Design and implementation methodology for rapid control prototyping of closed loop speed control for BLDC motor
Abstract：
This paper deals with rapid control prototyping implementation of closed loop speed control for a Brushless dc (BLDC) motor drive using dSPACE DS1103 controller board. Generally control algorithms which are developed for the motor drive might show good simulation results during steady state and transient conditions; however real-time performance of the drive greatly depends on execution of real time control software, speed and position measurements and data acquisition. The real challenge of hardware implementation lies in selecting appropriate hardware equipment and perfect configuration of the equipment with controller board.The dSPACE DS1103 controller board is suitable for high performance electric motor control as it has flexibility of converting the MATLAB/Simulink blocks into DSP enabled embedded code. In this paper a detailed procedure to effectively control the BLDC motor drive in real-time is presented.
1.Introduction
Electrical drives are important mechanical energy source component in all industrial, commercial and residential applications such as pumps, fans, mills, conveyer belts, elevators, riders, compressors, packaging equipment and many others (Bose, 2005; Hughes, 2013). These systems consume approximately 35% of generated electrical power throughout the world. Hence demand for energy efficient, less maintenance, good speed range, less noisy, high power,higher torque density and cost effective electric motor drives are emerging in the market (Bose, 2005; Gim, 1995; Jayaram,2009; de Almeida et al., 2014; Bist et al., 2014; Bist and Singh, 2013). Since 1970’s,the brushless DC (BLDC) motor has been used in different applications, for example, industrial automation, automotive, aerospace, instrumentation and appliances. Nowadays, the Brushless DC (BLDC) motor has given tough competition to the existing motors due to its superior characteristics like higher toque by current ratio,power density, speed range and noise less operation (Xie et al., 2013; Aydogmus and Sünter, 2012; Gargouri, 2012;Karthikeyan and Sekaran, 2011;Shehata, 2013). The three phase BLDC motors are increasingly being used in many industrial applications and more importantly in automotives over the past several years to reduce the carbon dioxide emissions, fuel consumption and control complexity.The BLDC motor retains the characteristics of a brushed DC motor but eliminates the commutator and the brushes. It can be driven by DC voltage source, while the current commutation is electronically done by solid state switches. These make it needs less maintenance and in many applications the brushed DC motors are replaced by the BLDC motors. By literatures, the BLDC motor have many advantages over brushed DC motors. Among those, higher speed range, higher efficiency, better speed versus torque characteristics, longer operating life, noiseless operation and higher dynamic response can be found in BLDC usage.
The BLDC motor is a combination of a permanent magnet synchronous motor, a solid state inverter, electronic control circuitry and rotor position sensors (Singh and Bist, 2013; Kim and Youn, 2002). The inverter together with its control unit and rotor position sensor of BLDC motor imitates the mechanical commutation of DC motor and which is named as electronic commutation (Pillay and Krishnan, 1989; Pillay and Krishnan, 1988). There are basically two categories of BLDC motor viz. permanent magnet synchronous motor (PMSM) and BLDC motors depending on their back-emf wave shape. The one which has six-step trapezoidal wave shape is called as BLDC motors in which stator consists of three phase concentrated winding and rotor with permanent magnets and the PMSM has sinusoidal back-emf where in stator consists of three phase distributed winding and rotor with permanent magnets (Pillay and Krishnan,1989). To improve the performance of the drive, the researchers are mainly concentrating on speed control methods,torque ripple minimization, inverter topologies and design of the front converters (Xie et al., 2013; Aydogmus andSünter, 2012; Gargouri, 2012; Yildiz, 2012; Liu et al., 2010; Lee and Noh, 2011; Im et al., 2010; Baratam et al., 2014;Pan et al., 2015; Shao et al., 2003; Wang and Liu, 2009; Moseler and Isermann, 2000; Potnuru et al., 2016). Further to reduce the testing time, the rapid control prototyping plays, a greater role in designing the control strategies and interfacing to the existing electronic control unit. The rapid control prototyping is a process where in the mathematical models developed in MATLAB/Simulink can be easily imported on the real-time computer, with the RTI (Real Time Interface) blocks to connect the real-world systems.
BLDC motor speed control plays an important role in modern motor control (Venkatratnam, 2009; Darba et al.,2015). The BLDC motor has a trapezoidal back EMF, and rectangular stator currents are needed to produce a constant electric torque. However, ideal rectangular current shapes cannot be realized in practice due to the phase inductance and finite inverter voltage (Krishnan, 2001; Tariq et al., 2013; Tariq and Varshney, 2014). To maintain the actual currents flowing into the motor as close as possible to the rectangular reference values hysteresis or PWM current controllers are used (Krishnan, 2010; Miller, 1989). In literature dual closed-loop speed control is found common. The outer loop is for speed whereas the inner loop is for current or torque control (Lajoie-Mazenc et al., 1985; Bose, 2006; Son et al.,2015).PID control has been one of the most developed strategies in the linear control systems for over 75 years and is still commonly used in industrial control systems. PID control is so popular because of its simplicity, robustness and easy tuning parameters (Gopal,2003; Tariq
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