Velocity and Position Control of The Burshless DC Motor.

3003
NAVAL POSTGRADUATE SCHOOL

Monterey, California
THESIS
BRUSHLESS DC MOTORS, VELOCITY AND POSITION
CONTROL OF THE BRUSHLESS DC MOTOR
by
Nezih
Y.
Durusu
June 1986
Thesis Advisor:
George
J.
Thaler
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BRUSHLESS DC MOTORS, VELOCITY AND POSITION CONTROL OF THE BRUSHLESS

DC MOTOR
PERSONAL AUTHOR(S)
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a
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ABSTRACT {Continue on
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Brushless DC Motors, Velocity and Position

Control, Microprocessor Controller
SUB-GROUP
necessary and identify by block number)
velocity feedback controller for the brushless DC motor was designed

sing the Hall effect sensors.
In addition, the position control of the
rushless DC motor was developed using an optical encoder to sense angular
osition changes and a microprocessor to provide the desired position
ontrol.
A Pittman 5111 wdg #1 brushless DC motor was used for this study,
he design of the digital tachometer and pulse width modulator for velocity
ontrol and the design of the Z-80 based microprocessor controller and
oftware design are described in detail.
I
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Brushless DC Motors, Velocity and Position Control of the

Brushless DC Motor
by
Nezih Y. Durusu
Lieutenant Junior Grade, Turkish Navy
B.S. ,' Turkish Naval Academy, 1978
Submitted in partial fulfillment of the

requirements for the degree of
MASTER OF SCIENCE IN ELECTRICAL ENGINEERING
from the
NAVAL POSTGRADUATE SCHOOL

June 1986
^-^
ABSTRACT
A
velocity feedback controller for the brushiess DC
motor was
designed using the Hall effect sensors.
addition,
the
was developed
position
control
of
the
motor
using an optical encoder to sense anguiar

microprocessor to provide the desired
position changes and
position control.
Pittman 5111 wdg
was used for this study.
and
brusnless DC
In
#1
brushiess DC motor
The design of tne. digital tachometer
pulse width modulator
for
velocity control and the
design of the Z-80 based microprocessor controller and

software design are described in detail.
TABLE OF CONTENTS
I.
II.
INTRODUCTION
11
CONSTRUCTION AND OPERATION OF BRUSHLESS

DC MOTORS
III.
A.
CONSTRUCTION OF BRUSHLESS DC MOTORS
15
B.
ELECTRONIC COMMUTATION AND DRIVE
17
C.
FOUR-PHASE DELTA BRUSHLESS dC MOTOR
21
D.
ADVANTAGES AND DISADVANTAGES OF THE

BRUSHLESS DC MOTOR
25
VELOCITY CONTROL OF THE 3RUSHLESS DC MOTOR
V.
27
A.
GENERAL
27
B.
DESIGN OF THE DIGITAL TACHOMETER FOR

VELOCITY CONTROL SYSTEM
30
PULSE WIDTH MODULATOR
34
C.
IV.
15
SYSTEM TESTING AND DATA COLLECTION FOR

VELOCITY CONTROL SYSTEM
39
A.
GENERAL
39
B.
OPEN LOOP VELOCITY CONTROL
40
C.
CLOSED LOOP VELOCITY CONTROL
43
D.
TRANSFER FUNCTION MEASURE AND SIMULATION

STUDIES
46
POSITION CONTROL OF THE DC MOTOR WITH

MICROPROCESSOR CONTROL
58
A.
GENERAL
53
3.
MICROPROCESSOR CONTROL OF DC MOTORS
58
C.
INCREMENTAL OPTICAL ENCODER
59
D.
MICROCOMPUTER SYSTEM
62
E.
SOFTWARE DESIGN
65
VI.
VII.
SYSTEM TESTING AND DATA COLLECTION FOR

POSITION CONTROL SYSTEM
70
A.
GENERAL
70
B.
SYSTEM CALIBRATION
71
C.
CLOSED LOOP POSITION CONTROL
71
SUMMARY AND CONCLUSION
76
A.
REMARKS AND CONCLUSIONS
76
B.
RECOMMENDATIONS FOR FURTHER STUDIES
77
...
APPENDIX
A:
RATING AND SPECIFICATIONS FOR MOTOR
APPENDIX
3:
THE DAC CALIBRATION FOR VELOCITY CONTROL
APPENDIX
APPENDIX
APPENDIX
C:
D:
E:
.30
SYSTEM
31
ARTWORK OF THE DIGITAL TACHOMETER AND

PULSE WIDTH MODULATOR CIRCUIT
32
THE DAC CALIBRATION FOR POSITION CONTROL

SYSTEM
84
CHARACTERISTICS OF THE OPTICAL

INCREMENTAL ENCODER
35
APPENDIX
MC 6366 1B OPERATION AND PROGRAMMING
APPENDIX
INTEL 8255A OPERATION AND PROGRAMMING
APPENDIX
MAIN PROGRAM
.37
.39
91
LIST OF REFERENCES
101
INITIAL DISTRIBUTION LIST
102
LIST OF TABLES
TABLE 4.1. FREQUENCY RESPONSE

AND PHASE
WITH MAGNITUDE
TABLE 6.1. COUNTS AND ANGULAR POSITIONS
50
74
LIST OF FIGURES
Figure 2.1.
Figure 2.2.
Cut-Away View of Conventional DC Motor

Assembly
15
Cut-Away View of Brushless DC .Motor

Assembly
16
Conventional DC
Essential Parts of
Motor
Figure 2.4.
Essential Parts of
Figure 2.5.
Figure 2.6.
Two-Phase Brushless DC Motor
22
Figure 2.7.
Four-Phase Commutation Circuit
24
Figure 2.8.
Four-Phase Logic Control
25
Figure 3.1.
Block Diagram of the Velocity Control

System
28
Figure 2.3-
13
Brushless DC Motor
.19
Three-Phase, Half Wave Brushless DC Motor

20
Controller
Figure 3.2.
Position of the Hall Effect Sensors
Figure 3.3.
.29
Flux in the Air Gap and Output Voltage

Wave Forms for Hall Effect Sensors
Figure 3.4.
One Channel Output of Hall Sensor
Figure 3.5.
Circuit Diagram of Digital Tachometer
Figure 3.6.
Output of the Flip Flop
33
Figure 3.7.
Output of the Multivibrator
33
Figure 3.8.
Digital
Figure 3.9.
Pulse Width Modulator
35
Figure 3.10.
Error and Dither Signal
36
Figure 3.11.
Circuit Diagram of the Pulse Width

Modulator
37
Figure 3.12.
to
Analog Conversion
.29
.31
.32
34
Circuit Diagram of the Digital Tachometer

and Pulse Width Modulator
38
Block Diagram of the Velocity Control

System
39
Hall Sensor Output of the Motor

for 3750 RPM
41
Pulse Width Modulated Signal

for 3750 RPM
42

for 3260 RPM
42

for 3260 RPM
43
Figure 4.6.
Dither Signal
44
Figure 4.7.

for 1275 RPM
45

1275 RPM
45
Figure 4.1.
Figure 4.2.
Figure 4.3.
Figure 4.4.
Figure 4.5.
Figure 4.3.
for
Figure 4.9.
Figure 4.10.
Pulse Width Modulated Signal with

External Force on the Shaft Motor
Closed Loop System with Spectrum

Analyzer
.46
47
Figure 4.11a
Open Loop Frequency Response of the System

with Magnitude Curve
47
Figure 4.11b

with Phase Curve
43
Figure 4.12.
Bode Plot of the System
53
Figure 4.13.
Frequency Response of the System
54
Figure 4.14.
Transient Response of the System

from Computer Simulation
55
Open Loop Transient Response of the

System from the Strip Chart
56
Closed Loop Transient Response of the

System from the Strip Chart
56
Closed Loop Transient Response of

System from Storage Oscilloscope
57
Figure 4.15.
Figure 4.16.
Figure 4.17.
Figure 5.1.
Position Control System

3
the.
59
Figure 5.2.
Direction Sensor
60
Figure 5.3.
Incremental Optical Encoder
60
Figure 5.4a
Encoder Channel Outputs for CW Rotation
Figure 5.4b
Encoder Channel Outputs for CCU Rotation .63
Figure 5.5.
Microcomputer System
Figure 5.6.
Circuit Diagram of the Microprocessor
Figure 5.7.
Flow Chart of the Main Program
Figure 6.1.
CRT Terminal Menu for Program Options
Figure 6.2.
CRT Terminal Menu for Calibration of
.63
64
.
.68
69
System
.72
73
Figure 6.3.
CRT Terminal Menu for Position Control
Figure 6.4.
Block Diagram of the Position

Control System
75
Curve Following Block
75
Figure 6.5.
.73
ACKNOWLEDGMENT
wish
to
express
my
deepest
thanks
to
Dr.
George
Thaler for nis confidence and guidance which contributed to

the completion of this thesis.
my
gratitude
to
my
wife,
Candi,
would also like to express

for
her
well as her typing and editing abilities.
10
loving support as
recent years,
In
I.
INTRODUCTION
the
brushless DC motor has found more
applications because of its many advantages.
It offers long
operational life, it eliminates brushwear particles and arcing,

and it is adaptable to spacecraft requirements.
As more specialized needs become obvious, the versatility
of the brushless DC motor in applications to control systems
was discovered and developed.

The brushless DC motor
is
The rotor consists of permanent
of the conventional DC motor.

the windings are
magnets and
the areas where
motor differ
motor
On
the
motor
is
other
are
done
the
in
The
by
hand,
performed
is
the
by
usually transistors.
dissipated through
decline in
The
is
to
in
the conventional
amplifier design.
DC
mainly an inside out version
Besides this,
the stator.
DC motor
and
brushless DC
commutation processes and
the
commutation of the conventional

mechanical
commutator and
brushes.
commutation of the brushless DC

semiconductor switching elements,
The
inductive switching energy
is
diode path which allows the current to
controlled fashion.
commutation sensor system for
brushless DC
motors
required to control the logic functions of the controller
maintain current to the proper coils
in
tne
stator.
Hall effect sensors and optical incremental encoder sensors
11
are the most commonly used methods for the angular position
sensing system.
The
effect sensing system is based on sensors
Hall
which are usually
placed
the
in
stator structure to sense
the polarity and magnitude of the permanent magnet field in

the air gap.
The optical increment encoder provides
increment of angular resolution.
It
is
most
combination of light-emitting diode (LED),

mask and phototransistor
The Pittman 5111 Wdg
commonly
rotating disk,
brushless DC motor and four-pnase
#1
drives were used for this study.

and another motor had
pulse for eacn
One motor had
Hall sensor
Hall sensor and an optical incremental
encoder as well.
The velocity control of the system was designed by using
the fact that the Hall sensor gives two pulses per revolution
for
pole
four
motor.
each revolution,
this
idea
the
mind,
in
counting the intervals between
By
digital
speed
can
be
obtained.
V/iuh
digital tachometer was designed.
The
speed command was given by dip switches and converted

the
analog signal.
from the digital

signal with
The
The
digital
speed
to
which was obtained
tachometer was converted
to
an
analog
Digital to Analog Converter (DAC).
Pittman four-phase drive accepts four inputs.
Two
of them are the logic signals from the Hall effect sensors.
One
of
the
inputs
is
the
direction command.
12
The
other
input
used
is
for
on-off control
convenient logic input

signal
for
in mind,
speed
apply
to
of
a
tdrque control.
and
the
motor which
is
pulse width modulation
Keeping this feature
the pulse width modulator was designed.
recent years microprocessor systems have been useful
In
tools with many applications.
These involve the use of the
brushless DC motor,
and
the
microprocessor control
brushless DC motor.
Of
its
many features one of the most
important is the ease with which
new
software program.
be
used
for
system can be modified to
Assembly language or
languages such as Forth, Basic,

can
the
This can be easily done by writing
perform new functions.

a
of
Fortran,
C,
high level
Pascal and Ada
programming and can be downloaded
to
the
EPROM.
The microprocessor controller was designed by using
Parallel interfacing was used
Z-80 control processor unit.

to communicate
with the outside world (the CRT terminal and
pulse width modulator).

the CRT
Position commands were given from
terminal and the updated position of the motor was
observed from the terminal also.

In
Chapter Two the brushless DC motor is compared with
conventional DC motors and drive circuits. The third chapter's

emphasis is on the velocity control of the brushless DC motor
and
the
building of the digital tachometer and pulse width
modulator.
the
In
Chapter Four testing and data collection of
velocity control
system are studied.

13
The
position
control of the system with the microprocessor controller is
discussed in Chapter Five.
In Chapter Six
testing and data
collection of the position control system are studied.
14
II.
CONSTRUCTION AND OPERATION OF BRUSHLESS DC MOTORS
CONSTRUCTION OF BRUSHLESS DC MOTORS
A.
Brushless DC motors, unlike conventional DC motors have

a
permanent-magnet rotor and
said
that
the
multi-coil stator.
brushless DC motor
basic
is
essentially an
"inside out" version of the conventional DC motor.
of
conventional DC motor
equivalent version of
2.2.
Here we can
see
is
shown
in
It can be
Figure 2.1
cut-away
and
an
brushless DC motor is shown in Figure

the
permanent magnet rotor and
multi-coil stator.
MAGNET
ROTOR
Figure 2.1.
Cut-Away View of Conventional DC Motor Assembly.

15
STATOR
PERMANENT
MAGNET
ROTOR
Cut-Away View of Brushless DC Motor Assembly.
Figure 2.2.
significant difference can be seen in the winding and
magnet locations.
The conventional DC motor has the active
conductors in the slots of the rotor,
and
in
contrast,
the
brushless DC motor has the active conductors in slots of the

Since the windings are closer to the environment the
stator.
removal of the neat produced in the active windings is easier

in the brushless DC motor.
DC
motor
is
The result is that the brushless
more stable mechanical device from
thermal
point of view.
Another basic difference from the conventional DC motor

is
The commutation of the conven-
the commutation process.
tional
DC
brushes.
motor
is
done
by
mechanical
The brushless DC motor,
commutated electronically.
16
on
the
commutator and
other
hand,
is
ELECTRONIC COMMUTATION AND DRIVE
B.
In order to see the
similarities and differences between
conventional and brushless DC motor systems, two sketches are

shown
Figures 2.3
in
2.4.
and
In
Figure
the rotor windings and the commutator are shown.
commutation control stage
the
different from tne
is
electronic commutator work in such
direction of the rotation

the
power
DC
In Figure
Slots, windings, magnetic poles, and
conventional DC motor.
the
the
The connections between
elements of DC motor and control.
2.4
have
2.3 we
supply.
that
the
controlled by the polarity of
is
By
way
electronic commutator,
an
the
current is switched from one coil group to the adjacent one

with
from one
coil
to
can
place
the
next
four
times
electronic commutation,
in
per
revolution for
Since the switching transistors are already
two pole motor.

in
Switching takes place
section stator winding.
four
be
applied
sensor
creates
to
the
circuit.
logic
pulses
to
generate
The
logic
position
shaft
signals which
control the commutation of the windings.
One
the
of
circuits
is
simple,
shown
in
control circuit with

shown,
each winding
logic control
is
three-phase
Figure 2.5.
a
brushless DC
This
is
used one
of the system is
"half-wave"
conduction angle of
third of the
motor
120.
time
not complicated.
As
and
is
the
The speed
and torque output of the motor can be controlled by varying
the
power
supply voltage
17
In
the
lower
part
of
the
diagram the same system can be seen

The
torque reversal
in
in
reversed
torque.
conventional DC motor is achieved
by reversing the power supply voltage.
In the brushiess DC
motor the same tning can be done by shifting all the logic
180.
functions by
This example
illustrates one of the
basic differences between conventional and brushiess DC motors.

In the illustration of Figure 2.5, the inductive transient
current in each winding
is
ignored.
Due
to
the
voltage
produced by the stored
0RivE=
C.PCblT
17
LOGIC
ORCuiT
CGMMANO
SIGNAL
BRUSHES
LOGIC POWER
INPUT
POWER
POWER
COMMUTATOR
Supply
AC OR
DC
Figure 2.3.
Essential Parts of
18
Conventional DC Motor
COMMUTATION CONTROLLER
STAGE
Figure 2.4.
Essential Parts of
Brushless DC Motor.
energy in each winding, the circuit creates
low-power systems,
tolerated.
However,
if
reverse breakdown
Since stored energy is low in
voltage on each transistor.

the
such break-down conditions
can
be
any significant amounts of current
and voltage are handled in such
system, breakdown conditions
would cause damage to the semiconductor junctions.
Therefore
other methods are used to maintain proper commutation of

the
inductive energy
in
each winding.
two-phase brushless DC motor using

and -V s
two
Figure 2.6 shows

power
supplies +V
We now have four power transistors and four
19
+v
Sha
GO
120
130
240
300
360
60
It
angle
120
POSI TIVE
TORQUE
Figure
2.5.
Three-Phase,
Controller.
20
Half Wave
Brushless Motor
Each half of the circuit controls it's own winding,
diodes.
and the two operate independently of each other.
The diagram shows
the
current response with respect to
position and current versus time at
rotor
shaft
given
velocity.
can be seen that the current Iq^
It
initial increase to
steady state value which is maintained
until tne 90 position has been reached.

to the off condition.
has an exponential
Then Q1 is switched
The stored energy is dispelled through
the power supply by using diode D3, and an exponential decline

is shown
when the current rise is now progressing in
Tnus there is
Q2.
in
in Ipo,
the
continuous torque production maintained
motor as one stage
is
turned
off
and
the
next
is
turned on.
FOUR-PHASE DELTA BRUSHLESS DC MOTOR
C.
four-phase Delta motor from the Pittman Corporation (see
Appendix A)
is
used for the following experiments.
four
pole structure is used for this motor.
There are several reasons to fabricate the rotor as
four
pole structure:
i)
Mechanical arc lengths of 60 per magnet segment yield

a higher material utilization than 120 arc used for
a two pole structure and therefore lower cost.
ii)
High performance magnetic materials do not accept radial

magnet paths and thus are not as efficient magnetically
if made in long arc lengths.
iii)
The four-pole structure doubles the number of commutation

cycles per mechanical revolution of the shaft.
21
V
.
02
CO
n
nrjy^-, D
>
D4
f
D4
90
180
270
360
90
o-^WJP-o
ISO
iiKirmi dcgrM*
Transistor
2 Tranirstor
Figure 2.6.
Two-Phase Brushless DC Motor

22
ON
OFF
four-phase commutation circuit is shown in Figure 2.7.
The
BCD
logic
outputs
from
are connected
sensors
the
decimal decoder by using the "A" and
to
"B"
to
inputs.
The "C" input is used to control the rotation of the motor.
on-off control of the decoder.
"D"
input
"D"
input of the decoder in the motor drive is
used
is
for
input to apply
logic
later
the
sections.
The
flux
rotation
the "on", "off" position of the transistors.

is
on,
signal
for
More details will be discussed
speed and/or torque control.

in
convenient
The
provided
is
When
transistor
creates current on the related windings.
it
by
The
current passing through the transistor will create flux on

the
excitation.
For
the clock-wise
transistors Q1 and Qg
rotation,
phase will
have
will
be
phase
continue in the order:

and
Q2
'
To
reverse
the
operating program will be transistors
transistors QU
and
Q2
transistors Q2 and Q4
voltage,
and
'
on,
on.
'
nave
the
on
and tran-
direction,
and
Q3
'
transistors Q3 and Q1'

Shaft
angle
position,
23
on,
on,
phase
corresponding sensor signals are shown
Figure 2.8.
This will
flux
Q1
transistors
'
phase.
transistors Q3 and Q1
on.
tat or
phase will
Q2 and Q4
negative voltage at the
sistors QU
This will create positive voltage at
on.
and
This means that
are on.
In the next step,
the
direction of the flux
(CW)
positive voltage and
negative voltage.
the
The driver controls
related windings.
in
3NI1
t?
01 3NH 8
n
a3aoo3a
<
CD
O Q
Nouo3yia
;
-N/vSr
WMd
Sb0SN3S
319NV 13VHS
Figure 2.7
Four-Phase Commutation Circuit
24
CW
TORQ.UE
PHASE
Electrical SENSOR SENSOR
angular
position
A
2
02
90
03
130
270
-t-
GL4-'
0.4
TRAN VOL TRAN VOL TRAN VOL TRAN VOL

ON
ON
ON
ON
02
01
4-
Ol'
Ol
-r
03'
Ol'
COW TORQUE
I
270
04-'
03
180
04
02
4-
02'
-4-
90
03'
-h
Figure 2.3.
D.
Four-Phase Logic Control.
ADVANTAGES AND DISADVANTAGES OF THE BRUSHLESS DC MOTOR

1
Advantages
Brushless DC motors are more expensive for the same
horsepower rating than conventional DC motors, but they have

some advantages over DC commutator-brush motors:
because
does
not
a)
The motor has

have brushes.
b)
Due to the elimination of brush arcing, there is

a reduction in electromagnetic interference.
c)
There is
d)
Little or no maintenance is required.
e)
motor permits a small signal control of

speed and on-off operation since tne power
circuitry is included as part of the brushless
long
life
it
reduction in acoustic noise.
The
DC motor.
25
f)
2.
When they are properly sealed, they are capable

of operation in fluids or vapors.
Disadvantages
following are
The
important disadvantages of the
brushless DC motor:
a)
The total size of the motor is bigger overall

because of the additional space required for the
electronic devices.
b)
Overall cost is higher compared to conventional

commutator types of the same horsepower.
c)
Choice is somewhat limited at present in "stock"

sizes and horsepower rating, necessitating
"special" orders for particular applications.
Even
though the brushless DC motor has some dis-
advantages, developing electronic technologies and applications

in space and the military make it preferable to conventional
DC motors.
26
VELOCITY CONTROL OF THE BRUSHLESS DC MOTOR
III.
General
A.
Before
motor,
it
will
speed
helpful
be
to
control
study
brushless DC
the
of
components of the
the
The block diagram of the velocity control circuit
system.
is
studying the
shown in Figure 3.1.

The Hall effect sensing system is based on sensors which
are
located adjacent to the end of the stator winding to
sense the
field
polarity and magnitude of the permanent magnet

the
in
gap.
The
position of the
Hall
sensors
are
The Hall effect device is made of two
sensors which are placed 90 electrical degrees apart
to
sense the rotational position of the rotor relative- to the
stator coil groups.
The flux
in
the gap between
and 'stator and the output of each sensor is shown
As can be seen
3.3.
switches
sensor
sensed
for
rotor
flux
in Figure
from logic
3.3,
the rotor
in
Figure
the output of each Hall
high to logic
passes through zero.
north magnetic pole and low for
low when
the
The output is high
south pole (or vice
versa if Hall sensors are reverse mounted).
[Ref 4]
The two rotor position signals are decoded by digital logic
gates
in
controls
the motor drive

8
power
to
give
four phase output which
transistors in such
way that sequential
switching from one stator coil to the next occurs at intervals

of 90
mechanical rotor rotation.

27
Both the outputs of the
DIRECTION
ref
PWM
PWM
tach
D/A
CONVERTER
MOTOR
A DRIVE
B [76-6-1]
DIGITAL
TACHOMETER
ii
0A
0B
HALL
SENSOR
PITTMAN
Figure 3.1.
rrrr
MOTOR
5111
WDGttl
Block Diagram of the Velocity Control System

28
DIRECTION OF ROTATION
N
ROTOR MAGNETS
HALL SENSORS
STATOR
WINDINGS
Figure 3.2.
Position of the Hall Effect Sensors
FLUX
'
\
f
Time
ZERO CROSSING
SENSORS
SENSOR A
5V
OV
Time
SENSOR
5V
OV
TIME
Figure 3.3
Flux in the Air Gap and Output Voltage

Wave Forms for Hall Effect Sensors.
29
The
Hall
sensor will
produce square waves
Following from this- concept
speed.
related
digital
to
the
tachometer
will be built and discussed in the next section.
The
"D"
input
of

signal
B.
to
the
in
apply
pulse
and/or torque control.
for speed
be discussed
decoder
the
motor drive
is
width modulation
More details will
later sections.
in
DESIGN OF THE DIGITAL TACHOMETER FOR SPEED CONTROL

The speed of the brushless DC motor can be observed from
the
output of the Hall
square waves
found.
measured,
be
the
Hall
sensors
If elapsed
produce
time
for
each
speed of the motor can be
One channel of the Hall sensor output of the brushless
DC motor
is
^The arrows
of
each rotation.
for
revolution can
sensors.
Indicate the beginning and end of the period
revolution.
The
relation between the period of the
revolution and the speed of the motor can be shown with the
following example:
Period
speed
=
=
Revolution
50
10~3 sec
20 revolutions per second
(RPS).
This is equal to 1200 revolutions per minute (RPM).

By starting from this approach,
designed
by
the
author.
The main
digital tachometer was
idea was
to
measure the
period of revolution by using counters and inverting to the
voltage value by using
Digital to Analog converter (DAC).
30
Mb/DlV
One Channel Output of Hall Sensor.
Figure 3.4.
A
circuit diagram of the digital tachometer is shown in

3.5.
Fig.,
A
used
oV/DiV
7474 Dual-D-Type positive-edge-triggered flip flop was

to
obtain
pulse per revolution by dividing the Hall
sensor signal by two.

in Figure
The output of the flip-flop is shown
3.6.
74LS161 synchronous 4-bit counters were used to count for
Clock pulses were used for the counters.
each period.
this design
the
16
bit
procedure was found
appropriate from
was running at
slow RPM,
high and
the
hardware point of view.
to
be
tne
For
most
When the motor
the period of the revolution was
counter registered high.
From an overflow
point of view, the maximum count on the counter should nj*

31
REGISTER (74374)
REGISTER (74374)
osc
>i
600 KHZ
4X4 CASCADED COUNTERS

(74LSI6I)
Figure 3.5.
Circuit Diagram of Digital Tachometer.

32
PERIODIC
<
\_i
o
>
T IME(SEC)
Figure 3.6.
have
exceeded 65536.
Output of the Flip Flop.
Keeping in mind
tnat wnen
counter overflows,
the motor
runs under
600
became
minimum speed restriction for the motor.
the
RPM
the
this
criteria
A
74121 monostable multivibrator was used to get short, clear
pulses
for
(one shot)
the
is
counters.
The
output of the multivibrator
PERIODUJ
<
\_i
>
23NAN0SEC
T
Figure 3.7.
ME(SEC)
Output of the Multivibrator
33
The 7^374 Register stored the counts for each period until
the new count came.
Two 8-bit DAC Digital to Analog converters were used to
convert the counts to the voltage as

speed.
The
logic
of
Digital
the
it
related
to
Analog conversion
to
the
is
The
volts.
be
voltage related with speed
is
between
and
10
When the speed is -40 rpm the output of the DAC will
volts; when the speed
is
24,000 rpm the output of tne
The lowest speed
DAC will be 10 volts.
highest speed is equal to
10
is
equal to
0,
the
volts.
V,_ CO TO 9.96 VOLTS)
0/A
MOST
CONVERTER
SIGNIFICANT 3ITS
9 TO 16
Figure 3.8.
C.
0/A
CONVERTER
LEAST SIGNIFICANT 3ITS
TO
3ITS
Digital to Analog Conversion.
PULSE WIDTH MODULATOR

The "D" input to the decoder is
to
7 9ITS
which the pulse-width modulated logic signal can be

34
applied.
It
should
be
recognized
that
low mechanical
tine
time constant of these motors could cause
speed
variation at slow speeds when
used in tne pulse width modulation.

is
obtained by mixing
a
instantaneous
low duty
cycle
is
The pulse-width modulator
pulse width modulated signal was
low frequency
input error signal witn
high frequency triangular "dither" signal.
Twenty kilohertz
was the frequency chosen for the dither signal.
The sum of
the error and triangular signal e(t) is shown in Figure 3.10A
Figure 3.9.
2T
Pulse Width Modulator.
35
'dJ/tSt u\\J
5v'.'
DlV
Error and Dither Signal.
Figure 3.10.
signal was fed to the "zero crossing circuit."
An e(t)
zero crossing circuit converts the resulting sum into
level
signal
e'(t)
shown
as
in
Figure
3.103.
shifts between the two digital levels

Input,
signal.
assumed
is
to
DC
volts and
two
signal
volts.
level or slowly cnanging
Added to the triangular signal d(t), which oscillates
between -10 volts and
signal was
added
then fed to
shown
be
The
The
to
to
volts,
e
to
and
produce
has
e(t).
period,
This
T.
This
result was
zero crossing detector, which in this case is
switch from plus
volts
(logic
1)
to
volts
(logic 0)
A
in
circuit diagram of the pulse width modulator is shown
Figure 3.11.
circuit diagram of the digital tachometer

36
and
artwork
20K
o-A/W?
of
the
circuit
is
is
shown
shown
in
Figure
in Appendix
3.12.
The
C.
20K
D(t)0-A/W
ZERO CROSSING DETlCTOR
Figure 3.11.
Circuit Diagram of the Pulse Width Modulator
37
I*
iS
I) ll
it
10
13
i)
(.
i*
lb
> 8
.2
2
IT
N
it
11
l>
Ji
<
5
S
I*
lb IS IH II I?
ir5
II
10
7474.
11 k S
t>
13
11
Ik If
1
2
1
J
i 'i
II
'i
'o
74LSIol
mn
> t
5 o > 51
S
it
It
'III
HO
r
ia
7404
"
zO_bg
Figure 3.12.
in
10
11
74LSIGI
liu mi
~
I
IK >>
74LSI6I
74=LSI6I
>
1*
11
.0
K)
3 8
741ZI
I
I
1
2 J
LI
II
9.
PWM
Circuit Diagram of the Digital Tachometer

and Pulse Width Modulator.
33
SYSTEM TESTING AND DATA COLLE CTION FOR VELOCITY CONTROL,
IV.
GENERAL
A.
After building the velocity control

brushless DC motor
on
how
the
some
system for the
experiments were done to get data
system works.
The
instruments used
for
these
experiments are shown below:

1.
2.
3.
4.
5.
6.
7.
8.
PS 150E
Power supply unit
Hewlett-Packard 6216A power supply
.Wavetek model 145 pulse/function generator
Textronix 2213 oscilloscope
Textronix 464 storage oscilloscope
Hewlett-Packard 3582A spectrum analyzer
Hewlett-Packard 85 plotter
Hewlett-Packard 124A camera.
The power requirements for the system were + 15V, -15V,
+5V,
-10V, -15V.
PWM
DIP
SWITCH
(E>D/A
CONVERTER
DIGITAL
(CK)
Figure 4.1.
D/A
CONVERTER
TACHOMETER
(0A
31ock Diagram of the Velocity Control System

39
test points were defined by letters.
For simplicity,
block diagram
test
(and
points)
of
the
system is shown in
Figure 4.1.
These test points are the same on the circuit board.
velocity command,
four position dip switch was used.
For
Fifteen
different speeds are produced depending on the relevant motor

power supply.
calibration of tne system is
The
accurate data.
For
important
calibration purposes,
resistors were used in the system.
to
getting
many adjustable
The calibration of the
system is explained in Appendix B.

B.
OPEN LOOP VELOCITY CONTROL

For open loop studies,
the
15V.
open
loop
The
(OL)
Speed
the feedback switch is turned to
position.
command was
The power supply was set
given
by
dip
switch.
to
The
position of the dip switch and the equivalent RPM values

are as shown below:
Dip switch position
3peed (RPM)
3000
3260
3410
3570
3660
3750
3300
3845
0001
0010
0011
0100
0101
0110
0111
1000
40
The 3750 RPM speed (Dip switch
first experiment.
motor
is
0110) was chosen for the
The two channel Hall sensor output of the
From the Hall sensor output
the speed of the motor can be calculated.
V/UIV
Figure 4.2.
Hall Sensor Output of the Motor for 3750 RPM.
Since the Hall sensor sends
pulses per revolution, Figure
4.2 shows that

1
rev
210"3
16
msec.
1/16 msec
60
The pulse width modulated signal
3750 RPM.
(test point P)
is shown
in
Figure 4.3.
When the shaft of the motor is held, the motor slows down
and
no
seen.
change of the pulse width modulated signal can be
Another experiment was done by changing the power
supply of the motor.
The
speed of the motor was changed.
41
Figure 4.3.
Pulse Width Modulated Signal.
Both these observations

system.
switch
In
=
the
show that
this
second experiment 3260
0010) was chosen.
is
open
loop
speed
(dip
an
RPM
The Hall sensor and PWM signals
are, shown in Figure 4.4 and Figure 4.5 respectively.
1 iVIb/UIV
Figure 4.4.
Div
42
^O/Ji
Figure 4.5.
C.
'
ZV
Pulse Width Modulated Signal for 3260 RPM.
CLOSED LOOP VELOCITY CONTROL

For the closed loop system, the feedback switch was turned
on
to
the closed
set to 30 V.
loop position (CD.
The power supply was
The position of the dip switch and equivalent
RPM values are as snown below.
Dip switch position
Speed (RPM)
0100
0101
1275
1500
1580
1375
01 10
0111
Due to hardware restrictions,
16
bit system was used.
That brought some unwanted results in low speed experiments.
For
that
reason -2
Dither signal.
steady
state error was
added
to
the
The Dither signal is shown in Figure 4.6.
43
ov/uiv
ZQ)i6iQiv
Figure 4.6.
The Dither Signal.
control
For the first experiment on closed loop velocity
the speed of 1275 RPM was chosen.
The dip switch was set to
0100.
Figure
The Hall sensor output of the motor is shown in
4.7.
From this picture the speed of the motor can be
calculated
Its
4.8.
speed
in
is
the
1275
same
RPM.
fashion as the previous section.

The
PWM signal
is
shown
in
Figure
PWM
When the shaft of the motor was held slightly the
command
signal was changed to keep up with the given speed
(see Figure 4.9).
closed loop system.
This is one of the expected results of
Another experiment was done by changing
the power supply of the motor.
observed.
No change
in
This is another expected result of
system.
44
the speed was

a
closed loop
?y/ uiy
b/pjy
Figure 4.7.
Hall Sensor Output of the Motor for 1275 RPM
l_
Figure 4.8.
0/Jo
'
bV/ uiV
UlV"
Pulse Width Modulated Signal for 1275 RPM

45
DV
Figure 4.9.
'
Pulse Width Modulated Signal with External

Force on the Motor Shaft.
TRANSFER FUNCTION MEASUREMENT AND SIMULATION STUDIES
D.
^The transfer function of the motor can be found by using

a
spectrum analyzer.
Hewlett-Packard 3582A spectrum analyzer
was used for this experiment.

A
block diagram of the closed loop velocity system and
its connections to the HP spectrum analyzer are shown in Figure

4. 10.
Random noise was used in the system and was fed to the
summing junction (test point N).
the
noise was 1.0,
to the noise.
the
When the forward gain of
the speed of the system was changed due
This unwanted result was eliminated by choosing
noise gain equal
to
0.2.
46
The
frequency
response of
the
system found by the HP spectrum analyzer as shown
Figure 4.11a and Figure 4.11b.
MOTOR
HP SPECTRUM ANALYZER
12
NOISE
?
test/
POINTS
CIRCUIT BOARD
Figure 4.10.
Closed Loop System with Spectrum Analyzer

X FR
FCTN
MK R
+
-
29dB
2 3
FS
2dB
9dB
III
CD
r ".
,
-20
rj
-30
'M A,
<
v>
r
il
i
1
1
it
L
r
9
K R
Hz
1
Hz
I
Bl' 1
.5
1"
:5 _H
2 i rnHz
25
frequencyChz)
4.11a. Open Loop Frequency response of the system
with magnitude curve.
47
in
FR
FR
FCTN
FCT N
+ 89dB
MK R
1
F 3
So
9 d B D
5 o/d
IV
i
Lj
\
no
uu
ift ITT
1
f 4
LU
LU
<
X
--
H-.
u
rt
I
i
i1
'I it
"jit"jTl"
on
VJ VJ
rx
II
\_
Hz
..
1KR
25
19.2 Hz
1
B U
'
72 6
mHz
25
2.5
frequency(hz)
Figure 4.11b.
In
the

with Phase Curve.
velocity control system there are
various digital components,

and
D/A converters.
The
such as
flip-flops,
number of
counters
counters which were used
system are synchronous devices,
this
means
they
use
in
the
clock
pulses
The following events take place in the system.
1.
Wait for
2.
Determine the speed for one revolution of the motor.
3.
Perform digital to analog conversion.
4.
Send the updated control variable to the motor.
Go to step
clock pulse.
48
Because the computation of the speed and sending the
variable takes some time,
control
between steps two and four.
The
there
sampling interval
equal
During the transfer
motor.
speed
is
chosen was
RPM.
1360
time delay
D/A converter
the
revolution of the
one
to
holds
This implies that
signal over one revolution of the motor.
the
is
function measurements,
the
With simple calculation,
one
revolution of the motor can be found to be 44 milliseconds.

The
/0.044
Nyquist frequency is thus
71.2 rad/sec or
11.3 hz.
frequencies which are greater
At
frequency,
the
than
Nyquist
the
ambiguities of the transfer function for
both the gain and phase curves can be seen in Figure 4.11a
and
this part of the experimental
For that reason,
4.11b.
data was not included in the calculations.
The
magnitude and phase of the transfer
frequency,
function which was found from Figure 4.11a and

in
Table
The
1.
data in Table
is
plot which was
Bode
are shown
drawn by using
the
The transient response of the closed loop and open loop
system were found from

in
Figure 4.15 and
strip chart recorder and are shown
Figure
4.16.
On
the
other
hand,
the
transient response of the system can also be observed from

the storage oscilloscope.
A
Textronix 464 storage oscilloscope was used
the transient response of the system.
49
to
get
The step input (from
rpm to
1035
1305
rpm)
was applied
to
system as
the
step
The closed loop transient response of the system is
input.
shown
in
Figure 4.17.
transient
This
response correlates
with the transient response which was found from the strip
chart (see Figure 4.16).
As can be seen, the system is type
pole
at
7.0
rad/sec
and
one
pole
[Ref.
1]
at
and has one

27
rad/sec.
The open loop transfer function of the system is shown below.
GCa)
-^
(s/7.0+1 )(s/27.0+1
TABLE 4.1
FREQUENCY RESPONSE WITH MAGNITUDE AND PHASE
Magnitude(db)
w(rad/sec)
2.5
2.6
2.6
0.7
-0.9
-3.3
-6.8
-9.2
6. 2
8. 7
10
15
20
25
-11 .7
30
35
-13.5
-14.8
40
45
50
55
60
65
70
-17.
-18.3
-19.6
-22.2
-24.9
-28.9
Phase(desrrees)
-91
-91
-94
-107
-111
-123
-138
-153
-164
-176
-195
-207
-212
-230
-241
-246
-250
This transfer function was used for computer simulation

of
the
system.
The
open loop frequency response of the
50
system is
shown
Figure
in
4.13
and
transient response
the
of the system is shown in Figure 4.14.

The time constant of the system was found from the open
loop transient
response
Figure 4.15).
(see
The
time
it
takes to get 63$ of velocity gives the time constant of the
of
system.
the
found
to
be
140
From Figure 4.15 the time constant was
milliseconds.
On
the
other hand,
the
time constant of the system can be found from the transfer
function which was determined using the data from the HP

spectrum analyzer.
The low frequency pole of the system as
determined from Figure 4.12 was 7.0 rad/sec,
then the time
constant
142 milliseconds
7.0
This
time constant correlates with the time constant which
was found from the strip chart recorder.
This indicates
thai:
the frequency response of the system which was found from the
HP spectrum analyzer was accurate.
The
time constant of the
calculated
from the closed
system which was shown

the
transient
Figure
in
4.16.
response of the
From the
figure,
settling time of the system was found to be 320 milli-
seconds.
was
loop
closed loop system can be
320
Thus
the
time
milliseconds/4
constant of the closed loop system

=
80
51
milliseconds.
It
can be
seen
that the time constant of the closed loop system was faster
than the open loop system.
Another
important subject arises from the usage of
converter
D/A
creates
cause phase
lag
the
in
the
in
Since
system.
related
delay
This was the expected result.
system.
D/A converter
the
sampling rate,
the
to
will
this
This phase difference can
be seen by comparing the measured open loop frequency response
with
that
calculated
from
transfer
the
function.
The
calculated phase does not include time delay, which the

measured phase does.
It
is
seen
that
measured
the
phase
lag exceeds the calculated lag by 15 at the corner frequency

w
Thus the time delay is approximately
7.0 rad/sec.
<P
37.4 milliseconds
The
time
constant of the motor which was given by tne
factory specifications was 14.4 milliseconds.
that
the
time
constant of the motor
system time constant.
is
This difference
It is obvious
faster
is
than
caused
by
the
the
time delay of the pulse width modulator and the D/A converter.
52
FREQUENCYCW,RAD/SEC)
Figure 4.12.
Bode Plot of the System.

53
(2fap)
asVHd
0*581-
O-CT-
0'C2-
(ap)
Figure 4.13-
0'BB-
<TB>-
0-B3-
(T08T-.
0*B-
O'Si-
aanxiNovw
Frequency Response of the System

from Computer Simulation.
54
o1E
s
1
j
!
i
!
i
i i
i
1
1
1
2
1
T*T
O'l
6*0
9-0
i'O
9*0
9-0
ro
S'O
ro
ro
^r
o-o
C^da oooi v)a33ds indino
Figure 4.14.
Transient Response of the System from

Computer Simulation.
55
1-
-i
ggagSB
ts2
:v..~
TTfvr^
it-
-j
^;~Uh*t
i:
-:M:
i-
...
n 1
^-H
-:-:i
"i^::r:
r^MMrSEe
H
Figure 4.15.
1-
Open Loop Transient Response of the System

from the Strip Chart.
PRINTED
^
-S-
t.
U S *
TVVT
h
^_i._L
HP*f
2SBMZSBS
H
Figure 4.16.
1-
-+
-I
It
1
(-
Closed Loop Transient Response of the System

from the Strip Chart.
56
Figure 4.17.
Closed Loop Transient Response of the System

from Storage Oscilloscope.
57
POSITION CONTROL OF THE DC MOTOR WITH MICROPROCESSOR CONTROL
V.
GENERAL
A.
Microprocessor control of brushless DC motors has many

advantages over an analog control.
since
that
it
can
be
One of the advantages is
built with
couple of integrated
circuits, it is smaller and lighter than an analog controller.

It
is
also easy to debug the system.
There are some advantages and disadvantages to consider

in software design and
its
implementation as well.
Some of
the advantages are:

1
2)
By changing the software program,

system can be changed.
By.
the function of the
modifying the input/output devices, this system can

for other control systems.
be used
B.
3)
By standardizing the hardware, system design emphasis

can be increased on software programs and subroutines.
4)
Since the system is constructed of standardized units,

it is easy to debug the system.
MICROPROCESSOR CONTROL OF DC MOTORS

There are two approaches to microprocessor control.
approach
approach.
is
One
the "direct" approach, another is the "indirect"

In the direct approach the data obtained from the
system are fed into
microprocessor to compute the new value
of control. In the "indirect" method of microprocessor control,

the motor has an analog servo controller and microprocessor
58
is
used
to
turn
the
servo on
and
off.
{Ref.
In
2]
this
thesis the "direct" approach is used.

The block diagram of the microprocessor-controlled position
control system is shown in Figure 5.1 [Ref 33.
The position
PWM
MICROPROCESSOR
MOTOR
CONTROLLER
DIRECTION
DRIVE
A
B
Figure 5.1.
and
<
"
"
"
ii
OPTICAL
0A 0B
HALL
ENCODER SENSOR
MOTOR
Position Control System.
direction commands are given from the cathode ray tube
(CRT)
terminal.
controller
is
the
Another
actual
input
to
the
microprocessor
direction of the motor which
is
determined by using two channels of the optical encoder.

The direction sensing system is shown in Figure 5.2.
C.
INCREMENTAL OPTICAL ENCODER

The
incremental optical encoders are used for position
confirmation and for feedback signal generation.

optical
encoders
provide
59
pulse
for
each
Incremental
increment
of resolution.
a
An incremental encoder has four main parts:
light source,
rotation disk,
sensor as shown in Figure 5.3.
Heds-6000 series
incremental
stationary mask,
[Ref.
optical
2]
encoder was used
DIRECTION
SENSORS
Figure 5.2. Direction Sensor.
SENSOR
LIGHT
(
LAMP, LED)
PHOTOVOLTAIC CELL,
PHOTOTRANSISTOR,
PHOTODIODE
)
STATIONARY
ROTATING
DISK
Figure 5.3.
MASK
Incremental Optical Encoder

60
Hewlett-Packard
the system.
SOURCE
and
for
The
Heds-6000
optical encoder.
body,
series
It
is
high resolution
consists of three parts:
incremental
the encoder
metal code wheel, and emitter and plate.
The incremental shaft encoder operates by translating the
rotation of
shaft into interruptions of
light beam which
provides output as electrical pulses.

The standard code wheel is
metal disc which has N=1000
equally spaced slits around its circumference.
An aperture
matching pattern is positioned on the stationary phase
plate.
The light beam is transmitted only when the slits in
with
the code wheel and the aperture line up.

a
Therefore, during
complete shaft revolution, there will be N=1000 alternating
light and dark periods.

plate aperture collects
molded
lens
beneath the phase
the modulated light
into
silicon
detector.
The encoder body contains the phase plate and the detection
elements for three channels.

pulses for each revolution.
The first channel gives N=1000

The second channel has
similar
configuration but the location of its aperture pair provides

an output which is
phase
difference
in
quadrature to the first channel.
is
90
electrical.
The
The direction of
rotation is determined by observing the leading form of the

channel 8.
The
The outputs are TTL logic level signals.
index channel
is
similar in optical and electrical
configuration to the A,B channel described above.
61
An
index
pulse of typically one cycle width
is
generated
each
for
rotation of the code wheel.

For counter clockwise and clockwise rotation of the code
channel A,
wheel,
channel
B,
index channel outputs are
and
shown in Figure 5.4a and Figure 5.4b respectively.
characteristics,
operating conditions
recommended
definitions are shown in Appendix

D.
Encoding
and
E.
MICROCOMPUTER SYSTEM
The general block diagram of the microcomputer system is
shown
in
The microprocessor unit
Figure 5.5.
(MPU),
Z-80,
implements the function of the central-processing unit (CPU)
within one chip.

(ALU),
It
includes
an
plus internal registers,
and
charge of sequencing the system.

buss.es:
arithmetic-logical
a
control unit (CU),
The
an 8-bit bidirectional data bus,
tional address bus and
The data
unit
in
Z-80 creates- three

a
16 bit
unidirec-
control bus.
bus carries
the
data
different elements of the system.
being exchanged
by
the
Mainly, it will carry data
from the memory to the Z-80 or from the Z-80 to an input/output

chip.
The
input/output chip is the component in charge of
communication with an external device.

The address bus carries an address generated by the Z-80
which will
select one
For this system
o.
t"be
chips attached to the system.
741S138 decoder was used.
This address specifies the source or the destination of

the data which will transit along the data bus.
62
.CHANNEL A
-r
UJ
CHANNEL B
CHANNEL
TIME OR ROTATION
Figure 5.4a.
Encoder Channel Outputs for CW Rotation
CHANNEL
CHANNEL
LU
Q
_J
<
CHANNEL
TIME OR ROTATION
Figure 5.4b.
Encoder Channel Outputs for CCW Rotation

63
osc
^> PORT A
^> PORT
*!
Microcomputer System.
Figure 5.5.
The control bus carries the various synchronization signals
required by the system.

The
Z-80
supplied by
requires
a
precise
timing
4.915 MHz crystal.
The RAM (random-access memory)

for
the
reference which is
system.
MOSTEK MK 4118
is
(P/N)
the read/write memory
series,
1KX8
static
RAM was used for the microcomputer.
The system contained two interface cnips so that it could
communicate with the external world.
The MC 68661B, Enhanced
Programmable Communications Interface (EPCI) was used

communicate with the CRT terminal.
programming are explained
in
64
to
The details on the EPCI
Appendix
F.
An
Intel
M8255A
Programmable Peripheral Interface (PPI) was used to interface

with the motor.
used
The M8255A PPI has three ports which can be
input or output purposes.
for
The operating modes of
the chip are explained in Appendix G.
The 2716 16K(2Kx8) UV Erasable Prom (EPROM) was used to
load
the
program for the system.
The
function of the
system can be changed
entirely by writing the new program
and loading the EPROM.
The circuit diagram of the microcom-
puter is shown in Figure 5.6.
SOFTWARE DESIGN
E.
General
The
software was designed in such
fashion that
position command to the motor is given from the CRT terminal.

The direction of the motor is calculated by the program which
chooses the CW or CCW direction for the shortest path
to
its destination.
The system software was written in Assembly language
(Appendix H)
at
Zenith Z-100 microcomputer,
instruction sets [Ref 31.
using
Z-80
The program was assembled and the
hex files downloaded to the EPROM by using
SYS19 routine.
The main program consists of:

1)
an
initialization routine for the ports and
interfacing
2)
calibration routine for
3)
position control routine and subroutines.
65
D/A converter, and
CRT
2.
Main program components.
initialization routine sends
The
control word to
the parallel ports of the computer, setting them to the output
mode.
Tnere are two options given to the user.
First
is
the calibration of the D/A converter (Appendix D) and second

is the
position control of the system.
After the calibration
of the system, the position command to the motor can be given
from the CRT terminal.
For simplicity,
motor should be given as
count of pulses.
mental optical encoder gives

pulse
represents 0.36.
the position of the
1000
the
If
Since the incre-
pulses per revolution,
command
is
100
counts,
it
will represent 36.
The direction of the motor

following fashion.
is
determined
If the position command
is
in
the
greater than
180 (500 counts) the direction of the motor will be counter-
clockwise (CCW).
The program takes 300 states to calculate the position
of
the
actual
motor
time
determine the
and
the
program takes
new
to
control
command.
execute can
be
found
multiplying the number of states by the clock period.

4.915 MHz clock was used
for
this
microcomputer,
so
The
by
A
the
period of the pulse is:

1/4.915
10 6
0.2035 microsecond.
Each state would correspond
time.
By
to
0.2035 microseconds of real
adding up the total number of states that the
program requires to execute and multiplying this by the clock

66
period,
determined how long this program will take
it can be
to execute.
300 states
0.2035 microseconds
On the other hand,
from the
sent
60.6 microsecond.
the period of the pulses that are
incremental optical encoder should be longer
than 60.6 microseconds.
Otherwise,
the microcomputer will
miss the pulses and go to the wrong position.

At maximum, 810 rpm was found to be
for the brushless DC motor.

in 74
sufficient speed
The motor will make one rotation
milliseconds and each encoder pulse period will be 74
microseconds long.
for the motor.
This corresponds to
volt power supply
When the position error is maximum, the motor
speed will be 810 rpm and it will decrease with
error signal.
speed
of
the
When the error signal is between
motor will
be
600
rpm.
The
decreasing
O
torque
-^
'
at
the
this
speed was found sufficient to overcome friction in the motor.

The flow chart of the system is shown in Figure 5.7.
3.
Description of the subroutines

To
make the program useful
and understandable some
subroutines were written.

The Getchar
subroutine gets
the
character from CRT
terminal and stores it in register.

The Echo subroutine sends message string to the CRT
terminal
The
terminal
Recall
subroutine sends characters
67
to
the
CRT
'
The
..
'
subroutine waits for the next positive rism,
edge of the encoder pulse.

The CPY88 subroutine calculates 6x3 bit mui tipiicaticn
in
<t
r-
rt
m
+
n
Z
r- h- N. o
IS
IT
^r
+
co
U.
'
> I
O (Mr^^m^r-oOcnO
<MKW
'
'
'
'
'
'
IT)
rOKjrorOw-itorOKlrorOr}-
2ur
f-
.1
_l
_)
in
INI
(0
3 3
"3
Z2
ro
>z
to
N.(T>
I9IS1
tf
r 1
**>/> f\Jc0t^-<r>O
08Z
WTT
00
ro
i
o
o O
2 2
N.
m * o
1
1 5
91
01
%
.
Circuit Diagram of the Microprocessor

63
o
-t
N.
:0
Z>
INITIALIZE
STA RT
PORTS
DECREMENT
POSITION
GET POSITION
/-SPEED
-DIR=CW
COMMAND
INCREMENT
CHECK ENCODER
PULSE i
DIRECTION
POSITION
GET ACTUAL
DIRECTION
ERROR
DlR=CCW/
YES
DIRECTION
SPEED
/_
ERROR
_DIR=CW
GET ACTUAL
FIND POSITION
FIND POSITION
'-SEPEED
GET ACTUAL
DIRECTION
INCREMENT
POSITION
.SPEED
DECREMENT
DlR-CCW/
POSITION
INCREMENT
GET ACTUAL
DIRECTION
POSITION
DIR=CCW/
'-SPEED
DIRzCW
SPEED
DICREMENT
POSITION
Figure 5.7.
-SPEED
-DIR=CW
Flow Chart of the Main Program.

69
SYSTEM TESTING AND DATA COLLECTION

FOR POSITION CONTROL SYSTEM
VI.
GENERAL
A.
for
microprocessor controller using tne Z-80 was built

position control system.
the
During
the
testing
the
following equipment was used:

1.
Power supply unit PS 150E
2.
Hewlett-Packard 121
3.
Wavetek model 145 pulse/function generator.
4.
Power supply model 3650.5.
5.
Hewlett-Packard 124A camera.

The
power supply.
6A
requirements for the microprocessor were
power
+15V, -15V, -10V, +15V and 3-30V.
The power requirement for
motor drive as well as the incremental optical encoder was

+5V.
A four
The
volt power supply was used for the motor.
sequence for turning on the power supplies for the
system is important.
processor
and
supply
the motor
of
First,
motor drive
the power supply of the micro-
should be turned on.
The
power
should be turned on at the very last.
The microprocessor system draws
total of 450 milliampers.
The maximum current limit of 500 milliampers should be set
before adjusting the five volt power supply.

To start the microprocessor the reset button should be
set.
the
an
The
dial
which was mounted
on
the
shaft
to
observe
angular position of the motor can be adjusted to 0 as

initial position.
70
SYSTEM CALIBRATION
B.
The calibration of
using
system.
the
written.
was
For
After
system should be done before
the
purpose
this
"
"
options
two
(See Figure 6.1)
system calibration,
for
instructions appear on the CRT Terminal.
voltage on test point
The
calibration program
resetting the system,
appear on the CRT terminal.
After entering
"C"
set
of
(See Figure 6.2)
should
adjusted
be
to
-4.96 volts.
CLOSED LOOP POSITION CONTROL
C.
After choosing the position control option from the

menu,
set
of
instructions appear on the CRT terminal.
(See Figure 6.3)
Since the optical

of
1000,
incremental encoder has
resolution
each pulse of the encoder represents 0.36.
position command
should
be
given
as
counts.
The
relation
between counts and angular positions is given in Table

A
was
dial
used
to
The
2.
easily observe the angular position of
the motor.
The
shown
in
block diagram of the
Figure 6.4.
position control
blow up picture of the curve
The
following block is shown in Figure 6.5.
error
is
maximum the
system is
velocity will
be
When the position

810
rpm.
When
the
position error is between minus 5 and plus 5 the velocity
will
be
600
rpm.
When the position error
is
minus,
direction of the motor is changed from the CW direction

71
tne
to
the
CCVJ
direction or from CCW direction to the CW direction,
depending on the initial direction of the motor.
software program was written
The
when the position error
zero
is
the
in
such
motor will
way
not
that
shop.
When the position error is 0.36 the direction of the motor

is
changed to the other direction and position error
-0.36 the motor
create
is
reversed
dither signal
This dither
behavior
again.
This
algorithm will
between +0.36 at the position.

will
hold
the
motor shaft at
given position within +0.36.
USE?
t-SKIHT
2-R^lliffliaHTSDL
Figure 6.1.
is
CRT Terminal Menu for Program Options
72
tne
mi shut a^iiiluE
- IF YOU OH Kn fflJlKTHIW
FWB
Figure 6.2.
[C
Pflr
AiOGiCfffr TIE RETURN
CRT Terminal Menu for Calibration of System
mnVM COHTraLflEOQWf t
-EMTIS IHb H1K111UH
- wixonr a
Iff
courts c
OHWTS
j&a oekees)
- EHTER D THREE DIGITS (812)
-HIT THE RETURN
Figure 6.3.
CRT Terminal Menu for Position Control
73
TABLE 6.1
COUNTS AND ANGULAR POSITIONS
Angular Position (degrees)
Counts
000
142
15
083
30
45
60
75
90
135
180
125
167
208
250
375
500
625
750
875
997
225
270
315
359
The software program was written in such
when the position command was bigger than 180,
fashion that
the program
would chose the shortest path for its destination.
Fifty runs for the position commands which were smaller
than
130
and
fifty
runs
for
the
positions whicn were
greater than 180 were done.

For
and
all
the runs,
the motor went: to the given
dither signal was found to be +0.48.
position
This was close
enough to +0.36 to be satisfactory.
The
transient response and frequency response of the
system can be found by using the additional system interfacing
chips and
by
writing
new software
program.
recommended for further studies in Chapter Seven.
74
This
is
MICROPROCESSOR
]
VELOCITY
y^-^
ry~M
COMMAND*" V-^y
position.
1
POSITION
!/
ERROR^
PWM
MOTOR
DRIVE
^"-1
1
l_
MOTOR
J\
OPTICAL
ENCODER
Figure 6.4.
Block Diagram of the Position Control System.
POSITION
Figure 6.5.
ERROR(DEG)
Curve Following Block

75
SUMMARY AND CONCLUSION
VII.
REMARKS AND CONCLUSIONS
A.
The brushless
motor has
DC
been
shown
to
advantages compare to the conventional DC motor.
have
some
Brushless
DC motors with their disadvantages still are more favorable
Since commutation
for use in incremental motion applications.
done by switching transistors, pulse width modulation is
is
a
desirable option in system design.

The low-cost position sensors such as Hall effect circuits
optical sensing integrated circuits have been found to
and
be
highly practical
for servo designs.
velocity control
system designed by using the Hall effect sensors.
From the analyses,
the
time
constant of the motor as
given in the factory specifications was considerably faster
than
the
the measured
time
time delay of the
constant.
This was
the
result of
and
the
D/A
converter
The
transfer function of the system was developed by
using an HP spectrum analyzer.
The
constant of tne
time
system was found by using the transient response data which

was measured using
strip chart and storage oscilloscope.
The measure of the time constant was found
to
be
identical
with the computer simulations of the system transfer function.

The position control of the brushless DC motor was studied
by using a Z-80
microprocessor controller.
76
Position feedback
was obtained from an incremental optical encoder.
The encoder
had 1000 resolution per revolution which provided high accuracy
for position control.

a
Assembly language was used to write
program for position control.
clock was used.
This
For the Z-80 CPU
brought
the
4.915 MHz
limitation for maximum
speed of the motor to 810 rpm.

The
done
and
system testing for the position control system was

was
found
to
be
accurate.
Since the
incremental
encoder gives one pulse for 0.36 angular position,
the
steady state error was programmed to be +0.36 to hold the
torque on the
shaft.
steady state error whicn was
The
found from the position control system was +0.48.
B.
RECOMMENDATIONS FOR FURTHER STUDIES

For the digital tachometer
system was used.
By
"a
16
bit
(4x4
bit
counter
using the 24 bit counter system,
the
performance of the system can be improved.

Eight bit D/A converters were used for both the velocity
and position control systems.
the
By using 12 bit D/A converters,
resolution of the system can be
increased
from 0.2
volts to 0.01 volts.
Instead
of
the
Hall
effect
sensor,
an
incremental
optical encoder can be used with the velocity estimator to
measure the motor speed.
The
sampling
rate
will
then
faster than the sampling rate using Hall effect sensors.
77
be
2222 transistor
2N
signal
PWM
the
in
motor drive
applied will burn out
is
transistor logic
To avoid this,
(TTL)
signal
collector
open
the
used
is
which
to
the
i -f
the
transistor
for
the
PWM
signal.
with an
signal
logic
820 ohms pull-up resistor should be used for the PWM signal.
Assembly language was used to program the position

control
system.
may
used
be
There
such as
many
are
Forth,
high level
Basic,
There are many advantages
Ada.
Fortran,
using
in
languages that
C,
a
Pascal
high-level
language rather than assembly language because

much less time to develop
more
readable and
with
couple more parallel
written
and
modifying
by
the
one output as
programmed
It
to
the
interfacing devices
program
by
(Intel
program which was already
to
using botn outputs instead of
position sensor the steady state error can

be +0.18.
This will require another CPU
faster clock.
is
recommended that after the circuits are built and
it is certain that it is working properly,

to
modify
incremental encoder has two outputs with 90
electrical phase difference,
The code is also much
Since the
with
takes
transfer function of the system can be found
8255A)
be
easier
therefore,
it
high-level language.
The
using
system.
and
build
the
it would be better
circuit using wire-wrap technique
78
to
improve
the wire layout and also to reduce possible trouble shootini
errors
79
APPENDIX
RATING AND SPECIFICATIONS FOR PITTMAN 511 WDG

BRUSHLESS DC MOTOR
MOTOR PARAMETER
UNITS
DAMPING CONSTANT (K K /Rj
MOTOR CONSTANT
R)
(K /
MECHANICAL TIME CONST.

ELECTRICAL TIME CONST.
N.m/(rad/s)
N.m/ W
ms
cj/v
tvv
MOMENT OF INTERIA
VISCOUS DAMPING
kg.m
*D
*M
T
T
ras
.
SYMBOL
N.m/(rad/s)
M
E
VALUE
1.42xl0~
37.7xl0~
FRICTION TORQUE
N.m
MOTOR MASS
kg
THERMAL TIME CONSTANT
min
THERMAL IMPEDENCE (WDG- -AMBIENT)
C/W
MAXIMUM WINDING TEMP.
14.4
0.155
20.5xl0"
#1
13xl0~
3.0xl0~"
0.60
TH
TH
~MX
15
3.2
155
WINDING PARAMETER
UNITS
SYMBOL
TORQUE CONSTANT
N.m/A
**
29.9xl0"
29.9xl0~
BECK EMF CONSTANT
V/(rad/s)
STATOR RESISTANCE
ohms
STATOR INDUCTANCE
mH
80
*T
L
VALUE
0.631
0.0975
3
3
APPENDIX
THE DAC CALIBRATION FOR VELOCITY CONTROL SYSTEM
to -10
The DAC system was set to
volts output range.
If the system range is to be changed an adjustment in the gain
offset will be necessary.
To
adjust the gain offset of the DAC the
following
procedure snould be applied.
1)
Turn off the power of the motor.
2)
Turn on the power of the system.
3)
Connect the
4)
Adjust the
5)
Adjust the P2 pot until -5.00 volts is shown.
test-
P1
point
'0'
to the ground.
pot until -5.00 volts is shown.
81

APPENDIX
ARTWORK FOR THE DIGITAL TACHOMETER AND PULSE WIDTH

MODULATOR CIRCUIT
TacHOfMTER
niGiTai.
NEIU
on
ooa
a a a a
fl
oia
8tt,ftaof
aaaJ
aoj ao>-
aa oa
o)
10?
pwm
aa aJ
aaa?
ff
(Li
^
iota
^s
o o o o o a
i-~A aoo
aooaoeoa
)<<ti
oooooooa
aoaisosoo
S-aaaaaa
JooooJo
"\9J>fy
0;
a
^T
82
"*
*3
Q
I
io
\\
tr
83
APPENDIX
THE DAC CALIBRATION FOR POSITION CONTROL SYSTEM
The DAC system was set to

Trie
to
-10 volts output range.
gain offset adjustment will be necessary for good system
performance
pushing the start button,
After
tne
to select an option for making calibrations.
the calibration option,

to the DAC.
'C'.
If
it
program will
ask
After selecting
tne microprocessor sends the signal
Minus 4.96 volts should oe seen from test point

is
not,
tne P1
pot should be adjusted.
34
APPENDIX
CHARACTERISTIC OF THE OPTICAL ENCODER

Definitions
Electrical Degrees:
1
shaft rotation
cycle
360 mechanical degrees

=
electrical cycles
360 electrical degrees.
Position Error:
The
angular difference between the actual shaft position
and
its
position as calculated by counting the encoder's
cycles
Cycle Error:
An indication of cycle uniformity.
The difference between
an observed shaft angle which gives rise to one electrical
cycle, and the nominal angular increment of 1/N of
lution
revo-
Phase
The angle between the center of pulse A and the center of
pulse
B.
Index Phase:
For counter-clockwise
rotation
is
illustrated above,
the
index phase is defined as
is the angle,
in
*2
electrical degrees, between the falling

85
edge of
and
falling
electrical degrees,
rising edge of
edge
of
B.
is
the
angle,
in
between the rising edge of A and the
I.
Index Phase Error:

The Index Phase Error
A$ 9
describes the change in the
Index Pulse position after assembly with respect to the A

and B channels over the recommended operating conditions.
86
APPENDIX
MC 68661B OPERATION AND PROGRAMMING
the MC 68661B
initiating data communications,
Prior to
operational mode must be programmed
by
performing write
The EPCI can
operations to the mode and command registers.

be
reconfigured at any time during the execution of the
program.
The MC 68661B register formats are summarized as follows:
MODE REGISTER
MR 17
(MR
1)
MR 16
MR1S
Sync Asvnc
Async: Stop
Invalid
00
01 =
stoo
2 stoo
Type
Parity
Parity Control
MR12
MR
MR
10
Mode and Baud
Character
Length
Rate Factor
Length
=
bit
10
1'i
Bit
MR13
MR 14
Odd
* Even
00 =
= Di'aplfd
= Enabled
10
00 = Synchronous IX rate
01 = Asynchronous IX rate
10 = Asynchronous 16X rate
= Asynchronous 64X rate
5 bits
0i=6
stoo oils
bits
T hits
n=8 bits
oils
Sync:
Sync:
Number of
SYN char
Transparency
Control
Normal
Oouble
SYN
Transparent
Single
SYN
MODE REGISTER
(MR2)
MR27 -MR24
0000
0001
00 10
0011
0100
0101
1
RiC
P\n 9
Pin 25
E
1
T.C
T.C
RC
IX
IX
R.C
10 10
IX
IX
T.C
TC
R.C
16X
R.C
16X
I6X
01 10
01
T.C
16X
COMMAND REGISTER
CR7
R.C
Pin 9
Pin 25
1000
XbVNC
1001
R.C T-C
BKOET
R.C
BKDET
R.C T.C
BKDET
R.C
BKOET
lOi
i
ioo
T.C
XSYNC
IX
xSmnC
101
T.C
10
xsrNC
I6X
Baud Rata Selection
Sync
async
sync
async
See baud
rates
CR4
CR3
CR2
Request
Mod*
To
00 = Normal rj^waiiun
Ol ASyDC
Sand
Normal
Foicm RTS
output n.ijn
Sync Aiync
Reset Error
CRO
CR1
Heiel
one ciork iimo
error flags
ecno
rm.tl*
ditbf r*brt
Sync
SYN
ii ii./j'-i"
(FE Ofc PE OLE
fc
.,nx3
stripping
Local
or
moo
i-ioo r>acn
= flemoie in
<u
Force
TS
Normal
slfu<. rmjister
uulot
Transmit
Control
Oat* Terminal
Control
iR>EN)
Ready
(TEN>
Async
Force oreah
Automatic
Ol
i0
labia
sync
async
Receive
Operating
in
sync
async
(CR)
CR5
CH6
MR23-MR20
Mode
T.C
=*Foir.e fwea*
Force OTR
* Onarjtt)
i
- Endtiie
output
i
OUtPut
rl
Output low
oa^h
Sync.
Send OLE
u a Normal
i
87
Sena OLE
riign
* Force OTR
luaat
Disable
i
Enable
There is one MC 6866 B device in the system.

1
address is CE Hex,
mode register
command register address is
88
Hex.
Mode register
address is 7D Hex and
APPENDIX G
INTEL 8255A OPERATION AND PROGRAMMING
Intel
The
C).
8255A contains
All can be configured
in
8-bit
three
a
ports
(A,
B,
wide variety of functional
There are three basic
characteristics by the system software.
modes of operation that can be selected:
Mode
Basic Input/Output
Mode
Strobed Input/Output
Mode
Bi-directional Bus
Mode definition control word format is as follows:
CONTROL WORD
D
ID,
GROUP
PORT
(LOWER)
- INPUT
- OUTPUT
PORT 3
- INPUT
I
- OUTPUT
MODE SELECTION
0- MODE
_ MODE
GROUP
PORT C(UPPER)
- INPUT
- OUTPUT
PORT A
I
INPUT
0- OUTPUT
MODE SELECTION
00 -MODE
-MODE
02-MODE
I
MODE SET FLAG

I
89
and
-ACTIVE
There is one 82557A device in the system.

is
C
39
is
Hex.
at
This means port
input mode.
90
Port address
and port 3 are at output;
port
5 H
APPENDIX
MAIN PROGRAM
POSITION CONTROL
PPIA
FFI3
PPIC
FPICONT
EDATA
EST AT
emote
ECOMD
RAM BASF
PCS
DIR
DIRE
CHAR
COUNT
PEA I
MFRAD
I"!
RES AD
SUM1
SDM2
CUM 3
ML1
ML2
M.L3
VEL
CR
L001
1522.1
1 32 1
V^
2DP.
1=23?
1222P.
1ZZ1H
1Z22H
1223F.
3223
SZ1H
32 3 P
32 1i
5ZSH
325B
SZ7H
309 H
32EH
S1ZH
5125
514H
51 ~H
317H
31 5 P.
51 3R
2
CP.3
2222
?P 2EFEH
AH
,
(zmode:
A
(
1
,a
j_
L-
*ODEl
P.EC-ISTE?.
FOR EPCI
L.
-T.
A,
TQQ^^
^
A.S9H
'PPICONT
A
(
SET COMMAND REGISTER FOR EFCI
>
,A
SET MODE REGISTER
FOP.
,2
FP I A
IX.HEAD1
ECHO
I
SET
SET MODE? REGISTER FOR EPCI
>
ECHC
IX.HEAD2
ECHO
IX.HEAD3
ECHO
STACK POINTER
.7DR
CMor
J r
CALL
CALL
CALL
SEI
A.ZCEE
LD
LD
:all
1S2 2P.
ECU
CALL
LCQ11
EOJ
r CU
EOJ
ZCJ
ECJ
EOJ
fou
ECJ
EOJ
ECU
ec:
ECJ
ECU
ECJ
ECJ
ECU
ECJ
ECJ
ECU
ECJ
EOJ
ECU
ECJ
ECU
LD
LD
LD
LD
LD
LD
LD
LD
LD
LD
LD
LD
CALIBRATION PROGRAM
S.
P A C
C-E7CHAF.
[A
91
ACT
ED
ro
C!
PPI
l:
RECALL
ALL
LD
*.3EH
C?
J?
LE
SBC
A, (CHAR)
A, 523
CP
JF
(CHAR)
Z.LCC2
Z.STARTl
ERROR
JP
LD
LCOll
CALL
ECHO
IX, SPACE
ECHO
IX.5EAD5
ECHO
IX.HEAD7
ECHO
IX, HEADS
ECHO
IX, HEADS
ECHO
LD
CALL
Lr
CALL
LE
CALL
LC
CALL
LC
CALL
IX. HEADS
7 EH
(ppia; ,a
LD
LE
CALL
GETCHAR
CP
JP
LE
:r
CALL
START1
SEC
CALL
L002:
x caa?
J?
LE
CALL
LE
CALL
LE
CALL
LD
CALL
Z.LOOl
IX, ERROR
ECHO
L002
IX.EEAD12
ECHO
IX.HEAE11
ECHC
IX.HEAE12
ECHC
IX.EEAD12
ECHO
FCSITIC'I CONTROL PP.CSHAK
CALIBRAIION PROGRAM
SEND CALIBRATION SIGNAL

SEND TO THE PORT
IS
IT
CARRIAGE
LE
IX.HEAD14
ECHO
CETCHAR
LD
LE
A, (CHAR)
IX. CHAR
CALL
RECALL
SBC
LD
CALL
GETCHAR
A, (CHAR)
IX. CHAR
CALL
RECALL
A.32H
PRINT HEADER
IGET POSITION FROM CRT

POSITION (ASCII
>
STRIP ASCII
FIRST DIGIT
GET POSITION FROM CRT
POSITION (ASCII
> A
,3ZH
(KL1) ,A
LD
LD
CALL
CALEBRAIION PF.D3PJW
CALL
CALL
SBC
LD
STRIF ASCII
SECOND DIGIT
GET POSITION E"OM CRT
(ML2) ,A
GETCHAR
92
LD
Lr
CALL
SEC
LD
CALL
CP
JF
LD
CALL
JP
LD
LD
LD
LD
LD
LD
GO:
A.32H
(MLS) ,A
C-ETCEAR
CH
z,c-c
IX.IP.P.CR
ECHO
START1
LD
LD
LD
LD
LD
LD
ADD
LD
ADD
LD
LD
LD
LD
LD
AND
SIC
JP
JP
JP
LD
LD
JP
LD
LD
>
STRIP ASCII
I3IRE DIGIT
IT
CARRIAGE RETURN
I?
yes, CONTINUE
ERROR ENTER AGAIN
5,2
L.54E
(KPMD; ,HL
E,2
A, (ML1)
L.A
(MPP.AD) ,51
LD
POSITION (ASCII)
',
CPY89
ix,Tresad)
LD
CCVD:
LD
CALL
A. (CHAR)
IX.C-AF.
P.ZCALL
CALL
LD
LD
LD
LD
LD
LD
LD
LD
LD
CVD
(SMI)
,IX
MJLTIPLEXTION
FIRST BINARY
MJLTIPLEXTION
SECOND BINARY
TEIRC BINARY
5,2
L.ZAE
(MPDAD) ,EL
5,2
A,(ML2)
L,A
(MPRAD) ,HL
CPY3B
IX,(RESAD^
(SUM2) ,IX
5.2
A, (MLS)
L,A
(SUM3),EI
ix, (scmi:
DE,(SUM2)
IX, DE
DE.(SUMS)
IX, DF
(POS) ,IX
E,2
C,2
',
DE.(PCS)
5L.21F4E
POSITION
IN
BIMARY
v
LOAD POSITION
DE
132 DEGREES (530 COUNT)
IS
Ca'=0
ccv=i
LIMIT
BL,DE
Z.CVD
P.CWD
M.CCVD
A,
(DIE),
ANSC
A,l
(DIR) .A
93
IT
GREATER TEEN 1E0 DEG
AA
3
ANSC
START2:
Lr
Lr
LC
LD
LD
AND
JF
JP
LD
W2
C0.NT2A
P0SIT2:
CV2A:
A.(DIR)
(ppib;,a
A.S2E
(PPIA),A
A.(DIR)
Z1H
Z.STAP.T2
STRTZA
A,(PPIC)
j
;
LE
3,
AND
JR
3ie
LD
A,H
223
Z.CW2
A,l
(EIRE) ,A
C0NT2A
A.Z
(EIRE),
HL,(F0S)
AND
CCW2:
JP
LD
LD
JP
LD
LD
LD
AND
SBC
JP
JP
JP
LD
AND
JP
IMC
LD
AND
SEC
JP
LD
SEP1:
CONT1
WAIT1
>
SET POSITION
COMPARE THE POSITION

AT THE POINT
BETOND T3E POINT
NOT AT THE POINT
DIRECTION OF THE MOTOR
HL.BC
Z.ME5AT2
M..NEGAT2
P.POSIT2
A, (DIRE)
213
NZ.CCW2A
CCtf = l
EC
3L, (PCS)
CLOCK VISE ROTATION

LOAD POSITION
CLEAR FLAGS
COMPARE THE POSITIN
EL, EC
,P0S1A
CV.'=2
A, 3
LC
LD
A.L
CPL
ADD
LD
A,l
L.A
LE
LD
LD
LD
SEC
JF
LD
JR
LD
LD
LD
LD
LE
LD
nc pulsf check again

P3ASE B
> A
C*'=2 CCV = 1
Z.START2
CFL
P0S1A
c*=? ccw=i
DIRECTION
>
CV
> ccv:
direction
check the sncoeer
CCMFLE M EMT
COMPLEMENT
3.
3
i'.i
D
L.13E
.76
de:
POSITION LIMIT
3.2
5L.DE
M.SEP1
A.2D5B
CONT1
SPEED COMMAND
SEND SPEFD COMMAND
,ZES5
3,2
A
(PFIA),A
A,
(PPIE).A
A.(PPIC)
94
SFNB DIRECTION
CHECK THE ENCODER
a
2
CCW2A
AND
JF
JP
DEC
LD
AND
SEC
JP
LD
31H
NZ.VAIT1
STAP.T2
EC
5L, (POS)
3L,BC
P .PDS2A
',
A ,a
J
COMPLEMENT
COMPLEMENT
D,a
E.L
L.1ZH
5.76 DEC. POSITION LI W IT
a,
CPL
P0S2A:
SFP2:
C0NT2
WAIT2:
NEGAT2:
CV2B:
LD
LD
CPL
a, a
ADD
A ,1
LD
LD
LD
LD
LD
SEC
J?
LD
JR
LD
ED
LD
LD
LD
LD
AND
J?
JP
LD
A,L
L.A
HL.DE
M.SEP2
A.2DSH
C0NT2
A.ZESH
a,
(PPIA) ,A
A.H
(PPIB).A
A.(PPIC)
Z1E
SPEED COMMAND
ctf=e
SEND SPEED COMMAND
',
21H
NZ.CCW2B
INC
LD
BC
HL, (F3S)
AND
SBC
HL.EC
P.P0S3A
A,H
LD
LD
LD
LD
LD
LD
SBC
JP
LD
JR
CCW=1 CV.=2
CLOCK WISE ROTATION
LOAD POSITION
CLEAR FLAGS
COMPARE THE POSITIN
COMPLEMENT
COMPLEMENT
5.76 DEC. POSITION LIMIT
SPEED COMMAND
H,A
A,L
CPL
ADD
LD
SEND DIRECTION
CHECK THE ENCODER
NZ.WAIT2
STARTS
A.(DIRD)
AND
JF
JP
LD
CPL
P0S3A:
COJNTERCLOC WISE ROTATION

LOAD POSITION
CLEAR FLAGS
COMPARE THE POSITIN
A .1
L.A
D,E
E.L
L.12H
H, 2
HL.DE
M
,SEP3
A,2D2H
CCMT3
95
2
a
SZP3
CCNT3
:
V-AIT3:
CCV2B
LC
LD
le
LD
LE
LD
AND
JP
JP
DEC
LD
AND
SEC
JP
LE
.ZEES
2.1
A.
CPL
ADD
P0S4A
LE
LE
LE
LE
LE
SEP4:
C0NT4:
WAIT4:
SEC
JP
LD
JR
LE
LB
LE
LD
LE
LD
A"'E
STRT2A
STARTS:
JP
JP
LE
LE
AND
SEC
LE
LD
LE
AND
J
CCW3:
CW3
P.
LD
AND
JP
LE
LE
JP
LD
LD
A.E
(PPIB) ,A
A.(PPIC
SEND DIRECTION
CHECK TEE ENCODE?.
J
;
Z1H
NZ.WAIT2
STARTS
CCUNTERCLCCK VISE ROTATION

LOAD POSITION
CLEAR FLAGS
COMPARE THE POSITIM
COMPLEMENT
COMPLEMENT
5.75 DEC. POSITION LIMIT
SPEED COMMAND
EC
HL.(PDS)
HL.BC
P .P0S4A
A
,fl
CFL
LD
LD
:r*=i
SEND SPEEE COM1ANE
(FPU), A
H.A
A,L
A,l
L,A
D ,H
E,I
L.10H
a.
HL.DP
M.SEP4
A.2DSH
CQNT4
A.2EEH
3,1
(PPIA).A
CCrf=l
SEND SPEED COM1ANE
A,
(PPIE) ,A
A.(PPIC)
Z1E
M7.WAIT4
STARTS
SEND DIRECTION
CHECK THE ENCODER
192 DEC.
DE. (PCS)
HL.Z3E7E
LIMIT
3L.DE
(POS) ,HL
A.(PPIC)
H.A
215
Z, STARTS
A,H
Z2K
Z
C V/3
A.l
(EIRD).A
C0NT3A
A, 2
(DIRD),A
96
SHORTEST PATH
CHECK THE ENCODER
NO PJLSE CHEC"! AGAIN
cv=? ccw=i
P0SIT3:
CW3A:
LD
3L,(FCS)
AMD
S EC
P.L.EC
JP
JP
JP
LD
AND
JF
DEC
LD
AND
SBC
JP
LD
.NEGA.T3
P.P0SIT3
M.NZGAT3
A.fDIRD)
aiH
NZ.CCW3A
HL.EC
ccw=i cv=?
CLOCK WISE ROTATION
LOAD POSITION
CLEAR FLAGS
COMPARE THE POSITIN
COMPLEMENT
COMPLEMENT
5.75 DEG. POSITION LIMIT
SPEED COMMAND
BC
-,
HL.(PDS)
P.FCS5A
A ,H
CPL
P0S5A:
SEP5:
C0NT5:
WAITS:
CCV3A:
LD
LD
E,A
A,L
CPL
ADD
A .1
LD
LD
LD
LD
LD
SBC
JP
LD
JR
LD
LD
LD
LD
LD
LD
AND
JP
JP
INC
LD
AND
SBC
JF
LD
L,A
D,H
E ,L
L.12E
a, 2
HL.DE
M.SEP5
A.2DSB
C0NT5
,ZESH
H.l
A
(PPIA),A
A,H
(PPIE),A
A.(PPIC)
21H
NZ, WAITS
START3
P0S5A:
LD
LD
SBC
CCW = 1
SEND SPEED COMMAND
SEND DIRECTION
CHEC? THE ENCODER
HL.(POS)
ICOUNTERCLOCK WISE ROTATION

LOAD POSITION
BC
HL.EC
P.PCS5A
A.H
CLEAR FLAGS
COMPARE THE POSITIN
COMPLEMENT
COMPLEMENT
H.A
A,L
CPL
ADD
LD
LD
LD
CPL
LD
LD
GET FCSITIG."
A.l
L,A
D,H
E.L
L.1ZS
',
a,
HL.DE
97
5.75 DEG. POSITION LIMIT
::
JP
M ,?EPS
LD
A.3D8E
C0NT5
A.ZESE
SEP6:
CONTS
WAIT6:
NEGAT3:
W3 B
P.
LD
LD
LC
LD
LD
LD
EP 7
C0NT7
WAIT7:
CCW3B:
c:w=i
SEND SPEED COMMAND
A ,H
(PPIE) ,A
SEND DIRECTION
CHECK THE- ENCODER
GO CHECK
AND
JP
JP
LD
A.(DIP.D)
AND
JP
DEC
Z1H
NZ.CCWSl
BC
LD
HL.(POS)
AND
SEC
JP
LD
CPL
LD
LD
a.
LD
LD
LD
LD
LD
SEC
JF
LD
JR
S
3,1
(PPIA) ,A
A.(PPIC)
Z1H
NZ, WAITS
START3
CPL
ADD
P0S7A:
SPEED COMMAND
LD
LD
Lr
LD
LD
LD
AND
JP
JP
INC
LD
AND
SEC
JP
LD
COMPLEMENT
COMPLEMENT
E,L
L.1ZH
5.75
H.2
>
HL.3C
P.POS7A
A,H
A,L
A,l
L.A
D.H
HL.DE
M.SEP7
A,ZD9H
CONT7
A.ZESa
H.Z
(PPIA) ,A
A,H
(PPIE) ,A
A.(PPIC)
31H
NZ.WAIT7
START3
BC
SFEED COMMAND
cw=0
SEND SPEED COMMAND
SEND DIRECTION
CHECK THE ENCODER
COMPLEMENT
COMPLEMENT
A, 3
H,A
A,L
A.l
98
POSITION LIMIT
',
EL.BC
P .POSSA
DEC-.
COJNTERCLOCK WISE ROTATION

LOAD POSITION
CLEAR FLAGS
COMPARE THE POSITIN
HL.(PCS)
CPL
ADD
ENCODER
CLOCK WISE ROTATION

LOAD POSITION
CLEAR FLAGS
COMPARE THE POSITIN
CPL
LC
LD
POP.
pose a
SEP 9:
C0NT3:
WAIT8:
HEAD1
HEAD2:
head:
HEAD4:
HEADS:
HEAD5:
HEAD7:
HEADS:
FEAD9:
HEAD12:
HEAD11:
HEAD12:
HEAD13:
HEAD14:
SPACE:
QUEl:
0UE2A:
3UE2E:
SONM
ERROR:
COUN:
:
Rl:
R2:
LD
LE
LD
L,A
D,H
E,L
LD
LD
SBC
JP
L.1ZH
LC
A.2DSH
CONTS
A.ZESH
JR
LD
LD
LC
LD
LD
LD
AMD
JP
JP
DB
DE
D3
DB
DE
DB
DB
DE
DE
DB
DE
DB
DE
DE
DB
DB
DB
DE
DB
DE
DE
DE
DB
'
'
5.75 DEO. POSITION LIMI
SPEED COMMAND
3.2
HL.DF
M .SEP^
B,2
SEND DIRECTION
CHECK THE ENCODER
(PPIC
zia
NZ. WAITS
A
cw=e
SEND SPEED COMMAND
(PPIA).A
A.H
(PPIB),A
>
START3
CR.LF,
'CR.LF,
CR.LF.
CR.LF,
CR.LF,
CR.LF,
CR,LF.
CR.LF.
CR.LF,
CR.LF,
CR.LF,
CR.LF,
CR.LF,
CR.LF.
CR.LF,
CR.LF,
CR.LF.
CR.LF,
CR.LF,
CR.LF,
CR.LF,
CR.LF,
CR.LF,
WHICH PRO CRAM

ULD YOU LIKE TO USE ?' CP ,LF, '4
1- SYS TEM CAL IERATIO^ ',CR.LF,'$'
2- PCS ITION C CNTROL
.CE.LF.'i'
'
EMTER THE NUMBEP AND HIT THF RETURN ', CR, IT, 4
* SYSTEM CA LI BRAT I ON PROG?. AM *',CR,LF.'$
- CHEC i r HE CHEC
POINT C '.CP.LF,'?'
- you S50 ULD SEE -4.35 7 OLTS '.CR.LF,' %'
- if r CU DC NOT, ADJUST WITH 52 POT .', CR.LF '
- IF Y CU ARF DON F HIT TH E RETURN
,CR, LF, '%'
* PCSITI *M CONTROL PROGRAM *',CR,LF,
*
- ENTE
HE POSI TION IN COUNTS '.CR.LF /%
- MAXI vlfTM 939 CO UNTS
CR .LF, '4T
3 59.4 DEGREES
'
- ENTE R I N THREE DIGITS (212
'.CR.LF, '4
- HIT
RETURN ', CR.LF '4
'.CR.LF .'$
ENTER TH 1 P OSITION IN C0UNTS'292"1 ' ,C?.,L F.'$
ENTER T3 E D IRECTION '.CR.LF,' '%'
*
'
'
EC
'
<p
'
'
CV =
ccv;
' ,
Z P.
LI ,
'
MOTOR AT TH E JIVEN POSITION ' CR.LF.T

E^ROR
T RY AGAIN '.CR.LF, 'S'
+++ POSI TIO N + + +',CR, LF, '$'
ND COUNT' .CR.LF. '$'
READY TO
COUNT HA
ENT' .CR.LF. '%'
?
99
subroutines
HTCHAR:
LD
AND
JR
LD
LD
(ESTAT)
;]ET EPCI STATUS
CHARACTER ENTERED
CHECK AGAIN
ITES
C-ET CHARACTER
STORE IN A
J
Z.GETCHAR
A
(EDATA
X
(CHAR),
IS
;\'C,
RET
ECHO
ir
A,(ESTAT
AND
JR
LC
CP
A, (IX)
J P.
Z.FIN
(EDATA) ,A
LD
INC
JP.
'%'
IX
ECHO
RET
FIN
RECALL:
CPY83:
NOADD
ESTAT)
LD
A,
AND
JR
LD
LD
RET
A, (IX)
LD
LD
BC
LD
MUL
Z.ECH3
JGET EFCI STATUS

;is EPCI READY ?
.NO, CHECK AGAIN
;lca D MESSAGE
;che CK THE LAST CHARACTER
;las T CHARACTER
;sen D CHARACTER
;nex T CHARACTER
;xmi T NEXT CHARACTER
LD
LD
SRL
JR
ADD
SLA
RL
DFC
JP
LD
RET
DS
5ND
Z,
(
<
RECALL
EDATA), A
(YPRAD)
E,S
DE. (MPDAD)
D,3
HL.2
,
NOADD
HL.DE
NC
JC-ET
E
D
B
NZ.MULT
(RESAD) ,HL
22
100
EPCI STATUS
JIS EPCI READY ?

;W0, CHECK AGAIN
J
LOAD CHARACTER
SEND CHARACTER
LIST OF REFERENCES
1.
Thaler,
J.
Hutchingson
G.
&
Design of Feedback
Ross,
Inc.,
Systems
Dowden,
1973.
DC Motors
1978.
and Co ntrol
Systems
2.
Kuo, B. C. and Tal

J.
SRL Publishing Company,
3.
Zaks,
4.
Sears, F. W. and Zemansky, M. W.,

University Phvsics
Addison-Wesley Publishing Company, Inc., 1964.
R.
Programming the Z-80. Sybex Inc,
101
1982.
,
INITIAL DISTRIBUTION LIST

No. Copies
1
Defense Technical Information Center

Cameron Station
Alexandria, Virginia 22304-6145
2.
Library, Code 0142

Monterey, California 93943-5000
3.
Professor Harriett Rigas, Chairwoman

Department of Electrical and
Computer Engineering
Code 62Rr
4.
Professor George J. Thaler

Code 62Tr
5.
Professor Alex Gerba Jr.

Code 62Ge
6.
Istanbul Teknik Universi t iesi

jilektrik Fakdltesi
GdmQssuyu/ Istanbul
TURKEY
7.
Deniz Harb Okulu Komutanligi

Okul KQtQphanesi ve Elektrik
BSiama KQtaphanesi
Tuzla/Istanbul
TURKEY
8.
Cochrane, M.S.
Lake Hazel
Meridian, Idaho 83642
Mr.
J.
C.
665 W.
Nusret YUrdtUcU, M.S.

7220 Trenton Place
Gilroy, CA 95020
9.
Mr.
10.
LTJG Nezih Durusu

Menpare sokak
No.
Heybeliada
Istanbul TURKEY
1
102
DTr
LIBRARY
,,DU ATE SCHOOL
A 93945-6003
Thesis
D906
c.l
219517
Durusu
Brushless DC motors,
velocity and position
control of the brushless
DC motor.
213517
Thesis
D906
c.l
Durusu
Brushless DC motors,
velocity and position
control of the brushless
DC motor.

Velocity and Position Control of The Burshless DC Motor.

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3003

NAVAL POSTGRADUATE SCHOOL

Approved for public release; distribution is

REPORT DOCUMENTATION PAGE

Approved for public release;

PERFORMING ORGANIZATION REPORT NUMBER(S)

NAME OF PERFORMING ORGANIZATION

aval Postgraduate School

NAME OF MONITORING ORGANIZATION

Naval Postgraduate School

NAME OF FUNDING /SPONSORING

and ZIP Code)

MONITORING ORGANIZATION REPORT NUM8ER(S)

DISTRIBUTION /AVAILABILITY OF REPORT

PROCUREMENT INSTRUMENT IDENTIFICATION NUMBER

SOURCE OF FUNDING NUMBERS

TITLE (Include Security Classification)

BRUSHLESS DC MOTORS, VELOCITY AND POSITION CONTROL OF THE BRUSHLESS

SUBJECT TERMS (Continue on reverse

necessary and identify by block number)

Brushless DC Motors, Velocity and Position

necessary and identify by block number)

velocity feedback controller for the brushless DC motor was designed

NAME OF RESPONSIBLE INDIVIDUAL

ABSTRACT SECURITY CLASSIFICATION

22b TELEPHONE (Include Area Code)

other editions are obsolete

Approved for public release; distribution is unlimited.

Brushless DC Motors, Velocity and Position Control of the

Submitted in partial fulfillment of the

NAVAL POSTGRADUATE SCHOOL

velocity feedback controller for the brushiess DC

designed using the Hall effect sensors.

using an optical encoder to sense anguiar

position changes and

Pittman 5111 wdg

was used for this study.

The design of tne. digital tachometer

pulse width modulator

velocity control and the

design of the Z-80 based microprocessor controller and

CONSTRUCTION AND OPERATION OF BRUSHLESS

CONSTRUCTION OF BRUSHLESS DC MOTORS

ELECTRONIC COMMUTATION AND DRIVE

FOUR-PHASE DELTA BRUSHLESS dC MOTOR

ADVANTAGES AND DISADVANTAGES OF THE

VELOCITY CONTROL OF THE 3RUSHLESS DC MOTOR

DESIGN OF THE DIGITAL TACHOMETER FOR

PULSE WIDTH MODULATOR

SYSTEM TESTING AND DATA COLLECTION FOR

OPEN LOOP VELOCITY CONTROL

CLOSED LOOP VELOCITY CONTROL

TRANSFER FUNCTION MEASURE AND SIMULATION

POSITION CONTROL OF THE DC MOTOR WITH

MICROPROCESSOR CONTROL OF DC MOTORS

INCREMENTAL OPTICAL ENCODER

SYSTEM TESTING AND DATA COLLECTION FOR

CLOSED LOOP POSITION CONTROL