R8C/25 microcontroller Used to speed & Current Control of Universal Motor

Rakesh Sing Lodhi (ME Scholar), Dr.H.K.Verma (Prof. SGSITS, Indore)

rakeshlodhigs@gmail.com

Abstract
This paper introduces a Speed & Current Control of universal motor by microcontroller. The new system adds
the inner current control to improve dynamic response. Complete control schemes have been developed &
implemented in a low cost R8C/25 16-bit microcontroller. It has been shown that the proposed DC Chopper
control of the universal motor with both speed & current control has good speed regulation and fast response. It
also has low acoustic noise, less current harmonics, low motor temperature & more torque.

INTRODUCTION:
The universal motor is a low-cost solution with limited performance. It is used widely in the
consumer-products industry, especially for power tools and home appliances such as washers, mixers,
vacuum cleaners, etc. This type of motor is called a universal motor because it can run on either AC
or DC power [1-4].
To implement universal motor speed control, generally a triode AC switch (TRIAC) phase-angle firing
control or DC chopper with a speed loop is applied. A TRIAC-based control scheme, as shown in Fig.
1, is a simple and cost-effective solution for controlling the universal motor speed by changing the
phase angle. Actual speed, measured with a simple tachometer is coupled with the desired speed to
change the firing time of the TRIAC. This solution has many disadvantages, unfortunately, including
high phase current and current harmonics, high motor temperature, noise, and low control frequency.
A DC chopper provides a better solution for universal motor speed control. Fig. 2 shows a typical
layout for DC chopper control of a universal motor. Driving the universal motor with a PWM signal
reduces current ripple and harmonics and therefore results in better performance. Compared to the
TRIAC control approach, the DC chopper control method has lower acoustic noise, less current and
fewer current harmonics [5-9].
Traditionally the type of DC chopper control shown in Fig. 2 provides speed control only. It does not
control the current. The speed is asynchronous, so the regulation frequency is dependent on the speed
level. At low and medium speeds, the speed regulation is poor and the average error is large. The
speed regulation improves at high speeds. But at Also, the speed dynamic response is somewhat slow.
In other words, the control system takes a long time to get back to a steady state when load changes or
external disturbances occur. Obviously, a control scheme that responds more quickly to load variations
is preferable [10].

Fig. 1: TRIAC Based Speed Control of DC Motor

Fig.2: DC Chopper Speed Control

To better meet the requirements of universal motor control, this paper investigates and applies inner
current control to the universal motor control system. The motor starts up with the closed speed and
current loops. Complete control schemes, which have been developed and implemented in a low cost
R8C/25 microcontroller, are used. A series of experimental tests has been conducted to evaluate and
verify the system performance. The results show that the DC chopper with both speed and current
control provides good speed regulation and fast response. This proposed universal motor control
system has great potential and much practical significance for industrial applications.
UNIVERSAL MOTOR CONTROL SYSTEM:
A universal motor consists of three main parts:1. A stator with field windings to generate magnetic flux.
2. A rotor with armature windings supplied with current via the carbon brushes to generate
magnetic flux.
3. Brushes for mechanical linking of the power supply and rotor windings. If the universal motor
is connected to a DC power supply, it behaves like a DC motor with a direction.

The equivalent circuit of a proposed universal motor with speed and current control is shown in Fig. 3.

Fig:-3: Equivalent Circuit of Universal Motor of DC Chopper Controller

The model of the proposed universal motor control can be described mathematically as:

di
RV f Lf 0 I
f dt f
*
V a di Ia
K1 Ra La
dt

If Ia

E K 1wIa
Where E is the motor back emf
K1 is the motor constant dependent on the motor characteristics.
Because the universal motor is a serial excitation motor, the motor torque is proportional to the square
of the motor current.
Te TL J

dw
k 2 w K1 I a 2
dt

The overall control system is composed of a speed proportional-integral (PI) regulator, a current PI
controller, a speed measurement sensor, and a pulse width modulation (PWM) generator, as shown in
Fig. 4. The system has two control loops: an inner current loop and an outer speed loop.
Both the speed and current controller use a typical PI control loop format. The speed PI loop outputs
the reference current required for the proper torque. The current PI control loop generates the voltage
necessary to maintain the torque.
The current control loop is designed to be much faster than the speed control, so that the proposed DC
chopper control system has a fast dynamic response to load changes and system variations. For this
reason the addition of current control is crucial to the application.

Fig.4: Block Dig of Proposed speed & Current DC Chopper Control

MICROCONTROLLER CONFIGURATION & THEIR BLOCK DIAGRAM REPRESENTATION:

The proposed speed and current DC chopper for universal motor control has been implemented using a
low-cost, low pin- count 16-bit R8C/25 microcontroller to regulate both speed and current in the
system. The R8C/25 operates at a 20 MHz clock speed and has 16KB of on-chip flash memory and
1KB of RAM. It also provides useful on-chip peripherals including an I2C-bus interface (IIC)/chipselect clock synchronous serial interface (SSU), 10-bit A/D converter (ADC), output-compare timer,
voltage-detection circuit, power-on reset circuit, high/low speed on-chip oscillator, sub-clock
generation circuit, and LIN module hardware. The R8C/25-based microcontroller configuration is
shown in Fig. 5.

Fig:5 R8C/25 based universal motor control configuration.

The hall sensor interrupt has the highest priority, and the rate varies from 240 Hz to 1200 Hz. The
ADC interrupt has the second highest priority, and the rate is identical to the PWM rate because it is
triggered in the PWM interrupt. The PWM interrupt is ranked third in priority and occurs at the 12
kHz carrier frequency.
EXPERIMENTAL TEST & ANALYSIS:To verify the proposed speed and current DC chopper control, a series of experimental tests was
conducted on the dynamometer. The dynamometer setup consists of the following: a universal motor,
brake (with max torque of 3.25 Nm and max speed of 15,000 rpm) and Magtrol DSP6001
dynamometer controller. The entire speed range with the maximum load will be evaluated.
CONCLUSIONS:
A DC chopper-based system for speed and current control of universal motors has been developed
successfully. The system can deliver maximum torque in the entire speed range, from 2,000 rpm to
13,000 rpm. Compared to traditional TRIAC systems and systems that use DC chopper control with a
speed loop only, the newly developed speed-and-current DC chopper control system offers
significantly improved performance.
It provides the known mechanical advantages of a DC chopper over a TRIAC systemincluding more
efficient motor operation (low power usage, low temperature (operation), elimination of audible
dimmer switch noise, and overall reduced acoustic noise. Moreover, tests show that the DC chopper
speed and current control system offers the following benefits:
Better speed regulation;
Speed and current loop combination for faster response to load changes and external
disturbances;
More torque available to the motor (about 20% more estimated).

These experimental results suggest that the proposed universal motor control has great practical
significance for industrial applications.
REFERENCES:
[1] H. Toliyat, G. Kliman, Handbook of Electric Motors, 2nd edition, Marcel Dekker, 2003.
[2] P. Vas, Sensorless Vector and Direct Torque Control, Oxford Science Publications, New York, 1998.
[3]Gopal K.Dubey Handbook of Fundamental of Electrical DrivesNarosa publisher
[4]H.Bodur, A.Bakan, & M.Sarul Universal motor speed, Current Controlled PWM AC Chopper using microcontroller,
IEEE Proc. Industrial Technology 2000 vol.1 pages 394-398.
[5]N.K.De. & P.K.Sen Handbook of Electric DrivesPHI Publisher
[6]Raymond G. Jacquat Handbook of Modern Digital Control System
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