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Bist PFC Cuk BLDC 201502
Bist PFC Cuk BLDC 201502
Bist PFC Cuk BLDC 201502
2, FEBRUARY 2015
871
I. INTRODUCTION
RUSHLESS dc (BLDC) motors are recommended for
many low- and medium-power drives applications because of their high efficiency, high flux density per unit volume,
low maintenance requirement, low electromagnetic interference
(EMI) problems, high ruggedness, and a wide range of speed
control [1], [2]. Due to these advantages, they find applications
in numerous areas such as household application [3], transportation (hybrid vehicle) [4], aerospace [5], heating, ventilation and
air conditioning [6], motion control and robotics [7], renewable energy applications [8], [9], etc. The BLDC motor is a
three-phase synchronous motor consisting of a stator having a
three-phase concentrated windings and a rotor having permanent magnets [10], [11]. It does not have mechanical brushes
and commutator assembly; hence, wear and tear of the brushes
and sparking issues as in case of conventional dc machines are
eliminated in BLDC motor and thus it has low EMI problems.
This motor is also referred as an electronically commutated motor since an electronic commutation based on the Hall-effect
rotor position signals is used rather than a mechanical commutation [12], [13].
There is a requirement of an improved power quality (PQ)
as per the international PQ standard IEC 61000-3-2 which recommends a high power factor (PF) and low total harmonic
distortion (THD) of ac mains current for Class-A applications
(<600 W, <16 A) which includes many household equipments [14]. The conventional scheme of a BLDC motor fed
by a diode bridge rectifier (DBR) and a high value of dc-link
capacitor draws a nonsinusoidal current, from ac mains which is
rich in harmonics such that the THD of supply current is as high
as 65%, which results in PF as low as 0.8 [15]. These types of
PQ indices cannot comply with the international PQ standards
such as IEC 61000-3-2 [14]. Hence, single-phase power factor
correction (PFC) converters are used to attain a unity PF at ac
mains [16], [17]. These converters have gained attention due to
single-stage requirement for dc-link voltage control with unity
PF at ac mains. It also has low component count as compared to
a multistage converter and therefore offers reduced losses [17].
Conventional schemes of PFC converter-fed BLDC motor
drive utilize an approach of constant dc-link voltage of the VSI
and controlling the speed by controlling the duty ratio of high
frequency pulse width modulation (PWM) signals [18][21].
The losses of VSI in such type of configuration are considerable since switching losses depend on the square of switching
frequency (Psw loss fS2 ). Ozturk et al. [18] have proposed
a boost PFC converter-based direct torque controlled (DTC)
BLDC motor drive. They have the disadvantages of using a
complex control which requires large amount of sensors and
higher end digital signal processor (DSP) for attaining a DTC
operation with PFC at ac mains. Hence, this scheme is not suited
for low-cost applications. Ho et al. [19] have proposed an active
power factor correction scheme which uses a PWM switching of
VSI and hence has high switching losses. Wu et al. [20] have proposed a cascaded buckboost converter-fed BLDC motor drive,
which utilizes two switches for PFC operation. This offers high
switching losses in the front-end converter due to double switch
and reduces the efficiency of the overall system. Gopalarathnam
et al. [21] have proposed a single-ended primary inductance converter (SEPIC) as a front-end converter for PFC with a dc-link
voltage control approach, but utilizes a PWM switching of VSI
which has high switching losses. Bridgeless configurations of
PFC buckboost, Cuk, SEPIC, and Zeta converters have been
proposed in [22][25], respectively. These configurations offer
reduced losses in the front-end converter but at the cost of high
number of passive and active components [22][25].
Selection of operating mode of the front-end converter is a
tradeoff between the allowed stresses on PFC switch and cost
of the overall system. Continuous conduction mode (CCM) and
discontinuous conduction mode (DCM) are the two different
modes of operation in which a front-end converter is designed to
operate [16], [17]. A voltage follower approach is one of the control techniques which is used for a PFC converter operating in the
DCM. This voltage follower technique requires a single voltage
sensor for controlling the dc-link voltage with a unity PF. Therefore, voltage follower control has an advantage over a current
multiplier control of requiring a single voltage sensor. This
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872
Fig. 1.
BLDC motor drive fed by a PFC Cuk converter using a current multiplier approach.
Fig. 2.
BLDC motor drive fed by a PFC Cuk converter using a voltage follower approach.
Fig. 3. Operation of the Cuk converter in the CCM during (a, b) different intervals of switching period and (c) associated waveforms. (a) Interval I.
(b) Interval II. (c) Waveforms.
873
874
Fig. 5. Operation of the Cuk converter in DICM (L o ) during (a)(c) different intervals of switching period and (d) associated waveforms. (a) Interval I.
(b) Interval II. (c) Interval III. (d) Waveforms.
(1)
vs (t) = Vm Sin(2fL t) = 220 2 Sin(314t)V
875
Lic200 =
2fS Pm ax
2Vs m in + Vdc m ax
2
85
200
1
=
= 322.3 H.
2 20 000 350
85 2 + 200
TABLE I
SPECIFICATIONS OF A BLDC MOTOR
(6)
D
Vin (t)
(1 D)
(7)
(3)
Vdc
Vdc
=
.
Vin (t) + Vdc
|Vm Sin (t)| + Vdc
And the critical value of the input inductor at the minimum value
of dc-link voltages of 40 V at the peak value of supply voltage
is calculated as
2
Vs m in
Vdc m in
1
Lic40 =
2fS
Pm in
2Vs m in + Vdc m in
2
85
40
1
=
= 644.25 H.
2 20 000 70
85 2 + 40
(4)
Liccm =
fS Pm ax
2Vs m in + Vdc
2
85
200
1
=
= 2.57 mH
0.25 20 000 350
85 2 + 200
(9)
where the permitted amount of ripple current () is selected as
25% of the input current.
Hence, the input side inductor of 2.5 mH is selected for its
operation in continuous conduction.
876
Lo c200 =
Pm ax 2 2Vs m in fS
2Vs m in + Vdc m ax
2
85
200
200
=
350 2 2 85 20 000 85 2 + 200
= 536 H.
(11)
Lo c40 =
Pm in 2 2Vs m in fS
2Vs m in + Vdc m in
2
85
40
40
=
70 2 2 85 20 000 85 2 + 40
= 214.4 H.
(12)
Lo ccm =
Fig. 7. Variation of THD of supply current at ac mains with change in dc-link
voltage for (a) different values of input side inductors (L i ) and (b) different
values of output side inductors (L o ).
Vdc (1 D(t))
Vdc D(t)
Rin Vdc D(t)
=
=
2IL o (t)fS
2Iin (t)fS
2Vin (t)fS
2
VS
Vdc
Vdc
=
.
(10)
Pi 2Vin (t)fS Vin (t) + Vdc
Lo c =
dc m ax
Lo ccm =
Pm ax 2Vs m in fS
2Vs m in + Vdc m ax
2
85
200
200
=
350 0.25 2 85 20 000 85 2 + 200
= 4.29 mH.
(14)
Vdc D (t)
.
2VC 1 (t) fS RL
(15)
877
Hence, by substituting the expressions of intermediate capacitor voltage, VC 1 (t) = {Vdc +Vin (t)}, emulated load resistance,
2
/Pi and D(t) from (4) in (15) and rearranging it one
RL = Vdc
obtains
Vdc
Vdc
C1c =
2 P
Vin (t) + Vdc
2 {Vdc + Vin (t)} fS Vdc
i
=
Pi
.
2fS (Vin (t) + Vdc )2
TABLE II
DESIGN PARAMETERS IN DIFFERENT MODES OF OPERATION
(16)
Now, the maximum ripple in the intermediate capacitor occurs at the maximum value of supply voltage (i.e., Vsm ax =
270 V). Hence, the critical value of the intermediate capacitance
is calculated at maximum dc-link voltage (Vdcm ax = 200 V) as
C1c200 =
=
Pm ax
2
2fS
2Vs m ax + Vdc m ax
350
2 = 25.84 nF. (17)
2 20 000 270 2 + 200
2fS
Pm in
2Vs m ax + Vdc m in
2
70
2 = 9.83 nF.
2 20 000 270 2 + 40
Vdc D (t)
VC 1 (t) fS RL
{Vdc
(18)
Vdc
2
Pi
+ Vin (t)} fS Vdc
Vdc
Vin (t) + Vdc
Pi
.
fS (Vin (t) + Vdc )2
(19)
fS
Pm ax
2Vs m ax + Vdc m ax
2
350
2 = 0.516 F
0.1 20 000 270 2 + 200
Idc
(Pi /Vdc )
Pi
=
=
2 .
2Vdc
2Vdc
2Vdc
(21)
Now, the value of the dc-link capacitor is calculated at maximum value of dc-link voltage given as
Pm ax
350
=
= 348.33 F
2
2Vdc m ax
2 314 0.04 2002
(22)
where represents the permitted ripple in dc-link voltage which
is taken as 4% of Vdc .
And the dc-link capacitance at minimum value of dc-link
voltage (Vdcm in ) is expressed as
Cd200 =
Pm in
70
=
= 1741.6 F.
2
2Vdc
2
314
0.04 402
m in
(23)
Hence, the value of the dc-link capacitor is taken higher than
the Cd40 to ensure a ripple of dc-link voltage less than 4% even
at lower values of dc-link voltages. Hence, the dc-link capacitor
of 2200 F is selected for the application.
Table II shows the specification of the PFC Cuk converter and
the selected values of input and output inductors, intermediate
capacitor, and the dc-link capacitor for a PFC Cuk converter
operating in different modes of conduction.
Cd40 =
878
(30)
Vdc
= kb N .
(26)
Ve (k) = Vdc
(k) Vdc (k).
(27)
Vc (k)
iin (k) =
(29)
Vm
= kb N
Vdc
(33)
(34)
(36)
879
TABLE III
PERFORMANCE OF THE BLDC MOTOR DRIVE WITH THE CUK CONVERTER
OPERATING IN THE CCM
inductor current iL i , output inductor current iL o , and intermediate capacitors voltage VC 1 are continuous in operation while
the supply current iS is sinusoidal and in phase with the supply
voltage vS which shows a unity PF at ac mains. Table III shows
the performance of the proposed BLDC motor fed by a PFC Cuk
converter operating in the CCM over a wide range of dc-link
voltage control (i.e., speed control) with unity PF operation at ac
mains [14]. Table VII shows the peak voltage and current stress
of the PFC converter switch for different modes of operation.
The peak voltage and current stresses of 560 V and 8.1 A are
obtained under rated condition in this mode of the CCM.
B. Performance of the BLDC Motor Fed by a Cuk Converter
Operating in the DICM (Li )
Fig. 8. Simulated performance of the BLDC motor drive with the Cuk converter operating in the CCM.
The circuit configuration and control of the PFC Cuk converter operating in the DICM of operation with input inductor
(Li ) operating in discontinuous conduction are shown in Fig. 2.
The parameters selected for this converter to operate in DICM
(Li ) are as follows:
Input inductor Li = 100 H, output inductor Lo = 4.3 mH,
intermediate capacitor C1 = 0.66 F, and dc-link capacitor
Cd = 2200 F.
The steady-state performance of the Cuk converter-fed BLDC
motor drive operating in the DICM with input inductor operating
in discontinuous conduction is shown in Fig. 9. The input inductor current iL i is discontinuous as shown in Fig. 9, while the
output inductor current iL o and intermediate capacitors voltage
VC 1 remain continuous. Table IV shows the improved PQ operation of the BLDC motor fed by a Cuk converter operating in
the DICM (Li ) over a wide range of speed control. As shown in
Table VII, peak voltage stress of 570 V and peak current stress
of 33.1 A are obtained under rated condition in this mode of the
DICM (Li ).
C. Performance of the BLDC Motor Fed by a Cuk Converter
Operating in the DICM (Lo )
The circuit configuration and control of the PFC Cuk converter operating in the DICM of operation with output inductor
(Lo ) operating in discontinuous conduction are shown in Fig. 2.
880
Fig. 9. Simulated performance of the BLDC motor drive with the Cuk converter operating in the DICM (L i ).
TABLE IV
PERFORMANCE OF THE BLDC MOTOR DRIVE WITH THE CUK CONVERTER
OPERATING IN THE DICM (L i )
Fig. 10. Simulated performance of the BLDC motor drive with the Cuk converter operating in the DICM (L o ).
TABLE V
PERFORMANCE OF THE BLDC MOTOR DRIVE WITH THE CUK CONVERTER
OPERATING IN THE DICM (L o )
881
TABLE VI
PERFORMANCE OF THE BLDC MOTOR DRIVE WITH THE CUK CONVERTER
OPERATING IN THE DCVM (C 1 )
882
TABLE VII
STRESS ON PFC CONVERTER SWITCH FOR DIFFERENT CONFIGURATION OF THE CUK CONVERTER-FED BLDC MOTOR DRIVE
Fig. 12. Variation of (a) THD of supply current and (b) PF with dc-link voltage
for different configuration of the PFC Cuk converter-fed BLDC motor drive.
Fig. 13. Variation of (a) switch peak voltage and (b) peak current with load
for different configuration of the Cuk converter-fed BLDC motor drive.
TABLE VIII
COMPARATIVE ANALYSIS OF VARIOUS MODES OF OPERATION
TABLE IX
COMPARATIVE ANALYSIS OF THE PROPOSED CONFIGURATION WITH
CONVENTIONAL SCHEMES
883
TABLE X
VARIATION OF DC-LINK VOLTAGE AND SPEED WITH REFERENCE VOLTAGE
the Cuk converter operating in DICM (Lo ) is developed as discussed in the next section.
F. Comparative Evaluation of the Proposed Configuration
With Conventional Schemes
This section deals with a comparative study of three configurations of BLDC motor drive. The proposed configuration
is compared with a conventional DBR-fed BLDC motor drive
and a conventional single-switch PFC converter feeding BLDC
motor drive via a PWM-based switching of VSI [18][20]. The
evaluation is based on the control requirement, sensor requirement, system complexity, losses in a drive system, and the overall cost of the system.
Table IX shows a comparative performance of the proposed
configuration with the conventional scheme of BLDC motor
drives. The proposed configuration requires a single voltage
sensor for dc-link voltage control as compared to other two
configurations, which reduces the cost of the overall system.
The sensor requirement in a conventional PFC-based BLDC
motor drive is highest due to the use of PWM-based switching
of BLDC motor which requires two current sensors and one
voltage sensor for dc-link voltage control. Moreover, a simple
Fig. 14(a) and (b) shows the operation of the proposed BLDC
motor drive for a dc-link voltage (Vdc ) of 200 and 50 V, respectively. The supply current is achieved is sinusoidal in nature and
is in phase with the supply voltage vs demonstrating the unity
PF at ac mains. The dc-link voltage Vdc is maintained at the desired value and the frequency of stator current ia of the BLDC
motor is used for the determination of speed of the BLDC motor. The frequency of the stator current as shown in Fig. 14(a)
and (b) is of the order of 80 and 18 Hz, respectively (electronic
commutation of the BLDC motor). This frequency is very low
as compared to PWM-based control of VSI for controlling the
speed of the BLDC motor drive. Hence, the switching losses
in VSI corresponding to such low frequency are very low as
compared to PWM based switching of VSI. The variation of
speed and the dc-link voltage with reference voltage at analogto-digital converter (ADC) of DSP is shown in Table X.
B. Operation of the Cuk Converter Operating in the
DICM (Lo )
Fig. 15(a) and (b) shows the waveforms of current in input
and output inductors (iL i and iL o ) and intermediate capacitors
voltage (VC 1 ) to demonstrate the DICM operation of output
inductor Lo . As shown in these figures, the current in input
inductor (iL i ) and voltage across intermediate capacitor (VC 1 )
884
Fig. 14. Steady-state performance of the Cuk converter-fed BLDC motor drive
under rated condition with dc-link voltage as (a) 200 V and (b) 50 V.
Fig. 15. Test results of the proposed BLDC motor drive showing (a) supply
voltage with inductors currents and intermediate capacitors voltage and (b)
its enlarged waveforms. (c) Waveform of voltage and current stress on PFC
converter switch.
885
Fig. 17. PQ indices of the proposed BLDC motor drive at rated load on the
BLDC motor with: (a)(c) dc-link voltage as 200 V under rated conditions,
(d)(f) dc-link voltage as 50 V under rated conditions, (g)(i) dc-link voltage as
200 V and supply voltage as 90 V at rated load, (j)(l) dc-link voltage as 200 V
and supply voltage as 270 V at rated load.
Fig. 16. Test results of the proposed BLDC motor drive at rated load on
BLDC motor during: (a) starting at dc-link voltage of 50 V, (b) step change in
dc-link voltage from 100 to 150 V, and (c) change in supply voltage from 250 to
170 V.
886
REFERENCES
Fig. 18. Waveform of the supply current showing the control detuning phenomenon in a Cuk converter operating in the DICM (L o ).
VIII. CONCLUSION
A Cuk converter for VSI-fed BLDC motor drive has been
designed for achieving a unity PF at ac mains for the development of the low-cost PFC motor for numerous low-power
equipments such fans, blowers, water pumps, etc. The speed
of the BLDC motor drive has been controlled by varying the
dc-link voltage of VSI, which allows the VSI to operate in the
fundamental frequency switching mode for reduced switching
losses. Four different modes of the Cuk converter operating in
the CCM and DCM have been explored for the development of
the BLDC motor drive with unity PF at ac mains. A detailed
comparison of all modes of operation has been presented on the
basis of feasibility in design and the cost constraint in the development of such drive for low-power applications. Finally, a
best suited mode of the Cuk converter with output inductor current operating in the DICM has been selected for experimental
verifications. The proposed drive system has shown satisfactory results in all aspects and is a recommended solution for
low-power BLDC motor drives.
APPENDIX
Detuning phenomenon in a Cuk converter: Detuning phenomenon represents the inability of a PFC converter to maintain a sinusoidal supply current at near zero-crossings of the
supply voltage [38]. This distortion of the supply current at its
zero crossing results in high THD of supply current and directly
affects the PF at ac mains. Now, considering a case of a PFC
Cuk converter-fed BLDC motor drive with the Cuk converter
operating in the DCM with output inductor (Lo ) is designed
to operate in the DCM. During the PFC operation, the supply
current is in phase with the supply voltage and it is sinusoidal
in nature. The input power at zero crossings of supply voltage
is very low and the duty ratio is unity. Hence, a distortion in
input inductor current occurs due to inability of the input inductor to maintain a continuous current through it. Fig. 18 shows
the distortion of supply current near zero crossing for a PFC
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