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Solar PV Array Fed Cuk Converter-VSI Controlled

BLDC Motor Drive for Water Pumping


Rajan Kumar, Student Member, IEEE Bhim Singh, Fellow, IEEE
Department of Electrical Engineering Department of Electrical Engineering
Indian Institute of Technology Delhi Indian Institute of Technology Delhi
Hauz Khas, New Delhi-110016, India Hauz Khas, New Delhi-110016, India
sonkar.rajankumar36@gmail.com bhimsinghr@gmail.com

Abstract— This paper presents a solar photovoltaic (SPV) SPV generator and one conversion stage (VSI-Voltage Source
array fed permanent magnet brushless DC (BLDC) motor drive Inverter) can be avoided. The directly coupled SPV-motor-
for a water pumping system. An intermediate DC-DC Cuk pump system necessitates a complete knowledge of the whole
converter is used between PV array and a voltage source inverter system so that the system parameters can be chosen in such a
(VSI) to track the maximum power by using an incremental way that the operating curve of the load should match with the
conductance maximum power point tracking (INC-MPPT)
PV array MPP (Maximum Power Point) locus [3-4].
technique. The Cuk converter has not been used in SPV array
based water pumping system so far despite of having a number of Performance improvement of SPV powered permanent
advantages which are undoubtedly sufficient to replace the other magnet DC motor for water pumping application using
DC-DC converters. A new approach for the design of low valued various maximum power point tracking (MPPT) techniques
DC link capacitor of VSI is proposed. Besides these, the soft [5-12] has been studied in [7-8] using an intermediate DC-DC
starting of BLDC motor is achieved by selecting the optimum buck converter, in [9] using buck-boost converter and in [10]
value of step size in the MPPT algorithm. A centrifugal pump, using Cuk converter. However, a DC motor is not preferred
characterized by its torque speed relationship is coupled to the because of the frequent maintenance requirement caused by
BLDC motor as a load for the water pumping. The size of PV the commutators and brushes. The water pumping system
array and motor rating are selected such that the water can also
based on an induction motor is more reliable and maintenance
be pumped during the period of low solar insolation levels. This
study evaluates starting, dynamic and steady state performances free as compared to the DC motor driven pumping system.
under varying atmospheric conditions and examines the Requirement of complex control is the only limitation of
effectiveness of the BLDC motor for SPV based water pumping induction motors [13] otherwise it is suitable for use even in
system. Simulated results using MATLAB/Simulink demonstrate hazardous and contaminated areas. Current controlled VSI fed
suitability of this drive for SPV water pumping system. cage induction motor [14] and field oriented controlled 3-
Keywords— BLDC motor, SPV, Cuk converter, INC-MPPT, phase induction motor [15] have been used for solar powered
soft starting. pumping system with a DC-DC boost converter. A high
efficiency of permanent magnet synchronous motor (PMSM)
I. INTRODUCTION as compared to the induction motor and usefulness in
submersible installation has turned the attention towards it for
Renewable energy generations such as solar photovoltaic high power SPV based water pumping [16]. A DC motor,
(SPV) array and wind energies are receiving wide attention PMSM and the induction motor are compared and concluded
now a days due to the global energy crisis in near future. that the PMSM is better choice for global efficiency
Despite of low efficiency of SPV generating system and its
optimization of SPV fed water pumping system [17].
dependence on variable atmospheric conditions, its several
advantages such as everlasting energy source, pollution free Because of low inertia and friction, permanent magnet
generation and no running cost are attracting the researchers brushless DC (BLDC) motor can run at much higher speed.
towards SPV array installations. Worldwide annual and High efficiency, long life, high reliability, low radio frequency
cumulative SPV array productions have reached 36,241 MW interference and noise and no maintenance are the other
and 128,550 MW respectively in 2012 [1]. Likewise, important features of this motor. These features attract to use
worldwide cumulative SPV installation has reached 102,156 this motor in SPV array fed pumping application. Dynamic
MW in 2012 [2]. Application of SPV generation in water performance of BLDC motor for this application has been
pumping is appreciable and economical especially in remote
analyzed in [18] without introducing the MPPT technique,
areas where the transmission of conventionally generated
hence requires the complete knowledge of the PV-motor-
electricity is either not possible or very costly.
pump system to match the optimum operating point of the
The DC motor and various AC motors have been used to SPV characteristics. Nevertheless the MPP can be changed
drive the water pumps for household and irrigation purposes in with the variation of weather condition. Fuzzy logic
the agriculture. The DC motor can be directly connected to the incremental conductance (FL-IC) MPPT is introduced,

978-1-4799-6042-2/14/$31.00 ©2014 IEEE


utilizing the Z-source inverter (ZSI) fed BLDC motor driven III. DESIGN OF PROPOSED SYSTEM
SPV based pumping system in [19]. Implementation of FL is The proposed system consists of a solar PV array, a Cuk
difficult and a skilled user is an essential requirement. A boost converter, a VSI, a BLDC motor and a water pump. These
converter for the same application is used in [20] which components such as the solar PV array, the Cuk converter and
cannot ensure the soft starting of the motor. Other DC-DC a centrifugal pump are designed as per the requirement of SPV
converters e.g. buck-boost, Cuk, zeta, SEPIC (Single Ended fed pump system. A centrifugal pump of 6 kW and a BLDC
Primary Inductor Converter) converters are also used with motor of 6.14 kW power rating are selected. According to the
BLDC motor but not in SPV array based water pumping power rating of the centrifugal pump and a BLDC motor, each
applications. stage of the proposed system is designed as follows.
A DC-DC Cuk converter is employed in different SPV
array based applications [10-12] for MPPT. Nonetheless, the A. Design of Solar PV Array
SPV array based BLDC motor driven water pumping is still The maximum power capacity of 6.87 kW of a SPV array
unexplored with the use of a Cuk converter. In this paper, a is selected and it is designed for a 6 kW pump because SPV
Cuk converter is used as an intermediate DC-DC converter in generating system should generate somewhat slightly more
SPV array based BLDC motor driven water pump. The Cuk power than required by motor-pump so that extra generated
converter is operated in both buck and boost modes hence power can be used to meet converters and motor losses.
does not have any kind of restrictions on MPPT unlike a
simple buck or boost converter where the MPP can be tracked First of all, a module consisting of 36 cells connected in
if it lies within a bounded region. This feature is also very series is designed which has an open circuit voltage = 13.32 V
important to achieve soft starting of the motor. It has low and short circuit current = 4.0 A. The maximum power, Pmpp
switching losses and high efficiency. In addition, another generally occurs at 80% of open circuit voltage and short
important advantage of Cuk converter is a continuous current circuit current. Hence, the voltage at MPP is as, Vm =
at its input and output. It is possible to simultaneously 0.8*13.32 = 10.66 V and the current at MPP is as, Im = 0.8*4 =
eliminate the ripples in input and output currents, hence 3.2 A for a module.
external filtering is not required. An inductor at the input of The maximum power of the SPV array, Pmpp is given as,
the boost converter works as input ripple filter also but using Pmpp = Vmpp * Impp = 6.87 kW (1)
this boost converter cannot provide soft starting of the motor
As per the requirement of the proposed system, the voltage at
because this always increases the input voltage level at its MPP is as, Vmpp = 286 V which is considered and it gives a
output. On the other hand, in SPV array based applications,
current at MPP, Impp = Pmpp / Vmpp = 6.87*1000/286 = 24.02 A.
buck and buck-boost converters are always needed a ripple
Numbers of modules connected in series are as, Ns =
filter to limit the current and voltage ripple at its input. In 286/10.66 = 26.83 § 27.
conclusion, a Cuk type buck-boost converter is a simple DC- Numbers of modules connected in parallel are as, Np =
DC converter which suits for SPV array based applications. 24.02/3.2 = 7.5 § 8.
An incremental conductance MPPT algorithm is used to
Based on these selected parameters, the PV array of
control the SPV array to operate at its optimum operating appropriate size is used in the proposed system.
point. An electronically commutated BLDC motor with inbuilt
encoder is used to drive centrifugal pump as a load. Transient,
B. Design of Cuk Converter
dynamic and steady state performances of the BLDC motor
fed by SPV-Cuk converter under varying insolation levels are An output voltage polarity of the Cuk converter is opposite
analyzed based on simulated results using MATLAB/ to that of the input voltage. The rated DC voltage of the BLDC
Simulink. motor is as, Vdc = 310 V and the PV voltage at MPP is as, Vpv
= Vmpp = 286 V. The relationship between the duty ratio, D of
the insulated gate bipolar transistor (IGBT) switch, output
II. SYSTEM CONFIGURATION
voltage, Vdc and input voltage, Vpv of the Cuk converter is
Fig.1 shows the configuration of the proposed SPV-BLDC given as [21],
motor drive based water pumping system. A DC-DC Cuk Vdc D Vdc 310
converter is used between a PV array and a voltage source =− ŸD= = = 0.52 (2)
inverter (VSI). The VSI feeds the BLDC motor which drives a V pv 1− D Vdc + V pv 310 + 286
pump load. Switching pulses for VSI are generated through A high value of switching frequency, fsw = 20 kHz is
electronic commutation using the Hall Effect position signals. selected to keep ripples in the current flowing through the ind-
An inbuilt encoder provides the Hall signals according to the
rotor position. Switching pulse for the Cuk converter is
generated by MPPT algorithm. The design and working
principle of each stage of the configuration are elaborated in
the following sections.
Since 6th harmonic component of the motor voltage appears on
the DC link, allowing 8% voltage ripple across C, it is
estimated corresponding to Ȧh as,
I dc 22.16
C= = = 206.1 μ F (8)
6 × ωh × ΔVdc 6 × 722.57 × 310 × 0.08
where Idc is current flowing through the DC link = Ppv/Vdc =
6870/310 = 22.16 A; ǻVdc is an amount of ripple voltage
allowed across C.
Similarly, the lowest value of VSI output voltage frequency,
Fig.1 Configuration of the SPV-Cuk converter fed BLDC motor driven water Ȧl (in rad/sec.) is calculated corresponding to the minimum
pumping system. speed of a motor required to pump the water (N = 1100 rpm)
as,
uctors as low as possible even with the lower values of
inductors. The current flowing through L1, equal to the SPV N×P 1100 × 6
ωl = 2π f = 2π × = 2π × = 345.57 rad/sec. (9)
current at MPP is as, Ipv = IL1 = 24.02 A. Allowing 6% current 120 120
ripples, an input inductor, L1 is estimated as [21], Allowing 8% voltage ripple across C, it is calculated
V pv D 286 × 0.52 corresponding to Ȧl as,
L1 = = = 5.1 mH (3)
f sw ΔI L1 20000 × 24.02 × 0.06 I dc 22.16
where ǻIL1 is an amount of ripple current allowed through L1. C= = = 431 μ F  (10)
6 × ωl × ΔVdc 6 × 345.57 × 310 × 0.08
The current flowing through an output inductor, L2 is as, IL2 =
Ppv / Vdc = 6870/310 = 22.16 A. Allowing 6% current ripples, Out of the two estimated values of C, a higher value (C = 431
L2 is estimated as [21], ȝF § 470 ȝF) is selected to ensure the satisfactory operation
and performance of the BLDC motor pump system.
V pv D 286 × 0.52
L2 = = = 5.5 mH (4) Since the speed of the BLDC motor is controlled through
f sw ΔI L 2 20000 × 22.16 × 0.06 varying DC link voltage and it is not required to be maintained
where ǻIL2 is an amount of ripple current allowed through L2. at a constant value. Therefore such a small value, as calculated
Values of inductors have been chosen such that the converter is sufficient for successful operation of the system.
should be operated in continuous conduction mode to reduce
the stress on the IGBT switch in all operating conditions. D. Design of Centrifugal Pump
The voltage, Vc1 across an energy transfer capacitor, C1 is A centrifugal pump of 6 kW power rating is selected for
calculated as [21], proposed system. An output power, P of a centrifugal water
V pv 286 pump is given as [22],
VC1 = = = 595.8 V (5)
1 − D 1 − 0.52 P = kω ωm3   (11)
Allowing a 4% voltage ripple in Vc1, C1 is estimated as [21], where kȦ is a constant in Watt/(rad/sec)3 and Ȧm is the
I pv (1 − D) mechanical speed of the rotor in rad/sec.
24.02(1 − 0.52)
C1 = = = 24 μ F (6) Under steady state condition, an electromagnetic torque of
f sw ΔVC1 20000 × 595.8 × 0.04
the BLDC motor is equal to the load torque. Since the rated
where ǻVC1 is an amount of ripple voltage allowed across C1. torque and rated speed of selected BLDC motor is 25.5 Nm
and 2300 rpm respectively, constant kȦ is calculated using the
C. Design of DC Link Capacitor of VSI torque-speed characteristics of a centrifugal pump as [22],
A new approach to design a low valued DC link capacitor TL 25.5
is used. To design a DC link capacitor, C, the lowest and kω = = = 4.396 *10−4 Watt/(rad/sec)3 (12)
ω ( 2π * 2300 / 60 )
2 2
m
highest frequencies of the VSI output voltage to the motor are
taken into account. The highest value of VSI output voltage A suitable pump with these data is selected for proposed
frequency, Ȧh (in rad/sec.) is calculated corresponding to the system and detailed data are given in Appendix.
rated speed of the BLDC motor as,
IV. CONTROL OF PROPOSED SYSTEM
N rated × P 2300 × 6
ωh = 2π f = 2π × = 2π × = 722.57 rad/sec. (7) The control of the proposed SPV array fed Cuk converter
120 120
operated VSI-BLDC motor for water pumping system is
where f is the frequency of VSI output voltage in Hz; Nrated is classified into two parts as follows.
rated speed of the BLDC motor; P is the numbers of poles in
the BLDC motor. A. Maximum Power Point Tracking (MPPT)
An incremental conductance MPPT algorithm is used in
order to find the optimum operating point. This is simple to
develop and it is also proved efficient than other commonly An intermediate DC-DC Cuk converter is used in
used MPPT techniques [8]. This method is based on the continuous conduction mode to reduce the stress on the IGBT
concept that the incremental conductance, ˜Ipv/˜Vpv should be switch. Figs. 2(b) and 3(b) show the currents flowing through
equal to the conductance, Ipv/Vpv at the MPP [23]. input and output inductors IL1 and IL2 respectively. It shows
that the converter is operating in continuous conduction mode
B. Electronic Commutation of BLDC Motor for each solar insolation level. The voltage across energy
An appropriate switching sequence for gating the IGBTs of transfer capacitor, VC1 is also continuous. DC link voltage, Vdc
VSI is generated through the electronic commutation using an contains negligible amount of ripple. An external filtering is
inbuilt Hall-effect position sensor, which senses the rotor not required as the input and output inductors and the
position, ș on 60o span and generates 3 Hall signals such that 2 capacitor serve as the ripple filter. The voltage stress, Vsw
switches conduct at a time (neither from the same leg nor from across the IGBT switch of Cuk converter is the addition of
the same group i.e. upper and lower group) to draw input and output voltage of the converter, Vpv and Vdc
symmetrical phase currents of 120o span, placed on the centre respectively. Similarly, when an IGBT switch of Cuk
of phase voltage. Table-I shows the switching states of VSI converter is ON, current flowing through it, Isw is addition of
according to the Hall signal states for clockwise (CW) rotation two currents, IL1 and IL2. All these Cuk converter variables
[24]. It can be noticed that switching of only 2 switches are vary smoothly according to a variation in solar insolation
required to change from one state to another because VSI is level.
operated in 120o conduction mode, avoiding the high
frequency switching losses in VSI. Selected values of various C. Performance of SPV Array Fed BLDC Motor Pump System
parameters of the BLDC motor are given in Appendix. at 1000 W/m2
TABLE I. SWITCHES COMMUTATION FOR CW ROTATION The performance under starting and steady state conditions
o
Hall Signals Switching States
of SPV-Cuk converter fed BLDC motor pump system at
ș( )
h3 h2 h1 S1 S2 S3 S4 S5 S6 standard insolation of 1000 W/m2 is shown in Fig. 2(c). The
NA 0 0 0 0 0 0 0 0 0 DC link voltage, Vdc and hence the back EMF of phase ‘a,’ Ea
0-60 1 0 1 1 0 0 1 0 0 are increased and reach their rated values. The stator current of
60-120 0 0 1 1 0 0 0 0 1 phase ‘a,’ Isa also increases and takes time to settle at its rated
120-180 0 1 1 0 0 1 0 0 1 value which manifests the soft starting of the BLDC motor.
180-240 0 1 0 0 1 1 0 0 0 The back EMF and stator current of only phase ‘a’ are shown
240-300 1 1 0 0 1 0 0 1 0 in these results in view of clarity.
300-360 1 0 0 0 0 0 1 1 0
NA 1 1 1 0 0 0 0 0 0 Since the motor is operating at full load, its speed, N
increases and settles at the rated value under steady state
V. RESULTS AND DISCUSSION condition. The BLDC motor develops an electromagnetic
The performance of the proposed system has been verified torque, Te equal to the pump load torque, TL to balance the
by simulating the behavior of BLDC motor pump system load and to achieve a stable operation. A small pulsation in the
under varying insolation levels of SPV array using MATLAB torque as shown in Fig. 2(c) results in from electronic
environment along with Simulink and Sim-Power-Systems commutation of the BLDC motor and high frequency
toolboxes. The configuration of the system shown in Fig.1 is components with a period of ʌ/3 angle [25].
used to simulate its performance considering the variation in
insolation level, S ranging from 200 W/m2 to 1000 W/m2. D. Dynamic Performance of SPV Array Fed BLDC Motor
Figs. 2-3 demonstrate various performances of the proposed Pump System
water pumping system under fixed and varying operating The satisfactory dynamic performance of a SPV array fed
conditions. Cuk converter supplying VSI-BLDC motor pump system is
shown in Fig. 3(c). The solar insolation level has been varied
A. Maximum Power Point Tracking (MPPT)
dynamically in 5 steps; 200 W/m2 from 0 to 0.2 s., 600 W/m2
An INC-MPPT algorithm is used to extract the maximum from 0.2 to 0.4 s., 1000 W/m2 from 0.4 to 0.6 s., 800 W/m2
power available from the SPV array. A low value of step size from 0.6 to 0.8 s. and 400 W/m2 from 0.8 to 1.0 s. This large
(i.e. the perturbation in duty ratio, ǻD = 0.001) is selected to and random variation in solar insolation is applied to
avoid the oscillations. The purpose behind selecting so low demonstrate fast and precise response of the BLDC motor and
step size and hence increasing the tracking time intentionally its capability to drive the water pump such that it can pump
is to get a soft starting of the motor. Figs. 2(a) and 3(a) show the water even under minimum solar insolation level
that the optimum operating point of the PV array has been condition.
tracked properly even under the dynamic variation in solar
insolation levels. This INC-MPPT technique shows Fig. 3(c) shows the dynamic performance of SPV array fed
appreciable efficiency of 95%. Cuk converter supplying a VSI-BLDC motor pump system. At
the starting, SPV maximum power is tracked properly. The
B. Performance of Cuk Converter DC link voltage and hence the back EMF, stator current and
speed are increased and reached steady state condition. Since
the minimum solar insolation level i.e. 200 W/m2 is observed link voltage, back EMF, stator current and speed are also
at this time, values of all insolation dependent parameters are changed smoothly according to the change in solar insolation
also low comparatively. Nevertheless, the motor speed, N is level as shown in Fig. 3(c). The BLDC motor exhibits high
1200 rpm, sufficient to pump the considerable amount of efficiency of the order of 85% for all insolation level except
water. for 200 W/m2 where efficiency is 78.25% because the load
torque is 6.85 Nm, which is only 26.8% of full load torque, as
Since the speed of motor depends on the solar insolation
shown in Table-II. Table-II summarizes the changes in the
level, the load torque, TL which is speed dependent, also varies
various performance indices following the change in solar
according to the change in the solar insolation level. The DC
insolation levels.

(a) (b) (c)


2
Fig.2 Performance of SPV-Cuk converter fed VSI-BLDC motor pump system at 1000 W/m , (a) SPV array variables, (b) Cuk converter variables, (c) BLDC
motor-pump variables.

(a) (b) (c)


Fig.3 Performance of SPV-Cuk converter fed VSI-BLDC motor pump system under varying solar insolation level conditions (a) SPV array variables (b) Cuk
converter variables (c) BLDC motor-pump variables
TABLE II. PERFORMANCE OF BLDC MOTOR UNDER VARYING SOLAR INSOLATION LEVEL
Efficiency
S Ppv,max Vdc Ea,peak Isa,peak N TL & Te Power drawn by
(P/Ppv,max)*100
(W/m2) (W) (V) (V) (A) (rpm) (Nm) motor, P=Ȧm*Te (W)
%
200 1100 140 61 10 1200 6.85 860.8 78.25
400 2390 195 82 15 1595 12.25 2046.1 85.61
600 3740 230 94 20 1850 16.45 3186.9 85.21
800 5108 268 105 25 2055 20.35 4379.3 85.73
1000 6490 300 114 30 2222 23.8 5538 85.33
VI. CONCLUSION [1] J. Matthew Roney.(2013, July 31).World Solar Photovoltaics
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The proposed SPV array-Cuk converter fed VSI-BLDC policy.org/data_center/C23͘
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and its transient, dynamic and steady state performances have [Online]. Available: https://www.earth-policy.org/data_center/C23͘
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