ID 610C: Introduction to BLDC Motor Control

Avnet

Jim Carver
Technical Director, Advanced Architectures
12 October 2010
Version 1.0

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(17.1% on unit basis).

Renesas Technology and Solution Portfolio

Microcontrollers
& Microprocessors
#1 Market share
worldwide *

Solutions
for
Innovation
ASIC, ASSP
& Memory
Advanced and
proven technologies

Analog and
Power Devices
#1 Market share
in low-voltage
MOSFET**
* MCU: 31% revenue
basis from Gartner
"Semiconductor
Applications Worldwide
Annual Market Share:
Database" 25
March 2010
** Power MOSFET: 17.1%
on unit basis from
Marketing Eye 2009
(17.1% on unit basis).

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Microcontroller and Microprocessor Line-up

Superscalar, MMU, Multimedia

High Performance CPU, Low Power

High Performance CPU, FPU, DSC

Up to 1200 DMIPS, 45, 65 & 90nm process

Video and audio processing on Linux
Server, Industrial & Automotive

Up to 500 DMIPS, 150 & 90nm process

600uA/MHz, 1.5 uA standby
Medical, Automotive & Industrial

Up to 165 DMIPS, 90nm process

500uA/MHz, 2.5 uA standby
Ethernet, CAN, USB, Motor Control, TFT Display
Legacy Cores
Next-generation migration to RX

General Purpose
Up to 10 DMIPS, 130nm process
350 uA/MHz, 1uA standby
Capacitive touch

Ultra Low Power

Embedded Security

Up to 25 DMIPS, 150nm process Up to 25 DMIPS, 180, 90nm process

190 uA/MHz, 0.3uA standby
1mA/MHz, 100uA standby
Application-specific integration Crypto engine, Hardware security

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
Introduction to BLDC Motor Control Evaluation Kit
Summary
6

Motor Types

Expanding BLDC Motor Control Applications

Transition to
AC, DC
and
Universal
Motors

As consumers demand
more energy efficient
products, more BLDC
motors are being used.

BLDC

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

10

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
+
U
11

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

12

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

13

U
V
W

Six-step Commutation
STEP1

STEP2

STEP3

STEP4

U
V
W

14

STEP5

STEP6

STEP1

STEP2

STEP3

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

15

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

H1
N
S

H2
H3

16

H3

H2

Hall Sensor Commutation

STEP1

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

17

STEP2

STEP3

STEP4

STEP5

STEP6

STEP1

STEP2

STEP3

3-Phase PWM

We can divide up the

phase data into
individual transistor
gate signals
Now we can see how
we can modulate one
transistor at a time to
regulate the motor
voltage, and also the
speed

UP
UN
VP
VN
WP
WN

18

Sensorless Commutation
Instead of using sensors like Halls, we can let the motor tell
us which phase should be energized
The Brushless DC motor acts as a generator when it rotates,
creating voltages

The three phases produce three voltages 120-degrees apart

The voltage generated by the motor is called Back ElectroMotive Force, a.k.a. Back-EMF or just BEMF

19

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

20

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

21

Startup of BEMF System

Since only a spinning motor generates BEMF signals
Start the motor in open loop
First align rotor to a known angle
Then energize the windings to step rotor to next
step
Accelerate steps until speed is sufficient to see
BEMF zero crossings reliably

Switch to BEMF commutation

Once operating, this is almost identical to six-step
operation with Hall sensors

22

Sinusoidal Methods
Stepped commutation methods work well, but
The Back-EMF waveform is more sinusoidal than trapezoidal
If we can match the sinusoidal waveform, we can improve
performance
We will show two sinusoidal methods:
180-Degree Sinusoidal
Field Oriented or Vector control

23

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
24

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

*

Cons:
Complicated Algorithm
Needs powerful processor

DC Bus

iq

Speed Regulator

id 0
*

id

iq

iq PI
Regulator

Uq

d,q

to

id PI
Regulator

Ud

,
T 1 ( )

iq

PWM1~6

,
to
a, b, c

to
d,q

ia
i

T ( )

Voltage
Source
3-phase
Inverter

SIN
PWM

Motor Model
Based Flux and
Position Observer

id

25

a,b,c
to

Speed Estimation

ib

3-phase
PMSM

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
Speed
Command

26

Pulse Width
Modulator

Transistors

Motor

Load

Closed-Loop Control
To get automatic speed control, feedback is needed
Feedback systems could be Hall Sensors, Encoders,
Resolvers, tachometers or other devices
The resolution and bandwidth of the feedback sensor limit
the resolution and bandwidth of the speed loop
Below is a block diagram of a simple control loop
Our Reference Command is the speed we desire, and the
Control Mechanism is our motor and motor control

Feedback

Reference
Command

27

Control
Mechanism

Sensor

Closed Loop Speed Control

The generic terms can be replaced with terms common to
motor control
The speed is often referred to as the Greek Letter Omega
and motor angle is Theta
The Reference input is shown as Omega star *
The Control Mechanism is a mathematical function, usually
a Proportional-Integral (PI) algorithm
The speed sensors can be the same Hall sensors used for
commutation, where the speed is calculated from the time
between steps
Motor
PI
Controller

Speed
Calculation
28

PWM
Generation
Hall
Sensors

Closed Loop Speed Control

The way the loop works is to first measure the difference
between the commanded speed and the actual speed
If the speed is to low, the PI controller increases the PWM
duty which sends more voltage to the motor, correcting
speed
If the speed to too high, the PI controller reduces the PWM,
reducing the average voltage, so the motor slows down to
the correct speed
The Proportional and Integral parameters have to be tuned
to optimized the speed loop response-prevent speed Motor
oscillations
PI
Controller

Speed
Calculation
29

PWM
Generation
Hall
Sensors

Motor Kit for Trapezoidal Control

BLDC Motor, Board, Software, Schematics, Tool and GUI

R8C/25
30

Motor Control Evaluation Kit

In order to help users decide on what kind of motor control
they need, Renesas has introduced the YMCRPR8C25 Motor
Control Evaluation Kit
The kit includes all that is needed to try Hall and BEMF
commutated Brushless DC motor control with closed speed
loops including, the control board, motor, debugger, power
supply and software

31

YMCRPR8C25 Block Diagram

R8C25 MCRP Kit
V
B
U
S

CN-4

24v DC
Supply

Power Supply
&
Conditioning

TP-1

TP-5
BLDC
Motor

Speed
Control

R8C/25
MCU

6-PWM

International
Rectifier
(IPM)

CN-1

Shutdown

RS232
I/F

Comparators
( Back-EMF)
E8
Debug
I/F

TP-2
OP-AMP
(Signal Conditioning)
Jumper-1

Hall Sensor
Inputs
Shunt
Current

LCD Segment
Display
CN-3

32

CN-2

TP-3

TP-4

4-LED
PWM / PWR
Status

Push-Button
Switch

Motor Control Board

IGBT module capable of 10

amps.
3-Phase output capable of
running DC and BLDC
motors
15V and 5V regulators on
board.
Voltage input from a single
24V (18-36VDC) supply,
no shock hazard.

33

Board User Interface

Large potentiometer
for speed control
setting
2x8 LCD display with
contrast pot for
monitoring speed,
current, etc.
Four push-buttons
Bus voltage monitoring
to MCU
Current monitoring to
the module for
automatic protection

34

Commutation Options

Back-EMF detection
comparators
Jumper selection (no
soldering) between
Hall and BEMF
modes
Input connector for
Hall signals from
motor

35

Debugging Capabilities

Optically Isolated RS232 communication

Optically Isolated
E8(a) connector
Prototyping areas
(under LCD)
LEDs for monitoring
PWM lines, and GPIO
Abundant test points

36

Motor Control Graphical User Interface

Speed Slider
Target Speed

Actual Speed

Stop
Motor
Current

System
Status
37

Project Navigator

HEW Development Environment

Source Code Editor

Output Window

38

Summary
DC and BLDC motors were compared
BLDC motors were shown to offer better performance
A large number of applications are moving from other motor
types to BLDC motors
Electronic BLDC motor control can be as simple as six-step
or as complicated as Vector Control
Closed Loop Speed Control was explained
The Renesas BLDC Motor Control Evaluation Kit was
introduced as a way to help get started in BLDC motor
control development

39

Questions?

40

Appendix

41

50MHz

M16C

20MHz

32MHz

32-bit
32-bit

R32C

78K0R

100MHz

V850ES

32-bit

General
Purpose

20MHz

RX600

100MHz

200MHz

H8S/SX

8-bit

32-bit

V850ES

RX600

SH-3

78K0

8-bit

Ultra Low
Power

200MHz

32-bit

32-bit

SH-2A

200MHz

240MHz

32-bit

TFT LCD
Control

High-end
Connectivity

600MHz

SH-4

16-bit

32-bit

SH-2A

Application
Processor

16-bit

32-bit

SH-4A

32-bit

32-bit

Renesas MCU and MPU Solutions

R8C

50MHz

50MHz

10MHz

20MHz

Application Focused Solutions

WiFi
SH, RX, R8C

42

Motor Control
SH, V850, RX,
78K0R, R8C

Capacitive
Touch
R8C

Industrial CAN

Lighting

R8C, R32C, SH

78K0

Motor Control Applications & Renesas Solutions

SuperH
RX
V850
78K0R
R8C

Fans, Kitchen Appliances,

Pumps, Power-Tools

SPEED CONTROL
Torque Control (Limited)

Low-Range
43

Medical
Industrial, Washers,
Compressors
Motion Control

Pool Pumps, Washers

Health-Equipment
Compressors

SPEED + TORQUE
CONTROL

Mid-Range

SPEED + DYNAMIC TORQUE

+ MOTION CONTROL

High-End

Renesas Motor Control Solutions

Renesas covers every motor control application from lowend to high-end
Renesas can provide all motor algorithms from Trapezoidal
control to Sensor-less Vector control
Wide product portfolio
16bit MCU (20MHz): R8C, 78K0R
32bit MCU (48MHz to 200MHz): RX, V850, SH
These products have peripherals dedicated for Motor
Control such as Timers and ADC

44

Motor Control Solution Summary

Motor Type
1- ACIM (PSC)
1- BLDC

Universal
(Brushed) DC

3- ACIM

Algorithm

R8C

V/f, Open Loop

Fixed Duty (Hall)

Closed Loop (Hall)

TRIAC Control ( speed loop

w/Tachometer)

PWM Chopper (speed loop

w/Tachometer)

V/f, Open Loop

78K0R

RX

Y
Y

Speed Loop w/Tachometer

Sensorless Vector Control

3- BLDC

V850

SH2/
SH2A

120-deg Trapezoidal (Hall)

120-deg Trapezoidal (BEMF)

180-deg Sine (HALL)

Sensor based Vector Control

Position Control (Encoder + Hall)

Sensorless Vector Control,
2 DCCT, 3-shunt, 1-shunt
45

Y
Y
*: Under development