2012 Interational Conference on Computing, Electronics and Electrical Technologies [ICCEET]

PMBLDC Motor Drive with Power Factor

Correction Controller
Gishin Jacob George, Rakesh R, N.Arun
h5lrJcl--This paper presents a boost converter
confguration, control scheme and design of single phase
power factor controller for permanent magnet brushless
DC motor (PMBLDCM) drive. PMBLDC motors are the
latest choice of researchers, due to the high efciency,
silent operation, compact size, high reliability, and low
maintenance requirements. The proposed Power Factor
Controller topology improves power quality by improving
performance of PMBLDCM drive, such as reduction of
AC main current harmonics, near unity power factor.
PFC converter forces the drive to draw sinusoidal supply
current in phase with supply voltage. It uses a boost
converter to obtain unity power factor with improved
performance. The system includes a speed controller for
PMBLDC drive and a voltage controller for boost
converter .. The voltage or speed controllers can be realized
using proportional integral (PI) controller. Simulations
are done using MA TLABI SIMULINK sofware.
Index Terms-PMBLDC Motor, Power factor
correction, Voltage Controller, Speed Controller, VSI,
Boost Converter.
I. INTRODUCTION
BLDC motors are widely used in industries
such as Appliances, Consumer, Automotive, Medical,
Aerospace, Industrial Automation Equipment and
Instrumentation. Usually, the low-power adjustable
speed drives (AS Os) are powered fom single-phase AC
mains through a diode bridge rectifer (OBR) with
smoothening DC capacitor and voltage source inverter
(VSI). Fig. 1 shows the OBR-VSI fed PMBLOCM
drive with DC link capacitor. The AC mains current
waveform, as shown in Fig. 2 and Fig.3 is far fom
sinusoidal, because of the fact that, the DBR does not
draw any current fom the AC network when the AC
voltage is less than the DC link voltage, as the diodes
are reverse biased during that period; however, it draws
a peaky current when the AC voltage is higher than the
DC link voltage. This result in a pulsed input current
waveform featuring a peak value higher than the peak
of the fndamental input current [13], thereby, 71.97%
total harmonic distortion (THO) in the input current.
The PMBL motors belong to three-phase
synchronous motor family and can be categorised as
permanent magnet synchronous motor (PMSM) and
Gishin Jacob George is with School of Electrical Engineering. VIT
University, Vellore, India. (Email: -jacobgishinhoo.co.in)
Rakesh R. is with School of Electrical Engineering, VIT University,
Vel\ore, India. (Email: -rakeshramachandran.k!gmail.com)
N.Arun, Asst.Professor (Sr.), School of Electrical Engineering, VIT
University, Vel\ore, India.(Email:-narun@vit.ac.in).
978-1-4673-0210-4112/$31.00 2012 IEEE 63
Y0L1AO
=f
M010k
Fig. : Conventional OBR-VSI fed PMBLOCM drive
topology
T0
0
__
4? 021 J.? J 0Z 0Z O.Z5 0Zl

@ 0

>0
i 40
"
u

1m
Fig. 2: Input current waveform
w0|M J50z)" 6I19 ^= I1.9I%
20
\U
O -I
1 1
M e|t
Fig. 3: THD for conventional DBR-VSI fed PMBLDCM
drive.
PMBLDCM [14]. The PMSM uses continuous rotor
position feedback for supplying sinusoidal voltages and
currents to the motor with sinusoidal back EMF, so that
the interaction with sinusoidal currents produces
constant torque with very low ripple. However, the
PMBLOCM is supplied by three-phase rectangular
current blocks of 120

electrical duration, in which the
back EMF is trapezoidal, with the constant part of the
waveform timed to coincide with the intervals of
constant phase curent. Therefore PMBLDC motors
need rotor-position information only at the
commutation points, for example, every 60

electrical in
the three phases [1]. PMBL machines are best suited for
position control and medium size industrial drive
because of their excellent dynamic capability, reduced
losses and high torquelweight ratio. The applications of
PMBL motors have been reported in diverse felds such
2012 Interational Conference on Computing, Electronics and Electrical Technologies [ICCEET]
as computers, automobiles, transportation, aerospace
equipment, power tools, toys, vision and sound
equipment and healthcare equipments ranging fom
microwatt to megawatts. Advanced control algorithms
and ultra-fast processors have made PMBL motors
suitable for position control B machine tools, robotics
and high precision servos, speed control and torque
control in various industrial drives and process control
application. A PFC converter forces the drive to draw
sinusoidal supply current in phase with the supply
voltage. It uses a DC-DC converter topology, boost
converter, to obtain unity PF with improved
performance, such as reduction of AC mains current
harmonics, reduction of acoustic noise minimum
number of components, maximum efciency, etc.
II. STATE OF THE ART
PMBLDC motors are generally powered by a
conventional three-phase voltage source inverter (VSI)
or current source inverter (CSI) which is controlled
using rotor position. The rotor position can be sensed
using Hall sensors, resolvers, or optical encoders. These
position sensors increase cost, size and complexity of
control thereby reducing the reliability and acceptability
of these drives. Due to the high cost of the motor and
controller, very few commercial applications of
PMBLDC motors have been reported. Recently some
additional applications of PMBLDC motors have been
reported in electric vehicles (EVs) and hybrid electric
vehicles (HEVs) due to environmental concers of
vehicular emissions. PMBLDC motors have been found
more suitable for EVs/HEVs and other low power
applications, due to high power density, reduced
volume, high torque, high efciency, easy to control,
simple hardware and sofware and low maintenance.
Due to ease of control in PMBLDC motors, they are
preferred for numerous applications in low power and
variable speed drives.
III. REVIEW OF BOOST CONVERTER
The topology of boost converter is shown in
Figure 4. The diode bridge rectifes the AC line voltage,
and the power switch S, the inductor L and the output
diode do operate as a boost converter. The ripple in the
output voltage is reduced by using the capacitor C. The
load is assumed to be purely resistive (R).
|
L

D
I mb!dsts
HM
r J
\
Figure 4: Boost converter
64
The input line flter reduces the high-fequency
components in the input current. The power switch is
operated at a constant switching fequency, and the
output voltage is varied by varying the duty cycle. It is
assumed that the boost converter operates at CCM and
the switching fequency is much higher than the line
fequency. Hence, the input voltage can be assumed as
a constant during one switching cycle.
IV. MODELLING OF PMBLDC MOTOR
The modelling of PMBLDC motor drive
includes the modelling of a speed controller, reference
curent generator, current controller and modelling of
PMBLDC motor [13] as shown in Fig. 5. Each of the
above components of PMBLDCM drive can be
modelled by mathematical equations and combination
of such models represent complete PMBLDCM drive
[7]. The modelling of a speed controller is of prime
importance as the performance of the system depends
on this controller. Assuming that at t
lh
instant of time,
(t) is the actual rotor speed, ; (t) is the reference
speed, then the speed error (t) can be calculated
as [7]:
(t) = : (t) - _(t)
A speed controller is used to process this speed error to
obtain desired control signal.
. Speed Controller
The PI controller is used as the speed
controller. The PI controller output at t
lh
instant T(t) is
given as[7]
T(
t
) =T(
t
-l) +kp{U
(t)
-a-1
)
}+lU
(t)
where Kp and KJ are the proportional and integral gains
of the PI controller respectively.
Let 1*= T(t)/Kb , where Kb is the back-emf
constant of the PMBLDCM.
D. Reference Current Generation
The reference phase currents of the motor
windings are la *, Ib * and Ie * for phases a, b, c,
respectively. For duration of 0-60

the reference
currents can be given as
la*= 1 *, Ib* =1 * and le*= 0
Similarly, the reference currents for the other duration
can be generated, which will follow the trapezoidal
voltage of respective phases. These reference currents
are compared with sensed phase currents for error
current generation as
Ia =( la *- la),
M
b = (Ib * - Ib),
M
e= (Ie *- Ie)

C. Current Controller
The switching sequence for the VSI is
generated by the current controller, afer comparing the
curent eror of each phase with fxed fequency carrier
waveform. The current errors I., Ib, Ie are
amplifed by gain kl before comparing with carrier
waveform met). The switching sequence is obtained
based on the logic given for phase 'a' as
2012 Interational Conference on Computing, Electronics and Electrical Technologies [ICCEET]
If k1 I- met) then b= 1
If k1 D met) then b= 0
Similarly the switching sequences Sb and Sc are
generated.
V. PROPOSED PFC TOPOLOGY
In the proposed PFC Topology a boost
converter is used to boost the input voltage which is fed
to a voltage source inverter (VSI), the PMBLDC motor
is given its supply fom this VSI. A Speed Controller
and a Voltage Controller is used in the motor side and
the input side respectively. Both Controllers are realised
using Proportional Integral (PI) controller.
The control loop of VSI-based topology,
employed to execute PFC operation involves inner
current loop and outer voltage loop. The complete
control scheme block diagram is shown in Fig.S with a
DBR connected to single-phase AC mains, followed by
a Boost Converter and output ripple flters.

|i

gM0I0B
-(I _
\0|TAG
0
KJEK
0UBCE
' T

:
Fig.S : Proposed DBR-VSI fed PMBLDCM drive
topology
For the Voltage Controller, the DC linl
voltage is sensed and compared with the reference DC
link voltage. The error voltage is passed through a PI
Controller, and multiplied with a unit template of
absolute input voltage so as to generate the reference
current signal. This signal is compared with sensed
converter current which gives the modulating wave for
the PWM. This current eror is the modulating signal
and a triangular wave is taken as the carrier signal so as
to generate the PWM gate pulses for ting on/off the
Boost converter switch. The fowchart for Voltage
Controller is shown in Fig: 6.
The control of PMBLDC motors can be
accomplished by control algorithms using conventional
six pulse inverters which can be either VSI or CSI. The
control of these inverters for PMBLDCM needs rotor
position information only at the commutation points, for
example, every 60

electrical in the three phases;
therefore comparatively simple controller is required for
commutation and control. The rotor position is sensed
using Hall Effect sensors. The speed of the motor is
measured and is compared with the reference speed.
The error signal is passed through a PI controller to give
6S
a reference signal. This reference signal is compared
with the Boost converter output current so as to give
modulating signal for PWM. This signal is compared
with triangular carrier signal to generate the PWM
pulses for turing on/off the VSI switches. The
fowchart for Speed Controller is given in Fig: 7.
Obt UtDc LVolrage,Rectfer Output LuH AL Source Voltage
Yl
IR geneaton using I Coniolle mutply WH absolute L Source Voltage
Gneraton for b0lConvete S"itch
Fig: 6 Control Flowchart for Voltage Controller
0otJcAcuHc|crS,0cuCm|haSc:o:Stgm:
Fig : 7 Flowchart for Speed Controller
2012 Interational Conference on Computing, Electronics and Electrical Technologies [ICCEET]
VI. SIMULA nON RESULTS
The proposed PFC topologies of PMBLDCM
drive are modelled in the MATLAB/Simulink
environment for a YS[ fed PM BLOC motor. The P[
controller is utilized for voltage as well as speed control
and PWM signals are generated for YS[ using 40 kHz
triangular carrier waves. The YS[ fed PMBLOC motor
is started at no load for stabilising of DC link voltage.
The power quality is monitored through FFT analysis of
source current (i.e. current at AC mains) under steady
state condition. Boost PFC topology is evaluated for a
dc linl voltage of 400Y to drive PMBLDC motor at
1100 rpm with rated load torque. Boost PFC converter
shows very good response with input AC mains current
THD of l. 51 %, along with PF ofO.99l.
The harmonic spectrum shows 7 [.97% THO in
the AC mains curent at rated torque for conventional
YSI. The THO of AC mains current is reduced to
[. 51 % with the boost PFC topology at same load on the
motor. The PQ performance analysis of proposed PFC
topology shows that the THO of AC mains current
always remains within the limit imposed by IEC 61000-
3-2 and other international PQ standards [5, 6].
FFwmow oZ5 cyle olsekc|d sina
0.3 0.1 0.3 0.3J O. 0.35 O.3 0.37
1me (sJ
amnice|
Fig.S : Current at AC mains and its harmonic spectra of
Boost PFC converter Feeding YS[ based PMBLOCM
drive.
[t is observed that source current is always in
phase with the source voltage and results in close to
unity PF operation of PFC converter during load
perturbation as well as during steady-state operation.
Moreover, the PMBLDCM drive shows an improved
performance in terms of reduced current and torque
ripples during steady state as well as transient
conditions.

s
X
66
10
W
M
8
6
4W

0
D ? 0? 0.4 0 1 7
F
|
Fig. [3 : Torque
# 0#
2012 Interational Conference on Computing, Electronics and Electrical Technologies [ICCEET]
Above fgures shows source voltage, source
current, motor speed, stator current and torque for
proposed VSI based topology fed PMBLDCM drives in
steady state condition. Fig. 9 and fg. 1 0 shows that the
source voltage and curent is in phase with each other at
steady state. From Fig 11 shows the speed of the motor
following the reference with minimum ripples. The
performance of the PMBLDCM drive is improved with
boost PFC topology in terms of low torque ripples,
smooth speed variation and unity power factor at AC
mains.
The PMBLDCM drives use either uncontrolled
rectifer (i.e. Diode Bridge) or controlled PWM rectifer
(i.e. PWMVSC). The PWM-VSC is used only if
bidirectional power fow or regeneration is required,
otherwise DBR is most commonly used font end
converter for PFC topology. Boost PFC topology is the
best option for most of the drives as their rated DC
voltage is higher than the single-phase supply RMS
voltage. The non-isolated boost PFC topology does not
have any protection to load over current or short-circuit
conditions. For low-power drives, for example
computer peripherals, robotics and many such
applications, the PMBLDCM drives are generally
preferred at low voltages.
VII. PERFORMANCE ANALYSIS OF SPEED
VOLTAGE CONTROLLER
The efcient working of the Speed Controller
Voltage Controller can be analysed by giving
disturbances by changing reference values and
observing the machine to follow the given reference
values of the control parameters.
The Speed reference is varied at different time instants
Speed variations at time, t=l.205 sec (Nref = 1000),
t=l.605 sec (Nref = 1500), t=3.704sec (Nref = 2000).
Fig 14 shows that the motor speed follows the reference
given, the red line is the reference speed and the blue
line actual motor speed.
|m:::-
Fig 14 : Speed Variations with Reference Speed
67
Fig 15: DC link Voltage Variations with Reference
Voltage
The DC link Voltage reference is varied at
different time instants Speed variations at time D
t=2.004 sec (Vref=300V), t = 2.471sec (Vref=400V), t =
4.623 sec (Vref=500V). It can be observed that the DC
link voltage is affected by variations in Speed and
Torque. Fig.14 and Fig. 15 shows that the actual values
of the control parameters follow the reference values.
VIII. APPLICATIONS
PMBLDC motors are best suited for low
power appliances in commercial and domestic
applications. Majority of them use single-phase AC
induction motors with capacitor or split phase starting.
These motors operate at constant speed directly fom
AC mains irrespective of efciency; however,
PMBLDC motors can offer low-energy consumption,
improved performance, reduced acoustic noise and
many more convenience features. Therefore household
appliances are expected to be one of largest end product
market for PMBLDC motors, over the next few years.
The major household appliances include fans, blowers,
washing machines, room air-conditioners, refigerators,
food processors etc. The rotor-position sensors (Hall
effect sensors, resolvers or optical encoders) increase
the cost and the size of the motor. special mechanical
arrangement is also required for mounting the sensors.
The system reliability also reduces because of the
additional components and wiring. The sensor less
control of PMBLDC motors reduces the drive cost up to
some extent, while little increased control complexity.
Owing to the features of high-power density, less
volume, high torque, high effciency, easy to control
and low maintenance, the applications of PMBLDC
motors have been reported in EVs and HEVs, vehicular
air conditioner, aerospace application, traction, robotics,
tread mills, washers, wheelchair,]computer hard disc
drives, compressors of household air conditioner, and
commercial feezers, fans and pumps [12].
2012 Interational Conference on Computing, Electronics and Electrical Technologies [ICCEET]
IX. CONCLUSION
The PFC converter topology for Power quality
improvement in PMBLDC motor drives is designed and
their performance is simulated to provide in depth
understanding on various aspects of these drives. The
performance of this topology has been evaluated
through simulation for validation of their designs. Boost
PFC topology is used as this is the best option for
applications having rated DC voltage higher than single
phase supply RMS voltage. The PMBLDCM drives
incorporating PFC converter can be a milestone towards
the widespread application of these drives.
X. REFERENCES
[1]. MILLER T.lE. : 'Brushless permanent magnet and
reluctance motor drive' (Clarendon Press, Oxford, 1989
[2]. DUBEY G.K. : 'Power semiconductor controlled
drives' (Prentice Hall, New Jersey, 1989)
[3]. KRISHNAN R. : 'Electric motor drives: modelling,
analysis and control' (Pearson Education, India, 2003)
[4]. RASHID M.H. : 'Power electronics: circuits,
devices and applications' (Pearson Education, India,
2004)
[5]. IEC 555-2: 'Harmonics, equipment for connection
to the public low voltage supply system', 1990
[6]. IEEE 1159: 'Recommended practice for monitoring
electric power quality', 1995
[7]. B.SINGH, S.SINGH. : 'Single-phase power factor
controller topologies for permanent magnet brush less
DC motor drives', lET Power Electron., 2010, Vol. 3,
Iss. 2, pp. 147-175
[8]. ANAND SATHY AN. : ' Digital PWM Control of
Brushless DC (BLDC) Motor Drives', PhD thesis, lIT,
Chicago, Illinois,2008
[9]. NED MOHAN, TORE M. UNDELAND,
WILLIAM P. ROBBINS: 'Power Electronics', Third
Edition, John Wiley and Sons, New Delhi.
[10]. H. S. ATHAB, D.D.C. LU: 'Simple Controller for
single phase power factor correction rectifer' ,I ET
Power Electron., 2010, Vol. 3(4), pp. 590-600.
[II]. KATSUHIKO OGATA: 'Modem Control
Engineering', Fourth Edition, Prentice Hall, India.
[12]. BHIM SINGH , SANJEEV SINGH. : 'State of the
Art on Permanent Magnet Brushless DC Motor Drives',
Joual of Power Electronics, Vol. 9, No. 1, January
2009
[13]. Sanjeev Singh, 'An adjustable speed PMBLDCM
drive for air conditioner using PFC Zeta converter',
Interational Joual of Power Electronics, 2011
[14]. Padmaraja Yedamale, 'Brushless DC (BLOC)
Motor Fundamentals', Microchip Technology Inc.,
2003.
[15]. Vladimir Blasko,' A Novel Method for Selective
Harmonic Elimination in Power Electronic Equipment',
IEEE transactions on Power Electronics, vol. 22,
January 2007
68
VII. BIOGRAPHIES
GshnJacob Gcorgc was born in India in
1987.He graduated fom M. G. University
and currently doing his post -graduation at
VIT University. His aeas of interests ae
Power Electronics applications in power
system, power factor correction, boost
converters, EMI/EMC etc.
Hakcsh H. was born in India in 1987. He
graduated fom Kerala University and
doing his post-graduation at VIT
University. His employment experience
includes Lecturer at MEA Engineering
College, Kerala and Project Trainee at
LRDE, DRDO, Bangalore. His areas of
interests are Power Electronics
applications in power system, power factor
correction, boost converters, etc.
^.Arun. is currently working as a Assistant
Professor (Sf.), VIT University. He received
M.Tech in Power Electronics & Drives fom
Pondicherry College of Engineering. His
area of research is non-linear controller
design for drives.