258 PRZEGLD ELEKTROTECHNICZNY (Electrical Review), ISSN 0033-2097, R.

87 NR 3/2011
Wael A. SALAH, Dahaman ISHAK, Khaleel J. HAMMADI, Soib TAIB
Universiti Sains Malaysia


Development of a BLDC motor drive with improved output
characteristics


Abstract. A brushless DC (BLDC) motor control based on rotor position sensing scheme is discussed in this paper. A PIC microcontroller is
employed to generate pulse width modulation (PWM) signals for driving the power inverter bridge. Parameters required for power PWM generations
have been programmed, which provide flexible and online source code modifications in accordance with the motor and circuit requirements.
Hardware implementation and simulation results show the effectiveness of the developed motor drive. The flexibility offered by the developed motor
control and drive enables the implementation of difference control algorithms for improving the output characteristics of the BLDC motor.

Streszczenie. W artykule przedstawiono sterowanie silnikiem bezszczotkowym DC bazujce na czujnikach pozycji wirnika. Mikrokontroler jest
wykorzystywany do wytwarzania sygnau PWM zasilajcego przeksztatnik. Parametry wymagane do generacji sygnau PWM s programowane w
zalenoci od wymaga silnika i napdu. Badania modelu i symulacje pokazuj skuteczno zaproponowanej metody. (Napd silnika
bezszczotkowego z ulepszon charakterystyk wyjciow)

Keywords: BLDC, Motor Drive, Microcontroller, PWM.
Sowa kluczowe: silniki bezszczotkowe DC, .PWM, napd.


Introduction
In conventional DC motors with brushes, the field
winding is on the stator and armature winding is on the
rotor. The motor is expensive and needs maintenance
because of the brushes, the accumulation of the brush
debris and dust, and commutator surface wear. Moreover,
in certain hazardous locations, the application of DC
brushed motors is limited because of the arcing. This could
be solved by replacing the mechanical switching
components (commutator and brushes) with electronic
semiconductor switches. Brushless DC (BLDC) motor has a
permanent magnet rotor and a wound field stator connected
to a power electronic switching circuit. BLDC motor drives
have high efficiency, low maintenance and long life, low
noise, control simplicity, low weight, and compact
construction.
BLDC control drive systems are based on the feedback
of rotor position obtained at fixed points typically every 60
electrical degrees for six-step commutation of the phase
currents [1].
Brushless motors can be classified as either trapezoidal
or sinusoidal based on the shape of their back-EMF. In
BLDC motors with trapezoidal back-EMFs, the permanent
magnets produce a trapezoidal air gap flux density
distribution. These motors have higher torque and larger
torque ripples compared with motors that have sinusoidal-
shaped back-EMF. They are also cheaper and used for
general applications [2].
The BLDC drive system consists of BLDC motor, power
electronics converter, sensor, and controller as shown in
Fig. 1.


Fig.1: BLDC drive system components

BLDC Motor Control
The pulse width modulation (PWM)-controlled BLDC
motor drive system is the most commonly applied technique
for driving a motor inverter bridge. An effective comparison
of PWM-controlled and pulse-amplitude modulation (PAM)-
controlled sensorless BLDC motor drives for refrigerator
applications has been presented by Lai et al. [3]. For BLDC
motor drives, the inverter can be controlled through either
PWM with a fixed DC-link voltage or PAM with controlled
DC-link voltage amplitude. A novel microcontroller-based
sensorless BLDC motor drive for automotive fuel pumps
has been presented in Ref. [4]. The paper describes the
speed control of a BLDC motor drive that employs a hard-
chopping PWM technique using a digital signal processor.
According to the input command, feedback command, and
control algorithm, the PWM pulses for each phase
generated by the DSP are given to MOSFET/insulated gate
bipolar transistor (IGBT) driver [5].
Yen-Shin et al. [6] presented a PWM technique for
small-power BLDC motor drives that significantly reduces
conduction losses and heat dissipation. Comparative results
using conventional PWM techniques have been fully
explored to highlight the advantages of the proposed
technique [6]. A PWM technique with switching-loss
reduction for a five-leg inverter has been presented by Oka
et al. [7]. The method advantages in the DC-bus voltage
can be fully available. Information on the motor frequency,
phase, and amplitude of phase voltage commands is not
required in this PWM strategy [7].
To switch the motor stator coils in the correct sequence
and at the correct time, the position of the rotor field
magnets must be known. The exact location of the rotor
field magnets can be detected by Hall Effect sensors or by
an encoder. In this paper, the position information fed to the
controller will be implemented using Hall Effect sensors.
The function of the controller is to switch the right
currents in the right stator coils at the right time in the right
sequence using the information supplied by the sensor and
processing it with pre-programmed commands to make the
motor perform as desired. Embedded microcontrollers are a
widely used technology in many devices and systems;
nowadays, fewer electrical devices are controlled by means
of analogue. Instead, many devices and systems are
operated digitally using microcontrollers that can be
programmed to perform multiple tasks, which provides
easier and flexible control [8].
One of the popular microcontroller products suitable for
such motor control applications is the 8-bit PIC18
microcontroller from Microchip. This microcontroller unit
(MCU) offers a moderate price/performance ratio with
reliable and easy development technology [9].
PRZEGLD ELEKTROTECHNICZNY (Electrical Review), ISSN 0033-2097, R. 87 NR 3/2011 259
Implementation of drive control
Digital controller systems are used extensively in the
field of motion control. High-performance digital control
systems usually require the fast execution of control
algorithms. These controllers, which are typically run at a
moderate clock frequency and use multiple instruction
cycles for each processing step, could provide a flexible
and fast motion control system [10].


Fig. 2: Block diagram of microcontroller system

The 8-bit microcontroller produced by Microchip
Technology Inc. that has special advanced motor control
peripherals could deliver better efficiency, quieter operation,
wide speed range, and extend the life of motors. This chip
provides a complete solution for precise and energy-
efficient operation in sophisticated motor control
applications through advanced analogue and digital
feedback, and three-phase complimentary PWM modules.
A block diagram showing the digital signal controller
functionality is shown in Fig. 2 [11].
The new IGBTs lead the market today for medium and
high power applications. IGBTs feature many desirable
properties including high switching speed, low conduction
voltage drop, high current-carrying capability, and a high
degree of strength. The availability of IGBTs has lowered
the cost of systems and made its use economically viable in
many practical applications. A recommended switch driver
from the IGBT manufacturer is used in this paper. The
online design tools provided by the manufacturers and the
customer support aids in the selection of a proper switch
driver. The gate drive is needed to amplify gate signals
generated by an embedded controller and to provide
electrical isolation between the control circuit and the power
circuit [12], [13].
For a drive system with sensors, the Hall Effect position
sensors are used to determine the actual rotor position. The
Hall outputs are monitored by the controller, and an
appropriate commutation sequence is applied for
commutating the motor [14].
A block diagram showing the system connection is
illustrated in Fig. 3. A reference speed is given by the user,
a popper PWM scheme is applied to the power switch
driver, and then the motor is connected to the output of the
power bridge. The feedback signals of the BLDC rotor
position are fed back using the assembled Hall Effect
sensors.
The speed of the motor is varied using PWM outputs on
the output voltages. The speed of the motor is directly
proportional to the applied voltage. By varying the average
voltage across the windings, the motor speed can be
changed. This is achieved by altering the duty cycle of the
base PWM signal. Maximum speed is achieved when the
PWM duty is 100%. In this case, the power switches are
ON for 100% of the commutation period. When PWM is less
than 100%, the speed is proportional to the duty cycle
setting. The speed reference is determined using a
potentiometer. Then this reference is converted to a digital
signal that is used as a reference for the PWM duty cycle
register.


Fig. 3: System connection

The programming task is performed under the MPLAB
IDE environment with C18 compiler and ICD2 module. The
basic configuration of the PIC 18F4431, the initialization of
the PWM module, the ADC module for speed reference and
Hall sensors, and duty cycles of the power PWM are
presented. At any time, the stop button can be activated to
stop the machine and jump back to the beginning of the
program. The flow of the program code for BLDC drive
based on the Hall Effect sensing of rotor position is shown
in Fig. 5.
As an interrupt routine for change notification of rotor
position by the Hall sensor, when a Hall sensor changes
state, an interrupt pointer is generated in the ISR routine.
The program then reads the IC1, IC2, and IC3 inputs, which
are then used to load a corresponding value from the state
table, and sends the correct PWM output to energize the
IGBT switch.

BLDC drive system model
The BLDC motor produces a trapezoidal back-EMF and the
applied current waveform is rectangular. The stator
resistances of all the windings are assumed equal, and the
self-inductance and mutual inductance are constant. The
three-phase voltage equations can be expressed as in
Equation (1) [15]. The rotor induced currents are neglected
and the damper windings are not modelled in this equation.

(1)
0 0 0 0
0 0 0 0
0 0 0 0
a S a S a a
b S b S b b
c S c S c c
v R i L M i e
d
v R i L M i e
dt
v R i L M i e
( ( ( ( ( (
( ( ( ( ( (
= + +
( ( ( ( ( (
( ( ( ( ( (



R
s
is the phase resistance, L
s
is the self-inductance in L,
and M is the mutual inductance. The variables v
a
, v
b
, and v
c

are the phase voltages; i
a
, i
b
, and i
c
are the phase currents;
e
a
, e
b
, and e
c
are the phase back-EMF voltages.

The equivalent circuit of the BLDC motor is shown Fig. 4.

Fig. 4: Brushless DC motor equivalent circuit
260 PRZEGLD ELEKTROTECHNICZNY (Electrical Review), ISSN 0033-2097, R. 87 NR 3/2011
Due to the interaction of the current in the stator windings
and the magnetic field in rotor magnet, the electromagnetic
torque is generated in the BLDC motor.
The electromagnetic torque is given by
(2) ( )
e a a b b c c m
T e i e i e i e = + +
where
m
e is the mechanical speed of the rotor. The
equation of motion is
(3) ( )
m e L m
d
T T B J
dt
e e =
where
L
T is the load torque, B is the damping constant,
and J is the moment of inertia of the rotor shaft and the
load [2].


Fig. 5: Flowchart of sensor-controlled BLDC motor

Simulation results
Fig. 6 shows the setup configuration of the BLDC motor
simulation using the PSIM. The signals from the Hall
sensors are used to generate the proper commutation
sequence for the BLDC motor drive. Based on the output of
the built-in Hall sensors, the corresponding switch will be
energized in accordance to the six-step BLDC commutation
principle. There is one transition from high to low or low to
high at each 60; the conduction of each sensor is 120.
Fig. 7 shows the simulated phase currents of the BLDC
motor based on Hall sensor control. There is a transition
from high to low or low to high at each 60; the conduction
of each sensor is 120 electrical.

Fig. 6: Simulation setup for the Hall-sensed BLDC drive

Fig. 7: Phase current waveforms

Experimental results
Fig. 8 shows the hardware implementations consisting
of a control board, a three-phase inverter board, and a
three-phase permanent magnet brushless motor.
The developed prototype three-phase inverter bridge
with the HV driver is connected to the MCU through opto-
coupler drivers to provide isolation between the power and
the control sides. The developed motor control offers Hall
sensor and/or encoder input ports for rotor position
feedback. Details regarding the experimental motor are
shown in Table 1.
As shown in Fig. 9 (lower waveform), the generated
PWM driving signal for the inverter bridge power switches
have been chopped to a train of pulses utilized by the PIC
microcontroller PWM module.



Fig. 8: Hardware implementations

PRZEGLD ELEKTROTECHNICZNY (Electrical Review), ISSN 0033-2097, R. 87 NR 3/2011 261
The upper waveform in Fig. 9 shows the measured
current of the BLDC motor; the shape of motor current is
matched with the current recorded in the simulation. The
lower waveform shows the control PWM signal driving the
power switch.


(a) Speed: 1440 rpm

(b) Speed: 900 rpm
Fig. 9: Measured motor current and PWM

Conclusion
The generated PWM signals for driving the power
inverter bridge for BLDC motor have been successfully
implemented using an 8-bit PIC18F4431, as well a
PIC18F18F2431 microcontroller. The BLDC motor control
based on rotor position sensing scheme has been
discussed and successfully implemented. The required
references for power PWM generation have been
implemented in the PIC code, through which it will provide a
flexible and easy-to-change or modify source code in
accordance with the motor and circuit requirements. The
developed control and power board is functions properly
and satisfies the application requirements. Simulation and
experimental results verify the effective developed drive
operation.

Acknowledgements
The authors wish to thank the Universiti Sains Malaysia for
providing the USM Fellowship Scheme.

REFERENCES
[1] H. A. Toliyat and S. Campbell, DSP-Based electromechanical
motion control. Boca Raton [Fla.]: CRC Press, 2004.
[2] A. Emadi and J. C. Andreas, Energy-efficient electric motors.
New York: Marcel Dekker, 2005.
[3] Y. S. Lai, et al., "Efficiency comparison of PWM-controlled and
PAM-controlled sensorless BLDCM drives for refrigerator
applications," in Conference Record - IAS Annual Meeting
(IEEE Industry Applications Society), 2007, pp. 268-273.
[4] S. Jianwen, et al., "A novel microcontroller-based sensorless
brushless DC (BLDC) motor drive for automotive fuel pumps,",
IEEE Transactions on Industry Applications, vol. 39, pp. 1734-
1740, 2003.
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with loss reduction for small power brushless DC motor drives,"
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three-phase AC motors," The IEEE Energy Conversion
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[11] PIC18F2331/2431/4331/4431 Data Sheet," Microchip
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APPENDIX
Table 1: Brushless DC motor from Hurst
(Model: DMB0224C10002)
Rated power 26.46 W
Rated speed 2054 rpm
Rated voltage 24 V
Rated current 1.16 A
Number of poles 10 Poles
Phase resistance (R) 4.03 O
Phase inductance (L) 4.6 mH at 1 kHz
Torque constant (Kt) 0.069 Nm/A
Back EMF constant (Ke) 7.24 Vp/rpm


Authors:
Wael A. Salah is currently a PhD candidate in the fields of Energy
conversion and Power Control at the School of Electrical and
Electronic Engineering, Universiti Sains Malaysia.
Tel. +604-599-6073 Fax +604-594-1023
Email: wael_sal@yahoo.com
Dahaman Ishak is a senior lecturer at School of Electrical and
Electronic Engineering, Universiti Sains Malaysia.
Email: dahaman@eng.usm.my.
Khaleel J. Hammadi is currently a PhD candidate at the School of
Electrical and Electronic Engineering, Universiti Sains Malaysia.
Email: khal.dr59@yahoo.com.
Soib Taib is an associate professor at School of Electrical and
Electronic Engineering, Universiti Sains Malaysia.
Email: soibtaib@eng.usm.my.