Abstract:
Drive voltages to a sensorless brushless DC motor are regulated by varying the width of a single drive pulse (PWM pulse) centered in each of the commutation periods. Switching losses are thereby cut to an absolute minimum because there are only two transitions (on and off) in each drive commutation period. Back EMF zero-cross detectors determine the electrical timing relationships during each electrical cycle. Since the PWM drive pulses are always centered in each of the commutation periods, there will always be back EMF available for measurement of “zero-crossings.” A digital device controls power switching transistors to produce one single PWM pulse during each of the commutation periods.

Description:
RELATED PATENT APPLICATION 
       [0001]    This application claims priority to commonly owned U.S. Provisional Patent Application Ser. No. 61/249,729; filed Oct. 8, 2009; entitled “Synchronized Minimum Frequency Pulse Width Modulation Drive for Sensorless Brushless Direct Current Motor,” by Ward R. Brown; and is related to commonly owned U.S. patent application Ser. No. ______; filed ______, 2010; entitled “Variable Pulse Width Modulation for Reduced Zero-Crossing Granularity in Sensorless Brushless Direct Current Motors,” by Ward R. Brown; and U.S. patent application Ser. No. ______; filed ______, 2010; entitled “Slow Speed Operation of Brushless Direct Current Motors by Gating Pulse Width Modulation Drive,” by Ward R. Brown; wherein all are hereby incorporated by reference herein for all purposes. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates to sensorless brushless direct current (BLDC) motors, and more particularly, to synchronized minimum frequency pulse width modulation (PWM) drive for a sensorless BLDC motor. 
       BACKGROUND 
       [0003]    Brushless direct current (BLDC) motors are used in industries such as appliances, automotive, aerospace, consumer, medical, industrial automation equipment and instrumentation. BLDC motors do not use brushes for commutation, instead, electronic commutation is used. BLDC motors have advantages over brushed DC motors and induction motors such as: better speed versus torque characteristics, high dynamic response, high efficiency, long operating life, longer time intervals between service, substantially noiseless operation, and higher speed ranges. More detailed information on BLDC motors may be found in Microchip Application Notes: AN857, entitled “Brushless DC Motor. Control Made Easy,” (2002); AN885, entitled “Brushless DC (BLDC) Motor Fundamentals,” (2003); AN894, entitled “Motor Control Sensor Feedback Circuits,” (2003); AN901, entitled “Using the dsPIC30F for Sensorless BLDC Control,” (2004); and AN970, entitled “Using the PIC18F2431 for Sensorless BLDC Motor Control,” (2005); all are hereby incorporated by reference herein for all purposes. 
         [0004]    A three-phase BLDC motor completes an electrical cycle, i.e., 360 electrical degrees of rotation, in six steps at 60 electrical degrees per step. Synchronously at every 60 electrical degrees, phase current switching is updated (commutation). However, one electrical cycle may not correspond to one mechanical revolution (360 mechanical degrees) of the motor rotor. The number of electrical cycles to be repeated to complete one mechanical revolution depends upon the number of rotor pole pairs. For example, a four-pole BLDC motor will require two electrical cycles to complete one mechanical revolution of the motor rotor (see  FIG. 3 ). 
         [0005]    Drive commutation for a sensorless BLDC motor may also be determined by monitoring the back electromotive force (EMF) voltages at each phase (A-B-C) of the motor. The drive commutation is synchronized with the motor when the back EMF of the un-driven phase crosses one-half of the motor supply voltage during a commutation period. This is referred to as “zero-crossing” where the back EMF is equal to one-half of the motor supply voltage, over each electrical cycle. Zero-crossing is detected on the un-driven phase when the drive voltage is being applied to the driven phases. A voltage polarity change about the zero-crossing voltage of the back EMF on the un-driven phase may also be used in detecting a zero-crossing event, e.g., from positive to negative or negative to positive during application of the drive voltage to the driven phases within certain limits. 
         [0006]    The rotational speed of a BLDC motor is dependent upon the amplitude of the average DC voltages applied to the stator windings of the motor. The higher the average DC voltage applied, the faster will the BLDC motor rotate. Generally, DC voltages are generated using pulse width modulation (PWM) to control the voltage amplitudes applied to the stator windings. The PWM maximum frequency is limited by the switching losses of the drive transistors. The PWM minimum frequency is limited by the undesirable audio emissions at frequencies in the audio range. An acceptable compromise is in the 15 KHz to 20 KHz range. PWM duty cycle can only be reduced to the point where the drive pulse width can still propagate through the drive power field effect transistors (FETs) and low-pass filter characteristics inherent in all motor designs. Reducing the PWM frequency would allow longer drive periods but this would also introduce audible noise from the motor. Every PWM signal pulse requires power switching transistors, e.g., power field effect transistors (FETS), to turn on and off. Rapidly turning power switching transistors on and off creates power losses as the transistors go from an off-condition through a voltage/current transition to an on-condition. Typically, power losses are low when the power switching transistor is saturated to full conduction in the on-state, and substantially no current flow in the off-state. Getting power switching transistors from the off-state to the on-state and visa-versa, creates significant power losses in these transistors. The more the power transistors are switched between the on and off states, the greater the power losses and power dissipation in the power transistors. 
         [0007]    Motor drive switching losses in the power transistors at high power loads are exacerbated because power dissipated therein is the square of the current times the increased resistance during the on-off-on-off transition times. As drive current increases the power dissipated in the power switching transistors increase exponentially. Gaps in drive voltage caused by the PWM off periods create timing errors in sensorless zero cross detection. Furthermore PWM signal generation at high frequencies lead to inefficiencies of the power switching transistors and failures due to overheating of the power switching transistors. 
       SUMMARY 
       [0008]    The aforementioned problems are solved, and other and further benefits achieved by reducing the number of on and off transitions of the power transistors in a commutation period. The lowest number of on and off transitions in a commutation period is two, thereby creating one PWM drive pulse per commutation period. According to the teachings of this disclosure, the drive voltage to the sensorless brushless DC motor is regulated by varying the width of a single drive pulse (PWM pulse) centered in each of the commutation periods. Switching losses are thereby cut to an absolute minimum because there are only two transitions (on and off) in each drive commutation period. 
         [0009]    According to a specific example embodiment of this disclosure, a method for controlling speed of a sensorless brushless direct current motor comprises the steps of: determining each commutation period in an electrical cycle of a sensorless brushless direct current motor by measuring back electromotive force voltage at each phase connection of the sensorless brushless direct current motor; generating pulse width modulation (PWM) control pulses, the PWM control pulses each having one on and one off transition during respective ones of the commutation periods, wherein each single PWM control pulse is substantially centered within its respective commutation period; and driving power switching transistors with the PWM control pulses for each of the commutation periods, wherein the power switching transistors are connected between stator coils of the sensorless brushless direct current motor and a direct current power source. 
         [0010]    According to another specific example embodiment of this disclosure, a method for controlling speed of a sensorless brushless direct current motor comprises the steps of: determining electrical timing centers for each of a plurality of commutation periods of a sensorless brushless direct current motor by measuring back electromotive force voltages at each stator coil of the sensorless brushless direct current motor, and determining from the measured back electromotive force voltages when each of the measured back electromotive force voltages is at substantially a zero-crossing voltage value, wherein the zero-crossing voltage value is about one-half of a voltage value of a direct current power source; generating a single pulse width modulation (PWM) control pulse during each of the plurality of commutation periods, wherein each single PWM control pulse has one on and one off transition during its respective commutation period and the single PWM control pulse for the respective commutation period is substantially centered within that respective commutation period; and driving power switching transistors with the PWM control pulses during the plurality commutation periods, wherein the power switching transistors are connected between the stator coils of the sensorless brushless direct current motor and the direct current power source. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    A more complete understanding of the present disclosure thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings wherein: 
           [0012]      FIG. 1  illustrates a schematic diagram of a three-phase sensorless brushless direct current motor and electronically commutating motor controller, according to a specific example embodiment of this disclosure; 
           [0013]      FIG. 2  illustrates schematic diagrams showing current flows in each of the three stator windings of a three-phase sensorless brushless direct current motor during each 60 degree commutation period; 
           [0014]      FIG. 3  illustrates schematic timing and amplitude graphs of a four-pole motor showing back electromotive force (EMF) voltages at each of the three stator windings during each 60 degree commutation period; 
           [0015]      FIG. 4  illustrates a more detailed schematic diagram of the back EMF zero-cross detectors shown in  FIG. 1 ; and 
           [0016]      FIG. 5  illustrates schematic amplitude and timing graphs of voltages at one phase of the sensorless BLDC motor during each commutation period for different PWM duty cycles, according to the teachings of this disclosure. 
       
    
    
       [0017]    While the present disclosure is susceptible to various modifications and alternative forms, specific example embodiments thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific example embodiments is not intended to limit the disclosure to the particular forms disclosed herein, but on the contrary, this disclosure is to cover all modifications and equivalents as defined by the appended claims. 
       DETAILED DESCRIPTION 
       [0018]    Referring now to the drawing, the details of specific example embodiments are schematically illustrated. Like elements in the drawings will be represented by like numbers, and similar elements will be represented by like numbers with a different lower case letter suffix. 
         [0019]    Referring to  FIG. 1 , depicted is a schematic diagram of a three-phase sensorless brushless direct current motor and electronically commutating motor controller, according to a specific example embodiment of this disclosure. A three-phase sensorless brushless direct current motor, generally represented by the numeral  100 , comprises a plurality of stator coils  102  and a rotor (not shown) having magnets arranged in a three-phase configuration. For discussion purposes the motor  100  described herein will be in a two pole three-phase configuration requiring 360 degrees of electrical rotation to produce one mechanical revolution of 360 degrees. The motor  100  is electronically commutated with power switching transistors  108  and  110  connected to the three-phase sensorless brushless direct current motor  100  and a direct current (DC) power source. Back electromotive force (EMF) zero-cross detectors  104  and a digital device  106 , e.g., a microcontroller, having PWM generators that provide pulse width modulation (PWM) outputs coupled to power transistor drivers. The power transistor drivers (PWM 0 -PWM 5 ) control turn-on and turn-off of the power switching transistors  108  and  110 . 
         [0020]    The motor  100  is electronically commutated from a direct current (DC) source (not shown) through the power switching power transistors  108  and  110 , e.g., power field effect transistors (one pair per phase for a three-phase motor). The power transistors  108  and  110  are controlled by the digital device  106 , e.g., a microcontroller, that is coupled to the power transistors  108  and  110  through drivers for the power transistors (not shown). The digital device  106  provides six pulse width modulation (PWM) outputs, PWM 0 -PWM 5 , that control both the motor rotation direction and speed by turning on and off selected phase pairs of the power transistors  108  and  110  according to PWM signals appropriately sequenced and timed. 
         [0021]    Each stator coil  102  is connected to the positive of the DC power source for two commutation periods, the negative of the DC power source for two commutation periods, and is disconnected from both the positive and negative of the DC power source for two commutation periods. The motor phase position is determined by back electromotive force (EMF) voltages measured at a stator coil  102  when not connected to the DC power source at the time of measurement while the other two stator coils  102  are connected to the DC power source. The back EMF voltages at each of the stator coils  102  are monitored by the back EMF zero-cross detectors  104  (one per phase). However, the back EMF voltage to be measured requires connection to the positive of the DC power source of one of the stator coils  102  so as to enable current flow therethrough, thereby biasing the motor generated voltage to a level centered around the detection reference level (“zero-crossing” event), e.g., one-half the supply voltage. The other stator coil  102  of the pair of coils having current flow therethrough is connected to the negative of the DC power source. 
         [0022]    Referring to  FIG. 2 , depicted are schematic diagrams showing current flows in each of the three stator windings (coils  102 ) of a three-phase sensorless brushless direct current motor during each 60 degree commutation period. Rotation of the motor  100  is divided into six commutation periods ( 1 ) through ( 6 ), and current flows through different combinations of two of the three coils  102  during each of the six commutation periods. While combinations of two of the coils  102  are connected to the DC power source, a third coil  102  (three-phase motor) is not connected to the power source. However the unconnected coil  102  is monitored by the back EMF zero-cross detectors  104  such that upon detection of a “zero crossing” event, i.e., back EMF voltage on the unconnected coil  102  changes polarity while going through a substantially zero voltage (“zero voltage” is defined herein as one-half of the DC supply voltage). At approximately the zero voltage point detected by a respective one of the back EMF zero-cross detectors  104 , a synchronization relationship of the motor  100  stator coils  102  is ascertained, as more fully described hereinbelow. 
         [0023]    Referring to  FIG. 3 , depicted are schematic timing and amplitude graphs of a four-pole motor showing back electromotive force (EMF) voltages at each of the three stator windings during each 60 degree commutation period. When a phase coil is not connected to the DC power source no current flows therethrough. When a phase coil is connected to the positive (DC+) power source, current flows in a positive direction for two commutation periods (120 electrical degrees), then no current flows (coil is unconnected from the DC power source) for a subsequent commutation period (60 electrical degrees), and after the unconnected commutation period the very same coil has current flow in a negative direction for two commutation periods (120 electrical degrees) when connected to the negative (DC−) power source, and then no current flows in a next commutation period (60 electrical degrees) before the aforementioned electrical cycle repeats, i.e., for another 360 degree electrical cycle. 
         [0024]    When using a sensorless BLDC motor, the back EMF voltage on the unconnected coil is transitioning from the positively driven polarity to the negatively driven polarity and does so throughout the 60 degree period when not being connected. If current is initially going into the coil when the connection is broken then the current will continue to flow thereby forward biasing a diode in parallel with the low-side drive transistor  110  presenting a voltage on the motor coil terminal equal to the negative (DC−) power source voltage plus the forward bias voltage of the diode. This negative spike persists until the energy in the coil is dissipated. 
         [0025]    A “zero crossing” is where the measured voltage at each phase coil  102  goes to substantially one-half of the DC supply voltage (in the graphs normalized to “zero”), and is illustrated by the small circles of the back EMF graphs. When the PWM duty cycle is 100% in a commutation period, the measured back EMF varies between the full positive (DC+) rail voltage and the full negative (DC−) rail voltage of the power source. When the PWM duty cycle is 50% in a commutation period, the measured back EMF varies between 50% (one-half) of the full positive (DC+) rail voltage and 50% (one-half) of the full negative (DC−) rail voltage of the power source. When the PWM duty cycle is 25% in a commutation period, the measured back EMF varies between 25% (one-half) of the full positive (DC+) rail voltage and 25% (one-half) of the full negative (DC−) rail voltage of the power source. Therefore there is a direct correlation between the PWM duty cycle applied to the two current carrying coils  102  and the measured back EMF on the unconnected coil  102 . However, the back EMF always passes through the “zero crossing” point at substantially the center (e.g., middle, half-way point) of a commutation period when the other two coils are excited (current flowing therethrough). Just at lower PWM duty cycles, there is less variation of the back EMF voltage in the commutation period. This is not problematic since the “zero crossing” point is what is of interest. 
         [0026]    It is important to remember that back EMF on the unconnected coil  102  is biased properly for detection only when the other two coils  102  are connected to the positive (DC+) and negative (DC−) power source rails and current flows, through them. If there is no current flow in the two connected coils  102  at the time when a “zero crossing” should occur then the back EMF voltage at the unconnected coil  102  will not be centered relative to the reference voltage, and detection of the exact “zero crossing” will not be possible. However, missing detection of the exact “zero crossing” point in time because power drive is off (no current flow) at the instant of exact zero crossing may not be fatal so long as a change in polarity, e.g., positive to negative or visa versa, of the back EMF is determined when the power drive returns soon after zero crossing, and that this occurs close enough in time (electrical degrees) so as not to cause too great of a commutation timing error in normal operation. Instability problems do result when low duty cycle PWM signals cause significant commutation timing errors. As illustrated in the back EMF graphs shown in  FIG. 5 , “zero crossing” points occur at approximately 30 electrical degrees from a commutation period change, i.e., substantially in the center (middle) of a commutation period. 
         [0027]    Referring to  FIG. 4 , depicted is a more detailed schematic block diagram of the back EMF zero-cross detectors shown in  FIG. 1 . The back EMF zero-cross detectors  104  may comprise three-phase voltage divider resistors  418  and  420 , phase low-pass filters  422 , reference low-pass filter  430 , reference voltage divider resistors  426  and  428 , and voltage comparators  424 . The reference voltage divider resistors  426  and  428  are used to derive a “virtual” neutral reference voltage for use by the comparators  424  and/or the digital device  106  having analog inputs. The three-phase voltage divider resistors  418  and  420  reduce the stator coils  102  voltages to much lower voltages for use by the low-pass filters  422  and comparators  424 . Preferred resistance relationships for the resistors  418 ,  420 ,  426  and  428  are as follows: 
         [0000]      Raa=Rbb=Rcc=Rrr 
         [0000]        Ra=Rb=Rc= 2 *Rr    
         [0000]        Ra /( Raa+Ra )=Vcomparator_maximum_input/((DC+)−(DC−))
 
         [0028]    The low pass filters  422  may be used to substantially reduce unwanted noise from the inputs to the comparators  424 . The comparators  424  are used in determining when a back EMF voltage on an unconnected coil  102  is greater than the neutral reference voltage, or less than or equal to the neutral reference voltage. The outputs of the comparators  424  when at a logic high (“1”) may represent that the back EMF voltage is greater than the neutral reference voltage, and when at a logic low (“0”) may represent that the back EMF voltage is less than or equal to the neutral reference voltage, or visa-versa (designer&#39;s choice). The outputs of each of the comparators  424  may thereby be used to indicate when the back EMF voltage is at its “zero” transition point or when a back EMF polarity transition occurs, and indicate same to the digital device  106 . If the digital device has analog inputs and analog-to-digital (ADC) conversion capabilities and/or voltage comparators, the external comparators may not be required. When this is the case, the outputs from the low pass filters and the neutral reference voltage from the resistors  426  and  428  may be connected directly to the analog inputs (not shown) of the digital device  106  (e.g., mixed signal device). 
         [0029]    Referring to  FIG. 5 , depicted are schematic amplitude and timing graphs of voltages at one phase of the sensorless BLDC motor during each commutation period for different PWM duty cycles, according to the teachings of this disclosure. The BLDC motor operates at rotational speeds that are dependent upon the average voltages on each stator coil  102  during appropriate 60 degree commutation periods. Direction of rotation of the motor  100  is dependent upon the commutation connection order of the coils  102  to the DC power source over each (360 degree) electrical cycle. 
         [0030]    Graph  530  represents a 100 percent PWM drive duty cycle over one electrical cycle at one phase of the motor  100 . The 100 percent duty cycle will result in maximum voltages resulting in maximum rotational speed of the motor  100 . Graph  532  represents approximately a 66 percent PWM drive duty cycle over one electrical cycle at one phase of the motor  100 . And graph  534  represents approximately a 34 percent PWM drive duty cycle over one electrical cycle at one phase of the motor  100 . At lower duty cycles, less average voltages will be created and thus slower rotational speeds will result. Note that the PWM pulses are substantially centered within each of the commutation periods, e.g., at 30, 90, 150, 210, 270, 330 degrees. The exact electrical center for each of the commutation periods may be shifted slightly +/− from the +30 degree values depending upon inductive lag and motor characteristics. Determination of commutation period timing relationships are determined by the digital device  106  from “zero crossing” information supplied by the back EMF zero-cross detectors  104 . Since only one PWM pulse is used, two transitions (on and off), in each appropriate drive commutation period, switching losses of the power switching transistors  108  and  110  are thereby minimized. In addition, since the one PWM pulse during each commutation period is substantially centered therein, there will always be back EMF excitation voltage in an unconnected coil  102  during a “zero-crossing” (e.g., at points  540 ,  542  and  544 ). Therefore, even during low PWM drive duty cycles where the off times of the PWM signals in each commutation period are significant, a “zero-crossing” (points  540 ,  542  and  544 ) will be accurately and precisely detected. 
         [0031]    While embodiments of this disclosure have been depicted, described, and are defined by reference to example embodiments of the disclosure, such references do not imply a limitation on the disclosure, and no such limitation is to be inferred. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent art and having the benefit of this disclosure. The depicted and described embodiments of this disclosure are examples only, and are not exhaustive of the scope of the disclosure.