Bldc motor control

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Sensorless Direct Torque and Indirect Flux Control

of Brushless DC Motor with Non-sinusoidal


Back-EMF
Salih Baris Ozturk Hamid A. Toliyat
IEEE, Student Member IEEE, Fellow

Advanced Electric Machines and Power Electronics Laboratory


Department of Electrical & Computer Engineering
Texas A&M University
College Station, TX 77843-3128
Phone: (979) 862-3034
E-mail: Toliyat@ece.tamu.edu

Abstract— In this paper, the position sensorless direct torque and simplicity in their control.
and indirect flux control (DTIFC) of BLDC motor with non- Direct torque control (DTC) scheme was first proposed by
sinusoidal (non-ideal trapezoidal) back-EMF has been Takahashi [1] and Depenbrock [2] for induction motor drives
extensively investigated using three-phase conduction scheme
in the mid 1980s. More than a decade later, in the late 1990s,
with six-switch inverter. In the literature, several methods have
been proposed to eliminate the low-frequency torque pulsations DTC techniques for both interior and surface-mounted
for BLDC motor drives such as Fourier series analysis of synchronous motors (PMSM) were analyzed [3]. More
current waveforms and either iterative or least-mean-square recently, application of DTC scheme is extended to BLDC
minimization techniques. Most methods do not consider the motor drives to minimize the low-frequency torque ripples
stator flux linkage control, therefore possible high-speed and torque response time as compared to conventional PWM
operations are not feasible. In this work, a novel and simple
current controlled BLDC motor drives [4], [5]. In [4] and [5],
approach to achieve a low-frequency torque ripple-free direct
torque control with maximum efficiency based on dq reference the voltage space vectors in a two-phase conduction mode are
frame similar to permanent magnet synchronous motor (PMSM) defined and a stationary reference frame electromagnetic
drives is presented. The electrical rotor position is estimated torque equation is derived for surface-mounted permanent
using winding inductance, and the stationary reference frame magnet synchronous machines with non-sinusoidal back-
stator flux linkages and currents. The proposed sensorless DTC EMF (BLDC, and etc.). It is shown in [5] that only
method controls the torque directly and stator flux amplitude
electromagnetic torque in the DTC of BLDC motor drive
indirectly using d–axis current. Since stator flux is controllable,
flux-weakening operation is possible. Moreover, this method also under two-phase conduction mode can be controlled. Flux
permits to regulate the varying signals. Simple voltage vector control is not trivial due to the sharp changes whose
selection look-up table is designed to obtain fast torque and flux amplitudes are unpredictable depending on several factors
control. Furthermore, to eliminate the low-frequency torque such as load torque, dc-link voltage, winding inductance, etc.
oscillations, two actual and easily available line-to-line back- In this work, the torque control method presented in [4] and
EMF constants (kba and kca) according to electrical rotor position
[5] is adapted to the position sensorless direct torque control
are obtained offline and converted to the dq frame equivalents
using the new Line-to-Line Park Transformation. Then, they are scheme for three-phase conduction BLDC motor by using the
set up in the look-up table for torque estimation. The validity new Line-to-Line Park Transformation which forms a 2x2
and practical applications of the proposed three-phase matrix instead of the conventional 2x3 matrix. Therefore,
conduction DTC of BLDC motor drive scheme are verified rather than three line-to-neutral back-EMF waveforms which
through simulations and experimental results. are not directly available in the motor easily accessible two
line-to-line back-EMF waveforms (!"# and !$# ) are obtained
Index Terms— Brushless dc (BLDC) motor, position
sensorless control, direct torque control (DTC), stator flux
offline and converted to the electrical rotor position
control, fast torque response, non-sinusoidal back-EMF, low- dependant line-to-line back-EMF constants (%"# &'() * and
frequency torque ripples. %$# &'() *). Then, they are converted to dq–axes equivalents
(%+ &'() * and %, &'() *) using Line-to-Line Park
I. INTRODUCTION Transformation. dq–axes back-EMF constants versus

T HE permanent magnet synchronous motor (PMSM) and


brushless dc (BLDC) motor drives are used extensively in
several high-performance applications, ranging from servos to
electrical rotor position data (%+ &'() * and %, &'() *) are stored
in a look-up table for the torque estimation. As opposed to the
prior two-phase conduction methods, this DTC technique can
traction drives, due to several distinct advantages such as high control both torque and stator flux of the BLDC motor
power density, high efficiency, large torque to inertia ratio, simultaneously, therefore field-weakening operation is

k,((( 
possible. The electrical rotor position is estimated using After (3) is expanded and multiplied by the original 2x3
winding inductance and stationary reference frame stator flux Park Transformation matrix in both sides, algebraic
linkages and currents. The proposed sensorless DTC method manipulations lead to simplifications using some
controls the torque directly and stator flux amplitude trigonometric equivalence. Therefore, the following 2x2 Line-
indirectly using d–axis current. Since the stator flux is to-Line Park Transformation matrix form is obtained:
estimated, position sensorless DTC of BLDC motor drive <+ H IJK &' 5 LMN* 5IJKO&' P LMN* <"#
scheme can be achieved. Unlike those for motor with F< G 1 F GF GC (4)
, 7 5QRI &' 5 LMN* QRIO&' P LMN* <$#
sinusoidal back-EMFs, optimal current references for a non-
sinusoidal back-EMF motor (BLDC) in the synchronous III. THE PROPOSED SENSORLESS DTC OF BLDC MOTOR
reference frame are not constant, therefore current wave DRIVE USING THREE-PHASE CONDUCTION
shapes require very fast controllers in particular at high speed.
Classical bandwidth of the controller (such as proportional- A. Principles of the Proposed Method
integral–PI) does not allow tracking all of the reference In this work, indirect torque control method of BLDC
current harmonics [6]. Since the hysteresis controllers used in motor explained in [7] is extended to a direct torque and
the proposed DTC scheme are not fast controllers like PI, indirect flux control technique which is suitable for sensorless
they can easily regulate not only constant but also the varying and field-weakening operations. The proposed method
references (torque and flux). Simulation and experimental transforms abc frame quantities to dq frame ones using the
results are presented to illustrate the validity and effectiveness new 2x2 Line-to-Line Park Transformation matrix. Rather
of the sensorless three-phase conduction DTC of a BLDC than three measured phase back-EMFs which are used in [7],
motor drive. in the proposed balanced system only two back-EMF
constants (%+ &'() * and %, &'() *) are required in the torque
II. THE PROPOSED LINE-TO-LINE PARK& CLARKE estimation algorithm. Since the numbers of input variables
TRANSFORMATIONS IN 2X2 MATRIX FORM (current and back-EMF) are reduced from three to two, much
Since the balanced systems in dq–axes reference frame do simpler Park Transformation can be used as given in (4).
not require a zero sequence term, first Line-to-Line Clarke Therefore, the amount of multiplications and sine/cosine
Transformation from the balanced three-phase quantities is functions are minimized.
derived and, then the Line-to-Line Park Transformation Unlike previous two-phase conduction DTC of BLDC
forming a 2x2 matrix instead of a 2x3 matrix for three-phase motor drive techniques which are proposed in [4] and [5], this
systems can be derived in the followings: method uses DTC technique with three-phase conduction,
Using some algebraic manipulations, the original Clarke therefore field-weakening operation as well as a much simpler
Transformation forming a 2x3 matrix excluding the zero- sensorless technique can easily be achieved. Compared to the
sequence term can be simplified to a 2x2 matrix as follows: two-phase conduction DTC scheme, this DTC method differs
6 6 by its torque estimation and voltage vector selection table
45 5 ; which is similar to the one used for DTC of PMSM drives
7 7:
-.// 0 1 3 (1) explained in [8]. Although, stator flux estimation algorithm in
3 87 87: both methods (two-phase and three-phase conduction) is the
2 7 5
79 same due to the similar machine model in which the back-
which requires only two input variables <"# and <$# where EMF shape separates the two from each other, in two-phase
<"# 1 <" 5 <# and <$# 1 <$ 5 <# . < represents machine conduction scheme the stator flux amplitude is uncontrollable.
variables such as currents, voltages, flux linkages, back- Since the proposed technique adopts three-phase conduction,
EMFs, and etc. there is a possibility to control the stator flux amplitude
To obtain the Line-to-Line Park Transformation forming a without commutation issue, therefore field-weakening and
2x2 matrix, the inverse of the original Clarke Transformation sensorless operations can easily be performed. Moreover, this
matrix -.=> 0 is required. Since the zero-sequence term is DTC method controls the voltage vectors directly from a
removed, -.=> 0 matrix is not square anymore, but it is still simple look-up table depending on the outcome of hysteresis
singular and therefore pseudo-inverse can be found in the torque and indirect flux controllers, thus the overall control is
followings: much simple and fast torque response can be achieved
-.=> 0? 1 -.=> 0@ &-.=> 0-.=> 0@ *AB (2) compared to the conventional PWM control techniques.
For machines with surface-mount magnet rotor (BLDC)
where -.=> 0? and -.=> 0@ are the pseudo-inverse and
stator flux linkages in rotor dq reference frame can be written
transpose of the original Clarke Transformation matrix -.=> 0,
as
respectively. \
Abc to ba–ca transformation can be represented as follows: ( (
S,T 1 UT V+T P S(W X&YZ[AB P YZ[?B *IJK &N^'( * (5)
<#
< []B
-.=> 0? C -.=> 0C D<" E 1 -.=> 0? C -.// 0C F "# G. (3)
<$#
<$

k,((( 
\
can be obtained respectively as
( (
S+T 1 UT V,T P S(W X&YZ[AB 5 YZ[?B * QRI&N^'( * P S(W (6)
g 1 IJKAB hU,T V,T
( b (
S,T i PQRI AB hU,T V,T
( b
ST i 5 LMHj (7)
[]B
where S(W is the peak value of the fundamental rotor magnetic
k 1 5&'T P g 5 LMH*j (8)
flux linkage of the BLDC motor, the coefficients YZ[AB and
YZ[?B represent the odd harmonics of the phase back-EMF and
other than the third and its multiples. YZ[AB equals ( b
l 1 LMH 5 QRI AB hU,T V,T ST i. (9)
-IJK&N^ 5 6* _0b-&N^ 5 6*` aV^_0, and YZ[?B can be Moreover, x in Fig. 1 can be expressed as
depicted as -IJK&N^ P 6* _0b-&N^ P 6*` aV^_0 where _ is the (
angle between zero-crossing and phase back-EMF where it m 1 S,T ( b
QRInIJKAB hU,T V,T ST io. (10)
becomes flat at the top. Fundamental peak value of the rotor B. Electromagnetic Torque Estimation in dq Reference Frame
magnet flux linkage S(W equals &c%) b_L*aV^_ where %) is the Because of the rotor position dependant terms in the dq
line-to-neutral back-EMF constant. frame stator flux linkages in (5)–(6) and inductances,
conventional torque estimation in stator reference frame used
for DTC of sinusoidal ac motors is no longer valid for BLDC
motor, therefore a new torque estimation algorithm is derived
in dq frame consisting of actual dq–axes back-EMF constants
and currents. Instead of the actual back-EMF waveforms,
Fourier approximation of the back-EMFs could have been
adopted in torque estimation, but the results would not truly
represent the reality and more complex computations are
required.
The torque estimation is the key factor in the proposed
DTC scheme. First, two line-to-line back-EMF waveforms
!"# &'() * and !$# &'() * are obtained offline and converted to
the ba–ca frame back-EMF constants %"# &'() * and %$# &'() *.
The Line-to-Line Park Transformation matrix in (4) is used to
obtain the dq reference frame back-EMF constants %+ &'() *
Fig. 1. Rotor and stator flux linkages of a BLDC motor in the stationary !"–
plane and synchronous dq–plane. and %, &'() *, where '() is the electrical rotor angular position.
Equations (5) and (6) are very close approximations of Then, they are stored in a look-up table for electromagnetic
stator flux linkages in dq reference frame for the PMSM with torque estimation.
non-sinusoidal back-EMF. It can be seen that they are not The electromagnetic torque .)p estimation algorithm can
constant as in pure sinusoidal ac machines. Inductances and be derived for a balanced system in dq reference frame by
stator flux linkages vary by the six times of the fundamental equating the electrical power absorbed by the motor to the
frequency. One of the reasons to discuss the dq frame stator mechanical power produced (qr 1 qp 1 .)p sp * as follows:
flux linkages in BLDC motor is that it can be easily 7q (
.)p 1 h! &' *V ( P !+ &'() *V+T i
observable which parameters affect the amplitude of the stator cs() , () ,T (11)
( e 7q
flux linkages. Stator flux linkage amplitude dST d 1 8&S+T P ( (
( e
1 &%, &'() *V,T P %+ &'() *V+T *
S,T * can be changed by varying the d–axis current V+T (
in c
(11) assuming the torque is constant and it is proportional to where q is the number of poles, s() is the electrical rotor
( (
(
V,T , therefore an indirect flux control can be achieved in the speed, !, &') * and !+ &') *, V,T and V+T , %, &') * and %+ &') * are
proposed DTC of BLDC motor drive. Although V,T (
is the dq–axes back-EMFs, currents, and back-EMF constants
assumed constant meaning that it has an offset to generate an according to the electrical rotor position, respectively. As it
average torque, to obtain a smooth electromagnetic torque it can be noticed that the right hand-side equation in (11)
varies by six times the fundamental frequency because flux eliminates the speed term in the denominator which causes
harmonics given in (5)–(6) generate torque pulsations on the problem at zero and near zero speeds.
order of six and multiples of six. Since flux-weakening C. Control of Stator Flux Linkage Amplitude
operation is not in the scope of this paper, d–axis current
The stator flux linkage equations of a BLDC motor can
reference is selected zero. The phasor diagram for stator flux
easily be represented in the stationary reference frame similar
linkage vectors in BLDC motor can be drawn in the rotor dq
to PMSM. During the sampling interval time, one out of the
and stationary (!") reference frames as shown in Fig. 1 where
six voltage vectors is applied, and each voltage vector applied
U+,T 1 U,+T 1 f. In Fig. 1, unlike PMSM with sinusoidal
( (
during the pre-defined sampling interval is constant, then the
back-EMF S,T and S+T vary with time, therefore stator flux stator flux estimation for BLDC motor can be written as:
amplitude dST d is not constant anymore. g, #, and $ in Fig. 1

k,((( 
to-Line Park Transformation can be found by
ST= 1 tT= u 5 vT w VT= xu P ST= &f*
(12) ST> 5 UT VT>
'() 1 yzKAB { |C (13)
ST> 1 tT> u 5 vT w VT> xu P ST> &f* ST= 5 UT VT=
To solve the common problems for integrators, special
where ST= &f* and ST> &f* are the initial stator flux linkages at
integration algorithm for estimating the stator flux linkage
the instant of switching. If the line-to-line back-EMF constant proposed in [9] is used in this work. Although the method in
%// is roughly known, and let say the rotor is brought to zero [9] is designed for sinewave systems, the algorithm is still
position (phase–a), initial stator flux linkages at start-up can applicable to a BLDC motor with varying stator flux linkage
be obtained by integrating the back-EMF in which ideal amplitude as shown in Fig. 2. Second algorithm in [9] which
trapezoidal is assumed. Therefore, approximate initial starting is the modified integrator with an amplitude limiter is used for
flux values at zero position can be obtained as ST= &f* 1 the stator flux linkage estimation. The maximum amplitude of
H%// LM&787* and ST> &f* 1 f. the stator flux linkage reference approximated as H%// LM
&787* is set for the limiter when the motor speed is less than
the base speed. If the motor operates in the field weakening
region, the limiter value should be selected properly, but this
is not in the scope of this paper.
V3 (010) V2 (110)

IV. SIMULATION AND EXPERIMENTAL RESULTS


V4 (011) 30 ! V1 (100) The drive system shown in Fig. 3 has been simulated in
!s order to demonstrate the validity of the proposed three-phase
conduction DTC of a BLDC motor drive scheme using line-
to-line machine model. The sampling interval is 15 !s. The
V5 (001) V6 (101)
magnitudes of the torque and flux hysteresis bands are 0.001
N·m, and 0.001 Wb, respectively. The dc-link voltage t+$
equals cf8H V.
In Fig. 4, the possibility of the flux-weakening region
Fig. 2. Decagon trajectory of stator flux linkage in the stationary !"–plane.
operation is simulated when idsr* is changed from 0 A to -5 A.
TABLE I As it can be seen in Fig. 4 that the shape of stator flux linkage
SWITCHING TABLE FOR DTC OF BLDC MOTOR USING THREE-PHASE trajectory is kept same, however its amplitude is smaller
CONDUCTION compared to the initial case which means that the flux in the
! " " machine is weakened to obtain maximum possible torque
"(1) "(2) "(3) "(4) "(5) "(6) above the base speed. It is concluded that in the proposed
" !1 V2(110) V3(010) V4(001) V5(101) V6(110) V1(110)
! !1 control scheme flux-weakening operation is viable by
" ! -01 V6(101) V1(100) V2(010) V3(011) V4(110) V5(110)
" !1 V3(010) V4(011) V5(101) V6(100) V1(110) V2(110)
properly selecting the d–axis current reference as in PMSM
! ! -01 drives. As a result, there is no need to use position-varying
" ! -01 V5(001) V6(101) V1(110) V2(010) V3(110) V4(110)
stator flux linkage amplitude dST &'() *d as a reference which is
Since BLDC motor does not have sinusoidal back-EMF, complicated to obtain especially in the field-weakening
the stator flux trajectory is not pure circle as in PMSM. It is region. Proper selection of the d–axis current reference
more like a decagonal shape as shown in Fig. 2. Thus, direct respective of speed for field-weakening region operation is
stator flux amplitude control in a BLDC motor is not trivial as not in the scope of this paper. This is left as a future research
in PMSM such that rotor position varying flux command study.
should be considered. However, this is a complicated way to Fig. 5 shows the dq frame back-EMF constants according
control the stator flux linkage amplitude. Therefore, in this to the electrical rotor position (%+ &'() * and %, &'() *) which
work instead of dST d itself its amplitude is indirectly are set up in the look-up tables for torque estimation both in
controlled by d–axis current. In the constant torque region idsr simulation and experiment.
is controlled as zero and in the flux-weakening region it is The feasibility and practical features of the proposed three-
decreased for a certain amount depending on the operational phase conduction DTC of a BLDC motor drive scheme have
speed to achieve maximum torque. As a result, in this work been evaluated using an experimental test-bed, as shown in
stator flux linkage amplitude is indirectly kept at its optimum Fig. 6. The same conditions are used as in simulation.
level while the motor speed is less than the base speed. Implementations of steady-state and transient q– and d–
The switching table for controlling both the amplitude and axis rotor reference frame stator currents, torque and line-to-
rotating direction of the stator flux linkage is given in Table I. line current responses of the proposed DTC of a BLDC motor
drive scheme are demonstrated in Fig. 7(a) through (d),
D. Estimation of Electrical Rotor Position respectively under 0.5 N·m load torque condition.
Electrical rotor position '() which is required in the Line-

k,((( 
2
Tem

30!

ids r *

iba % isb ( isa


$s ica % 2isa ( isb
ids r

iqs r
, + s) -
$ s % tan (1 . /
0 + s* 1

, + s) ( Ls is) - + s* % ' "Vs* ( Rs isa #dt


$re % tan (1 . /
0 + s* ( Ls is* 1 + s) % ' "Vs) ( Rs is) #dt

$ re
3P
Tem %
22
"
kd ($re )ids r & kq ($ re )iqs r #

Fig. 3. Overall block diagram of the position sensorless direct torque and indirect flux control (DTIFC) of BLDC motor drive using three-phase conduction
mode.

5
Beta-axis Stator Flux Linkage (Wb)

0.1
d-axis current reference iqs[A] 0 (a)
changed from 0 A to -5 A
0.05
-5
5
0

-0.05
ids[A] 0 (b)

-5
-0.1 1

-0.1 -0.05 0 0.05 0.1


Tem_est
Alfa-axis Stator Flux Linkage (W b)
0 (c)
[N.m]
Fig. 4. Simulated indirectly controlled stator flux linkage trajectory under the -1
8
sensorless three-phase conduction DTC of a BLDC motor drive when idsr* is
changed from 0 A to -5 A under 0.5 N·m load torque. iba
0 (d)
and ica[A]
0.14
-8
0.12 Time [0.07s/div]
back-EMF constants (Vs/rad)

q-axis rotor ref. frame back-EMF constant


dq-axes rotor ref. frame

0.1 Fig. 7. Steady-state and transient behavior of the experimental (a) q–axis
0.08 stator current, (b) d–axis stator current, (c) estimated electromagnetic torque
and (d) ba–ca frame currents when idsr* = 0 under 0.5 N·m load torque.
0.06
q– and d–axis currents used in (11) are illustrated in Fig.
0.04
d-axis rotor ref. frame back-EMF constant 7(a) and (b), respectively under 0.5 N·m load torque. At 0.65
0.02
second the torque reference is increased and the change in the
0
q–axis frame current is noted in Fig. 7(a). In the same figure,
-0.02
0 1 2 3 4 5 6 q–axis current fluctuates around a dc offset to obtain smooth
Electrical rotor position (rad)
Fig. 5. Actual q– and d–axis rotor reference frame back-EMF constants
electromagnetic torque. It is seen in Fig. 7(b) that the d–axis
versus electrical rotor position (%+ &'() * and %, &'() *). current oscillates around the desired zero reference value
which means that the stator flux amplitude equals the magnet
SEMIKRON
Inverter flux.
The torque reference is changed abruptly from 0.52 N·m to
Voltage 0.65 N·m at 0.65 second. As seen in Fig. 7(c) that fast torque
Sensor
response is obtained and the estimated torque tracks the
reference torque closely. Reference torque value in
experimental test is selected a little bit higher than the load
Position Hysteresis BLDC
Encoder Brake Motor
torque to compensate the friction of the total experimental
eZdspTM system such that the rotor speed is kept at steady-state level
(a) (b)
(30 mechanical rad/s). The high frequency ripples observed in
Fig. 6. Experimental test-bed. (a) Inverter and DSP control unit. (b) BLDC
motor (Tem_rated = 1.28352 N·m) coupled to dynamometer and position the torque and current can be minimized by properly selecting
encoder (2048 pulse/rev) is not used in the control system. the dc-link voltage and torque hysteresis band size.

k,((( 
weakening region by properly selecting the d–axis current

alfa-axis stator flux linkage [0.05 Wb/div]


reference in the proposed DTC scheme. First, practically
available actual two line-to-line back-EMF constants (%"# and
%$# ) versus electrical rotor position are obtained using
generator test and converted to the dq frame equivalents using
the new Line-to-Line Park Transformation in which only two
input variables are required. Then, they are used in the torque
estimation algorithm. Electrical rotor position required in the
torque estimation is obtained using winding inductance,
stationary reference frame currents and stator flux linkages.
Since the actual back-EMF waveforms are used in the
alfa-axis stator flux linkage [0.04 Wb/div] torque estimation, low-frequency torque oscillations can be
Fig. 8. Experimental indirectly controlled stator flux linkage trajectory under reduced convincingly compared to the one with the ideal-
the sensorless three-phase conduction DTC of a BLDC motor drive when
idsr*= 0 at 0.5 N·m load torque. trapezoidal waveforms having 120 electrical degree flat top.
A look-up table for the three-phase voltage vector selection is
7
designed similar to a DTC of PMSM drive to provide fast
Est. elec. pos Act. elec. pos

torque and flux control. Because the actual rotor flux linkage
[rad]

is not sinusoidal, stator flux control with constant reference is


-7
7 not viable anymore. Therefore, indirect stator flux control is
performed by controlling the flux related d–axis current using
[rad]

0
bang-bang (hysteresis) control which provides acceptable
-7 control of time-varying signals (reference and/or feedback)
Time [0.07 s/div]
quite well. Since the proposed DTC scheme does not involve
Fig. 9. Steady-state and transient behavior of the actual and estimated
electrical rotor positions from top to bottom, respectively under 0.5 N·m load any PWM strategies, PI controllers as well as inverse Park
torque. and Clarke Transformations to drive the motor, much simpler
overall control is achieved.
The !"–axes stator flux linkages are estimated using (12) in
which the !"–axes voltages are measured using a dc-link
voltage sensor and the estimated position of the stator flux ACKNOWLEDGMENT
linkage vector %s. The motor is initially locked at zero The first author would like to thank Amir Toliyat of
position (phase–a) for proper starting. Fig. 8 shows the Toshiba Inc. for his assistance in editing the paper.
experimental results of the indirectly controlled stator flux
linkage locus by controlling the d–axis rotor reference frame REFERENCES
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shown that the BLDC motor could also operate in the field-

k,((( 

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