DEVELOPMENT OF BLDC MOTOR FOR AUTOMOTIVE ENGINE

COOLING FAN
1
DIVYA.B 2 C. GOVINDARAJU
1
PG Scholar , Government College of Engineering, Salem
E-mail : 1divyabalaji1306@gmail.com
2
Associate Professor, Government College of Engineering, Salem
2
E-mail : @gcesalem.edu.in
ABSTRACT:
This paper presents a comprehensive review of Brushless DC (BLDC) motor control techniques and
their applications in the automotive industry. BLDC motors characterized by their efficiency, reliability,
and low maintenance requirements, have become increasingly prominent in automotive applications such
as electric vehicles (EVs), hybrid electric vehicles (HEVs), and various auxiliary systems. This paper
outlines the fundamental principles of BLDC motor operation, including the electronic commutation
process and the role of sensors. It explores various control strategies, such as Hall sensing control, field-
oriented control (FOC), current controller. The discussion includes practical challenges in automotive
applications, such as thermal management, noise reduction, and the integration of BLDC motors into
complex automotive systems. Through this review, the paper aims to provide insights into the current state
of BLDC motor control technology and its critical role in advancing modern automotive domain.

1.INTRODUCTION:
DC motors have been widely used for speed or position control applications because of their control
simplicity when compared with alternating current (AC) motors. However, since they require periodic
maintenance of brushes and commutators, their utilization has been reduced in many motor drive
applications, which require continuous running and enhanced system reliability.
To overcome this problem of DC motors, a motor called Brushless direct current motor was developed.
This motor has similar electrical characteristics to a DC motor, but it has an enhanced reliability by
replacing mechanical commutation with electronic commutation. To implement the electronic
commutation, BLDC motors use sensors and driving circuits. The sensors detect the position of magnets on
the rotor. By using the detected magnet position, the driving circuits excite a specific winding for
continuous rotation.
In BLDC motors, to eliminate the brushes of DC motors, the armature windings are placed on the stator
side and the magnets are placed on the rotor side. As a result, BLDC motors have a different configuration
from that of DC motors. Since there is a degree of freedom in the motor configuration when designing to
eliminate brushes, various BLDC motor designs to fit a wide application needs such as a smaller or thinner
configuration are possible. The BLDC motors have many merits such as high efficiency, high-power
density, high torque-to-inertia ratio, high-speed operation capability, simple drive method, and low cost.
Thus, nowadays, they are widely used for cost-effective solution in many small and medium motor drive
applications such as home applications, industrial, office products and light vehicles.

2.1 BLDC MOTOR FOR AUTOMOTIVE APPLICATION:

A brushless DC motor, is an advanced type of electric motor that operates using a direct current power
source. Unlike traditional brushed DC motors, which rely on brushes and commutators to transfer electrical
power to the rotor, brushless DC motors utilize a different mechanism for generating motion.
At the heart of a brushless DC motor is its construction, which eliminates the need for brushes and
commutators. Instead, BLDC motors feature a more complex internal structure that includes permanent magnets
on the rotor and a series of electromagnets on the stator. These electromagnets are energized in a specific
sequence by an electronic controller, which determines the direction and speed of the motor’s rotation.
One of the primary advantages of brushless DC motor is their efficiency. Because they lack the friction
and wear associated with brushes and commutators, BLDC motors experience less energy loss and heat
generation during operation. This results in higher overall efficiency, making brushless DC motors ideal for
applications where energy conservation is important.
Additionally, the absence of brushes and commutators in brushless DC motors leads to improved
reliability and longevity. Traditional brushed DC motors require periodic maintenance to replace worn brushes
and commutators, whereas BLDC motors have fewer moving parts and therefore experience less wear and tear
over time.
The electronic control system used in brushless DC motors also provides greater flexibility and
precision in motor control. By adjusting the timing and intensity of the current supplied to the stator windings,
the electronic controller can precisely regulate the motor’s speed and torque, making brushless DC motors
suitable for a wide range of applications with varying performance requirements.
Overall, brushless DC motors offer a compelling combination of efficiency, reliability, and
controllability, making them a popular choice for numerous applications across industries such as automotive,
aerospace, robotics, and consumer electronics. Their advanced design and performance characteristics make
brushless DC motors well-suited for demanding tasks where precision, reliability, and efficiency are paramount.

Fig.2.1 BLDC motor

2.2 AUTOMOTIVE APPLICATION

The integration of BLDC motors using the control techniques has transformed automotive engineering,
supporting the industry’s shift towards more sustainable and efficient transportation solutions. In electric
vehicles (EV) and hybrid electric vehicles (HEV), advanced control methods like FOC enable superior
performance, energy efficiency, and driving comfort. Hall sensing and current control techniques are pivotal in
auxiliary systems, enhancing functionality and reliability.

2.3 BLDC MOTOR IN AUTOMOTIVES

BLDC motors are increasingly used in automotive applications due to their efficiency, realibility,
and ability to provide precise control.
 Electric Power Steering : BLDC motors provide the required torque and responsiveness for power
steering systems, improving vehicle handling and fuel efficiency compared to hydraulic systems.

Fig.2.2 Power Steering

  Electric and Hybrid Vehicle Drivetrains : BLDC motors are commonly used in the propulsion
systems of electric vehicles and Hybrid electric vehicles due to their high efficiency, reliability, and
excellent torque characteristics.
 Cooling Fans: Used in engine cooling and HVAC systems, BLDC motors offer quiet operation and
efficient performance, contributing to better thermal management and passenger comfort.

Fig.2.3 Cooling Fans

 Fuel and water Pumps: BLDC motors drive fuel pumps and water pumps in modern vehicles,
offering precise control and reduced energy consumption.
 Window Regulators and Seat Adjustments: They are also used in electric window regulators and
seat adjustment mechanisms, providing smooth and reliable operation.
 Electric Parking Brake: BLDC motors are used in EPB systems to automatically engage and
release the parking brake, improving safety and convenience.
 Actuators: Various actuators, such as those for throttle control, turbochargers, and exhaust gas
recirculation valves, utilize BLDC motors for precise and reliable operation.

3. CONTROL TECHNIQUES OF BLDC MOTOR

BLDC motors are commonly controlled using several techniques:
 Trapezoidal Control : This method is based on powering the motor phases in a sequence that
creates a trapezoidal back EMF waveform. It involves using six-step commutation, where the current
is supplied to two phases at a time in a predetermined sequence. Hall effect sensors are commonly
used for rotor position detection in trapezoidal control.
 Sinusoidal Control : Sinusoidal control aims to approximate a sinusoidal back EMF waveform for
smoother operation and reduced torque ripple. It requires more complex algorithms to calculate the
required current vectors for each phase, usually using Park and Clarke transformations. Sinusoidal
control often leads to higher efficiency and quieter operation compared to trapezoidal control.
 Field Oriented Control : FOC decouples the control of torque and flux, allowing for independent
control of these parameters. It involves transforming the stator currents from the stationary frame to
a rotating frame to simplify control. FOC requires precise knowledge of the rotor position, often
obtained using encoders or sensorless techniques.
 Direct Torque Control : DTC directly controls the torque and flux of the motor without requiring
transformation to a synchronous reference frame. It operates by selecting the optimal voltage vector
based on the error between the actual and desired torque and flux. DTC offers fast dynamic response
and good robustness to parameter variations.
 Sensorless Control: Sensorless control techniques estimate the rotor position without the need for
Hall effect sensors or encoders. Methods include back EMF integration, observer-based techniques,
and sensorless FOC. Sensorless control reduces cost and complexity but may be less accurate at low
speeds or under dynamic conditions.
4. BLDC MOTOR DRIVE

The electronic controller circuit energizes appropriate motor winding by turning transistor or other solid
state switches to rotate the motor continuously. The figure below shows the simple BLDC motor drive which
consists of MOSFET bridge, electronic controller, hall effect sensor and BLDC motor.

Fig.4.1 Circuit Diagram of BLDC motor drive

Hall-effect sensors are used for position and speed feedback. The electronic controller can be a
microcontroller unit or microprocessor or DSP processor or FGPA unit or any other controller. This controller
receives these signals, processes them and sends the control signals to the MOSFET driver circuit.
In addition to the switching for a rated speed of the motor, additional electronic circuitry changes the
motor speed based on required application. These speed control units are generally implemented with PID
controllers to have precise control. It is also possible to produce four-quadrant operation from the motor whilst
maintaining good efficiency throughout the speed variations using modern drives.

Fig.4.2 BLDC motor with Hall sensors

4.1 HALL SENSING

Hall sensing is crucial technique used in Brushless DC motors for detecting the rotor position. This
information is vital for the precise control of the motor’s commutation.
BLDC motors typically use three Hall sensors embedded in the stator. These sensors are strategically
placed to detect the magnetic field of the rotor magnets. As the rotor turns, the magnetic poles pass by the Hall
sensors, which then produce a digital signal corresponding to the north or south pole of the rotor magnet.
The signals from the Hall sensors provide the electronic controller with the precise position of the
rotor. This positional information is critical for timing the switching of the transistors in the inverter circuit that
drives the motor. Accurate rotor position data ensures that the correct stator windings are energized to produce a
rotating magnetic field, which in turn drives the rotor efficiently.
Commutation in BLDC motors is the process of switching the current in the motor windings to
generate a continuous rotational motion. Based on the signals from the Hall sensors, the controller determines
which winding to energize to keep the motor running smoothly. Each combination of Hall sensor states
corresponds to a specific rotor position and commutation sequence.
4.2 MODELLING OF BLDC MOTOR

The Simulink model of BLDC motor with Hall sensor shown in figure 4.1 is done in MATLAB 2021A
version with ode45 solver. The discrete powergui with time constant of 1e-7 is used to run the simulation and
visualize the results. From the Simulink model the duty cycle has been obtained by sensing the hall signal from
the motor and decoded. The rotor speed has been sensed and compared with the reference value and given to
the PID controller. By performing the and operation of the above two feedbacks the gate signals have been
given the driver to excite any two windings of the stator.

Fig.4.1 Simulink model of BLDC motor with hall sensing

The table 4.1 portrays the results obtained from simulating the model of BLDC motor with the hall sensing .
The stator current , rotor speed and torque has been tabulated. The results has been analysed by verifying the
display and scope data.

Table.4.1 Parameters of BLDC motor with hall sensing

S.No Parameters Values

1 Stator current 4.627 A
2 Rotor speed 337.9 rad/sec
3 Rotor speed 3227 rpm
4 Electromagnetic torque 1.144 Nm
5 DC voltage 500V

The PWM Signals given to the driver of the BLDC motor to excite the windings appropriately. The PWM
signals magnitude ranges between 0 to 1. The turn on and turn off time periods are estimated by comparing the
feed back signals of rotor speed and hall signals.

The figure 4.2 showcases the resulting waveforms obtained from the simulation, the stator current indicates
which two windings has been excited and its value is around 4.627 A. The rotor rotates around 3227 rpm. The
electromagnetic torque obtained around 1.144 Nm.
 Fig.4.2 Stator current a , Stator current b, Rotor speed, Electromagnetic torque of BLDC motor –Hall sensing

The figure 4.3 portrays the Inverter output voltage, the voltage obtained across the three phase inverter in
120֯ conduction mode as the driver. In driver circuitry for every 60֯ two windings has been excited in cyclic
manner and the signals are used to rotate the rotor.

Fig.4.3 Inverter output voltage

4.3 APPLICATION
Hall sensors are easy to integrate and provide consistent performance under standard operating
condition However they may lack the precision required for high-speed or dynamically demanding
applications due to potential inaccuracies in position sensing and the limitations of discrete sensor
placement.
 Despite these limitations, Hall sensing is widely used in automotive applications such as fuel pumps,
cooling fans, and electric power steering systems, where the balance between cost-effectiveness and
sufficient performance is crucial. The methods straightforward implementation ensures dependable
operation with minimal maintenance requirements, contributing to overall vehicle reliability.

5 FIELD ORIENTED CONTROL

Field –Oriented Control also known as vector control, is an advanced method used for controlling
Brushless DC motors. It provides precise control over both the speed and torque by controlling the motor’s
magnetic field.
FOC aims to decouple the motor’s torque and flux control, allowing for independent control of the
magnetic field and torque-producing current. This decoupling is achieved by transforming the three-phase motor
currents into a two-axis coordinate system, which simplifies the control of the motor.
5.1 d-q TRANSFORMATIONS
The figure 5.1 showcases the transformation equations to convert from one transformation form to the
other transformation form.

Fig.5.1 Transformations
5.2 IMPLEMENTATION STEPS
 Current sensing : Measure the three –phase stator currents ( I a , I b , I c,)
 Clarke Transformation: Convert the three-phase currents into two-phase ( I α , I β )
 Park Transformation: Convert the two-phase stationary frame currents to d-q frame currents.
 PI Controllers: Use Proportional-Integral (PI) controllers to regulate I d and I q according to the
desired torque and flux.
 Inverse Park Transformation: Convert the controlled d-q currents back to two-phase currents.
 Inverse Clarke Transformation: Convert the two-phase currents back to three-phase currents (
I a , I b , I c,).

5.3 MODELLING OF BLDC MOTOR WITH FOC CONTROL

In figure 5.2 modelling of BLDC motor with Field oriented control has been done in Plex sim platform.
In this control the currents from the driver has been sensed and underwent Clarke transformation. In Clarke
transformation the currents I a , I b , I c are converted into I ds , I qs currents in stationary reference frame domain.
In Park transformation the I ds , I qs are converted into I de , I qe currents in rotational reference frame domain. In
inverse park transformation again the currents in rotational reference frame I de , I qe are converted into stationary
reference frame I ds , I qs. In inverse Clarke transformation the currents in stationary reference frame I ds , I qs are
again converted into three phase currents I a , I b , I c .

Fig.5.2 Simulink moddel of BLDC motor with Field Oriented controller

In table 5.1 the parameters such as stator current, rotor speed, back emf and electromagnetic torque are
tabulated by simulating the circuit with dc voltage of 500 V.

Table.5.1 Parameters of BLDC motor with Field Oriented controller

S.No Parameters Values

1 Stator current 5.0860 A
2 Rotor speed 448.207rad/sec
3 Back emf 179.373 V
4 Electromagnetic torque 4.0736 Nm
5 DC voltage 500V

In figure 5.3 the waveforms of the simulation parameters are obtained from the scope data. The stator
current of 5.0860 A , Back emf of 179.373 V, rotor speed of 448.20 rad/sec and electromagnetic torque of
4.0736 Nm are obtained from simulation results.
 Fig.5.3 Stator currents , Back emf , Rotor speed, Electromagnetic torque of BLDC motor –FOC

The figure 5.4 portrays the Clarke transformation, Park transformation, Inverse Park transformation and
Inverse Clarke transformation results.

Fig.5.4 Transformations
5.4 FIELD ORIENTED CONTROL
Field Oriented control is a sophisticated technique that optimizes the control of BLDC motors by
aligning the motor’s magnetic field with the stator current vector. This alignment maximizes torque
production and efficiency, allowing for precise and smooth motor operation across a wide range of speeds
and loads. FOC’s ability to decouple torque and flux control provides superior performance, making it
highly effective for high-demand applications such as electric vehicles and hybrid electric vehicles.
FOC requires advanced control algorithms and powerful processing capabilities, typically
implemented using DSPs or high performance microcontrollers. This complexity translates to higher
system costs and increased development effort, but the resulting benefits in performance and efficiency
often justify these investments. In automotive applications, FOC enables refined motor control,
contribution to smoother acceleration, improved energy efficiency, and enhanced driving experience in
EVs and HEVs

6. MODELLING OF BLDC MOTOR WITH CURRENT CONTROLLER

In figure 4.8 the model of BLDC motor with current controller has been simulated in Plex Sim platform.
The pulses for the driver has been obtained by comparing the three phase current with the reference current. The
theta value has been obtained from the feedback of angle sensor.

Fig.6.1 Simulink model of BLDC motor with current controller

The table 6.1 tabulate the simulation parameters such as stator current , rotor speed, back emf,
electromagnetic torque obtained by simulating the simulation with a dc voltage of 500v.

Table.6.1 Parameters of BLDC motor with current controller

S.No Parameters Values

1 Stator current 5.0860 A
2 Rotor speed 448.207rad/sec
3 Back emf 179.373 V
4 Electromagnetic torque 4.0736 Nm
5 DC voltage 500V

The figure 6.2 depicts the results obtained from simulating the above circuit and from analysing the
waveform its has obtained that stator current of 5.086 A and rotor speed of 448.207 rad/sec , Back emf of
179.373 V and Electromagnetic torque of 4.0736 Nm.
 Fig.6.2 Stator currents , Back emf, Rotor speed, Electromagnetic torque of BLDC motor –Current controller

6.1 CURRENT CONTROL

Current control techniques, including direct torque control, focus on maintaining precise control over
the motor’s current to regulate torque and speed. These methods offer a balance between performance and
complexity, providing rapid response to dynamic load changes and ensuring smooth operation. Current
control strategies are essential for applications requiring stringent control over motor performance, such as
advanced driver assistance systems, braking systems, and active suspension systems.

7. CONCLUSION

As can be seen in the above section, BLDC motor can be easily operated by a proper commutation of phase
currents based on the information of the rotor position. BLDC motors do not have the crucial weakness of DC
motors because the function of brushes and commutators is replaced with semiconductor switches operating
based on the information from the rotor position. Compared to the heavy rotor of DC motors consisting of many
conductors, BLDC motors have a low inertia rotor. Thus BLDC motors can provide a rapid speed response.
Moreover, windings placed on the stator side can easily dissipate heat, allowing BLDC motors to have a better
attainable peak torque capability. In addition , BLDC motors can operate at a higher speed because of
nonmechanical commutation devices.

In the automotive industry, the integration of BLDC motors using these control techniques leads to
enhanced vehicle performance, improved fuel efficiency and reduced emissions. They are pivotal in applications
ranging from main traction drives in EVs to auxiliary functions such as power steering, air conditioning, and
advanced driver assistance systems.
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