Direct Back EMF Detection Method for Sensorless Brushless DC (BLDC) Motor Drives

M.SIVA SANKARI1,G.ANUSHA2 Department of Electrical and Electronics Engineering 1,2 K.S.R. College of Engineering, Tiruchengode 637 215 shankarieee321@gmail.com1, anushagovindaraj13@gmail.com2
ABSTRACT Brushless motors and their dc (BLDC) are attenuation and filtering necessary for the back EMFs sensing. This unique back EMF sensing method has superior performance to existing methods which rely on neutral voltage information, providing much wider motor speed range at low cost.An advanced mixed-signal microcontroller is developed so that the EMF sensing scheme is embedded in this low cost 8-bit microcontroller. This device is truly product, Micro circuit, SOC with core, in (system-on-chip) high-throughput precision-analog the system drives

penetrating the market of home appliances, HVAC industry, and automotive applications in recent years because of their high efficiency, silent operation,

compact form, reliability, and low maintenance. Traditionally, BLDC motors are commutated in six-step pattern with commutation controlled by position sensors. To reduce cost and complexity of the drive system, sensorless drive is preferred. The existing sensorless control scheme with the conventional back EMF sensing based on motor neutral voltage for BLDC has certain drawbacks, A which limit its applications.

programmable memory and motor control peripherals integrated on a single die. A microcontroller-based sensorless BLDC drive system has been developed as well, which is suitable for various applications, including hard disk drive, fans, pumps, blowers, and home appliances, etc. Keywords: Microcontroller, Back EMF, synchronous motor, commutation, sensorless control scheme Introduction Brushless dc (BLDC) motors have been desired for small horsepower control motors due to

novel back EMF sensing scheme, direct back EMF detection, for sensorless BLDC drives is presented. For this scheme, the motor neutral voltage is not needed to measure the back EMFs. Therefore, this back EMF sensing method is immune to switching noise and common mode voltage. As a result, there are no

their high efficiency, silent operation, compact form, reliability, and low maintenance. Over the last decade, continuing technology development in speed schemes power drivers and semiconductors, (ASDs) control microprocessors/logic ICs, adjustable permanent-magnet

the fuel pump in a car is driven by a dc brushed motor. A brush type fuel pump motor is designed to last 6,000 hours because of limit lifetime of the brush. In certain fleet vehicles this can be expended in less than 1year. A BLDC motor life span is typically around 15,000 hours, extending the life of the motor by almost 3 times. It is in the similar situation for the airconditioning cooling fan. blower and engine-

brushless electric motor production have combined to enable reliable, cost-effective solution for a broad range of adjustable speed applications. For example, at present,

commutation phase sequence is like Brushless DC (BLDC) Motors and Sensorless Drives Brushless dc motor is one kind of permanent motor, magnet having synchronous AB-AC-BC-BA-CA-CB.

permanent magnets on the rotor and trapezoidal shape back EMF. The BLDC motor employs a dc power supply switched to the stator phase windings of the motor by power devices, the switching sequence being determined from the rotor position. The phase current of BLDC motor, in typically rectangular shape, is synchronized with the back EMF to produce constant torque at a constant speed. These sensors, particularly Hall motor sensors, to are temperature about 75oC..
Fig2:Typical BLDC control system fig1:Brushless DC motor

sensitive, limiting the operation of the below Typically, a Brushless dc motor is driven by a three-phase inverter with, what is called, six-step commutation. The conducting interval for each phase is 120o by electrical angle. The

Each conducting stage is called one step. Therefore, only two

phases conduct current at any time, leaving the third phase floating. In order to produce maximum torque, the inverter should be commutated every 60 so that current is in phase with the back EMF. Direct Back EMF Detection for Sensorless BLDC Drives Specially, a low cost mixedsignal microcontroller that is the first commercial one dedicated for sensorless BLDC drives is developed.integrating the detection circuit and motor control peripherals with the standard 8-bit microcontroller core. Conventional Back EMF Detection Schemes For three-phase BLDC motor, typically, it is driven with sixstep 120 degree conducting mode. At one time instant, only two out of three phases are conducting current. For example, when phase A and phase B conduct current, phase C is floating. This conducting interval lasts 60 electrical degrees, which is called one step. A transition from one step to another different step is called commutation. So totally, there are 6 steps in one cycle. Usually, the current is commutated in such way that the current is in phase with the phase backEMF to get the optimal control and maximum torque/ampere. In most cases, the motor neutral point is not available. In practice, the most commonly used method is to build a virtual neutral
o

point that will, in theory, be at the same potential as the center of a Y wound motor and then to sense the difference between the virtual neutral and the voltage at the floating terminal. The virtual neutral point is built by resistors, which is shown in fig2. This scheme is quite simple. It has been used for a long time since the invention.It generates very high common mode voltage and high frequency noise. So we need voltage dividers and low pass filters to reduce the common mode voltage and smooth the high frequency noise, shown in Fig3.

Fig3:Conventional control system

For instance, if the dc bus voltage is 300 V, the potential of the neutral point can vary from zero to 300 V. The allowable common mode voltage for a comparator is typically a few volts, i.e. 5 V. We will know how much attenuation should be. This delay will disturb current alignment with the back EMF and will cause severe problems for commutation at high speed. Consequently, this

method tends to have a narrow speed range. Proposed Direct Back EMF Detection Scheme As described before, the noisy motor neutral point causes problems for the sensorless system. The proposed back EMF detection is trying to avoid the neutral pointvoltage. If the proper PWM strategy is selected, the back EMF voltage referred to ground can be extracted directly from the motor terminal voltage.

instant of time. The PWM drive signal can be arranged in three ways: 1) On the high side: the PWM is applied only on the high side switch, the low side is on during the 2) On the low side: the PWM is applied on the low side switch, the high side is on during the step. 3) On both sides: the high side and low side are switched on/off together. In the proposed scheme, the PWM signal is applied on high side switches only, and the back EMF signal is detected during the PWM off time, it can be seen that during the off time of the PWM, which is the current freewheeling period, the terminal voltage of the floating phase is directly proportional to the back EMF voltage without any superimposed switching noise. It is step.

Fig4:A proposed back EMF zero crossing detection scheme

also important to note that this terminal voltage is referred to the ground instead of the floating neutral point. So, the neutral point voltage information is not needed to detect the back EMF zero crossing, and we dont need to worry about the common mode voltage. Since the true back EMF is extracted from the motor terminal voltage, the zero crossing of the phase back EMF can

Fig5:Proposed PWM stratergy for direct back EMF detection scheme

be detected very precisely. Therefore, the terminal voltage will see the third harmonics. However, since the zerocrossing of the fundamental wave will coincide with the zero crossing of the third harmonics, the third

For BLDC drive, only two out of three phases are excited at any

harmonic wont

affect

the zero

3)

This sensing technique can be easily used to either high voltage or low voltage systems without much effort to scale the voltage.

crossing of the fundamental wave. A few tests have been conducted to show the relationship between fundamental and third harmonics this proves that the third harmonics will not affect the zero crossing of fundamental wave. Therefore, we can neglect the third harmonics content in the terminal voltage for zero crossing detection. Several advantages of the proposed technique back over EMF the sensing conventional 4)

Fast motor start-up is possible crossing because of precise back EMF zero detection without attenuation.

5) It is simple and easy to implement, which will be discussed in the next section.

schemes can be listed as following: 1) It has high sensitivity. First, since we dont use voltage divider, there is no attenuation. It still has even high rejected good at resolution low speed

Hardware Implementation of the Proposed Back EMF Detection Scheme The synchronous sampling circuit is developed to detect the back EMF zero crossing.

operation. Second, the frequency because the switching noise can be back EMF is sampled during the PWM off time. The synchronous sampling can easily get rid of the switching noise. Third, because the back EMF is referenced to the ground now, the common mode voltage is minimized. 2) It is instant value because there is no filtering in the circuit, which will be good for high-speed operation.

Fig6:Hardware implementation of BLDC

The

figure6

shows

the

hardware implementation for the back

EMF zero crossing detection. The back EMF signals go through a multiplexer, and the controller selects which input to be sensed according to the motor commutation stages. Since only the zero crossing is of interest, the peak voltage is clamped at 5v by diodes, thereby keeping the voltage within the range of the sensing amplifier. The selected signal is compared proposed to a fixed voltage sampling reference, which is close to zero.. The synchronous circuit has been implemented in a hardware macro cell into a low cost 8-bit microcontroller ST72141, which is dedicated to the sensorless BLDC driver. The Macro cell is split into four main parts. 1) The back EMF ZeroCrossing Detector is the synchronous circuit. 2) The Delay Manager with a timer and an 8x8 bit hardware multiplier controls the proper delay from the zero crossing to commutation. 3) The PWM Manager selects the control mode, current mode control or voltage mode control. 4) The Channel Manager sends the PWM signals to right switches for six-step commutation. The motor terminal voltage is directly sampling

fed

into

the through

microcontroller

current limit resistors.

The novel microcontrollerbasedsensorless BLDC motor driver This is the first commercial available dedicated microcontroller with the hardware macro cell for sensorless BLDC motor drives in the commercial market. Compared with other commercial analog I.C.s, the new microcontroller has superior performance with low cost and more flexibility and intelligence as shown in figure7. The commutation will happen 30 electrical degrees after the back EMF zero crossing. This due to programmability of the the

microcontroller, the system has much flexibility, running the motor in speed open loop or speed close loop depending on applications. Back EMF Sensing very convenient to adjust the control parameters

Fig7:Microcontroller based sensorless BLDC

For example, the delay between the zero crossing and commutation can be easily adjusted by software. Usually, the delay from phase back EMF zero crossing to commutation is 30O to keep the phase current in phase with phase back EMF. For some high-speed applications, commutation can be done in advance to have the field weakening effect to expand the speed range. The delay manager section in the hardware core does the delay adjustment controlled by software. An application Example: Automotive Fuel Pump A brush type dc fuel pump motor is typically designed to last 6,000 hours. In certain fleet vehicles this can be expended in less than 1 year. A brushless dc motor life span is typically around 15,000 hours, extending the life of the motor by almost 3 times. Once a Microcontroller is used to perform the brushless commutation, other features can be incorporated into the application. Therefore, the fuel pump drive is a very good application for the proposed micro-controller based sensorless BLDC drive scheme. The challenges of the automotive fuel pump application include: 1) Wide input operating voltage range from 6v ~24v. The issue is that how to make the system work at 6v input;

2) Fast and very reliable start-up of the motor within 200ms; 3) Interface Compatibility for speed command and communication 4) Low cost. Due to the unique back EMF sensing scheme and the flexibility brought by the microcontroller, all these issues are solved. The battery voltage can vary from 6v to 24v. At 6v, the gate driver will not function well. The minimum voltage for the gate driver chip L6387 is around 6.5v.

Fig8:Supply conditioning circuit

A supply conditioning circuit, which is a simple charge pump circuit, is used to boost the voltage for the gate driver. The microcontroller will monitor the dc bus voltage (battery voltage). When the dc voltage is below certain threshold voltage (8v), the charge pump circuit will be activated. With the conventional sensorless method, it is very difficult to start the motor very quickly. Thanks to the proposed high

precision back EMF detection of the ST72141, quick starting of the BLDC motor can be accomplished. When the motor is stop, there is no back EMF. Usually, the controller forces the motor to rotate with open loop commutation. The motor will try to accelerate the speed if the commutation frequency is increasing. After the motor generates enough back EMF, it switches to synchronous commutation, which is determined by the back EMF zero crossing.. Since we dont attenuate the back EMF signals, the controller can detect the back EMF zero crossing at lower speed. Therefore, the motor can finish start process sooner than conventional method. Using this novel back EMF detection, it is possible to switch to synchronous commutation when the peak back EMF amplitude is as little as0.5v. The fuel pump finishes the start-up within 150ms. The pump can be controlled either by pressure sensor or Powertrain Control Module (PCM). If it is controlled by pressure sensor, the motor speed will be regulated according to the feedback pressure sensor to maintain the desired fuel by pressure. PCM, If the it is controlled speed

system. Meanwhile, fuel level, fuel tank pressure, and fuel temperature can be monitored by the microcontroller as well. All these information can be sent back to Powertrain Control Module (PCM) through this Fuel certain Pump protocol. Driver These Module monitoring functions are integrated in (FPDM). The integration reduces over all system cost. Improved Direct Back EMF Detection

Improved circuitry for low speed /low voltage and high voltage applications are described. The limitation of the back EMF detection during off time is that there is a requirement to have a minimum off time. Sometime this is undesirable for low voltage applications. An alternate back EMF detection during on time is proposed to make the duty cycle up to 100%, thus the bus voltage can be fully utilized. The complementary PWM algorithm is proposed to eliminate the offset voltage caused by the body diode voltage when current is freewheeling through the diode.

command will be PWM pulse train. The motor speed will directly follow the duty cycle of the PWM signal from PCM. The microcontroller can easily identify the control mode and control the motor. The communication is relatively easy when there is a microcontroller in the

the motor acts as a permanent magnet synchronous machine. Conclusion The applications of brushless DC (BLDC) motors and drives have grown significantly in recent years in the appliance industry
Fig 9: BLDC motor

and

the

automotive

industry.

Sensorless BLDC drives are very The improved circuitry greatly expands the motor speed range. For example, for a 48V motor, the speed operation range can be from 50rpm to 2500rpm. For high voltage operation, the sensorless rpm high system speed air has been blower successfully used for 300v/30,000 applications. Starting the Motor with the Sensorless Scheme The sensorless schemes are not self-starting. In order to sense the back EMF, the motor must be first started and brought up to a certain speed where the back EMF voltage can be detected. In practice, openloop starting the motor is accomplished by providing a rotating stator field with a certain increasing frequency profile. Once the rotor field begins to become attracted to the stator field enough to overcome friction and inertia, the rotor will turn. After the speed reaches a threshold voltage value, the back EMF can be detected, providing the position information, the system switches to synchronous commutation mode and preferable for compact, low cost, low maintenance, and high reliability system. The conventional sensorless method based on neutral motor point has limited its application since it has relative speed range, suffering from high common mode voltage noise and high frequency switching noise. The direct back EMF sensing scheme avoids the motor neutral point as the reference for the back EMF zero crossing detection. In this scheme, the PWM is applied to high side switches of the inverter, the back EMF is measured during the PWM off time in the floating winding. It is proved that the terminal voltage of the floating winding is directly proportional to the back EMF of that phase. Several advantages of the direct back EMF sensing scheme are summarized in the following. i. The scheme can detect the back EMF with very high resolution, because it doesnt have signal attenuation; ii. The switching noise is rejected by synchronous sampling;

iii. There is no phase shift or delay; iv. There is no common mode issue. A synchronous sampling circuit for the back EMF sensing is developed, and the circuit is integrated with a standard low cost 8-bit microcontroller to be a dedicated BLDC sensorless drive controller. This microcontroller has been commercialized and applied in real applications such as automotive fuel pumps and home appliances. An improved version of the direct back EMF sensing, detecting the back EMF signal during PWM on time, is presented. Since the original method detects back EMF signal during PWM off time, it can't go to 100% duty cycle. The start-up tuning procedure has optimized start-up performance and it is suitable for all sensorless systems. References BLDC motor drive voltage noise

[1] Thomas Kaporch, Driving the future, Appliance Manufacture, Sept.2001, pp43-46. [2] Joe Mattingly, More Efficiency Standards on Horizon, Appliance Manufacture, Oct.2001, Published on Internet. [3] J.Filla, ECMs Move into HVAC, Appliance Manufacture, Mar.2002, pp2527. [4] J.Jancsurak, Motoring into DSPs, Appliance Manufacture, Sept.2000, pp57-60. [5] T.J.E. Miller, Brushless Permanent-Magnet and Reluctant Motor Drives, Oxford, 1989. [6] K.Rajashekara, A.Kawamura, et al, Sensorless Control of AC Motor Drivers, IEEE press [7] US Patent No.4654566, Control system, method of operating an electronicallycommutated motor, and laundering apparatus, granted to GE. [8] K.Uzuka, H.Uzuhashi, et al., Microcomputer Control for Sensorless Brushless Motor, IEEE Trans. Industry Application, vol.IA-21, MayJune, 1985. [9] Jianwen Shao, Direct Back EMF Detection Method for Sensorless Brushless DC (BLDC) Motor Drives.