Chuck Raskin P.E. Principle R&D Engineer. Blaine, MN USA

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1 Chuck Raskin P.E. Principle R&D Engineer CMPL-ENGINEERING.com FOR AEROSPACE & AUTOMATION SOLUTIONS Blaine, MN USA

2 Dynamics of BLDC Motor & Drive Design 1. Control Loops & Commutation 2. Motor Commutation 3. BLDC vs. Brushed 4. BLDC Commutation Methods 4.1 Sensored vs. Sensorless Operation 4.2 Sensored Trapezoidal & Sinusoidal Operation 4.3 Sensorless Trapezoidal Operation 4.4 Sensorless FOC Operation 4.5 Sensorless Sinusoidal Commutation 2

3 Dynamics of BLDC Motor & Drive Design 1. CONTROL LOOPS AND COMMUTATION 2. Motor Commutation 3. BLDC vs. Brushed 4. BLDC Commutation Methods 4.1 Sensored vs. Sensorless Operation 4.2 Sensored Trapezoidal & SinusoidalOperation 4.3 Sensorless Trapezoidal Operation 4.4 Sensorless FOC Operation 4.5 Sensorless Sinusoidal Commutation 3

4 The Universe of Motor Control Loops... Commutation Current/Flux Voltage Speed/Velocity Position Environmental Other Feedback Loops 4

5 Dynamics of BLDC Motor & Drive Design 1. Control Loops & BLDC Commutation 2. MOTOR COMMUTATION 3. BLDC vs. Brushed 4. BLDC Commutation 4.1 Sensored vs. Sensorless Operation 4.2 Sensored Trapezoidal & Sinusoidal Operation 4.3 Sensorless Trapezoidal Operation 4.4 Sensorless FOC Operation 4.5 Sensorless Sinusoidal Commutation 5

6 Electric Motor Commutation is a Flux Control Problem Balanced Position Inducing Magnet Movement South South North North New Unbalanced Magnetic Position South North Upper Magnet will now try to move to the Left to Balance the Forces South North 6

7 Proper Commutation will Achieve Maximum Torque By Controlling Magnetic Alignment Vertical Attraction Magnitude Of Attraction Horizontal Attraction Extreme Left South Centered Extreme Right South North Moveable South Magnet... Fixed North Magnet 7

8 N Magnet S Magnet N Magnet S Magnet COMMUTATION EXAMPLE USING A BRUSHED MOTOR Repel Rotation Attract Rotation Commutator Bars Windings & Laminations Brush Brush Power Supply Commutator Bars Windings & Laminations Brush Brush Power Supply

9 Dynamics of BLDC Motor & Drive Design 1. Control Loops & BLDC Commutation 2. Motor Commutation 3. BLDC vs. BRUSHED 4. BLDC Commutation 4.1 Sensored vs. Sensorless Operation 4.2 Sensored Trapezoidal & Sinusoidal Operation 4.3 Sensorless Trapezoidal Operation 4.4 Sensorless FOC Operation 4.5 Sensorless Sinusoidal Commutation 9

10 BLDC Motor Advantages Compared to DC Brush: Reduced Sensitivity to Motor Construction Direct Flux and Torque Control High starting Torque Capability (2 to 4 Times RMS) Good to Excellent Speed regulation at High Speeds & Loads Fast Dynamic response High Efficiency Lower Internal Heating for the Same Power Output More... BRUSH Motor Advantages: Low Cost Very Low Speed Capability ( < 1 RPM) Does not require a drive 10

11 Dynamics of BLDC Motor & Drive Design 1. Control Loops & BLDC Commutation 2. Motor Commutation 3. BLDC vs. Brushed 4. BLDC COMMUTATION 4.1 Sensored vs. Sensorless Operation 4.2 Sensored Trapezoidal & Sinusoidal Operation 4.3 Sensorless Trapezoidal Operation 4.4 Sensorless FOC Operation 4.5 Sensorless Sinusoidal Commutation 11

12 Motion Control: Controlling Moving Objects in a Space filled with other moving and/or Non-Moving Objects Three primary Electric Motor Motion Control Applications are... Position Velocity Force/Torque (Sensorless) (Sensorless) Y Y Y x,y,z Z Z Z Force 0,0,0 X 0,0,0 X 0,0,0 X 12

13 Dynamics of BLDC Motor & Drive Design 1. Control Loops & BLDC Commutation 2. Motor Commutation 3. BLDC vs. Brushed 4. BLDC Commutation 4.1 SENSORED vs. SENSORLESS OPERATION 4.2 Sensored Trapezoidal Operation 4.3 Sensorless Trapezoidal Operation 4.4 Sensorless FOC Operation 4.5 Sensorless Sinusoidal Commutation 13

14 BLDC (PMSM) Commutation Types SENSORED: Trapezoidal or Sinusoidal using External Feedback Capable of ON-THE-FLY High-Torque Load Switching SENSORLESS: Trapezoidal using Zero-Crossover Phase Voltage Detection Sinusoidal using Phase Current Detection 14

15 Dynamics of BLDC Motor & Drive Design 1. Control Loops & BLDC Commutation 2. Motor Commutation 3. BLDC vs. Brushed 4. BLDC Commutation 4.1 Sensored vs. Sensorless Operation 4.2 SENSORED TRAPEZOIDAL OPERATION 4.3 Sensorless Trapezoidal Operation 4.4 Sensorless FOC Operation 4.5 Sensorless Sinusoidal Commutation 15

16 Sensored (Trapezoidal) Commutation Model Attracts Repels Attracts Repels Attracts Repels Rotor Rotor Rotor Repels Attracts Repels Attracts Repels Attracts Attracts Repels Attracts Repels Attracts Repels Rotor Rotor Rotor Repels Attracts Repels Attracts Repels Attracts BackEMF Waveform 16

17 Sensored (Trapezoidal) Hall Sequencing 17

18 Sensored (Trapezoidal) Switching a Motor from Y to Delta On-The-Fly 18

19 But if Sensored can Out Perform Sensorless Why Go Sensorless...? To Eliminate external feedback electronics To Eliminate feedback device errors & propagation delays To Allow Higher Operating Velocities To Allows operation in hostile environments such as: Vibration, Temperature, Chemicals, Explosion, etc. More... 19

20 Dynamics of BLDC Motor & Drive Design 1. Control Loops & BLDC Commutation 2. Motor Commutation 3. BLDC vs. Brushed 4. BLDC Commutation 4.1 Sensored vs. Sensorless Operation 4.2 Sensored Trapezoidal Operation 4.3 SENSORLESS TRAPEZOIDAL OPERATION 4.4 Sensorless FOC Operation 4.5 Sensorless Sinusoidal Commutation 20

21 Sensorless Advantages of Trapezoidal Over Sinusoidal Higher Starting Torque Low End Processors Low cost of Electronics Direct Microprocessor control of Digital hardware Can quickly change Torque requirements Disadvantages... High switching transients Relatively High RFI/EMI Higher Torque Ripple Higher Vibration Content 21

22 Amplitude Amplitude Sensorless Sinusoidal vs. Trapezoidal No-load Vibration Test Trapezoidal Frequency >>> Sinusoidal 22

23 Combined BackEMF & Trapezoidal Waveforms Combined PWM and BackEMF Switching 23

24 Combined BackEMF & Trapezoidal Waveforms Open-Loop Operation with BackEMF Switching 24

25 Sensorless 6-Step 3-Phase Trapezoidal Drive Example 25

26 Sensorless (Trapezoidal) Simplified Trapezoidal Logic Control Circuit 26

27 Sensorless (Trapezoidal) Simple Zero-Crossover Detection Circuit I/O Inputs and XOR used for Zero-Cross Interrupt Indication 27

28 Sensorless (Trapezoidal) Zero-Crossover Detection Circuit XOR Output 28

29 Sensorless (Trapezoidal) Zero-Crossover Detection Circuit HALL Outputs 29

30 Dynamics of BLDC Motor & Drive Design 1. Control Loops & BLDC Commutation 2. Motor Commutation 3. BLDC vs. Brushed 4. BLDC Commutation 4.1 Sensored vs. Sensorless Operation 4.3 Sensorless Trapezoidal Operation 4.4 SENSORLESS FOC OPERATION 4.5 Sensorless Sinusoidal Commutation 30

31 Dynamics of BLDC Motor & Drive Design 1. Control Loops & BLDC Commutation 2. Motor Commutation 3. BLDC vs. Brushed 4. BLDC Commutation 4.1 Sensored vs. Sensorless Operation 4.2 Sensored Trapezoidal Operation 4.3 Sensorless Trapezoidal Operation 4.4 SENSORLESS FOC OPERATION 4.5 SENSORLESS SINUSOIDAL COMMUTATION 31

32 Sensorless (Sinusoidal) Advantages of Sinusoidal Over Trapezoidal Smoother Control of Velocity Lower RFI/EMI emissions Lower Mechanical Noise due to reduced Current Pulsations Lower Electrical Audible Frequency Generation Lower Overall Motor Vibration Content Requirements... Sinusoidal Vector or FOC capable processor Multiple Shunt current Shift & Filter circuits or algorithms 32

33 Sensorless (Sinusoidal) Sequence to Achieving Sinusoidal Rotation 1. ACQUIRE MOTOR ROTOR LOCK POSITION 2. Start the Motor Open-Loop Commutation Sequence 3. Accelerate the motor Open-Loop 4. Acquire the Sinusoidal Shunt Current Voltages 5. Calculate the Motor Rotary Current and Flux Positions 6. Control Motor Torque to Maintain Speed Control 33

34 Sensorless (Trapezoidal or Sinusoidal ) 1. Acquiring a Motor Rotor Lock Position Watch Out For: Over-Current Excessive Hold-Times Power Supply Fold Back 34

35 Sensorless (Sinusoidal) Sequence to Achieving Sinusoidal Rotation 1. Acquire motor Rotor-Lock position 2. START THE MOTOR OPEN-LOOP COMMUTATION SEQUENCE 1. Accelerate the motor Open-Loop 2. Acquire the Sinusoidal Shunt Current Voltages 3. Calculate the Motor Rotary Current and Flux Positions 4. Control Motor Torque to Maintain Speed Control 35

36 Sensorless (Sinusoidal) 3-Phase Sinwave Hardware Generator 36

37 Sensorless (Sinusoidal) Hardware Sinusoidal Output Waveforms 37

38 Sensorless (Sinusoidal) up Software Generated Sinusoidal Waveforms 38

39 Sensorless (Sinusoidal) 2. Start the motor Open-Loop commutation sequence Start at a Speed that will allow the motor to rotate insuring Rotor Lock is not lost. One Shunt Current Profile 39

40 Sensorless (Sinusoidal) As is evident.... Producing Sinusoidal Waveforms is only the First Step to Developing Motor Motion. The bigger effort is: Determine the ACTUAL Motor Rotor Position Correct for angular error. 40

41 Sensorless (Sinusoidal) Sequence to Achieving Sinusoidal Rotation 1. Acquire motor Rotor-Lock position 2. Start the motor Open-Loop commutation sequence 3. ACCELERATE THE MOTOR OPEN-LOOP 4. Acquire the Sinusoidal Shunt Current Voltages 5. Calculate the Motor Rotary Current and Flux Positions 6. Control Motor Torque to Maintain Speed Control 41

42 Speed --->>> Sensorless (Sinusoidal) 3. ACCELERATE the Motor Open-Loop Motor/Load Capability Accelerate Slow enough to insure Motor Lock is maintained Time --->>> Do not exceed Open-Loop Torque or Speed Capability 42

43 Sensorless (Sinusoidal) Sequence to Achieving Sinusoidal Rotation 1. Acquire motor Rotor-Lock position 2. Start the motor Open-Loop commutation sequence 3. Accelerate the motor Open-Loop 4. ACQUIRE SINUSOIDAL SHUNT CURRENT VOLTAGES 5. Calculate the Motor Rotary Current and Flux Positions 6. Control Motor Torque to Maintain Speed Control 43

44 4. Acquire Sinusoidal Shunt Current Voltages VCC GND Sensorless (Sinusoidal) 3 VCC 4 GND L6385D HVG /8w 5% 0.1uf 50v G D S V_BUS N-Ch FQD16N25C up High PWM_ChX up Low 2 HIN 1 LIN Vbt 8 OUT 6 LVG 5 10uf 16v 22 1/8w 5% 22 1/8w 5% G 0.01 D S N-Ch FQD16N25C I-ChX % GND 1k 1k Motor Phase X 4.7k 4.7k VDD (1) (16)(15) (2) (3) (4) (13) 470nf 7pf (14) 4.7k 4.7k (5) (12) (11) (6) VDD I Gain GND & Filter 1 MC33072APGOS (8) (1) 0 2 _ 4 GND 4.7k (7) (10) (7) (2) (3) VDD (6) (5) (4) up Safety GND up (8) 7pf (9) Filter, Amplify, Shift Shunt Voltage +V _ V Output Voltage +V _ V 44

45 Sensorless (Sinusoidal) Sequence to Achieving Sinusoidal Rotation 1. Acquire motor Rotor-Lock position 2. Start the motor Open-Loop commutation sequence 3. Accelerate the motor Open-Loop 4. Acquire the Sinusoidal Shunt Current Voltages 5. CALCULATE THE MOTOR ROTARY CURRENT AND FLUX POSITIONS 6. Maintain Motor Torque & Speed Control 45

46 Sensorless (Sinusoidal) 5. Calculate the Motor 2-Phase Stationary Torque & Flux Objective: To determine the Angular Position of the Rotor... POWER IGBTs 46

47 Sensorless (Sinusoidal) PWM Generator Xa=Xa-(Xb+Xc) Xb=Xc-Xb) Clark Transformations X0=Xa+Xb+Xc Park Transformations Flux Component Torque Component 47

48 Sensorless (Sinusoidal) Calculating Motor Torque & Flux ROTOR Positions Xa, Xb, Xc are the actual phase currents Xa and Xbare the calculated two phase currents in a stationary reference frame Xd and Xq are the calculated two phase currents in a rotating reference frame This will allow the control to calculate current Angle & Amplitude information 48

49 Sensorless (Sinusoidal) Sequence to Achieving Sinusoidal Rotation 1. Acquire motor Rotor-Lock position 2. Start the motor Open-Loop commutation sequence 3. Accelerate the motor Open-Loop 4. Acquire the Sinusoidal Shunt Current Voltages 5. Calculate the Motor Rotary Current and Flux Positions 6. MAINTAIN MOTOR TORQUE AND SPEED CONTROL 49

50 Sensorless (Sinusoidal) 6. Maintain Motor Torque & Speed Control Objective: Apply Rotor Torque and Angular Correction... POWER IGBTs 50

51 Sensorless (Sinusoidal) Inverse Park & Clark Transforms 51

52 DC Brush Drive Styles Linear PWM H-Bridge SCR Motor & Drive Styles DC BLDC/PMSM Drive Styles Linear PWM Capacitive Logic MOSFET/IGBT Types Sensored Sensorless Modes Trapezoidal Sinusoidal FOC 52

53 Dynamics of BLDC Motor & Drive Design Chuck Raskin P.E. Value Added Engineering Some Images from application notes courtesy of... STMicroelectronics Microchip Freescale Animations courtesy of:

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