Back-EMF Detection Technique of Brushless DC Motor Drives for Wide Range Control

Yen-Shin Lai, Senior Member, IEEE Yong-Kai Lin Center for Power Electronics Technology, National Taipei University of Technology 1, Sec. 3, Chung-Hsiao E. Rd. Taipei, 106, Taiwan AbstractThis paper presents a new back-EMF detection technique which provides wide range control for Brushless DC Motor (BLDCM) drives. As compared with previous techniques which can be used either for low duty-ratio control or for high duty-ratio control only, the proposed technique deals with the above-mentioned problem to give both low and high duty-ratio control while not invoking any position and current sensors. The zero crossing point of back-EMF which is used for generating proper commutation control of inverter is calculated by sampling the voltage of floating phase. The presented method can be easily implemented using digital controller. An FPGA-based BLDCM driver system is set up to demonstrate that the presented technique works well from standstill to rated speed.
Index Terms Brushless DC Motor Drives

I. INTRODUCTION Although Brushless DC Motor (BLDCM) has some advantages over induction motor, which include higher efficiency for not having copper losses on the rotor side. For some low cost applications, Hall sensor required for commutation control of BLDCM drives brings potential reluctance. To reduce the cost of BLDCM drives, sensorless control of BLDCM is one of the main research topics. The term of sensorless control means no need of Hall sensor, current sensor, and shaft sensor. However, some technical issues for sensorless BLDCM control still exist. How to generate commutation signals without using expensive sensor is one of the most essential issues for the realization of BLDCM drives. Moreover, how to achieve wide duty-ratio range control is another main concern for such development. There are several techniques to derive the back-EMF signal to achieve proper commutation of BLDCM drives. These approaches uses the information derived from a resistor connected in series with DC-link voltage source [1-2], reconstruction of neutral voltage [3], and terminal voltages [3-12]. For the method determining the zero-crossing point of back-EMF via terminal voltages as shown in [4-5], filter is required to remove the high switching frequency noise signals caused by PWM control. This filter results in time delay and thereby deteriorating the performance of torque response and efficiency. Therefore, phase-shift delay compensation is required to cope with these issues. In [6], the zero-crossing of back-EMF is detected using the first non-zero current pulse after the free-wheeling period of the floating phase. Several independent voltage sources for detection circuit and proper isolation mechanisms are required in this approach. Similar principle is applied to derive the zero-crossing point of back-EMF as shown in [7-10]. However, these approaches are only for the applications with a particular kind of PWM
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control and not suitable for very high speed operation. This problem has been solved by the approach shown in [11], however, the approach is not suitable for low speed or duty ratio applications. In reference [12-13], the speed range can cover from low speed to very high speed by detecting the zero-crossing point of back-EMF when the PWM is on and off at high speed and low speed regions, respectively. This method can be implemented using logic circuits as shown in [12]. Alternatively, the zero-crossing point of back EMF can be determined by calculation as shown in [14]. This method considers the terminal voltage when PWM is on. As the speed goes low, the duty for PWM on is significantly reduced and thereby increasing the difficult for detection. In this paper, a method is presented to cope with the above-mentioned issue such that the zero-crossing point of back-EMF waveform is determined when the PWM is on and off at high speed and low speed regions, respectively. Therefore, the presented technique can be applied to both low speed and high speed regions. The presented method can be easily implemented using digital controller. An FPGA-based BLDCM driver system is set up to demonstrate that the presented technique works well from standstill to rated speed. II. PWM Control and Problem Description Fig. 1 shows the PWM control signals as presented in [4] [10] [15-17]. The high-side power device is controlled by chopper signal every consecutive 120 degrees in a fundamental period. The associated low-side control signal is shifted by 180 degrees, as compared to its high-side one, to clamp the related inverter output to the negative DC-link rail. This PWM technique is very popular for low power MOSFET-driven BLDCM drives because the bootstrap driver circuit can be adopted. As shown in [18], this PWM control technique is very promising for low power BLDCM drives, especially for the inverter with bootstrap driver circuit. This driver approach provides a cost effective solution for industry applications. Fig. 2 defines the terminal voltages of three-phase windings. As shown in Fig. 2, vP denotes the terminal voltage for the phase connected to the positive DC-link rail during PWM control period. vN indicates the terminal voltage for the phase connected to the negative DC-link rail. vO is the terminal voltage for the floating phase. The back-EMF voltage is detected via the terminal voltage of floating phase.

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Chopper

vO = vn + eO = v P + v N eP + eN + eO 2 2
(4)

U upper

Since

eP + eN = 0
U lower
Vupper
Equation (4) can be rewritten as:

(5)

vO =

v P + vN + eO 2

(6)

Vlower
Wupper

Wlower
0

60

120

180

240

300

360

Fig. 1 PWM technique [4] [10] [15-17]

vP

iP
rS
LS

+e

eN

vn

LS

rS

vO iO

eO

LS

As shown in (6), the terminal voltage of the floating phase depends upon the voltage applied to the phase connected to the positive and negative DC-link rails during PWM control period. For the sensorless BLDCM drives, either 0 V or near 0 V is taken as the reference for back-EMF detection, as shown in [7-10]. However, the allowable time interval for back-EMF detection using 0 V as reference voltage, which equals to (1-D)Ts, D = duty and Ts = sampling period, is significantly reduced for very high duty ratio. Another approach [11] [14] uses 0.5 Vdc as the reference for back-EMF detection. These approaches work well only for a certain duty-ratio range. However, this approach cant work at very low duty-ratio range. Fig. 3 illustrates the ideal waveforms of terminal voltage for very low duty ratio control. As shown in Fig. 3, the allowable time interval for back-EMF detection with 0.5 Vdc reference voltage, which equals to DTs, is significantly reduced for very low duty ratio. Under this condition, the voltage waveform for the floating phase will never be greater than 0.5 Vdc. Therefore, the approach shown in [11] [14] cant work under this circumstance. III. Proposed Technique Fig. 4 shows the block diagram for the proposed back-EMF detection technique which uses two reference voltages. For low duty-ratio range, e.g. less than 50%, 0 V is used as reference. In contrast, for high duty-ratio range, for example, greater than 50%, the reference voltage for zero-crossing detection is changed to 0.5Vdc. Therefore, the back-EMF can be detected in the full duty-ratio range. Experimental results will be presented to confirm this claim. The calculation of zero-crossing point shown in Fig. 4 is classified as two categories. One is for PWM on and the other is for PWM off. Fig. 5 illustrates the back-EMF waveforms and the voltage for PWM on is highlighted by red dot. As shown in Fig. 5 (A) and Fig. 5 (B), the following equation can be derived.

vN

iN

rS

Fig. 2 Definition of terminal voltages of BLDCM Since the back-EMF is detected from the terminal voltage of floating phase, the following equations can be derived: iP = iN and iO = 0 (1) By Fig. 2 and Kirchhoffs Voltage Law,

vn = vP (iP rS + LS

diP ) eP dt di = v N + (iP rS + LS P ) eN dt

By (2), the central-tap voltage is derived as:

By Fig. 2, the terminal voltage of the floating phase is shown as:

v + vN eP + eN vn = P 2 2

(2)

(3)

V 1 V V 2 V 1 t 1 tZ t 2 t1

(7)

By (7), the time instant of zero-crossing point can be determined as follow.

tZ = t 1 +
1007

t 2 t1 (V V 1) V 2 V 1

(8)

0.5VDC

0.5 VDC + eO
DTs

eO

(B). Decreasing of back-EMF Fig. 5 Illustration of back-EMF waveform, PWM on Fig. 6 shows the back-EMF waveforms and the voltage for PWM off is highlighted by red dot. As shown in Fig. 6 (A) and Fig. 6 (B), the following equation can be derived.

Fig. 3 Terminal voltage for very low duty ratio control

VU VV VW

0.5VDC

V 1 V V 2 V 1 t 1 tZ t 2 t1

(9)

0V

Fig. 4 Proposed back-EMF detection technique for wide duty-ratio range control of sensorless BLDCM drives The reference voltage, indicated by V, is equal to 0.5 Vdc and the terminal voltage is sampled when the chopper signal is PWM ON. (A). Increasing of back-EMF

0.5VDC

V2, t2 V, tZ V1, t1
V1, t1 V2, t2 V, tZ

0V

0V
(A). Increasing of back-EMF

(B). Decreasing of back-EMF Fig. 6 Illustration of back-EMF waveform, PWM off By (9), the time instant of zero-crossing point can be determined as follow.

tZ = t 1 +
1008

t 2 t1 (V V 1) V 2 V 1

(10)

The reference voltage, indicated by V, is equal to 0 V and the terminal voltage is sampled when the chopper signal is PWM OFF. As shown in (8) and (10), the calculation of the time instant of zero-crossing point of back EMF waveform for PWM ON and PWM OFF is the same. The only exception is the reference voltage level. IV. EXPERIMENTAL RESULTS Fig. 7 shows the block diagram of experimental set-up. As shown in Fig. 7, the experimental system consists of an FPGA controller, inverter, BLDM (the specifications are included in the Appendix), and back-EMF detection circuit. To confirm the back-EMF detection algorithm, neither current nor hall sensor is required. Fig. 8 shows the diagram for FPGA implementation. As shown in Fig. 8, only terminal voltages are sampled and used for determining the zero-crossing point of back EMF. Under very low speed range, the back-EMF signal is too trivial to be clearly identified. Under such circumstance, the program module entitled Open loop ZCP is used to start up the motor.

Once the back-EMF signal becomes relevant, the presented closed-loop zero-crossing point detection method is applied. The duty of the PWM control is decided by external setting or given signals via 8-bit AD converter. The details of the PWM and Chopper generators can be referred to [19].

Fig. 7 Experimental set-up

Fig. 8 Diagram for FPGA program Fig. 9-Fig. 16 shows the experimental results when the duty experimental BLDCM drive implemented using the proposed changes from 95% to 5%. Using Fig. 9 as an example, the technique starting from standstill to closed-loop operation. experimental results show that the current is in phase with its Moreover, Fig. 18 shows the measured results of linear related voltage waveform. Similar results can also be derived relationship between speed and duty ratio. As shown in these experimental results the presented technique works from for other cases with duty = 55%, 45% and 5%. Moreover, to verify the calculated zero-crossing point of standstill to rated speed range and thereby confirming that the back-EMF, the calculated commutation instant is compared presented method is suitable for wide speed range control. with that derived from Hall sensor. As shown in Fig. 10, Fig. 12, Fig. 14 and Fig. 16 when the duty changes from 95% to 5%, the calculated communication signals coincide with those determined by Hall sensors. According to our experimental results, the lowest duty in which the motor can operate is around 30% without using the presented technique. Fig. 17 shows the current waveform of the 1009 4

Fig. 9 Experimental results, Duty = 95%, Ch 2 = current, Ch 1 = volatge

Fig. 12 Experimental results, Duty = 55%, Ch 1 = voltage; commutation signals: Ch2= by calculation, Ch3 = by Hall sensor

Fig. 10 Experimental results, Duty = 95%, Ch 1 = voltage; commutation signals: Ch2= by calculation, Ch3 = by Hall sensor

Fig. 13 Experimental results, Duty = 45%, Ch 2 = current, Ch 1 = voltage

Fig. 11 Experimental results, Duty = 55%, Ch 2 = current, Ch 1 = voltage

Fig. 14 Experimental results, Duty = 45%, Ch 1 = voltage; commutation signals: Ch2= by calculation, Ch3 = by Hall sensor

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2. Present a novel back-EMF detection technique to provide wide duty-ratio range control for Brushless DC Motor (BLDCM) drives 3. Confirm the performance of the presented technique derived from an FPGA-based system The experimental results demonstrate the presented drive work well from standstill to extremely high duty ratio control. Appendix: Motor specifications
No. of poles = 8, rated power = 70 W, Vdc = 24 V, Rated speed = 2500 rpm

REFERENCES
[1].

Fig. 15 Experimental results, Duty = 5%, Ch 2 = current, Ch 1 = voltage

[2]. [3].

[4]. [5]. [6]. [7]. [8]. [9].

Fig. 16 Experimental results, Duty = 5%, Ch 1 = voltage; commutation signals: Ch2= by calculation, Ch3 = by Hall sensor

[10]. [11].

[12]. [13]. [14]. [15]. [16]. [17]. [18].

Fig. 17 Current waveform from standstill to closed-loop operation

Fig. 18 Experimental results, speed vs. duty, rated speed = 2500 rpm V. CONCLUSION The main contribution of this paper including: 1. Highlight the issue of back-EMF detection for sensorless BLDCM drives

[19].

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