Permanent Magnetic

Brushless DC Motor
Construction and principle of
PMBLDC Motor
2.1Construction

The stator of the BLPM dc motor is made up of silicon steel stampings with slots in
its interior surface. These slots accommodate either a closed or opened distributed armature
winding usually it is closed. This winding is to be wound for a specified number of poles.
This winding is suitably connected to a dc supply through a power electronic switching
circuitry (named as electronic commutator).

Fig 2.1 Arrangement of permanent magnet in the rotor

Rotor is made of forged steel. Rotor accommodates permanent magnet. Number of

poles of the rotor is the same as that of the stator. The rotor shaft carries a rotor position
sensor. This position sensor provides information about the position of the shaft at any instant
to the controller which sends suitable signals to the electronic commutator.

2.2​PRINCIPLE OF OPERATION OF BRUSHLESS PM DC MOTOR

Starting

When dc supply is switched on to the motor the armature winding draws a current. The
current distribution within the stator armature winding depends upon rotor position and the
devices turned on. An emf perpendicular to the permanent magnet field is set up. Then the
armature conductors experience a force. The reactive force develops a torque in the rotor. If
this torque is more than the opposing frictional and load torque the motor starts. It is a self-
starting motor.

Demagnetization curve

As the motor picks up speed, there exists a relative angular velocity between the
permanent magnet field and the armature conductors. AS per faradays law of electromagnetic
induction, an emf is dynamically induced in the armature conductors. This back emf as per
len‘s law opposes the cause armature current and is reduced. As a result the developed torque
reduces. Finally the rotor will attain a steady speed when the developed torque is exactly
equal to the opposing frictional load torque. Thus the motor attains a steady state condition.

Electromechanical transfer

When the load – torque is increased, the rotor speed tends to fall. As a result the back
emf generated in the armature winding tends to get reduced. Then the current drawn from the
mains is increased as the supply voltage remains constant. More torque is developed by the
motor. The motor will attain a new dynamic equilibrium position when the developed torque
is equal to the new torque. Then the power drawn from the mains V *I is equal to the
mechanical power delivered = υm =ωT and the various losses in the motor and in the
electronic switching circuitry.

2.3​CLASSIFICATION OF BLPM DC MOTOR

BLPM dc motors can be classified on the basis of the flux density distribution in the air
gap of the motor. They are

(a). BLPM Square wave dc motor [BLPM SQW DC Motor]

(b).BLPM sinusoidal wave dc motor [BLPM SINE WAVE DC Motor]

(a)​BLPM Square wave motor

These are two types: 180° pole arc.

120° pole arc.

Air gap flux density distribution in 180฀ BLPM SQW motor as shown in fig.

Fig 2.2 Air gap flux density distribution in

180° BLPM SQW motor.

Air gap density distribution of BLPM DC SQW

motor with 120° pole arc, as shown in fig.
 Fig 2.3 Air gap flux density distribution in 120° BLPM SQW motor

(b)​BLPM Sine wave DC Motor

Air gap density distribution of BLPM dc sine wave motor as shown in fig.

Fig 2.4 Flux density distribution of BLPM DC sine wave motor

Torque and E.M.F equation,

2.4​TORQUE EQUATION OF BLPM SQUARE WAVE MOTOR

Power input = VI
=[ 2 eph + 2 I Rph + 2 Vdd] I
VI=[ 2 eph + 2 I Rph + 2 Vdd] I
VI= electrical power input
2 eph I = power converted as mechanical
2 I2 Rph = power loss in the armature winding
2 Vdd I = power loss in the device
Mechanical power developed= 2 eph I
eph= 2(2BgrlTphωm)I
eph= 4BgrlTphωm
Mechanical power = (2πσ/60)T
= ωmT
Where N=Speed in rpm
T=Torque in N-m
ωm=Speed in rad/sec
Therefore T=4BgrlTphI
=KtT
Where Kt = 4BgrlTph=Ke

(a)​Case1: Starting Torque

ωm=0
Istg=(V/2Rph)
Tstg=4BgrlTph(V/2Rph)
Tstg=Kt(V/2Rph)
Starting torque or stalling torque depends upon V.
To vary the starting torque the supply voltage is to be varied.

(b)​Case 2: On load condition

T =KtI

= 4 Bgr lTph I

I = (V-2eph)/(2Rph)

2eph =V-2I Rph

4 Bg r l Tph ωm= V-2I Rph

Ke ωm = V-2I Rph

ωm = (V-2I Rph)/ Ke

ωm0 = V/ Ke

ωm/ ωm0 = ( (V-2I Rph)/ Ke) (V/ Ke )

=(V-2I Rph)/ V

ωm/ ωm0 =1- ((V-2I Rph)/ V)

I/(Tstg) =(KtI)/(KtIstg)

=I.(2Rph/V)

T/ Tstg=2I Rph/V

ωm/ ωm0=1-( T/ Tstg)

ωm/ ωm0=1-(I-Istg)

2.5​EMF EQUATION OF BLPM SQW DC MOTORS

The basic torque emf equations of the brushless dc motor are quite simple and
resemble those of the dc commutator motor.

The co-ordinate axis have been chosen so that the center of a north pole of the
magnetic is aligned with the x-axis at Ө = 0 .the stator has 12 slots and a three phasing
winding. Thus there are two slots per pole per phase.

❖​ Consider a BLPM SQW DC MOTOR

Let ‗p‘be the number of poles (υM)

‗Bg‘ be the flux density in the air gap in wb/m2.

Bk is assumed to be constant over the entire pole pitch in the air gap (180฀ pole arc)

‗r‘ be the radius of the airgap in m.

‗l‘ be the length of the armature in m.

‗Tc‘ be the number of turns per coil.

‗ωm‘ be the uniform angular velocity of the rotor in mechanical

rad/sec. ωm=2πσ/60 where σ is the speed in rpm.

Flux density distribution in the air gap is as shown in fig 2.5.At t=0 (it is assumed that
the axis of the coil coincides with the axis of the permanent magnet at time t=0).

Let at ωmt=0,the centre of N-pole magnet is aligned with x-axis.

At ωmt=0,x-axis is along PM axis.

Therefore flux enclosed by the coli is

Φmax=B x 2πr/p x l

=flux/pole

Φmax=rl∫0π B(θ)dθ

=Bg rl[θ] π

=Bgrl[π]

At ωmt=0,the flux linkage of the coil is

Λmax= (Bg x 2πr/p x l)Tc ωb-T

 Fig 2.5 Magnetic Flux Density around the Air gap.

Fig 2.6 Motor Showing two Coils of One Phase.

Let the rotor rotating in ccw direction and when ωmt=π/2, the flux enclosed by the coil Φ,
Therefore λ=0.

The flux linkages of the coil vary with θ variation of the flux linkage is as shown above.

The flux linkages of the coil changes from BgrlTcπ/p at ωmt=0 (i.e) t= 0 t0 θ at t=π/pωm.

Өhange of flux linkage of the coil (i.e) ∆λ is

∆λ/∆t =Final flux linkage – Initial flux linkage/time.

=0- (2BgrlTcπ/p)/ (π/pωm)

= -(2BgrlTcωm)

The emf induced in the coil ec= - dλ/dt

ec =2BgrlTcωm

Distribution of ec with respect to t is shown in fig 2.7

 Fig 2.7 Emf waveform of coil 1

It is seen that the emf waveform is rectangular and it toggles between + ec to - ec. The
period of the wave is 2πr/pωm sec and magnitude of ec is

ec =2BgrlTcωm volts

Consider two coils a1A1 and a2A2 as shown in fig 5.15.Coil a2A2 is adjacent to a1A1 is
displaced from a1A1 by an angle 30฀(i.e.) slot angle ϒ .

The magnitude of emf induced in the coil a1A1

ec2 =BgrlTcωm volts

The magnitude of emf induced in the coil a2A2

ec2 =BgrlTcωm volts

Its emf waveform is also rectangular but displaced by the emf of waveform of coil ec1 by
slot angle ϒ .

If the two coils are connected in series, the total phase voltage is the sum of the two
separate coil voltages.

ec1 +ec2 =2BgrlTcωm

Let nc be the number of coils that are connected in series per phase​ ncTc =Tph be the
number of turns/phase.

eph= nc [2BgrlTcωm ]

eph= 2BgrlTphωm volts

eph=resultant emf when all nc coils are connected in series.

The waveforms are as shown in fig 2.8

 Fig 2.8 Emf waveform of phase a

The waveform of eph is stepped and its amplitude is 2BgrlTphωm volts.

At any instant 2-phase windings are connected in series across the supply terminals as
shown in fig 2.9.

Fig. 2.9 converter of brushless dc motor with star connected phase winding.

Assumption

Armature winding is Y connected.

Electronic switches are so operated using rotor position sensor that the resultant
emfs across the winding terminals is always = 2 eph.
Amplitude of back emf generated in Y connected armature winding​ E=2
eph.

Commutation in DC motors,
2.6​ COMMUTATION IN MOTORS WITH 120° AND 180° MAGNET ARC

BLPM dc motor with 180° magnet arcs and 120° square wave phase currents arc
shown in fig. 2.10 and 2.11.
 Fig. 2.10 BLDC motor with 180° magnet arc and 120° square wave phase currents

Fig. 2.11 BLDC motor with 120° magnet arcs and 180° square wave phase currents

In Fig. 2.13 the rotor magnet poles are shaded to distinguish north and south. The
phase belts are shaded us complete 60° sector of the stator bore. There are two slots in each
of these phase belts. The current in these two slots are identical and conductors in them are in
series

Fig. 2.12 Flux density around air gap

 Fig. 2.13 Converter of brushless DC motor for star connected phase winding

Between the rotor ring and the stationary belt ring in fig. 2.13 there is a third ring called the
‖mmf ring‖. This represents the mmf distribution of the stator currents at a particular instant.

❖​ At the instant shown wt=0, phase A is conducting positive current and phase C is
conducting negative current. The resulting mmf distribution has the same shading as
the N and S rotor poles to indicate the generation of torque,
❖​ Where the mmf distribution has like shasing, positive torque is produced. Where mmf
and flux shading are unlike, negative torque is produced. Where one is zero, no torque
is zero, no torque is produced. The total torque is the integral of the contributions
from around the entire air gap periphery.

The rotor is rotating in the clockwise direction. After 60º of rotation, the rotor poles
start to ‗uncover‘ the Ө phase belts and the torque contribution of phase Ө starts to decrease
linearly.

өuring this period, the magnet poles, have been ‗covering‘ the B phase belts. Now if
the negative current is commutated from C to B exactly at then point 60º, then the torque will
be unaffected and will continue constant for a further 60º. After 120º, positive current must
be commutated from A to C.

Commutation tables for three-phase brushless dc motors.

TABLE 2.1 180º Magnet-Star Winding. 120º Square wave phase Currents

Rotor
A B C au(1) aL(4) bu(3) bL(6) cu(5) cL(2)
Position

0 – 60 +1 0 -1 1 0 0 0 0 1

60 – 120 +1 -1 0 1 0 0 1 0 0

120 – 180 0 -1 +1 0 0 0 1 1 0

180 – 240 -1 0 +1 0 1 0 0 1 0

240 –
-1 +1 0 0 1 1 0 0 0
300
300 -
0 +1 1 0 0 1 0 0 1
360

❖​ The production of smooth, ripple free torque depends on the fact the magnet pole arc
exceeds the mmf arc by 60º.
❖​ Here only 2/3 of the magnet and 2/3 of the stator conductors are active at any instant

Fig. 2.14 phase current waveforms of BLDC motor with 180º pole arc.

In a practical motor the magnet flux-density distribution cannot be perfectly

rectangular as shown in fig.2.14. for a highly coercive magnets and full 180º magnet
arcs there is a transition section of the order of 10-20º in width. This is due to fringing
effect. Likewise on the stator side, the mmf distribution is not rectangular but have a
stepped wave form as shown in fig.2.15 that reflects the slotting.

Fig 2.15 Air Gap Flux Density on Open Circuit

To some extent these effects cancel each other so that s that satisfactory results are
obtained with a magnet arc as short as 150º, and two slots per pole per phase.

But there is always dip in the torque in the neighborhood of the commutation angles.
This torque dip occurs every 60º elec degrees, giving rise to a torque ripple
component with a fundamental frequency equal to 6P times the rotation frequency
where P is the number of pole pairs. The magnitude and width of the torque dip
depends on the time taken to commutate the phase current.

Phase current waveforms corresponding to high speed and low speed operations are as
shown in fig. 2.16 (a & b)
 (a)​ High speed, full voltage. Note the dip caused by commutation of other 2 phases,
(b)​Low speed with current controlled by chopping.
Fig.2.16 Phase current wave forms.

❖​ The back emf is of equal value in the incoming phase and is in such a direction as to
oppose the current build up.
❖​ While the flux distribution of the magnet rotates in a continuous fashion, the mmf
distribution of the stator remains stationary for 60º and then jumps to a position 60º
ahead.

Similar analysis is made with a motor having 120 º pole arc magnets with delta connected armature
winding.

Table 2.2 120º Magnet Delta Winding, 180º Square Wave Phase Currents.

Rotor Position ab u ab L bc u bc L ca u ca L
A B C
(1) (4) (3) (6) (5) (2)

0 – 60 +1 +1 -1 0 0 1 0 0 1

60 – 120 +1 -1 -1 1 0 0 0 0 1

120 – 180 +1 -1 +1 1 0 0 1 0 0

180 – 240 -1 -1 +1 0 0 0 1 1 0

240 – 300 -1 +1 +1 0 1 0 0 1 0

300 - 360 -1 +1 1 0 1 1 0 0 0

Fig.2.17 phase currents wave forms of BLDC motor with120º pole arc
 Fig 2.18 converter of brushless dc motor for delta connected phase winding

❖​ C phase belt remains covered by the magnet poles. While the coverage of A phase
belt increases thereby decreasing that of B phase belt.
❖​ Since all the conductors are varying same current the increasing torque contribution of
phase A is balancing by the decreasing contribution of phase B. Therefore, the total
torque remains constant.
❖​ Similarly there is a linear increase in the back emf of A and equal and opposite
decrease in the back emf in phase B, Therefore the back emf at the terminals remains
constant.
❖​ Line current divides equally between two
paths One-phase C Second-phase A & B
series.

This balance is not perfect in practice because of the resistance and inductance of the
windings. But the current balance should be maintained, otherwise circulating current may
produce excessive torque ripple and additional losses.

When compared with 180° pole arc machine.

❖​ For the same ampere-conductors per slot and for the same peak flux density, the 120°
pole arc machine has 1.5 times copper losses, but produces the same torque.
❖​ Also the ampere-conductors per slot would have to be reduced because the duty cycle
is 1.0 instead of 2/3.

Merits

❖​ For the same magnet flux density the total flux is only 2/3 of that of 180° pole arc
motor, so that only 2/3 of the stator yoke thickness is required. If the stator outside
diameter is kept the same, the slots can be made deeper so that the loss of ampere
conductors can be at least partially covered .consequently the efficiency of the motor
may not be very much less than that of 180° pole arc machine.
❖​ In this machine also, the effects of fringing flux, slotting and communication overlap
combine to produce torque ripple.
❖​ Only emf and torque are discussed. The concept of hanging flux-linkage and energy
 balance can also be used to analyze the operation.

Electronic Commutation
2.7​Electronic commutator

The armature winding which is in the stator has 12 tapping‘s. each tapping is
connected to the positive of the dc supply node and through 12 switches designated as S1
,S2,….S12 and negative of the supply at node Y through switches S‘1,S‘2,…….S‘12.

Fig 2.19 Electronic Commutator

When S1 and S‘1 are closed the others are in open position, the dc supply is given to
the trappings 1 and 7.there are two armature parallel path.

(i)​ 1–2–3–4–5–6–7
(ii)​ 1 – 12 – 11 – 10 – 9 – 8 – 7
They set up armature mmf along the axis 7 to 1.

After a small interval S1 and S‘1 are kept open and S2 and S‘2 are closed. Then dc
current passes from tapping 2 to 8 sets up mmf in the direction 8 – 2.

Fig 2.20 switching circuit of electronics commutator

Thus by operating the switch in a sequential manner it is possible to get a revolving

mmf in the air gap. The switches S1 to S12 and S‘1 to S‘12 can be replaced by power
electronic switching devices such as SӨR‘s MτSFET‘s IGBT‘s, power transistor etc.

When SӨR‘s are used suitable commutating circuit should be included. өepending
upon the type of forced commutated employed, each switch requires on or two SCRs and
other commutating devices. As number of devices is increased, the circuit becomes
cumbersome.

Fig 2.21 Delta Connected Stator Armature Winding

For normal electronic commutator, usually six switching devices are employed. Then
the winding should have three tapping‘s. Therefore the winding can be connected either in
star or in delta.
 Fig 2.22 Star Connected Armature Winding

Difference between mechanical

and electronic commutators
2.8​Comparison between mechanical Commutator and brushes and
Electronic Commutator

S.
Mechanical Commutator Electronic Commutator
No

1. Commutator is made up of copper segment Power electronic switching device is used in the
and mica insulation. Brushes are of carbon or commutator.it requires a position sensor.
graphite.

2. Commutator arrangements are located in the It is located in the stator.

rotor.

3. Shaft position sensing is inherent in the Separate rotor position sensor is required.
arrangement

4. Numbers of commutator segments are very Number of switching devices is limited to 6.

high.

5. Highly reliable. Reliability is improved by specially designing

the devices and protective circuits.
6. Difficult to control the voltage available across The voltage available across armature tappings
the tappings. can be controlled by employing PWM
techniques.

7. Interpole windings are employed to have By suitable operating the switching devices,
sparkles commutation. better performance can be achieved.

Hall sensors,
2.9​Hall effect position sensor
Consider a small pellet of n-type semiconducting material as shown in fig 2.23.

Fig 2.23 Hall Effect

A current icis allowed to pass from the surface ABCD to the surface EFGH. Let the surface
ABEF be subjected to a North pole magnetic field of flux density B tesla. As per Fleming left
hand rule, the positive charge in the pellet get concentrated near surface ADHE and negative
charges near the surface BCFG. Since n-type material has free negative charges, there
electrons
gets concentrated near the surface BCGF.This charge in distribution makes the surface ADHE
more positive than the surface BCGF. This potential known as Hall emf or emf due to Hall
Effect.
It has been experimentally shown that emf due to hall effect is VH is given
by VH = RH(ic / d) volts
Where ic current through the pellet in
amps B- Flux density in tesla
d- Thickness of the pellet in m.
RH – Constant which depends upon the physical dimensions or physical properties of the
pellet. If the polarity of B is changed from North Pole to South Pole the polarity of the emf
due to Hall Effect also get changed.

2.9.1​ Hall Effect Position Sensor

Hall effect position sensor can be advantageously used in a BLPM motor. Consider a 2 pole
BLPM motor with two winding w1 and w2 as shown in fig.

Fig 2.24 2 pole BLPM motor

When w1 carries a current on closing S1 it set up a North Pole flux in the air gap. Similarly
when s2 is closed w2 is energized and sets up a North Pole flux.w1 and w2 are located in the
stator such that their axes are 180 degree apart. A Hall Effect position sensor is kept in an
axis of the winding.

When Hall Effect position sensor is influenced by North Pole flux the hall emf is made to
operate the switch S1. Then w1 sets up North Pole flux. The rotor experiences a torque and
South Pole of the rotor tends to align with the axis of w1.because of interia.it overshoot the
rotor hence rotates in clockwise direction. Now HEPS is under the influence of S pole flux of
the rotor. Then the polarity of hall emf gets changed. This make the switch S1 in off state and
S2 is closed. Now w2 sets up N pole flux in the air gap, the rotor rotates in clockwise
direction. So that the s pole gets aligned with w2 axis.Then this process continuous. The rotor
rotates continuously.

Optical sensors,
2.10​ Optical position sensor
This makes use of six photo transistors. This device is turned into ON state when light
rays fall on the devices. Otherwise the device is in OFF state the schematic
representation is shown in fig.
 Fig 2.25 Optical position sensor

The phototransistors are fixed at the end shield cover such that they are mutually displaced by 60
degree electrical by a suitable light source. The shaft carries a circular disc which rotates along
the shaft. The disc prevents the light ray falling on the devices. Suitable slot are punched in the
disc such turned into on state suitably turns the main switching devices of electronic
commutation circuitry into on state.

As the shaft rotates, the devices of electronic commutation which are turned into ON are
successively changed.

Torque-speed characteristics,
2.11​ TORQUE- SPEED CHARACTERSISTICS OF BLPM SQM DC MOTOR

Let the supply voltage V be constant. A family of torque speed characteristics for
various constant supply voltages is as shown in figure 2.26
 Fig 2.26 T-ωm curve for various supply voltages

Permissible region of operation in T-ωm plane

Torque speed characteristics of BLPM square wave motor is shown in fig.2.27. The
constraints are

1.​ The continues current should not exceed the permissible current limit In (i.e) Torques
should not exceed Kt In.
2.​ The maximum permissible supply voltage = Vn.
3.​ The speed should not exceed ωmn.

Fig. 2.27 Torque-speed characteristics

Line AB

Parallel to X-axis represents maximum permissible torque line which corresponds to

maximum permissible current In.

Line FG

It represents T-ωm characteristics corresponding to the maximum permissible Vn. B

and C are points in Fg. B is the point of intersection between AB and FG.

Line DH

It represents constant maximum permissible speed line (i.e) ωmn is constant. DH

intersects FG and x axis at D.

The area OABCDO is the permissible region of operation. To obtain a particular point
P corresponding to given load-torque and speed condition the only way to operate the motor
at P is by suitably adjusting the supply voltage fed to the motor.
 Fig.2.28 Torque speed characteristics of ideal brushless
DC motor

❖​ If the phase resistance is small as it should be in an efficient design, then

the characteristics to that of a shunt dc motor. The speed is essentially
controlled by the voltage V and may be changed by changing the supply
voltage. Then the current drawn just to drive the torque at its speed.
❖​ As the load torque is increased, the speed drops and the drop is directly
proportional to the phase resistance and the torque.
❖​ The voltage is usually controlled by chopping or PWM. This gives rise to a
family of torque speed characteristics as shown in fig. 2.28. The boundaries
of continuous and intermittent limits are shown.

Continuous limit - determined by the heat transfer and temperature rise.

Intermittent limit – determined by the maximum ratings of semiconductor devices in

circuit.

In practice the torque speed characteristics deviates from the ideal form
because of the effects of inductance and other parasitic influences.

Also the speed range can be extended by increasing the dwell of

conduction period relative to the rotor position.

Power Controllers
2.11.1​Power Circuit

Power Circuit of BLPM de motor is as shown fig consists of six power semiconductor
switching device connected in bridge configuration across a dc supply. A suitable shunt
resistance is connected in series to get the current feedback. Feedback diodes are connected
across the device. The armature winding is assumed to be star connected. Rotor has a rotor
position sensor and a techo-generator is coupled to the shaft to get feedback signal.
 Fig 2.29 structure of controller for brushless PM DC Motor

4.1.1​Control circuit

The control circuits consist of a commutation logic unit. Which get the information
about the rotor shaft position and decides which switching devices are to be turned on and
which devices are to be turned off. This provides six output signals out of which three are
used as the base drive for the upper leg devices. The other three output signal are logically
AND with the high frequency pulses and the resultant signals are used to drive the lower
leg devices.

A comparator compares the tachogenerator output with reference speed and the
output signal is considered as the reference current signal for the current comparator which
compare the reference current with the actual current and the error signal output is fed to
the monostable multivibrator which is excited by high frequency pulses. The duty cycle of
the output of monostable is controlled by error signal. This output signal influences the
conduction period and duty cycle of lower leg devices.

Drive Circuits,
Applications