IEEE PEDS 2005

AC/DC Flyback Converter with a Single Switch

Controlled DC Motor Drives
E. E. El-Kholy
Electrical Engineering Department,
Faculty of Engineering, Menoufiya University,
Shebin El-Kom, Egypt
e-mail: eelkhol (e(alioo.com

Abstract - In this paper a simplified approach for speed control of a Vc Capacitor voltage
separately-excited DC motor using single-phase, single-way c) Motor angular speed
rectifier is presented. This approach is based on the cascade
combination of a diode bridge rectifier and flyback converter. Step- Co Motor reference angular speed
down and step-up characteristics of the output voltage can be
obtained. The supply current is approximately sinusoidal with a high I. INTRODUCTION
power factor. A high performance is achieved with a ripple free for The flyback converter is used to obtain a constant output power
the output voltage and current. A digital signal processor (DSP- . . e
. . f .
dspacellO2) board is used to implement the converter in open and switching converter. It is attractive for multiple output application
closed-loop system. The proposed system modeling and simulation with a better output voltage tracking than most other switching
are performed using the differential equations describing the system topologies. The flyback converter is used as a buck-boost
behavior in different modes of operation. converter using one switch [1 -3].
The proposed program is a power-full tool to predict and describe Among the variety of switching-mode power converters, the
the system behavior in starting, transient and steady-state conditions. flyback converter is the favorite choice among design engineers
The effect of the duty-ratio on the motor performance characteristic for low power application due to its low component count, cost-
is investigated. The speed control with proportional integral effective structure as well as its large dynamic range. A variety of
controller is designed and the controller parameters are obtained to circuit topologies of quasi-resonant, zero-voltage switching
satisfy the best system responses for load disturbances. The
simulation results are given and prove a good agreement when
circui pologies ofuasionant, zr-vole chng
(ZVS), pulse width modulation (PWM) DC-DC power converters
comparedswith experimentalnresults. have some remarkable advantages such as lowered switching
power losses of power semiconductor devices and constant
Keywords - Flyback converter, AC to DC converter, Digital signal frequency operation [4-6].
processor, DCmotor.
In recent years, advanced development of flyback converters
LIST OF SYMBOL have attracted special in small machine rating drive applications.
A variety of circuit topologies of flyback converters using
B Viscous friction coefficient MOSFET s or IGBT s as well as static inductor power transistor
C Filter capacitance have some remarkable advantages such as, simple control scheme,
E DC flyback input voltage quick response and high performance in steady state and transient
fs : Switching frequency state operations [6-12].
*m Instantaneous motor current In this paper an AC/DC flyback converter fed a separately-
is*
I
Instantaneous supply current
oInstantaneous inductor current excited small DC motor is presented. Modeling and numerical
simulation for this system are established to study dynamic and
if Motor
fildecurrent steady state performances. A DSP board is utilized to implement
j Moment of inertia and control the converter switch in open and closed loop
Km Back e.m.f. coefficient
::Back
Motor a tefint
Km operations. The effect of duty ratio for different mode of operation
is given. The computed results are in a good agreement with the
Rm : Motor armature resistance experimental results.
Li, R1 Inductance and resistance of the transformer
primary side II. MODELING AND SYSTEM DESCRIPTION
L2, R2 Inductance and resistance of the transformer
secondary side AC/DC flyback converter cyclically stores energy in its
TL :sLoadetorque transformer from input rectified DC source when the switch is
Te Motordeveloped ON, then releases this stored energy into the outputs after the
VT Motor input voltage switch is tumed off. By adjusting the amount of energy stored and
Vm : Motor field voltage released per cycle, the output voltage can be regulated. Fig. 1,

0-7803-9296-5/05/$20.00 C 2005 IEEE

395
shows the schematic diagram of the system. This system consists will discharge its energy in the dc motor winding, while diode Dm
of an AC/DC flyback converter using one IGBT (MI) and a is turned off as shown in Fig. 2. The dynamic equations described
separately excited DC motor. The DSP board is used to control this mode are given as follows;
duty ratio of the IGBT operation to control the motor applied di1 r
voltage. The duty ratio for the gate pulses is given as follows; = [- E '-i1 R1 ] (2)
Ton
T_ (I)dt1' iDmin =00 (3)
Where, Ton is the ON period ofthe IGBT, and T is the total period. dVm i (
ON time period can be varied by changing the control voltage
Ton 1(4)
signal that is compared with the carrier signal to obtain the gate dt c m
pulses. dim (5
To determine the state of the switch and the diode (Dm), the dt Lm
following variables are defined:
dmm- (6)
A
rI
=
when M~ isON
~~I dt JT KmB]Bom-L 6

[0 when MI isoI where, Te = im

I1 when D iscoductig
p m * Mode2:
l when Dm is not conducting The switches state are ( A= 0, P 1 ). In this mode, also M1 is
=

turned off and Dm is turned ON to release the stored energy from

The variables A and P are standing for active and passive the transformer to charge the capacitor via diode D,m as shown in
switching respectively, and they take binary number, i.e. they are Fig. 3, the motor current will decay and still in the same direction
restricted to the set (1,0). An equation is derived for each states to freewheel the stored energy in the motor xwinding. The
of the active switching and passive switching throughout a following equations described the dynamic operation of the motor
complete switching cycle. From steady state analysis the circuit drives in this mode;
operation can be divided into three modes of operations. diDm = -V R (7)
dt L 'Dmn RI
* Mode 1:
0(8)
is~°°=

The state of the switches are (A=1, P = 0). In this mode of is

operation, the switch Ml is turned ON and then the energy dVm
dt I Dm
[i
Im
] (9)
transferred from the supply to the transformer. Also, the capacitor
~~ ~~~ D~~~~
0
i.
im~ ~ ~ iI[Vmn
d~~~~~~~~~~~~~~dt
L
-im -Rm - Km (m] (10)

1, do.)___t I
* Mode3:
In this mode of operation the switches are in states (A-O , P =
Gate
tPulseslnrmnaEnoe n E 0). The M1 is turned off and diode D. is turned off. When the
Pulses IncremenW Encoder
i. i, V. V, capacitor voltage turns off the diode, the capacitor discharges in
Basic the motor winding as shown in Fig. 4. The motor drives system
Driver performance in this mode can be expressed by the following
P1 Controller converteruations5
Encoder Intrfi
Incremental == 00.0 (2
(12)

PC Generator =*Algorithm Dm 0 (13)

Computer dv'm 1
DSPI 102 Board
dt
2..[...M]
C
(14)

Figure 1. Schematic diagram of proposed flyback converter and DSP control

396
dim _ LVm_im Rm 'Km Com] (15) T==I (18)
dt Lm f
do_ I1 The gate pluses have values of 5 volt or zero. It has a value of 5
[Te - B Ctm ' TL] (16) volt when the control voltage is greater than the timing voltage,
dt J and it has a zero volt when the control voltage less than the timing
voltage.
111. MODELING OF THE DRIVE CIRCUIT
The timing voltage of pluses can be represented by the IV. SIMULATION AND EXPERIMENTAL RESULTS
following equation [8]: The performance of the flyback converter is assessed by
X inspection of the simulation results in the steady state, starting and
Va=MA ]--2 T(17) transient conditions. The experimental system is built in the
laboratory for comparison with computed results. Fig. 5, shows
Where Va is the carrier voltage, MA is the maximum voltage (5 the gate signal of the IGBT with switching frequency 2200 Hz.
volt), X is the time instant which is changed from zero to X in Varying the control voltage from zero to maximum value (5 volt)
radians and T is the chopping period in radians which is given by; will control the duty ratio of IGBT. Fig. 6, shows the steady-state
is i iDm
_1m characteristics for motor voltage, motor current, supply current
m and motor speed versus duty ratio at no load and 0.25 Full load.
Fig. 7 shows the steady-state waveforms of the supply voltage,
z | $ + current, motor voltage, motor current and motor speed in the open
Vs e V loop operation with duty ratio 50% and 0.25 full load. Fig. 8,
1JE m M shows the experimental waveforms of duty ratio 75% and 2.5 full
Q w w / load. From these figures it is noticed that as the duty ratio
increased the supply current becomes more distorted and the
[* + | L || applied motor voltage decreases.
The transient operation condition of the system is shown in Fig.
9, where the motor starting from stand still to steady state
Figure 2. Mode (1) Equivalent circuit condition as the supply voltage is changed from zero to 70 volt. It
is noticed that the motor current and supply current increase due
is i Dm im to starting behavior.
The closed loop response of the motor speed due to a step
change in load torque is shown in Fig. 10, the figure shows that
r4 _ the motor speed will return to its initial value after 500 m.sec. due
VS | V to change in load by 20 % from the existing load.

lIE Vc'-+ V. CONCLUSION

I ,this paper a complete modeling and simulation of an open
and closed loop speed control system for a separately-excited DC
motor fed from single-phase single-way rectifier is suggested.
This is based on the cascade combination of a diode bridge
Figure 3. Mode (2) equivalent circuit rectifier and flyback converter.
15 ilDm D m DSP board is used to implement and control of the IGBT gate
pulses for open and closed loop speed control operation. The
supply current is approximately sinusoidal with almost unity
power factor. The output voltage and current are reasonably ripple
JEI Nr vS T
vm free. The dynamic and steady state behavior are predicted using
the proposed simulation program. The best responses for load
+ | change1 1 can be obtained with suitable value of controller
parameters. The controller parameters are selected for constant
^ ^I I I ~~~~~~~~~speed
operation when the load chanlges within 20% from existing
load. The comparison between simulation and experimental
results proved a good agreement with each other.
Figure 4. Mode (3) equivalent circuit

397
 Carrier and A,
Control signals
(volt) \

n
Gate pulses I T
4_ ~~~~~~~~~~Time
(s)
(volt) n

rTi Time (s)

Figure 5. Carrier, control and gate signals

08
Q7- V.*200 0
CQ6
0.5
o0.2Q000 06

~~~~~~~~~~04
0.3
V.,,*l00

03
01 02
o0o0
0 C
0 1 2 3 4 5 0 1 2 3 4 5
Control voltage Control voltage
a. No-load b. 0.25 Full load
Figure 6. Effect of control voltage on the system performance at no load and 0.25 full load condition at Steady - state characteristics.

V. V.
100 SW

s SI~~~~~~~l
mO _ _ s___
6h
0 . .............
-7 - Tiooa _ 1

Time(ms) _s
u LT-e(ma)
a. Expenmental results

398
 so
1 40
120

0
0 051
0,S Tunc(s) 1
5

2
1 5 1
0 0-13

3 3.01 3.02 3.03 3.04

Timc(s) Timo(s)
b. Simulation results
Figure 7. Steady-state simulation and experimental results at duty ratio 50 % and 0.25 full load.

BOOm~~~~~i
900m 2 ______,

_V __
40 ____250
_ _____.
_

0-
-152
_ ~ ~ ~ " (I I lunsj 7 20r r om(mg) 200r

Figure 8. Experimental waveforms at duty cycle 75 %

V.
200 80
J,
_1- l [

t1 - ~~~~~~~~Thims(s)

T 0
I4 AI ITi(s) I"T~
1 1 1 ¶ s.
_b T r 'Timo(s) t° it~~~~~~~~~~~Tmes)

ll ~ ~ ~ ~ im() | f icc t

a. Experimental Results

399
 f 500 10_ 18

Tine(s)

~21 -
E 1I 1

2 Tim( 40
0;
1

-0
Time(s)
b. Simulation Results
Figure 9. Simulation and experimental results during Run-up with duty ratio = 0.5 and 0.25 full load,

[5] B. K. H. Wong, and H. Chung, "A Systematic Graphing Tecinique for Small-
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0 _ . _. .
_____.____
_ Time(s) 2
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REFERENCES APPENDIX
[1] C. Ji, K. M. Smith, and K. M. Smedly, "Cross Regulation in Flyback
Converters Solution," 25' Annual Conference of IEEE Industrial Electronics The motor parameters:
Society (IECON 99), Achen, Germany, September 1999. The test motor is a separately excited dc motor, 220 volt, 0.5
[2] S. Lee, S. Han, and G. Moon, "Analysis and Design of Asymmetrical ZVS HP, 1.9 amp, 3000 r.p.m. It has the following measured
PWM Half Bridge Forward Converter with Flyback Type Transformer," 35"
Annual IEEE Power Electronics Specialists Conference (PESC'04), Aachen, parameters:
Germany, pp.1525-1530,2004. Rm=10.5 ', L, =0.11783H, RF= 550n,
[3] T. M. Chen, C. L. Chen, "Analysis and Design of Asymmetrical Half Bridge B = 0.0001 Nm / (rad/sec) Km = 0.345 Volt/ (rad/sec)
Flyback Converter," IEE Proc. on Electric Power Applications, Vol. 149, pp. J = 0.0015 Km. m2
433-440, 2002.
[4] M. Rukonuzzaman, M. Abdullh, S. Sato, and M. Serguei, "Soft Commutated The flyback converter parameters:
Power Converter With High Frequency Transformer Secondary Side Control The parameters ofthe designed system are:
Scheme," 10a International Power Electronics and Motion Control
Conference (EPE-PEMC'02), Dubrovnik & Cavtat, Crowatia, pp. 1-10, LI = L2 = 0.478 H, RI = R2 = 2 n, C = 2200 ji f,
September 2002, Fs = 2200 Hz

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