13

CHAPTER 2

MODELLING AND CONTROL OF BLDC MOTOR

This chapter describes the basic construction and mathematical

modelling of BLDC motor. The working of conventional six switch
commutation circuit is explained. The various modes of operation are also
discussed. The speed performance of the drive in open loop and closed loop
mode with designed PI controller is studied.

2.1 OVERVIEW OF BLDC MOTOR

Conventional DC motors are highly efficient, however, their only

drawback is that they need a mechanical commutator and brushes which are
subject to wear and require frequent maintenance. It is difficult to use DC
machines in hazardous situations as there may be sparking at the brush
surface due to reactance voltage in critical operating conditions like
fluctuating loads and sudden speed reversal. The BLDC motors are permanent
magnet motors where the functions of commutator and brushes are
implemented by solid state switches. The BLDC motors are distinguished not
only by the high efficiency but also due to low maintenance. The six switch
commutation circuit plays the role of mechanical commutator.

A brushless DC motor is simply a normal DC motor turned inside

out. That means that the coil is placed in the stator and permanent magnets on
the rotor. There is no physical contact between the stator and rotor. The stator
consists of several coils in which current is lead through creating a magnetic
field that makes the rotor turn. Three phases are usually used creating six
 14

different ways to let current run through the coils. For the BLDC motor, the
rotating parts are the magnets. This results in the absence of a commutator
and brushes in the BLDC motor, meaning high reliability and longer life time
as there is no erosion of commutator or brushes.

2.1.1 Structure and Block Diagram of BLDC Motor

Figure 2.1 Disassembled view of a brushless DC motor

The construction of modern brushless motors is very similar to the

AC motor, known as the permanent magnet synchronous motor. Figure 2.1
illustrates the structure of a disassembled view of brushless DC motor (Kenjo
& Nagamori 1985). The stator windings are similar to those in a poly phase
AC motor, and the rotor is composed of one or more permanent magnets.
BLDC motors are different from AC synchronous motors in that the former
incorporates some means to detect the rotor position (or magnetic poles) to
produce signals to control the electronic switches as shown in Figure 2.2. The
most common position/pole sensor is the Hall element, but some motors use
optical sensors.
 15

Figure 2.2 Block diagram of brushless DC motor

2.2 CONSTRUCTION OF BLDC MOTOR

2.2.1 Stator

The stator of a BLDC motor consists of stacked steel laminations

with windings placed in the slots and they are axially cut along the inner
periphery. BLDC motors have three stator windings connected in star fashion.
Each of these windings is constructed with numerous coils interconnected to
form a winding. One or more coils are placed in the slots and they are
interconnected to make a winding. These windings are distributed over the
stator periphery to form an even number of poles. There are two types of
stator winding variants as trapezoidal and sinusoidal motors. This
differentiation is made on the basis of the interconnection of coils in the stator
windings to give the different types of back electromotive force. As their
names indicate, the trapezoidal motor gives a back emf in trapezoidal fashion
and the Figure 2.3 shows the stator of a BLDC motor.
 16

Figure 2.3 Stator of a BLDC motor

2.2.2 Rotor

According to the placement of magnets on the rotor,

there are two field versions such as

Radial field: the flux direction is along the radius of the machine.

Axial field: the flux direction is parallel to the rotor shaft.

The radial-field PM machines are common; the axial-field

machines are coming into prominence in a small number of applications
because of their higher power density and acceleration. The magnets can be
placed in many ways on the rotor. The high power density synchronous
machines have surface PM with radial orientation intended generally for low
speed applications, whereas the interior magnet version is intended for high
speed applications. There are four types of magnet mounting method as

1. Surface mount

2. Surface inset mount

3. Interior PM

4. Interior PM with circumferential orientation

 17

(a) Surface mount

(b) Surface inset mount

(c) Interior PM

(d) Interior PM with circumferential orientation

Figure 2.4 Types of rotor construction

 18

The rotor is made of permanent magnets as shown in Figure 2.4

(Kenjo & Nagamori 1985) and can vary from two to eight pole pairs with
alternate North (N) and South (S) poles. Based on the required magnetic field
density in the rotor, the proper magnetic material is chosen to make the rotor.
Because of constant magnetic gap between the stator and rotor, surface
mounted magnets can provide a square flux distribution. Continuous research
is going on to improve the flux density to compress the rotor further.

2.2.2.1 Permanent magnets

Materials that retain magnetism are known as hard magnet

materials. Various materials, such as Alnico-5, ferrites, samarium-cobalt, and
neodymium-boron-iron are available as permanent magnets for use in
machines. Based on the required magnetic field density in the rotor, the
proper magnetic material is chosen to make the rotor. Ferrite magnets are
traditionally used to construct permanent magnets. As the technology
advances, rare earth alloy magnets are gaining popularity. The ferrite magnets
are less expensive, but they have the disadvantages of low flux density for a
given volume.

Alnico PM materials are metallic alloys of aluminium, nickel,

cobalt and iron and are characterized by relatively high residual flux density
Br and low coercive force Hc. The latter’s characteristic is undesirable from
the electrical machine standpoint. Ceramic magnets are the most widely used
used PMs in almost all applications, including rotating machines. They are
characterized by relatively low residual magnetic flux density and relatively
high coercive force. Samarium-cobalt PMs gave an “order-of-magnitude
leap” in energy product over other types of magnets. These magnets have
residual flux densities comparable with those of Alnico magnets and coercive
forces three to five times of those of ceramic magnets and are considered
ideal for electrical machines. Neodymium-Iron –Boron (NDFeB) PM
 19

materials offer the greatest promise with the highest coercive forces available
in commercial magnets and therefore are ideally suited for machine
applications. The residual flux density is relatively high comparable to that of
Alnico and the energy product is the highest.

2.3 POSITION SENSORS

In the BLDC drives, rotor position is essential for the stator phase
commutation and advanced angle control. The rotor position is usually
acquired by the position sensors. The commonly used position sensors are
phototransistors and photodiodes, Hall elements, magnetic sensors, pulse
encoders and variable differential transformers.

2.3.1 Phototransistor Sensors

The phototransistor sensor is based on the photoelectric principle.

Figure 2.5 shows the basic structure of the phototransistor sensor. As shown
in the Figure 2.5, a revolving shutter with a 120° electric angle gap is installed
on the rotor shaft, rotating with the rotor of the BLDC. Phototransistors of the
same number as the motor phases (three phases in the figure) are fixed on the
stator. When the gap is aligned with the phototransistor PT1, the
phototransistor will generate a current due to the light, while phototransistor
PT2 and PT3 have only a very small leakage currents because the light is
blocked by the revolving shutter. In this case, the stator phase associate with
PT1 should be turned on. Similar situation will occur when the gap of
revolving shutter is aligned with PT2 or PT3.
 20

PT1

PT3

PT2

Figure 2.5 Photo transistor sensors

2.3.2 Hall Position Sensors

The function of a Hall sensor is based on the physical principle of the

Hall effect named after E. H. Hall, who discovered this principle. It means that a
voltage is generated transversely to the current flow direction in an electric
conductor (the Hall voltage), if a magnetic field is applied perpendicularly to the
conductor. A typical structure of Hall position sensor for three phase motor is
illustrated in Figure 2.6. It is made up of three Hall components and a rotating
plate with permanent magnet fixed on the rotor shaft. Similar to the gap of the
phototransistor sensors, the permanent magnet on the rotating plate is installed
suitably so that the output of the Hall components can indicate the proper rotor
position for the phase current control.

Figure 2.6 Hall sensors

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2.4 MATHEMATICAL MODELLING OF BLDC MOTOR

The analysis of the system consists of two segments

Analysis of the motor

Analysis of the power inverter

To carry out the analysis, it is necessary to obtain proper model for the
motor and the power inverter. These models are then properly combined to obtain
the full analysis of the system. This model consists of differential equations for the
electrical part, mechanical part and the interconnection between them.

Modelling of a BLDC motor can be developed in the similar manner as

a three phase synchronous machine. Since its rotor is mounted with a permanent
magnet, some dynamic characteristics are different. Flux linkage from the rotor is
dependent upon the magnet. Therefore, saturation of magnetic flux linkage is
typical for this kind of motors. The source is not necessary to be sinusoidal. Square
wave or other wave shape can be applied as long as the peak voltage not exceeded
the maximum voltage limit of the motor.

2.4.1 Assumptions

As the PMBLDC machine has nonlinear model, the linear PI

controller may no longer be suitable . It is assumed to be a linear model for
analysis. The modelling is based on the following assumptions

The stator resistance of all windings are equal.

The self and mutual inductances of all windings are equal.

Rotor reluctance versus electrical angle is equal.

Power semiconductor devices in the inverter are ideal.

The motor is not saturated.

Iron losses are negligible.

 22

2.4.2 Equivalent Circuit

The equivalent circuit of the BLDC motor stator is shown in Figure 2.7.

Figure 2.7 Typical BLDC motor equivalent circuit

For simplification only phase A is taken under consideration during the

modelling of the BLDC motor. The equivalent circuit of the phase A winding of
the BLDC motor is given in Figure 2.8. The terminal voltage Va is taken as Vd.

Figure 2.8 Typical BLDC motor equivalent electrical characteristics

per phase

The phase voltage equation of the BLDC motor is identical to the

armature equation of DC machine. The free body diagram of the rotor is shown in
Figure 2.9.

Figure 2.9 Free body diagram of the rotor

 23

The modelling equations of BLDC motor can be represented in

matrix form as represented in Equation (2.1)

V 1 0 0 i M 0 0 i E
V =R 0 1 0 i + 0 M 0 i + E (2.1)
V 0 0 1 i 0 0 M i E

where Va, Vb, Vc are the terminal voltages

Ea, Eb, Ec are the trapezoidal back emf

ia, ib, ic are the motor input current

R = Ra = Rb = Rc is the terminal resistance

L, M are the equivalent line and mutual inductance of the winding

respectively

The phase current of the BLDC motor can be obtained by using the
following model equations

dia 1
= (Va - Ea -Ria ) (2.2)
dt L-M

dib 1
= (Vb - Eb -Rib ) (2.3)
dt L-M

dic 1
= (Vc - Ec-Ric ) (2.4)
dt L-M

Applying Kirchhoff’s voltage law in the equivalent circuit we get

di
Vd =Ra i+La +E (2.5)
dt
 24

The torque equation for a simple system with inertia J, friction

coefficient B, and load torque TL is

m
T=J +B m+ TL (2.6)
dt

T = Kt i (2.7)

J m B
i= + m (2.8)
Kt dt Kt

Substituting Equation (2.8) in (2.5) we get

La d2 m (Ra J+La B) m (R J+K K )

Vd = J + + a e t m (2.9)
Kt dt Kt dt Kt

Taking Laplace transform we get

m(s) Kt
= (2.10)
Vd (s) La Js2 +(Ra J+La B)s+(Ra B+Ke Kt )

where K , K are the back emf constant and the torque constant respectively.

Let us assume that

i. B tend to zero

ii. Ra J >> L B

iii. K K >> R B

Neglecting the terms L B and R B which is very less than R J and

K K respectively. The Equation (2.10) becomes,

m (s) Kt
= (2.11)
Vd (s) La Js2 +(Ra J)s+(Ke Kt )

The transfer function of the brushless DC motor Gi(s) is given below,

 25

( )
= (2.12)
( )

where = (R J)/( K K ) = /

Substituting the parameters of the BLDC motor under consideration

whose parameters are listed in Table 2.1, in the Equation (2.12), the final
transfer function is obtained.

.
Gi (s) = (2.13)
. .

Table 2.1 BLDC motor ratings and parameters

Motor characteristics Values (units)

Terminal resistance 0.323 ( )
Terminal inductance 0.389 (mH)
Voltage constant 6.99 (V/ k rpm)
Torque constant 6.68( Ncm/A)
Electrical time constant 1.205 (m-s)
Mechanical time constant 10.293 (m-s)
Rotor inertia 0.142e-3 (Kg.m2)
No load speed 3434( rpm)
Speed at rated torque 2641(rpm)
No load current 1.24 (A)
Full load current 7.9(A)
Rated power 123 (W)
Number of poles 8
Number of phases 3

This transfer function is used to design a PI controller for the

BLDC motor.
 26

1 1
V + +

Figure 2.10 Block diagram of BLDC motor model

The transfer function of Equation (2.12) is represented in terms of

back emf constant, mechanical time constant and electrical time constant. The
block diagram representation of the BLDC motor transfer function is shown
in Figure 2.10.

The transfer function of the pulse width modulator is given below.

( )
Gc ( ) = ( )
= (2.14)

The gain value K is determined by using the input voltage and

ramp voltage. In the pulse width modulation technique, the reference signal is
compared with the carrier signal. The carrier signal used here is ramp signal.
The ramp voltage varies in between the maximum V , and minimum
V , signal values.

Where Kc = c =
, ,

Where = Switching frequency

The gain and time delay values can be determined by the above
equations. The overall block diagram for implementing speed control of
BLDC motor including commutation circuit is shown in Figure 2.11.
 27

G (s)
( )
d V

Figure 2.11 BLDC motor closed loop control model

2.5 SPEED CONTROL OF SIX SWITCH INVERTER FED

BLDC MOTOR

The block diagram of the conventional closed loop speed control of

six switch BLDC motor drive is shown in Figure 2.12. It consists of DC
source, six switch inverter, commutation logic circuit, controller and BLDC
motor. The electronic commutation of BLDC motor achieved with power
electronic semiconductor device is called as inverters or commutation circuit.
It supplies power to the stator coils. The inverter has three arms, where each
of three arms has upper and lower part made of power semiconductor
switches.

Hall position DC input supply

Commutation Six Switch BLDC

logic circuit Drive motor

Actual Speed

Error
Controller
calculation

Reference Speed

Figure 2.12 Block diagram of six switch BLDC motor drive

 28

Figure 2.13 shows that each arm of inverter consists of two

switches. There are totally six switches from S1 to S6 which forms the
commutation circuit. The Hall position values decide the switching sequence
of the power semiconductor switches. The output status of Hall sensors
changes for every 60° of rotation thus defining six conduction zones. The
switching of the inverter is arranged to give symmetrical current pulses of
120° duration in both directions through each phase winding of motor.

Figure 2.13 Six switch commutation circuit

Process of switching ON and switching OFF the switches in the

inverter arms is based on the predefined pattern or sequence of the rotor
position information interpreted from back emf waveform. BLDC motor has
three sets of stator coils A, B and C. At any instant, current will flow through
any two out of three stator coils.

2.6 PRINCIPLE OF OPERATION OF SIX SWITCH INVERTER

FOR BLDC MOTOR

The three sets of stator coils A, B and C are shown in switching

sequence diagram. At every instant current passes through any two coils of
stator. The switching sequence with the Hall position values are given in the
Figure 2.14. Consider the stator coil AB pair and assume the switching pattern
as S1, S4. According to Faraday’s electromagnetic law, the magnetic field of
 29

the rotor magnet interacts with induced electro-magnetic field produced by

current carrying stator phase coil and as a result of interaction, torque is
developed. The developed torque will turn the rotor poles to a new direction,
then the rotor poles will face CB pairs of stator coil. When the rotor pole
reaches new position, the inverter switching pattern updates to S5, S4. Then
current will pass through the CB pair of the stator coil. Therefore the
magnetic rotor interacts with the induced electromagnetic field and develops
torque in the same direction.
A

110

010 100
BC AC

BA AB

101
CA CB
011

B 001
C

Figure 2.14 Switching sequence

As a result, the rotor pole advances to a new position. This process

continues as per the rotor position. The switch conducts for only 120° and
hence the switch utilization factor is very less. The conduction sequence of
the switches is S1, S6 – S1, S4 - S5, S4 – S5, S2 - S3, S2 – S3, S6. The rotor
position angle, corresponding Hall sensor values and the switching sequence
are tabulated in Table 2.2.
 30

Table 2.2 Switching sequence for six switch BLDC motor drive

HALL POSITION PHASE A PHASE B PHASE C S1 S2 S3 S4 S5 S6

000 0 0 0 0 0 0 0 0 0
001 -1 0 1 0 0 0 1 1 0
010 0 1 -1 0 1 1 0 0 0
011 -1 1 0 0 1 0 0 1 0
100 1 -1 0 1 0 0 0 0 1
101 0 -1 1 1 0 0 1 0 0
110 1 0 -1 0 0 1 0 0 1
111 0 0 0 0 0 0 0 0 0

2.7 SIMULATION OF SIX SWITCH INVERTER FED BLDC

MOTOR DRIVE

2.7.1 Open Loop Control without PWM

The brushless DC motor is a permanent magnet synchronous

machine supplied from an six switch inverter with the switching on/off of the
inverter determined by the rotor position. A BLDC motor needs quasi current
waveforms, which are synchronized with the back emf to generate constant
output torque and have 120° conduction and 60° non conduction regions.
Also, at every instant only two phases are conducting and the other phase is
inactive. Torque is produced because of the interaction between the magnetic
field generated by the stator coils and permanent magnet. Ideally the peak
torque occurs when these two fields are at 90° to each other and falls off as
the fields move together.
 31

The inverter usually employing any one of the solid-state switching

devices like power transistor, MOSFET and IGBT provides three-phase
voltages to the motor. To get performance characteristics similar to those of
the DC machine, Hall type position sensors have been employed for switching
the inverter. The Hall sensor module produces three phase square pulses with
120° displacement such that the Hall element produces positive polarity
voltage when it is influenced by the north pole and zero voltage under the
influence of the south pole. A controller/sensor decoder circuit generates and
directs triggering pulses to the switching devices of the inverter based on the
Hall sensor voltage levels, which are related to the rotor position with respect
to the stator axes.

The simulation block diagram of the six switch inverter fed BLDC
motor drive in open loop is shown in Figure 2.15. The waveforms such as
Hall sensor output, gate pulse, stator current and speed response are presented
in this section. For simulation, BLDC motor with the parameters shown in
Table 2.1 is used. The gating pulse generation for conventional six switch
BLDC motor drive is designed in such a manner that only two devices
conduct at a time. Based on the signal from the Hall sensor, the switches are
turned ON.
 32

Figure 2.15 Simulation block diagram of six switch BLDC motor drive
in open loop

The gate pulse waveform is shown in Figure 2.16 (a) and the
conduction period of each switch is 120º. Figure 2.16 (b) shows Hall sensor
output. Figure 2.16 (c) shows the stator current waveform. The stator current
obtained is quasi square in nature. Figure 2.17 shows the speed response for
different values of load torque.
 33

(a) Gate pulse

(b) Hall sensor output

(c) Stator current

Figure 2.16 Simulation graphs of six switch BLDC motor drive in open loop
 34

(a) 0% Loading (No-Load) (b) 50% Loading

(c) 75% Loading (d) 100% Loading

(e) Speed torque characteristics in open loop

Figure 2.17 Speed response of six switch BLDC motor drive for
different loading conditions in open loop
 35

Figure 2.17 (e) shows the dropping speed-torque characteristics,

which are plotted with respect to the speed and the load torque. The data used
for plotting this graph is taken from the Figure 2.17 (a) to 2.17 (d). When the
motor is in no load condition, it runs at the rated speed. At the instant when
the motor is loaded, the speed gets reduced. This can be observed clearly from
the above plotted graph. The open loop configuration cannot be employed for
variable load applications. This brings the necessity for closed loop
configuration.

2.7.2 Open Loop Control with PWM

The pulse width modulation technique can be employed in DC link

converter. By employing PWM control to the circuit, the speed can be
controlled over a wide range. The switching frequency used in PWM method
is 2.5 kHz. The simulation block diagram employing PWM method is shown
in Figure 2.18. A DC link capacitor is used as an energy storage element in
the circuit in between input AC rectifier and six switch inverter.

Figure 2.18 Simulation block diagram of AC to DC rectifier fed six

switch BLDC motor drive in open loop with PWM control
 36

In this topology, a high frequency signal is employed for generation

of gating pulses. By varying the modulation index of the circuit, the speed of
the motor can be varied. Figure 2.19 (a) shows the gating pulse generation for
PWM method. Figure 2.19 (b) shows the stator back emf waveforms. The
rectangular current was made to inject into the stator of the motor by PWM
pulse generation. This is shown in Figure 2.19 (c). The speed and the
electromagnetic torque are shown in Figure 2.19 (d). It is obvious from the
Figure 2.19 (e) that the source current in not purely sinusoidal.

(a) Gate pulse generation

(b) Stator back emf

Figure 2.19 (Continued)

 37

(c) Stator current

(d) Speed and torque

(e) Source current

Figure 2.19 (Continued)

 38

(f) FFT Analysis of source current

Figure 2.19 Simulation graphs of six switch BLDC motor drive in open
loop with PWM control

The total harmonic distortion was analyzed for the source current
using FFT tool. From the Figure 2.19(f) it was found to be 41%.

2.7.3 Closed Loop Control with PI Controller

The main objective of closed loop speed control is to maintain the

speed of the motor constant irrespective of load changes. The speed of a motor
generally drops with load. The speed of the motor has to be fed back and
compared with the reference speed continuously. The difference between the
reference speed and the actual speed gives an output that is used as the PWM
reference level. The change in this level modulates the width of the firing pulses to
the inverter switches and hence the inverter power output. Subsequently the motor
pulls up the speed to the set value. Figure 2.20 shows the simulation block diagram
of the BLDC motor drive with PI controller. The main function of the PI controller
is to get the steady state speed as quickly as possible.
 39

Figure 2.20 Simulation block diagram of six switch BLDC motor drive
in closed loop control with PI controller

2.7.3.1 PI controller design

A standard approach for speed control in industrial drives is to use

a proportional plus integral (PI) controller. Although the commonly used PI
control scheme is a conventional one, a PI controller is designed for the
BLDC motor drive for purposes of comparison of the responses of the drive
with different controllers. Tuning a PI controller involves setting the
proportional and integral values to get the best possible control for a particular
process. A proportional controller gain (K will have the effect of reducing
the rise time and will not eliminate the steady-state error. An integral control
gain (K ) will have the effect of eliminating the steady-state error but it may
make the transient response worse. The error signal is sent to the controller
and the controller will perform the proportional and integral computation on
 40

the error signal. The output from the controller is the sum of product of
proportional gain and error signal and product of integral gain and integral of
the error. Figure 2.21 shows the structure of the PI controller.

Proportional

PI Controller
K 1
S
Error Signal
Integral

Figure 2.21 PI controller structure

The commonly used tuning methods are

Trial and Error method

Ziegler Nichols method

Improved Ziegler Nichols method

Cohen – Coon method

Genetic Algorithm

2.7.3.2 Ziegler Nichols tuning

Ziegler Nichols empirical tuning method was proposed by Ziegler

and Nichols in the year 1942. The Ziegler Nichols method is used for
determining the values of proportional gain and integral gain based on the
response characteristics of the respective system. The formulae for calculating
the gain values are listed in Table 2.3.
 41

Table 2.3 Ziegler Nichols tuning equations for PI controller

From step response

Controller type

T L
PI 0.9 0
L 0.3

The steps involved in tuning are

Step 1: Determine the transfer function.

Step 2: Obtain step response of the system in .mat file format.

Step 3: The .mat file is imported to the m-file.

Step 4: Run .mat and .m file sequentially.

Step 5: Draw tangent line to the step response at its point of inflections
(both in horizontal and vertical axis) as shown in Figure 2.22.

Step 6: Obtain the delay time (L) and time constant (T).

Step 7: Based on the L and T values, determine K and Ti ,Td.

Figure 2.22 Ziegler–Nichols step response tuning (S-curve)

 42

2.7.3.3 Tuning of PI controller using MATLAB

Using the transfer function of the BLDC motor, obtain the step
response and save in the form of .mat file. During execution the .mat file will
be automatically loaded in the m-file. The simulink arrangement to determine
step response is shown in Figure 2.23.

Figure 2.23 Determination of step response in simulink

Let T* be the horizontal trace of the intersection. From the

Figure 2.22 delay time (L) and time constant (T) are computed. From the plot,
it is noted that point of intersection of the two lines results in T* and K and its
values are 27.3939×10-4 and 0.1482 respectively.

Substituting the values of T and L in K equation we get,

Ti = = =
.

Kp = 0.450196

Ti = 6.089 × 10 s

Figure 2.24 shows the block diagram of PI controller tuning in

MATALB tool box.
 43

Figure 2.24 Closed loop six switch BLDC motor block diagram with PI
controller

PI controllers may be tuned in a variety of ways, including hand

tuning, Ziegler Nichol’s tuning, loop shaping, analytical methods, by
optimization, pole placement or auto tuning. PI controller was tuned based on
the mathematical model. The controller in this work was tuned with automatic
tuning tool in MATLAB. The PI controller was tuned to obtain steady state
error within 1% and rise time less than 1 second. The controller works based
on the speed error. At the beginning there is a big system error, therefore a big
control action is desired in order to achieve a fast rise time. To produce a big
control signal, the PI controller should have a large proportional gain and a
large integral gain. Along with the decreasing of system error gradually, the
control action should go to a steady state.

2.7.3.4 Determination of response with PI controller

The response of the system determines the performance parameters

of the system. The response of the system should be determined both in time
domain and in the frequency domain. The parameters to be determined are
described in Table 2.4.
 44

Table 2.4 Performance parameters

TIME DOMAIN
Time required for the response to reach 10% to 90% of the
Rise time
final value
Peak time Time required for the response to reach peak of the first
overshoot
Maximum peak value of the response curve measured from
Maximum overshoot
unity
Time required for the response curve to stay within the
Settling time
tolerance band
Difference between the desired and actual output as time
Steady state error
tends to infinity
FREQUENCY DOMAIN
Gain margin Magnitude in decibels at phase cross over frequency
Phase margin Phase angle at gain cross over frequency

While designing the controller, the time domain specifications like

rise time, settling time, peak overshoot and steady state error must be
minimum. The peak time depends on peak overshoot. Peak time should also
be minimum.

Using the gain values obtained from the Ziegler–Nichols tuning

method the reponse of the PI controller is obtained as shown in Figure 2.25.
From the response curve of the PI controller, the values of rise time, settling
time, over shoots can be determined. The frequency domain parameters can
be determined by using bode plot. Figure 2.26 (a) shows the phase margin
determination for the proposed closed loop system, the value observed from
that plot is 60° at 197 rad/s. The determination of gain margin using bode plot
is shown in Figure 2.26(b). The magnitude at the gain cross over frequency is
24.1db at 1.27e+3 rad/s.
 45

Figure 2.25 Response of the closed loop system with PI controller

(a) Determination of phase margin

Figure 2.26 (Continued)

 46

(b) Determination of gain margin

Figure 2.26 Bode plot of the closed loop system

The values obtained from the tuning of the PI controller are

tabulated in Table 2.5. From the table, it is observed that the rise time, settling
time and over shoot values are well within the limit.

Table 2.5 Performance parameters values with designed PI controller

Proportional gain 0.450962

Integral gain 73.95104
Rise time (s) 0.00634
Settling time (s) 0.0253
Over shoots (%) 9.7
Gain margin(db @ rad/s) 24.1@1.27e+3
Phase margin (deg @ rad/s) 60 @ 197
Closed loop stability stable
 47

(a) Gate pulse

(b) Hall Sensor output

Figure 2.27 (Continued)

 48

(c) Stator current

Figure 2.27 Simulation graphs of six switch BLDC motor drive in closed
loop

Figure 2.27 (a) shows gate pulses generated for inverter switches.
Figure 2.27 (b) shows Hall sensor signal. Figure 2.27 (c) shows stator current
waveform.

Figure 2.28 shows the closed loop speed response for different
values of reference speed at rated torque condition at different times. The
designed controller is tracking different reference speed even at full load
condition.
 49

Figure 2.28 Closed loop transient speed response of six switch BLDC
motor with PI controller for different reference speeds at
rated load condition

Initially, the reference speed of the drive is set at 50% of the rated
speed. At 0.5 s, the reference speed is increased to 75% of the rated speed and
during the time interval 0.75 s to1.25 s, the rated speed is set as the reference
speed. Once again, the reference speed is changed to 75% of the rated speed
and 50% of the rated speed at 1.25 s and 1.5 s respectively. The waveform
reveals that the closed loop system brings the actual speed to the reference
speed and has better tracking capability.

Figure 2.29 shows the closed loop speed response with PI

controller for different values of load at rated speed condition. The motor runs
at rated speed of 3434 rpm even when the load is changed during running
condition. Initially, the drive was set to run at no load condition from 0 s to
0.25 s. During the time interval 0.25 s to 0.5 s the load was increased to 50%
 50

of its rated value. Later during 0.5 s to 0.75 s, the load was further increased
to 75% of its rated value. Finally, full load was applied between the time
interval 0.75 s to 1 s. The response reveals that the closed loop system runs at
the rated speed irrespective of changes in the load disturbances.

Figure 2.29 Closed loop speed response of six switch BLDC motor drive
with PI controller for different load at rated speed condition

According to simulation results, it can be seen that whether

working at low speed and under light load or rated speed under rated load, the
motor performs satisfactorily.

Figure 2.30 shows the closed loop speed response with PI

controller for 120% load at rated speed condition. The drive runs at rated
speed of 3434 rpm and reaches steady state value. The response reveals that
during overload condition also the designed PI controller performance is
satisfactory.
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Figure 2.30 Closed loop speed response of six switch BLDC motor drive
with PI controller for 120% load at rated speed condition

2.8 SUMMARY

In this chapter, mathematical modelling of BLDC motor is

presented. The performance of six switch BLDC motor drive in open loop
control without PWM and with PWM method is discussed. Closed loop speed
control was implemented by a PI controller. Speed variation has been
obtained upto rated speed on no load and load. The closed loop speed control
scheme has been verified for set speed changes and load torque. The scheme
developed is found to be satisfactory.