Documente Academic
Documente Profesional
Documente Cultură
5, MAY 2015
3277
I. I NTRODUCTION
countries, but they are increasingly expected to form an important role in a low-carbon future. This is largely because a future
of more efficient pumps is one of the lowest carbon footprint
cutting options [1][12]. Three-phase brushless direct current
(BLDC) motors are good candidates for their high-efficiency
capability, compactness, and easy-to-drive features [13].
The operational disadvantage of this kind of motor is the fact
that commutation of motor phases relies on its rotor position.
Although the rotor position is usually sensed by sensors,
there are applications that require sensorless control. Benefits
of the sensorless solution are elimination of the position sensor
and its connections between the control unit and the motor. The
sensorless rotor position technique detects the zero crossing
points of back electromotive force (BEMF)-induced in the
motor windings. The phase BEMF zero crossing points are
sensed while one-phase winding is not powered. The obtained
information is processed to commutate energized phase pair
and control the phase voltage using pulsewidth modulation
(PWM) of the inverter switches [1][12].
In [13], a new controller based on zero current crossing
was introduced, but it was complicated compared with the
simple methodology of this paper that uses coupled resistors
(preconditioning circuit) with the controller to provide the same
function. In [14], a new power circuit was introduced, but it
is expensive and bulky. This paper explores the technological,
economic, and social and energy supply factors that determine
the benefits servo motors could deliver in the North American
and other EU countries. In [2][6], the controller is fed by a
battery, which adds cost and reduces the reliability of the pump.
In [7][12], the controller is complicated with large number of
components, which makes it expensive to be commercialized.
In [9], the controller is optimized only for the constant power
region but does not work in the constant torque region and not
packaged with the motor in the same housing.
The main showstopper in the industry against using a costeffective sensorless control with the best efficiency point (BEP)
is the noise on the feedback signal, coming to the controller
from the motor side, as it causes high-torque ripples and can
cause motor stoppage or cogging. Hence, the presented work
starts with optimizing the motor design to minimize the torque
ripple [17][19]. Then, a mapping of the inputoutput characteristics at BEP is developed. The mapping algorithm is used
to program the controller. Therefore, the solution has the full
package of low cost and high efficiency with minimal torque
ripple. Another problem with the torque ripple is the harmonic
content of the ac supply current. This needs the use of an RF filter and an LF filter at the input side to meet the electromagnetic
compatibility requirements of the IEC 555-1 requirements (as
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3278
TABLE I
P OSITION V ERSUS R ESISTANCE
TABLE II
R EGION OF O PERATION V ERSUS U PDATE T IME
given in Fig. 13). The problems with these filters are the cost
and the voltage drop of the rectified voltage. Any drop of the
rectified voltage will cause a reduction of the speed range of the
motor. Hence, the minimization of the harmonics will allow the
use of small filters, which will save cost and allow a wider speed
range for the motor by these controllers. The motor, controller,
and housing will be integrated according to the IP42 standard
required by the National Electrical Manufacturers Association
(NEMA) directives in North America. Design procedure, simulation, and experimental results are presented in the paper to
highlight the technical and economical merits of the proposed
water pump.
Fig. 1.
Valves are most of the time open more than 75% Curve is
raised.
Sequence of Operations in the algorithm
1) Initially
A = 0.4 BEP_Head;
B = (BEP_Head A)/BEP_Flow2;
C = BEP_Head/BEP_Flow2 (all valves full open).
2) Calculate K = H/Q2 and count the time its greater than
6.5 (Count_1) and the time it is less than 6.5 (Count_2).
3) If Count_1 + Count_2 > 24 h (the pump has been running more than 24 h since the last check), then;
if Count_1 > Count_2 + 4 h, then decrease A by 1%;
if Count_1 + 4 h < Count_2, then increase A by 1%;
reset Count_1 and Count_2 to 0.
4) When K stays above 15 C, every 30 min
decrease A by 5%;
increase B by 5%.
5) When K stays below 2 C, every 30 min
increase A by 5%;
decrease B by 5%.
6) The minimum value of K averaged over 1 min achieved
D is stored.
7) If D < C, replace C with D.
8) After the first two days of operation
C is replaced with D;
D is reset to zero.
9) After every review interval is completed (see the
next step),
a. if K 3 C;
b. reduce speed to MinPumpSpeed (default 30%) for
15 min;
c. then reset D to zero and start a new review interval.
10) Review intervals are given in Table II as follows.
Fig. 1 shows the different combinations of the pressure
head and flow rate and how every combination requires a
certain speed of the motor. This speed is accompanied by a
YOUSSEF: DESIGN AND PERFORMANCE OF A COST-EFFECTIVE BLDC DRIVE FOR WATER PUMP APPLICATION
Fig. 2.
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Schematics of the power circuit and control circuit. (a) Schematics of motor drives. (b) Voltage sense logic. (c) Controller schematics.
3280
Fig. 3.
Fig. 4.
YOUSSEF: DESIGN AND PERFORMANCE OF A COST-EFFECTIVE BLDC DRIVE FOR WATER PUMP APPLICATION
3281
TABLE IV
E VALUATED M OTOR PARAMETERS AT T WO D IFFERENT F LUX D ENSITIES
Fig. 5. Cogging torque variation in space for two different remnant flux
densities: minimal values that reflect minimal harmonics.
Fig. 7. Input ac voltage and current at (a) no-load and (b) full-load
conditions. AC voltage is in cyan, 40 V/div.; current is in blue, 0.4 A/100
mV; and dc rectified bus voltage is in red, 75 V/div.
Fig. 6. Magnetic flux distribution within the proposed magnetic structure: hot magnetic spot.
Fig. 8.
Fig. 9.
3282
Fig. 10.
Three-phase currents of the motor under steady-state and transient conditions: balanced sinusoidal currents.
Fig. 11. Test rig of the developed pump with the measurement setup
of the flow versus the head of water circulation.
YOUSSEF: DESIGN AND PERFORMANCE OF A COST-EFFECTIVE BLDC DRIVE FOR WATER PUMP APPLICATION
Fig. 12.
Fig. 13.
V. C ONCLUSION
A more efficient and cost-effective water circulator has been
developed; the field-oriented controller has been implemented
on a cost-effective two-layer printed circuit board. The design
does not need a battery for powering the controller, which
reduces the cost. The zero crossing of the BEMF is precisely
detected through a simple resistor preconditioning circuit connected to the AN2030 or AN1627 trigger pin. The algorithm for
3283
A PPENDIX
See Figs. 12 and 13.
3284
R EFERENCES
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Mohamed Z. Youssef (S03M05SM08) received the Ph.D. degree from Queens University, Kingston, ON, Canada, in 2005.
He was an Adjunct Assistant Professor with
Queens University, where he was involved in
teaching and research. In 2007, he was with
Bombardier Transportation as a Senior Research and Development Engineer. In 2012,
he was with Alstom Transport as a Research
and Development Engineering Manager. He is
currently an Assistant Professor with the Department of Electrical, Computer and Software Engineering, University
of Ontario Institute of Technology, Oshawa, ON, Canada, where he
is also the Director of the Power Electronics and Drives Laboratory.
He has more than 60 papers published in top-tier IEEE journals and
conference proceedings with five U.S./Canadian patents. His research
interests include electromechanical systems for the transportation industry, electromagnetic compatibility for railways, and power electronics
applications for information technology.
Dr. Youssef is a Professional Engineer in the Province of Ontario,
Canada.