AMPLIFIER AND

CONTROLLER DESIGN
FOR
BRUSHLESS DC (BLDC)
MOTOR
Submitted by-: Submitted to-:
ANUJ SAINI Mr. Pushkar Praveen
190109
Assistant Professor
Electronics and Communication Engineering(ECE)
Electronics and Communication
4th Year Engineering(ECE)
Govind Ballabh Pant Institute of Govind Ballabh Pant Institute of
Engineering and Technology (GBPIET), Pauri,
Engineering and Technology (GBPIET), Pauri,
Uttarakhand.
Uttarakhand.
 CONTENTS
 Introduction
 Different types of Motor
 Difference between Brushed and Brushless DC Motor
 Brushless DC Motor Control System Design
 Microcontroller Unit (MCU)
 3-Phase Amplifier
 Brushless DC Motor
 Schematic Diagram
 Algorithm Used
 Conclusion
 INTRODUCTION
 MOTORS
 A motor converts supplied electrical energy into mechanical energy. Motors
also acts as Power Delivery Machines.
 Various types of DC and AC motors are in common use.

Different Types of Motors

Different Types of Motors
 BRUSHED DC MOTOR
 It is the simplest type of motor.
 Electrical current is passed through coils which
generates magnetic field in coil and coils tends to rotate.
 Rotation of commutator ensures reversal of current
and hence the rightward rotation of coil is ensured.
 Fixed conductive brushes supply electric energy to the
rotating commutator.
 One drawback, is that brushes and commutators tend
to wear quickly requiring frequent replacement and
periodic maintenance.
 The commutator and brushes are the key components distinguishing the
brushed DC motor from other motor types.
 BRUSHLESS DC (BLDC) MOTOR
 It is a synchronous motor which uses direct current (DC) electric power supply and
does not has brushes alike brushed dc motor.
 It uses an electronic controller to switch DC currents to the motor windings which
produces magnetic fields and to which permanent magnet motor follows.
 The controller adjusts the phase and amplitude of the DC current pulses to control
the speed and torque of the motor.
 The basic working principle for the brushed DC motor
and for brushless DC motor are same i.e. internal shaft
position feedback.
 Advantages-:
 Can be controlled using feedback mechanism.
 As brushes are absent, it makes motor more reliable,
efficient, free from mechanical losses and high life.
 Disadvantages-:
 Cost and complexity is more than brushed DC motor.
Difference b/w Brushed and
Brushless
DC Motor Brushed motor Brushless motor

Lifetime Short (brushes wear out) Long (no brushes to wear)

Speed and Acceleration Medium High

Efficiency Medium High

Electrical Noise Noisy (bush arcing) Quiet

Acoustic Noise & Torque Poor Medium (trapezoidal) or good

Ripple (sine)

Cost Lowest Medium (added electronics)

 Brushless DC Motor Control
System Design
 The primary disadvantage of BLDC motors, as opposed to brushed DC motors, is the
added complexity of controlling the electronic commutation system and the associate
cost that comes with it.
 This electrical commutation sequence requires accompanying hardware, and a motor
control algorithm as shown in figure.

 Figure 2.1 simplifies the block diagram to the three core components of the motor
control system, along with the motor, as well as the key inputs and outputs from
each component.
 MICROCONTOLLER UNIT (MCU)
 The microcontroller functions as the central processing element of the motor
control system.

 The MCU processes key control inputs, including the desired motor speed and
position feedback from the motor in the form of sensored feedback, and
outputs control signals to the 3-phase amplifier controlling the rotation speed
and direction of the motor.

 It is responsible for the processing of the motor control algorithm and

producing PWM pulses that control the motor.

 In this project, C8051F120 Microcontroller is used for all the functions.

 The basic and simplified block diagram of C8051F120 with circuitry used in
this project is shown in figure 2.4.
 Working of MCU
 UART0-: It provides serial communication between the microcontroller unit and
user using RS232.
 EXTERNAL OSCILLATOR -: It is used to produce the carrier frequency which is
entered by the user for the TIMER0 using set of instructions/algorithm.
 TIMER0 -: It is a 16-bit counter/timers. It is configured as pre-scaled to take the
carrier frequency as the clock signal (generally high carrier frequency is used,
more than 20KHz) using UART0 port to interact with user using programming.
When TIMER0 overflows, interrupt occurs and control goes to the Interrupt Service
Routine (ISR) which takes the program to the PCA.
 PCA (PROGRAMMABLE COUNTER ARRAY) -: It is a kind of a Timer/counter but a
specialized one. It contains 16-bit counter/timer and six 16-bit capture/compare
modules. When timer overflows, interrupt occurs and control goes to the Interrupt
Service Routine (ISR).This works using capture, compare and reload technique to
produce the PWM pulses and make these signal available at its own 6 modules
(CEX0-CEX5) which is further applied to the GATE of the 6 MOSFET in 3-phase
amplifier.
 ADC-: The hall sensors used in BLDC motor detects the position of the rotor and
produce the voltage values which are in Analog form and these analog voltage
values are feedbacked to the MCU. For this purpose, to convert the analog
voltage values to the digital, ADC is used in MCU.

It has 2.5MHz conversion speed i.e, 40 micro sec.

 After producing PWM pulses with the help of MCU of desired duty cycle, PWM pulses is
then applied to the gate of MOSFET’s in 3-phase amplifier.
 3-PHASE AMPLIFIER
 The 3-Phase amplifier circuit is a circuit
based around metal oxide semiconductor
field effect transistors (MOSFET)
designed in 3-full bridges to serve as a
series of switches for each phase of the
BLDC motor which is at 120˚ phase
difference with each other.

 In a three-phase BLDC motor control

system, six MOSFET’s are used to control
both the high and low side of each phase.

 By changing the duty cycle of the PWM

pulses, the speed and torque of the motor
can be varied.
 The main aim of the 3-phase amplifier is to
produce 3 sinusoidal waves with phase
difference of 120˚ to each other using full
bridges to give 120˚ phase difference to the
BLDC motor windings.
 The working principle The Pulse wave
(PW) is applied at point 1, 2.

During ON time of PWM pulses, both

MOSFET’s become ON and draws high
current and gives amplified voltage or
current to the BLDC motor windings
through point A.

On other hand, during OFF time of PWM

pulses, both MOSFET’s remain in OFF
condition drawing almost no current and
hence negligible amount of
voltage or current is transferred to the
BLDC motor windings.
 COMPONENT RATING-: In this project, 12V
of power supply (VCC) is used. In this
project, MOSFET which is rated for a
maximum of 60 V of drain-source voltage
and 120 A of drain current is used which is
suitable for 24V Motor control.
 PWM pulses is commuted to the sinusoidal
type with increased amplitude as shown in
figure 2.3 and this sinusoidal signal is
applied to the respective windings giving
120˚ phase shift between phase A, B, and
C.
 Brushless DC (BLDC) MOTOR
 Brushless dc motors are electronically commutated
motors, which are powered using ac electric current
and switching pulses from an amplifier through a
closed loop controller.
 For controlling the speed and torque of the BLDC
motor, controller provides current pulses to the
motor windings.
 Brushless motors are more efficient than brushed
motors when converting electricity into mechanical
power.
 The basic block diagram is shown in figure. In the
diagram, it is shown that it has a fixed stator,
moving rotor with permanent magnet (6 poles
magnet is used in this project), 3 windings namely
A, B, C and three hall sensors (U, V, W).
 In this project, 24V NEMA 17 42MM high speed
brushless DC motor is used
 TYPE OF COMMUTATION
 While brushed DC motors are self-commutating, BLDC motors require a
motor control algorithm, processed by the MCU, to determine the timing
and level of current supplied to each of the phases in the motor.
 In this project, SINUSOIDAL COMMUTATION is used.
 Sinusoidal Commutation directs current in the form of a sinewave through
all three phases of the motor, which is sinusoidally synchronized by the 3-
phase amplifier. Each sinewave has 120˚phase shift from each other.
 HALL SENSORS
 It is used to identify the rotor position which is feedbacked to the MCU for
speed or direction control.
 Hall effect sensors are sensing switches that produce logic level, based on the
detected magnetic field.
 These Hall sensors are distributed equally around the stator (120° apart) in a
way that its output can generate six different combinations in one electrical
cycle, which changes for every 60° of movement.
 These combinations can be translated into a number from one to six, which
are represented by three binary digits.
 Working of BLDC Motor
 MCU produces PWM pulses through its circuitry as explained earlier and is
applied to the gate of six MOSFET’s in 3- phase amplifier.
 In 3-phase amplifier, PWM pulses is applied to the bridge circuits and three
sinusoidal signals are generated which are 120˚ phase shifted from each
other.
 The output of 3-phase amplifier (3 sinusoidal signals) is applied to the
windings of the BLDC motor respectively at winding A, winding B and
winding C.
 Accordingly the rotor of BLDC motor starts moving in a particular direction
and at particular speed which is all controlled by the MCU and program
which is used to run the BLDC motor after taking inputs from user.
 Its speed and direction is controlled after reading the hall sensors value
which is feedbacked to the MCU.
SCHEMATIC
DIAGRAM
ALGORITHM USED
 CONCLUSION

 The 3-phase amplifier for the BLDC motor has been studied.

 The algorithm for closed loop control of BLDC motor using

microcontroller is designed and is used to generate PWM pulses to
drive the MOSFET’s of three phase fully controlled bridge amplifier.

 Output of amplifier is fed to the windings of the BLDC motor.

 By using the PWM technique speed and position of the BLDC motor
was controlled and it was made to run at exactly entered speed
THANK YOU