mechanical switches are replaced with transistors The windings are moved from the armature, to the stator The magnet is moved from the outside to become the rotor

U V W

Six-step Commutation
STEP1 STEP2 STEP3 STEP4 STEP5 STEP6 STEP1 STEP2 STEP3

U V W

Six-Step Current Waveform

Here we see the individual steps in a real trapezoidal current waveform The PWM ripple is visible when the phase is active

The rising and falling edges are sloped, giving the trapezoidal shape The amount of slope is a function of the winding inductance

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Hall Sensors
Hall Sensors detect magnetic fields, and can be used to sense rotor angle The output is a digital 1 or 0 for each sensor, depending on the magnetic field nearby Each is mounted 120-degrees apart on the back of the motor As the rotor turns, the Hall sensors output logic bits which indicate the angle
H1 H2 H3

H1 N S

H2

H3
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Hall Sensor Commutation

STEP1 STEP2 STEP3 STEP4 STEP5 STEP6 STEP1 STEP2 STEP3

H1

The combination of all three sensors produce six unique logic combinations or steps
These three bits are decoded into the motor phase combinations

H2 H3

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Brushless DC Motor BEMF

The Back-EMF is the voltage generated in stator windings as the rotor moves BEMF voltages are more or less sinusoidal (depending on the motor) and are symmetrical from phase to phase We detect the zero crossings of each phase to commutate The motor MUST be moving to generate BEMF voltages

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180 Sinusoidal Commutation

Modulates sine waves in all three windings Pros: No square edges

Lower Torque Ripple then six-step

drive Lower audible noise

Higher efficiency and torque

Stator angle is rotated smoothly

rather than in 60 degree jumps Each phase is utilized all of the time
Cons: Needs higher resolution feedback to calculate sine

waves with low distortion Needs more sophisticated processing to calculate sine PWM values on the fly Bandwidth of currents are limited due to motor impedance, this hurts high speed performance
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Vector (Field Oriented Control) Drive

This method mathematically converts the 3-phase voltage and

current into a simple DC motor representation Uses this data to calculate the best angle for commutation Creates new 3-phase sinusoidal PWM based on calculation Repeats the calculations at PWM frequency Pros:
Highest Torque efficiency Highest Bandwidth Widest Speed Range Lowest Audible Noise
r*
r
DC Bus

iq
Speed Regulator

id 0
*

iq

iq PI Regulator id PI Regulator

Uq

d,q
Ud
*

U
U

PWM1~6

,
*

, T 1 ( )

to

to a, b, c

SIN PWM

id

Voltage Source 3-phase Inverter

Cons: Complicated Algorithm Needs powerful processor

Motor Model Based Flux and Position Observer

iq

,
to d,q

ia i
i

id

T ( )

a,b,c to

ib

Speed Estimation

3-phase PMSM

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BLDC Motor Speed Control

The goal of most Electronic Motor Control Systems is Speed

Control Speed Control systems are more or less complicated, depending on accuracy required The simplest speed control is Open-Loop, that is, without speed feedback In this configuration, a speed command is converted to a fixed voltage (PWM duty) which is sent to the motor The motor may go the right speed, or it may not, it depends on the load Without feedback, there is no way to tell internally what the real speed is and so may require outside adjustment
Pulse Width Modulator Transistors Motor Load

Speed Command

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Closed-Loop Control
To get automatic speed control, feedback is needed Feedback systems could be Hall Sensors, Encoders,

Resolvers, tachometers or other devices Below is a block diagram of a simple control loop

PI Controller

PWM Generation

Motor

Speed Calculation
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Hall Sensors

Summary
PMBLDC Motor and its control strategies were seen.

Thank You