Senorless BLDC Control

EE 552
Joseph Bingham 5/9/2013

Introduction:
The purpose of this paper is to explore the sensorless commutation of the brushless DC motor. Specifically, I wish to explore the zero crossing back-EMF method. This method of senorless commutation is the most popular due to its ease of implementation and reliability.

Brushless DC Motor Operation:

Brushless DC Motors (BLDC) have many advantages over other motors. Compared to brushed DC motors BLDC are more reliable and efficient since they do not have brushes which cause excessive heating and friction. Compared to induction motors, BLDCs have a better dynamic response due to lower rotor inertia. Additionally, BLDCs have a flat speed- torque curve compared to the induction motors nonlinear speed-torque characteristic. The downside of BLDCs is the complicated drive circuit that is required for commutation . Figure 1 shows a cross section of a BLDC motor. BLDC is contructed from a perment magnet rotor and a wire wound stator poles. Mechanical energy is created by passing current throught the stator winding wich interacts with the rotor magnets creating torque. In order to create useful torque, the winding must be energized in the correct sequence. In order to commuate the windings correcting , information about the rotor postion is necessary. In sensored BLDC operation the hall sensors provide information about the rotor position.

Figure 1

Each hall sensor is offset by 120 degrees and outputs high for 180 out of 360 degrres. The waveform can be seen in figure 2.

Figure 2

The hall sensors output can be divided into 6 sectors. Each sector corresponds to 60 electrical degrees which provides the drive circuit (Figure 3) with switching information so that it can energize the correct phases.

Figure 3

When each phase is energized in sequence, the field rotates. The permanent magnet follows the rotating field in synchronous motion. (Figure 4)

Figure 4

Sensorless BLDC Operation:

As previously described, the BLDC needs information on the rotors position in order to commutate the winding currents. The back-EMF of a BLDC provides information on the rotors position. Back-EMF is created by the rotating permanent magnet as it interacts with each phase winding. A characteristic of BLDC back-EMF is its trapezoidal shape which can be seen in figure 5. As the Back-EMF transitions from high to low, it crosses zero or the zero crossing point ( ZCP). This ZCP is important because it occurs 30 degrees before the next commutation point. Therefore, by measuring the back-EMF signal it is possible to commutate the stator winding in the correct sequence.

Figure 5

Figure 5 shows an ideal back- EMF signal which does not occur in practical situations. The backEMF signal is corrupted by with switching noise and coupling to the other winding phases. A more accurate picture of a measured back-EMF signal is given in Figure 6.

Figure 6

Detecting the zero crossing point becomes increasingly difficult as the noise increases. The signal could cross zero several times with no way of detecting the true ZCP. Therefore, it becomes necessary to filter the signal. Filtering out the high frequency noise can be implemented digitally or by an analogue circuit. In either case, the filter introduces a phase delay that must be accounted for in the commutation timing (See figure 6).

Another challenge for sensorless commutation is that the back-EMF signal is proportional to the speed of the rotor. At startup or at low speed, the back-EMF signal is barely detectable or not detectable at all. Therefore, it is necessary to operate the BLDC in an open loop configuration. The motor is commutated blindly until the back-EMF signal is detectable.

Conclusion:
Senorless BLDC motor operation offers many advantages over sensored operation. Without the added expense and risk of failure of the hall sensors, the senorless BLDC is a cheaper and more reliable option. One disadvantage of the senorless BLDC is the increase in computation and control circuitry needed for commutation. With the recent advances in microelectronic devices, the cost and implementation of the added control circuitry is becoming trivial.

Credits
1. Sensorless BLDC Control With Back-EMF Filtering Reston Condit-- MicroChip Technology 2. Position and Speed Control of Brushless DC Motors Using Sensorless Techniques and Application Trends -- Jos Carlos Gamazo-Real, Ernesto Vzquez-Snchez