FPGA-based implementation of the back-EMF symmetric-threshold-tracking sensorless commutation method for brushless DC-machines

The operation of brushless DC permanent-magnet machines requires information of the rotor position to steer the semiconductor switches of the power-supply module which is commonly referred to as Brushless Commutation. Different sensorless techniques have been proposed to estimate the rotor position using current and voltage measurements of the machine. Detection of the back-electromotive force (EMF) zero-crossing moments is one of the methods most used to achieve sensorless control by predicting the commutation moments. Most of the techniques based on this phenomenon have the inherit disadvantage of an indirect detection of commutation moments. This is the result of the commutation moment occurring 30 electrical degrees after the zero-crossing of the induced back-emf in the unexcited phase. Often, the time difference between the zero crossing of the back-emf and the optimal current commutation is assumed constant. This assumption can be valid for steady-state operation, however a varying time difference should be taken into account during transient operation of the BLDC machine. This uncertainty degrades the performance of the drive during transients. To overcome this problem which improves the performance while keeping the simplicity of the back-emf zero-crossing detection method an enhancement is proposed. The proposed sensorless method operates parameterless in a way it uses none of the brushless dc-machine parameters. In this paper different aspects of experimental implementation of the new method as well as various aspects of the FPGA programming are discussed. Proposed control method is implemented within a Xilinx Spartan 3E XC3S500E board

Direct torque control of brushless DC drives with reduced torque ripple

The application of direct torque control (DTC) to brushless ac drives has been investigated extensively. This paper describes its application to brushless dc drives, and highlights the essential differences in its implementation, as regards torque estimation and the representation of the inverter voltage space vectors. Simulated and experimental results are presented, and it is shown that, compared with conventional current control, DTC results in reduced torque ripple and a faster dynamic response

Torque-ripple minimization in modular permanent-magnet brushless machines

This paper discusses the suitability of four-phase, five-phase, and six-phase modular machines, for use in applications where servo characteristics and fault tolerance are key requirements. It is shown that an optimum slot number and pole number combination exists, for which excellent servo characteristics could be achieved, under healthy operating conditions, with minimum effects on the power density of the machine. To eliminate torque ripple due to residual cogging and various fault conditions, the paper describes a novel optimal torque control strategy for the modular permanent-magnet machines operating in both constant torque and constant power modes. The proposed control strategy enables ripple-free torque operation to be achieved, while minimizing the copper loss under voltage and current constraints. The utility of the proposed strategy is demonstrated by computer simulations on a four-phase fault-tolerant drive system

Sensorless flux-weakening control of permanent-magnet brushless machines using third harmonic back EMF

The sensorless control of brushless machines by detecting the third harmonic back electromotive force is a relatively simple and potentially low-cost technique. However, its application has been reported only for brushless dc motors operating under normal commutation. In this paper, the utility of the method for the sensorless control of both brushless dc and ac motors, including operation in the flux-weakening mode, is demonstrated

Experimental characterization of a supercapacitor-based electrical torque-boost system for downsized ICE vehicles

The need to improve fuel economy and reduce the emission of CO2 and other harmful pollution from internal-combustion-engine vehicles has led to engine downsizing. However, downsized turbocharged engines exhibit a relatively low torque capability at low engine speeds. To overcome this problem, an electrical torque boost may be employed while accelerating and changing gear and to facilitate energy recovery during regenerative braking. This paper describes the operational requirements of a supercapacitor-based torque-boost system, outlines the design and sizing of the electrical drive-train components, and presents experimental characterization of a demonstrator system

Improved current-regulated delta modulator for reducing switching frequency and low-frequency current error in permanent magnet brushless AC drives

The conventional current-regulated delta modulator (CRDM) results in a high current ripple and a high switching frequency at low rotational speeds, and in low-frequency current harmonics, including a fundamental current error, at high rotational speeds. An improved current controller based on CRDM is proposed which introduces a zero-vector zone and a current error correction technique. It reduces the current ripple and switching frequency at low speeds, without the need to detect the back-emf, as well as the low-frequency error at high speeds. The performance of the modulator is verified by both simulation and measurements on a permanent magnet brushless ac drive

Improved direct torque control using Kalman filter: application to a doubly-fed machine

Direct Torque Control (DTC) has been extensively researched and applied during the last two decades. However, it has only first been applied to the Brushless Doubly Fed Reluctance Machine (BDFRM) a few years ago in its basic form inheriting its intrinsic flux estimation problems that propagate throughout the algorithm and hence compromise the DTC performance. In this paper, we propose the use of Kalman Filter (KF) as an alternative to improve the estimation and consequently the control performance of the DTC. The KF is designed around a nominal model, but is shown to be reliable over the whole operating range of the BDFRM. Moreover, we use a modified robust exact differentiator based on Sliding Mode (SM) techniques to calculate the angular velocity from an angular position encoder. Computer simulations are meticulously designed to take into account real-world physical constraints and thus show illustrative supporting results as expected from an experimental setup

Three-phase modular permanent magnet brushless machine for torque boosting on a downsized ICE vehicle

The paper describes a relatively new topology of 3-phase permanent magnet (PM) brushless machine, which offers a number of significant advantages over conventional PM brushless machines for automotive applications, such as electrical torque boosting at low engine speeds for vehicles equipped with downsized internal combustion engine (ICEs). The relative merits of feasible slot/pole number combinations for the proposed 3-phase modular PM brushless ac machine are discussed, and an analytical method for establishing the open-circuit and armature reaction magnetic field distributions when such a machine is equipped with a surface-mounted magnet rotor is presented. The results allow the prediction of the torque, the phase emf, and the self- and mutual winding inductances in closed forms, and provide a basis for comparative studies, design optimization and machine dynamic modeling. However, a more robust machine, in terms of improved containment of the magnets, results when the magnets are buried inside the rotor, which, since it introduces a reluctance torque, also serves to reduce the back-emf, the iron loss and the inverter voltage rating. The performance of a modular PM brushless machine equipped with an interior magnet rotor is demonstrated by measurements on a 22-pole/24-slot prototype torque boosting machine

A Study of the Degradation of Electronic Speed Controllers for Brushless DC Motors

Brushless DC motors are frequently used in electric aircraft and other direct drive applications. As these motors are notactually direct current machines but synchronous alternating current machines; they are electronically commutated by a power inverter. The power inverter for brushless DC motors typically used in small scale UAVs is a semiconductor base delectronic commutator that is external to the motor and is referred to as an electronic speed control (ESC). This paper examines the performance changes of a UAV electric propulsion system resulting from ESC degradation. ESC performance is evaluated in simulation and on a new developed test bed featuring propulsion components from a reference UAV. An increase in the rise fall times of the switched voltages is expected to cause timing issues at high motor speeds. This study paves the way for further development of diagnostic and prognostic methods for inverter circuits which are part of the overall electric UAV system