BLDC motor controller : design, implementation and bech test

Abstract

Brushless DC (BLDC) motors are one of the most widely used electrical drive in industrial applications because of its performances; high efficiency, high torque than other motors. In this work, the permanent BLDC motor has been driven with the three arms inverter circuit (MOSFET) controlled using mainly rotor hall-effect position sensors. The analysis of the BLDC motor is simulated in open loop and closed loop design, including the loaded and loaded cases using MATLAB/ SIMULINK software. The conventional PI controller parameters are tuned using Ziegler-Nicholas method for the closed loop speed control of the BLDC motor. The dc voltage provided by the controller is used for adjusting the motor DC supply voltage by means of the duty cycle of the PWM circuit. This variable dc motor supply voltage causes the BLDC motor speed control. The Motor closed loop speed controller system is implemented using a PC based hardware and software interfaces. The hardware interface NI DAQ -6009 is used to read the motor actual speed and generating a variable dc voltage to control the PWM circuit. The software part which is a real-time LABVIEW program, aimed to implement the continuous PI controller and safety algorithms used for a correct system operation. For a deep study and tests of the behavior of the PI controller in loaded mode, a DC motor shaft is mechanically tied with the BLDC motor through a coupling mechanism. A PMBLDC motor rated at 24 Vdc, 1.56 A, 3000 rpm is used for the experimental tests. A Buhler PMDC motor is used rated at 24 Vdc, 2.5 A and 5000 rpm is used as load for the PM BLDC motor.