A Brushless DC Motor Drive With Power Factor Correction Using Isolated Zeta Converter
A Brushless DC Motor Drive With Power Factor Correction Using Isolated Zeta Converter
4, NOVEMBER 2014
Abstract—This paper presents a brushless dc (BLDC) motor [9], [10]. This suffers from high switching losses in three-phase
drive with power factor correction (PFC) for low-power applica- VSI due to high frequency switching of PWM signals. Such
tions. In this work, the speed of the BLDC motor is controlled by losses are reduced by operating the VSI in fundamental fre-
adjusting the dc link voltage of the voltage source inverter (VSI)
feeding a BLDC motor. Therefore, VSI is used for achieving only quency switching by electronically commutating the BLDC
an electronic commutation of the BLDC motor and operates in motor. Moreover, the speed is controlled by varying the dc
a low frequency switching for reduced switching losses. A PFC- link voltage of VSI [11]. This reduces the switching losses
based isolated zeta converter operating in discontinuous conduc- of VSI and eliminates the requirement of current sensors
tion mode (DCM) is used for controlling the dc link voltage of the for PWM-based current control of BLDC motor for speed
VSI with inherent PFC at ac mains using single voltage sensor. The
proposed drive is implemented to achieve a unity power factor at control [11].
ac mains for a wide range of speed control and supply voltage fluc- Power factor correction (PFC) converters are widely used
tuations. An improved power quality is achieved with power qual- for improving the power quality at ac mains. Various config-
ity indices within limits of IEC 61000-3-2 standard. urations of nonisolated and isolated PFC converter have been
Index Terms—Brushless dc (BLDC) motor, discontinuous reported in the literature for improving the power quality at ac
conduction mode (DCM), isolated zeta converter, power factor mains [12]–[14]. The cost of these PFC converters is primar-
correction (PFC), power quality, voltage source inverter (VSI). ily decided by the sensing requirements which in turn depend
upon the mode of operation of the PFC converter. Continuous
I. I NTRODUCTION conduction mode (CCM) and discontinuous conduction mode
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BIST AND SINGH: BLDC MOTOR DRIVE WITH PFC USING ISOLATED ZETA CONVERTER 2065
Fig. 1. Proposed PFC-based isolated zeta converter fed BLDC motor drive.
II. P ROPOSED PFC-BASED BLDC M OTOR D RIVE W ITH intermediate capacitor (VC1 ) reduces, and the cur-
H IGH -F REQUENCY I SOLATION rent in output inductor (iLo ) and dc link voltage
Fig. 1 shows the proposed PFC-isolated zeta converter-fed (Vdc ) are increased as shown in Fig. 3.
Mode II: When switch (Sw ) is turned “OFF,” the current in
BLDC motor drive. A single-phase supply is used to feed a
magnetizing inductance (Lm ) of HFT and output
DBR followed by a filter and an isolated zeta converter. The fil-
ter is designed to avoid any switching ripple in the DBR and the inductor (Lo ) starts reducing. This energy of HFT
is transferred to the intermediate capacitor (C1 ),
supply system. An isolated zeta converter is designed to operate
and therefore voltage across it increases. Diode
in DCM to act as an inherent power factor corrector. This com-
bination of DBR and PFC converter is used to feed a BLDC (D) conducts in this mode of operation, and the
dc link voltage (Vdc ) increases as shown in Fig. 3.
motor drive via a three-phase VSI as shown in Fig. 1. The dc
link voltage of the VSI is controlled by varying the duty ratio Mode III: This mode is DCM such that the energy of HFT is
of the PWM pulses of PFC converter switch. However, VSI is completely discharged as shown in Fig. 2(c). The
intermediate capacitor (C1 ) and the dc link capac-
operated in a low frequency switching to achieve an electronic
commutation of BLDC motor for reduced switching losses. A itor (Cd ) supply the energy to the output inductor
single voltage sensor is used at the front-end converter for the (Lo ) and the load, respectively. Hence, the dc link
voltage (Vdc ) and intermediate capacitor’s voltage
control of dc link voltage for speed control of BLDC motor. The
proposed drive is designed and its performance is validated on (VC1 ) are reduced, and the output inductor current
a developed prototype for improved power quality at ac mains increases in this mode of operation as shown in
Fig. 3.
for a wide range of speed control and supply voltage variations.
Specifications of the BLDC motor selected for experimental
studies are given in Appendix. IV. D ESIGN OF I SOLATED PFC Z ETA C ONVERTER
An isolated PFC zeta converter is designed to operate in
DCM such that the current flowing in magnetizing inductance
III. O PERATION OF I SOLATED PFC Z ETA C ONVERTER
of HFT (Lm ) becomes discontinuous in a switching period. A
The operation of an isolated zeta converter is classified into PFC converter of 300 W (Pmax ) is designed for the selected
three different modes corresponding to switch turn-ON, switch BLDC motor (complete specifications are given in Appendix).
turn-OFF, and DCM. Three modes are shown in Fig. 2(a)–(c) For a wide range of speed control, the dc link voltage is con-
and their associated waveforms are shown in Fig. 3. These trolled from a low value of 50 V (Vdc min ) to a rated voltage
modes are described as follows. of 130 V (Vdc max ) with supply voltage variation from 170 V
Mode I: When switch (Sw ) is turned “ON,” a cur- (VS min ) to 270 V (VS max ).
rent in magnetizing inductance (Lm ) of high- The input voltage VS applied to the PFC converter as
frequency transformer (HFT) increases as shown √
VS (t) = Vm sin(ωL t) = 220 2 sin(314t)V (1)
in Fig. 2(a). The intermediate capacitor (C1 ) sup- √
plies energy to an output inductor (Lo ) and the where Vm is peak input voltage (i.e., 2VS ) and ωL = 2πfL ;
dc link capacitor (Cd ). Hence, voltage across fL is the line frequency, i.e., 50 Hz.
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BIST AND SINGH: BLDC MOTOR DRIVE WITH PFC USING ISOLATED ZETA CONVERTER 2067
possible value of supply voltage, i.e., 170 V (Vs min ) using The worst case design occurs for the minimum value of dc
(6) as link voltage, i.e., 50 V (Vdc min ) and is expressed as
2
Vdc max (1 − Da )
2 Pmin 1
Lmc = Cd =
Pmax 2 Vdc min 2ω(ηVdc min )
2Da (t)fS (N2 /N2 )
115 1
1302 (1 − 0.5196)
2
= = 2441.6 µF.
= = 2.52 mH 50 2 × 314 × (0.03 × 50)
300 2 × 0.5196 × 20 000 × (0.5)2
(13)
(7)
Therefore, the dc link capacitor (Cd ) with a nearest possible
where Da (t) is the duty ratio calculated at dc link voltage
√ of value of 2200 µF is selected for this application.
130
√ V (V dc max ) and peak value of supply voltage of 170 2V A low-pass LC filter is used to avoid the reflection of higher
( 2 ∗ Vs min ) as 0.5196. order harmonics in supply system. The maximum value of filter
Hence, to achieve a DCM, the value of magnetizing induc- capacitance (Cmax ) is given as [23]
tance of HFT (Lm ) is selected lower than Lmc [22]. Therefore, √
the value of Lm is selected around 1/10th of Lmc , i.e., 250 µH Ipeak (Pmax 2/VS )
Cmax = tan(θ) = √ tan(θ)
to achieve a discontinuous current conduction. ωL V m ωL 2VS
√
The expression for calculation of output inductor is as [13] (300 2/220)
= √ tan(1◦ ) = 344.56 nF (14)
314 × 220 2
Vdc {1 − D(t)} Vdc {1 − D(t)}
Lo = = . (8) where θ is the displacement angle between the fundamental
fS ΔiLo fS (κIo )
component of supply voltage and supply current which is taken
This output inductor is designed for rated dc link voltage of as 1◦ . Thus, a filter capacitor Cf of 330 nF is selected.
130 V (Vdc max ) for a minimum value of duty ratio (Db√ ) cor- The value of filter inductor is designed by considering the
responding
√ to a peak of maximum supply voltage of 270 2V source impedance (Ls ) of 3% of the base impedance. Hence,
( Vs max ) as [13] the additional value of inductance required (Lf ) is given as
Lf = Lreq + Ls ⇒ Lreq = Lf − Ls
Vdc {1 − Db } 130{1 − 0.4051} 2
Lo = = = 4.188 mH 1 1 VS
fS (κIo ) 20 000 × (0.4 × 2.308) Lreq = − 0.03
(9) 4π fc Cf
2 2 ωL Po
1
where κ represents the percentage ripple of the output inductor =
4π 2 × (2000) × 330 × 10−9
2
current which is taken as 40% of output inductor current (κ).
Therefore, an output inductor of 4.2 mH is selected. 1 2202
−0.03 = 3.77 mH (15)
An expression for intermediate capacitor (C1 ) is as [13] 314 300
Vdc D(t) Vdc D(t) Pi where fc is the cutoff frequency which is selected such that
C1 = = √ (10) fL < fc < fS . Therefore, fc is taken as fS /10.
ΔVC (t)fS RL η{ 2VS + Vdc }fS Vdc2
This LC filter with inductance Lf and capacitance Cf is
where η is the permitted ripple voltage across intermediate selected as 3.77 mH and 330 nF, respectively.
capacitor and is taken as 10% of VC1 .
The intermediate capacitor (C1 ) is calculated at maximum
V. C ONTROL OF I SOLATED PFC Z ETA C ONVERTER -F ED
value of dc link voltage (Vdc ) as
BLDC M OTOR D RIVE
Vdc max Db (t) Pmax The control of the proposed PFC-based BLDC motor drive is
C1 = √
η 2VS max + Vdc max fS Vdc2 max divided into two categories: control of PFC converter for dc link
voltage control and control of three-phase VSI for electronic
130 × 0.4051 300
= √ = 456.6 nF. commutation of BLDC motor.
0.1 × 270 2 + 130 × 20 000 1302 (11)
A. Control of Front-End PFC Converter
Hence, an intermediate capacitor of 0.44 µF is selected for
the application. A voltage-follower approach is used for the control of iso-
The value of dc link capacitor (Cd ) is calculated as [13] lated zeta converter operating in DCM. This control scheme
consists of a reference voltage generator, voltage error gener-
Idc Pi 1 ator, voltage controller, and a PWM generator. A “reference
Cd = = (12)
2ωΔVdc Vdc 2ω(ηVdc ) voltage generator” generates a reference voltage Vdc∗
by mul-
tiplying the reference speed (ω∗) with the motor’s voltage con-
where ΔVdc represents the permitted ripple in dc link voltage,
stant (kv ) as
η represents the percentage of permitted dc link voltage ripple
which is selected as 3% of Vdc min . Vdc∗ = kv ω ∗ . (16)
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BIST AND SINGH: BLDC MOTOR DRIVE WITH PFC USING ISOLATED ZETA CONVERTER 2069
TABLE I
S PEED OF BLDC M OTOR W ITH C HANGE IN DC L INK VOLTAGE
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Fig. 7. (a) Performance of the proposed drive at rated condition showing sup-
ply voltage (Vs ), voltage, and current of the PFC converter switch and its
(b) enlarged waveforms.
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BIST AND SINGH: BLDC MOTOR DRIVE WITH PFC USING ISOLATED ZETA CONVERTER 2071
Fig. 9. Measured power quality indices of proposed BLDC motor drive at rated load on BLDC motor with (a)–(c) Vs = 220 V and Vdc = 130 V, (d)–(f) Vs =
220 V and Vdc = 50 V, (g)–(i) Vs = 270 V and Vdc = 130 V, and (j)–(l) rated load on BLDCM with Vs = 170 V and Vdc = 130 V.
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