AbstractAn experimental single phase BLDC motor has been

fabricated in laboratory for gaining an insight into its operation.

The inner stator is having 20 slot stampings. It has a vertical
shaft and the rotor is in a form of a cylindrical hub rotor. Strip
magnets are bounded on the inner surface of hollow cylindrical
hub using epoxy resin. The controller is a Hall IC with latch. The
solid state control of developed motor using single switch
topology with and without current chopping have been reported.

Index Terms - Brushless DC motor, Hall IC & latch,
Permanent magnet motors, Permanent magnets.
INTRODUCTION

Brushless motors are having higher specific power density
as compared to other types of motor. These motors are
categorized as BLDC, BLAC, PMSM, micro-motor, DSPM
(doubly salient PM) motor etc [1,6,11,14, 16, 20]. The rotor
is in form of a cylindrical rotor, disk rotor or a hub-rotor. The
Surface Mounted PM (SMPM) BLDC motor has non-
sinusoidal or trapezoidal flux density distribution in air gap. In
case of inside Permanent Magnet (IPM) rotor, the magnets are
installed inside of the rotor. In these motors the air gap flux
density distribution in space is sinusoidal and there is presence
of reluctance torque. These motors are reported to be suitable
for high speed applications and traction applications [6, 13].
BLAC operation is superior below base speed, whereas BLDC
-180 operations is superior in flux weakening region [11].
Multiphase BL machines are expected to have low torque
pulsation. The brushless motors have found their applications
in computer peripherals , fans, household and office
applications like tape recorder, digital audio tape recorder
[1,16], EV , EHV [ 11,14,19], turret drive for combat vehicle
and aircraft [19 ], precision surgery [ 20 ], electric
propulsions for ship and under water vehicles, sub-sea
thrusters[10,19], pumps and compressors [7] etc.
In these motors switching of coils are synchronised with
rotor position. Yates and Skamfer [2] have reported high
frequency reluctance switch for rotor position sensing. Bosch
[3] has reported the use of Hall element for BLDC motor.
Unnewehr et al., [4]., have used light sensing with an optical
encoder type disc; light activated SCR and diodes; variable

reluctance of an external magnetic circuit; permanent magnet
actuation of reed switches; permanent magnet enhanced
sensing of the internal motor magnetic reluctance variation.
Tripathi et al., [5] state the use of search coil method for rotor
position detection in BLDC motor. Initial development of
BLDC motors were based on rotor position sensing.
In BLDC motor, the applied voltage must have same zero
crossing as that of the back EMF generated on the stator
windings. In sensorless control, it is slightly cumbersome to
extract the information of zero crossing of the induced back
EMF because of complex voltage and current waveforms
when machine is mechanically loaded. The instant of
commutation of coil currents is important for preventing the
demagnetization of permanent magnets.
The sensorless technology is also growing at a fast pace due
to availability of powerful and cheap microprocessors, micro-
controllers and DSP [8,10,13,19,20]. However the present
work is aimed at design, fabrication and operation using Hall
sensor.


Fig. 1. Stator of single phase BLDC motor

Single Switch Topology in Electronic
Commutation of BLDC Motor
Atul Tiwari Prem Kant S. K. Singh R. K. Srivastava, MIEEE
(atul.tiwari.eee10@itbhu.ac.in ) (prem.kant.eee10@itbhu.ac.in ) (sksingh.eee@itbhu.ac.in) (rksrivastava.eee@itbhu.ac.in)
Dept. of Elec. Engg. Dept of Elec. Engg. Dept. of Elec. Engg.
Hindustan College of Science and Technology Indian Institute of Technology
Sharda University Banaras Hindu University
Agra (U.P.) India Varanasi (U.P.) India

978-1-4799-2275-8/13/$31.00 2013 IEEE
2013 Annual IEEE India Conference (INDICON)



CONSTRUCTION OF PROPOSED MOTOR

To ease the experimental investigation, a low power prototype
having 20 slots, 20 poles, surface mount PMBLDC motor
have been developed in laboratory. The active surface of stator
is facing alternate PM arrangements on the outer cylindrical
hub rotor. Twenty strip PM of size 2 mm 10 mm 25 mm
are regularly bound on the inner surface of the hub rotor using
epoxy glue-Araldite. The details of developed BLDC motor
are given in Table 1.0. The developed prototype has a vertical
shaft. Its inner stator is depicted in Fig 1 and outer hub
cylindrical rotor is shown in Fig 2.


Fig. 2. Alternate PM arrangement on external Hub rotor



Fig.3. Developed vertical stationary shaft and outer hub rotor
BLDC motor-Hall sensor shown outside the hub rotor is actually
installed in one of the inner stator slot opening



ROTOR POSITION SENSING & POWER CIRCUIT

Single Hall effect bipolar IC and Latch is placed in one of
the slot opening. Such an IC is also an integral part of
inexpensive BLDC cooling fans, found on the SMPS of
personal computer. A typical Hall IC is shown in Fig 3, which
though shown outside the rotor is actually installed in one of
the stator slot opening. The output signals of Hall sensor IC
change sign once the flux density in proximity to it changes
sign. For example if N- pole is closer to it, the signal is
negative high till S- pole arrives. The reverse is true for signals
on other two terminals. The Hall IC output is either negative
or zero. The same need to be inverter using OP AMP 741 IC.
The Hall IC sensor signal has a natural firm relationship with
the induced EMF in the stator winding. The output of the Hall
IC sensor is used to switch ON /OFF the single switch and H-
bridge IGBT based power circuit. Schematic winding diagram
in linear form is shown in Fig 4. The winding pattern is single
coil per slot teeth which alternates. Typical circuits of Hall
effect sensor without current chopping is shown in Fig 5. The
output waveforms are shown in Fig 6.

Fig. 4. Schematic winding diagram of set up in linear form

Fig. 5. A typical bi-direction Hall Effect sensor without current
chopping

Fig.6. Single switch without current chopping waveform-IGBT
switching voltage waveform (1), IGBT collector voltage (2), Supply
voltage (M). Vs=24V, No load current I=36ma (Scale: Ch1 50 V/div,
Ch2 10 V/div, 100ms/div)

.
Fig.7. A typical bi-direction Hall Effect sensor with current chopping

Similarly, typical circuit of Hall effect sensor with single
switch with current chopping is shown in Fig 7. The output
waveforms across the IGBT and motor are shown in Fig 8(a)
& (b) respectively for no load and frictional loading. In the
latter case the speed drops due to loading. The voltage
waveform contains large number of harmonic. But with this
technique, when machine is started sudden rise in starting
current can be controlled. The steady state current almost
remains constant over a period. When DC power is obtained
after rectification; it suffers distortion when motor is loaded.

RESULTS

In BLDC prototype has been successfully operated with
single switch topology using two different techniques-
(i) without current chopping and (ii) with current chopping.

Fig. 8 (a). IGBT collector voltage (1), Supply voltage (2) for
Vs=24V, No load current I=30ma (Ch1 10 V/div, Ch210 V/div,
25 msec/div)


Fig. 8(b). Single switch with current chopping waveform M-(IGBT
collector voltage-supply voltage) Supply voltage=24V, with frictional
loading coil current I=33ma (Ch1 10 V/div, Ch210 V/div, 25 msec/div


The input supply voltage varies from 15 V to 260 V DC. In
single switch topology, although the machine is not utilized
effectively, the safe operation of electronic circuit is possible.
In case of without current chopping, smooth half wave quasi -
sinusoidal voltage appears across the motor winding.
Switching harmonics are more in case of circuit with current
chopping.
The present paper deals with the single switch topology. It
offered a reduced mode operation of BLDC motor, thereby
reducing the speed and power of motor to about half than as
compared to when H- bridge topology (refer Fig A-1 & A-2) is
used. The latter demands the blanking signals at zero flux
crossing. This ultimately requires more complicated
electronics circuit for safe operation. The detailed study is not
within the purview of the current paper.
The no-load speed and no-load current both increase due to
rise in the supply voltage, as have been depicted in Fig 9. The

inherent torque speed characteristics of typi
are drooping parallel lines as shown in Fig 1
been loaded with the varying frictional load
hub rotor for different applied voltages. As a
drops. However when voltage is raised the
also varies. The experimental torque was calc
principle. Several points on the torque
characteristics with varying voltage and v
shown in Fig 10. The scheme requires a
arrangement for loading. For similar case
power and power versus current also shown in Fi



Fig 9. Typical variation of No Load speed and No
change in supply voltage-single switch topology

Fig. 10. Typical Speed torque characteristics cu
BLDC motor






cal BLDC motor
10. The motor has
ding to the outer
a result the speed
frictional loading
culated using first
e versus speed
varying load are
a perfect loading
es, speed versus
g 11 and Fig 12.

load current with
urrent chopping of
Fig. 11. Typical Speed power characteris

Fig. 12. Typical Power current character


Speed v/s torque characteristic wa
variable friction loading when the i/
is shown in fig.10.The BLDC m
grouping characteristic, in the prese
varied for different speed under diffe


MOTIVATION OF

PMBLDC motor having many app
peripherals, fans, household and of
recorder, digital audio tape record
electric vehicle having PMBLDC m
Electric vehicle are supplied from D
vehicle is depends on value of DC v
increases, speed of vehicle increa
inertia of vehicle increases because
battery increases .Because of high
of vehicle is less compare to in
Because of these reasons voltage is
of vehicle is less so this paper has m
speed of vehicle by the means of in
the applied DC voltage to PMBLDC

stics of BLDC motor
ristics of BLDC motor
as obtained by applying a
/p voltage is also varied. It
motor should ideally give
ent case the voltage is also
erent frictional load.
F WORK
plications like in computer
ffice applications like tape
er, e-bike etc .e-bikes are
motor to drive the vehicle.
DC battery and the speed of
voltage. As the DC voltage
ases but the drawback is
of number of plates in DC
inertia increment in speed
ncrement in DC voltage.
s limited to 72V and speed
motivated to achieve higher
ncreasing the limitation on
C.


CONCLUSIONS

A prototype of outer hub PMBLDC motor has been
developed using ferrite magnets. The developed motor has
been actually operated using IGBT based single switch
topology- without and with current chopping.
The developed motor can be rated as with single switch
operation and with H-bridge operation. With single switch
operation it gives about 90% efficiency. In the development of
BLDC motor, ferrite strip magnets having maximum flux
density 0.3 T have been used. The power / torque of the motor
can be improved using commercially available Alnico and
NdFeB magnets. The developed machines give a better insight
into fabrication and operation of BLDC motor.
The developed single phase motor requires starting torque,
which is normally available in applications like e-bike, e-
trolley. It is expected that for multi phase BLDC motor, the
inherent starting torque will result. The present stator can be
re-wounded for two phase, four phases, five phases, ten
phases. Each one of such winding will require different
dispositions of Permanent magnets (PM) on the hub rotor.
Similarly, depending upon number of phases, multiple Hall
ICs and multiple IGBT based power circuits are required. For
large number of phases the machine is expected to exhibit
fault tolerant behaviours, i.e., in the event of failure of one of
the few phases the operation of BLDC motor will not be
seriously affected. With slight modification / provision of
prime mover, it can also be used as an excellent PMSG.

APPENDIX

A-1 Details of motor developed:

Table 1: Details of BLDC / BLAC motor developed
Items Details
Stator diameter 115mm
Rotor cup inner diameter 131.5mm
Cup height 66.5mm
Shaft diameter 10mm
No. of slots 20
Stator winding type Concentric type double layer winding
Cross sectional area of coil 39.825 mm
2
Diameter of bare conductor 0.27432mm
Copper space factor 0.6
S.W.G. No 32
Length of mean turn 120.836mm
Number of turns/ coil 281
Weight of total coil 0.4297 kg
Number of poles 20
Stack length 34.5mm
Resistance of coil 168 ohm
Type of magnet Ferrite 0.3T
Size of magnet 18mm x 10 mm x 2mm
Clearance 2.0 mm

The proposed circuits for H-bridge are shown in Fig A-1 and
A-2.






Fig. A-1. Gating signal for H-bridge using Hall sensor outputs (all the
power supplies / grounds of opto-couplers are completely isolated in
order to avoid cross short circuiting)
Fig. A-2. Power Circuit for H-bridge using IGBT


ACKNOWLEDGEMENTS
They are thankful to the Dept. of Electrical Engg., I.I.T.-
B.H.U., Varanasi (India) for providing necessary facilities for
fabrication and testing of motor. They are also thankful to
Prof S.N.Mahendra of Electrical Engg Dept and Prof Santosh
Kumar of Mechanical Engg dept for their encouragements.
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[21] http://www.datasheetarchive.com/dl/Datasheets-10/DSA-195140.pdf21