Download International Electrical Engineering Journal (IEEJ) Vol. 5 (2014) No.10, pp. 1567-1575

International Electrical Engineering Journal (IEEJ)
Vol. 5 (2014) No.10, pp. 1567-1575
ISSN 2078-2365
http://www.ieejournal.com/
A Review Paper on Torque Ripple
Reduction and Power Quality
Improvement in Brushless DC Motor
Drives
Arunkumar and Thangavel
[email protected]
Abstract— In recent years brushless DC motors (BLDC) are
the research hotspot in speed precision and household
applications due to its high reliability, simple frame, high
efficiency, fast dynamic response, compact size, low
maintenance, etc.., It is an electronically commutated motor.
The operation of these motors is based on the rotor position
sensing using sensors or sensor less scheme. Because of this
commutation, the ripples are generated in the electromagnetic
torque and the power factor of the AC mains gets affected due
to its operation. So, in order to improve the performance of
these motors the ripple in the electromagnetic torque could be
reduced and the power factor of the AC mains should be
increased. This paper presents the review of different torque
ripple reduction techniques used for reducing the ripple in the
electromagnetic torque and different converter topologies used
for improving the power factor of the AC mains near to the
unity.
Index Terms— Brushless direct current motor (BLDC),
multilevel inverter (MLI), back EMF, power factor corrected
(PFC), power quality, discontinuous inductor current mode
(DICM), bridge less (BL).
I. INTRODUCTION
Household appliances like washing machines, room air
conditioners, refrigerators, fans, water pumps, vacuum
cleaner and freezer are to be expected one of the fastest
growing end products in the market over the next few years
[1-4]. Conventionally DC motors are widely used in these
appliances and due to some drawbacks like frequent
maintenance and sparking in brushes, consumers are
switching over to single phase induction motors including
split phase, capacitor-start, capacitor-run type motors and
universal motors. These motors operate at constant speed
directly from AC mains with low efficiency. Now-a-days
acoustic consumer demand for high efficiency, low cost,
low noise and better performance motors for these
appliances. The conventional technologies doesn’t meet
these demands. The use of special electrical machines like
brushless DC motors (BLDC), permanent magnet
synchronous motors (PMSM) in these appliances are a
better choice due to the features of high reliability, high
efficiency, low maintenance, high flux density per unit
volume, high power density due to absence of field winding
and low electromagnetic interference problem [5-6]. By
comparing with PMSM, the speed adjusting performance of
BLDC motor is high and also power density. So BLDC
motor is preferable in many appliances. The other
applications of BLDC motors are robotics, medical
equipment, precise motion control systems, industrial tools,
heating and ventilation systems.
A BLDC motor has three phase distributed winding on
the stator, which is made up of stacked steel lamination.
Based on the construction of stator, the generated back EMF
is in trapezoidal waveform. For PMSM the generated back
EMF is in sinusoidal waveform. The rotor of the BLDC
motor is made up of permanent magnets. Based on the
application requirement, the configuration of permanent
magnet placed in the rotor is varied. The magnets are placed
either in surface mounted magnet type or buried magnet
type. The BLDC motor is powered by VSI or CSI, which is
controlled by rotor position. The rotor position can be
sensed by using sensors like hall sensors, resolvers, optical
encoders or sensor less scheme. As the name indicates, there
are no brushes in the BLDC motor. It is an electronically
commutated motor, based on rotor position, three square
wave signal with 1200 phase shift has been generated to
provide firing signals to commutate the power electronic
switches in the inverter [7].
1567
Arunkumar and Thangavel
A Review Paper on Torque Ripple Reduction and Power Quality Improvement in Brushless DC Motor Drives
International Electrical Engineering Journal (IEEJ)
Vol. 5 (2014) No.10, pp. 1567-1575
ISSN 2078-2365
http://www.ieejournal.com/
II. TORQUE RIPPLE REDUCTION TECHNIQUES
Owing to different applications of BLDC motors in
industries as well as household applications, the
performance of these motors is considered to be quite
important. Due to manufacturing limitation and design
consideration of magnetic materials, the generated
back-electromotive force (EMF) waveform departed from
its original shape. Also due to commutation of power
electronic switches and PWM switching that causes
generated electromagnetic torque containing ripple in its
waveform [8]. These torque ripple produces noise which
degrades the performance of the motor and affect the
speed-control characteristics especially at low speed. So
commutation torque ripple, torque ripple produced by diode
freewheeling in an inactive phase are the research hotspot in
recent years [9].
Conventional control techniques injecting the similar
rectangular phase current command to the stator without the
knowledge of non-linearity in the back EMF waveform
which causes more amount of ripple in the generated
electromagnetic torque. Calson et al. analyze the torque
ripple in the BLDC motor due to phase commutation and
proposed that the ripple in the electromagnetic torque is
related to the relative current and varies with speed. Two
levels of the current control scheme is proposed to minimize
the torque ripple in BLDC motor. The first method utilizes
the position sensor to determine the phase sequence and the
moment of current commutation from one phase to another
phase and the other method controls the current amplitude
by PWM switching [10].
Chuang et al. analyze the different PWM techniques used
for commutation torque ripple reduction in BLDC motor
drive with ideal back EMF waveform and proposed that
PWM_ON method is the best choice for BLDC motors. But
the non-linearity in the back EMF was not considered in this
method [11].
Zhang et al. adding the buck converter in front of the VSI
and regulating the DC link voltage by step down the supply
voltage to reduce the commutation torque ripple. PWM_ON
switching pattern is used for commutation of VSI. The
proposed method effectively reduced the torque spikes and
dips, but it doesn’t considered the bandwidth of the buck
converter, so it is suitable at the low speed range only [12].
Chen et al. proposed Superlift luo converter topology for
DC link voltage regulation, but this topology is more
complex compared to buck converter and give better
performance under high-speed operation only. The luo
converter is replaced with SEPIC converter which needs
three additional switches and their corresponding
inductance, capacitance and diodes [13].
The torque ripple due to diode freewheeling current in
inactive phase was analyzed with different modulation
techniques and while considering the power dissipation
PWM_ON_PWM is the better modulation method [14-15].
To reduce the torque ripple with non-linearity in the back
EMF there are mainly two kinds of resolvents. One is to
employ the direct torque control to regulate the armature
current [16-19] and the other one is to apply the motor’s
back EMF as a function to regulate the current. In direct
torque control, the measurement of back EMF and phase
current increase the complexity of the circuit [20-23].
Fang et al. analyze the torque ripple in gyro/BLDC motor
with novel automatic current control method. The
non-linearity in the back EMF was considered and
PWM_ON_PWM modulation method is used which reduces
the torque ripple due to the diode freewheeling current in
inactive phase [24].
In recent years, several control algorithms are proposed to
minimize the torque ripple with non-ideal back EMF
method. Some of them are harmonic injection method which
reduce the torque ripple due to back EMF harmonics. But
this method ignores the higher order fouries series terms
because of complexity and time-consuming calculations also
it is more complicated for practical implementation due to
real time harmonics calculation [25-26].
Torque control of the multiphase BLDC motor was
analyzed with inequality constraints via Kuhn-Tucker
theorem which leads to copper loss and torque ripple
reductions. But it requires feedback sensors like high
resolution encoders and torque transducer which increase
the overall cost of the system [27].
In direct torque and indirect flux control method, Clarke
and Park transformations are used for flux and torque
estimation. But the accuracy of the parameter estimation
was affected in these transformations which leads to more
time consuming [28-29].
Shakouhi et al. proposed phase to phase back EMF
estimation method for commutation torque ripple. But in
these method commutation torque ripple was achieved by
energizing all phases at a specific time before the end of
each conduction interval. Energizing all phases for
particular instant is quite complicated [30]. Modifying the
inverter topology is the one way to reduce the commutation
torque ripple. The voltage source inverter (VSI) is replaced
with current source inverter (CSI) and the circuit was
analyzed with different speed conditions. Conventionally
controlled rectifier with large value of inductor act as a
current source which increase the overall cost of the system.
Then controlled rectifier with large inductor is replaced with
a buck converter switching at high frequencies. The
additional converters increase the complexity of the circuit.
III. MULTILEVEL INVERTER TOPOLOGY
The practical BLDC motor setup and trapezoidal back
EMF waveforms are shown in Fig. 1 and Fig. 2. The square
wave output of the VSI is fed to the stator winding of the
motor. Based upon the rotor position the power electronic
switches in the inverter are commutated. Normally the
harmonic content is high in the square wave output of the
1568
Arunkumar and Thangavel
A Review Paper on Torque Ripple Reduction and Power Quality Improvement in Brushless DC Motor Drives
International Electrical Engineering Journal (IEEJ)
Vol. 5 (2014) No.10, pp. 1567-1575
ISSN 2078-2365
http://www.ieejournal.com/
VSI, which increase the THD of the output. Due to these
effects the ripples are created in the output electromagnetic
torque and distortion in the trapezoidal back EMF
waveform.
(b)
Fig.1 BLDC motor setup
Fig. 2 Trapezoidal back EMF waveform
(a)
Fig. 3 Comparative analysis of (a) Pmech and (b) efficiency of the two level
and multilevel inverter.
When the level of the output waveform is increased the
harmonic content is automatically gets reduced. So the
ripples created in the output torque are reduced. Also two
level inverter doesn’t suitable for high power rating
applications. Multilevel inverter is the alternative best
choice for these applications because the output waveform
of these inverters is staircase form which looks like a
sinusoidal waveform. When the level gets increased the
THD value gets reduced. It is obvious that an output with
voltage with low THD is desirable.
A comparative analysis between the two level inverter
and multilevel inverter with different modulation index
condition were tabulated in table 1. From the graphical
representation it was clearly depicted that multilevel inverter
is the best choice for motors as compared to two level
inverter. When the output voltage level gets increased,
harmonics content will automatically get reduced. Although
increasing the number of levels needs more hardware and
the control will be more complicated, which is often a
limitation for the use of the multi-level inverter, better
quality of load torque is considered to be the outcome of the
MLI fed BLDC motor. Compared to two level inverter fed
motor drives, the multilevel inverter fed motor drives offers
less noise and current distortions.
1569
Arunkumar and Thangavel
A Review Paper on Torque Ripple Reduction and Power Quality Improvement in Brushless DC Motor Drives
International Electrical Engineering Journal (IEEJ)
Vol. 5 (2014) No.10, pp. 1567-1575
ISSN 2078-2365
http://www.ieejournal.com/
(c)
(d)
Fig. 4 Comparative analysis of (c) Speed and (d) torque of the two level
and multilevel inverter.
Table. 1
Comparative Analysis of Two Level Inverter and Multilevel Inverter Fed Induction Motor under Different Modulation Index Condition
S.No
Two Level Inverter Fed Capacitor Start Run Induction Motor
M.I
Pmech
PF
Efficiency
Speed
Torque
(W)
(%)
(rpm)
(Nm)
Multilevel Inverter Fed Capacitor Start Run Induction Motor
Pmech
PF
Efficiency
Speed
Torque
(W)
(%)
(rpm)
(Nm)
1.
0.2
263.7
0.6
59.7
145.7
1.827
743.7
0.835
72.23
146.7
5.13
2.
0.4
256.6
0.59
54.4
151.3
1.724
784
0.83
69.67
149.9
5.253
3.
0.5
112.7
0.165
17
156.7
0.723
835.9
0.697
58.17
153.3
5.476
4.
0.7
190.2
0.159
16.14
159.2
1.3
798.2
0.684
47.78
152.5
5.237
5.
0.8
240.9
0.146
15.92
156.5
1.445
774.4
0.667
52.33
153
5.02
6.
0.9
310.7
0.137
15.2
157
1.9
866.3
0.63
55.3
154.6
4.96
A. Diode Clamped Multilevel Inverter
The voltage stress in the power devices is limited by
using diodes is the major concept of this inverter[41]. The
voltage over each capacitor and each switch are Vdc. The
components required for n-level inverter is (n-1) voltage
sources, 2(n-1) switching devices and (n-1)*(n-2) diodes. It
is also known as neutral clamped inverted. DC link voltage
unbalancing problems occur in this inverter. The circuit
configuration for 5-level inverter is shown in Fig 5. It is a
single leg. For three phase output, three legs are serially
connected.
1570
Arunkumar and Thangavel
A Review Paper on Torque Ripple Reduction and Power Quality Improvement in Brushless DC Motor Drives
International Electrical Engineering Journal (IEEJ)
Vol. 5 (2014) No.10, pp. 1567-1575
ISSN 2078-2365
http://www.ieejournal.com/
Fig. 5 Diode clamped multilevel inverter
Fig. 6 Flying capacitor multilevel inverter
B. Flying Capacitor Multilevel Inverter
The circuit configuration of this inverter is similar to the
neutral point clamped converter but it requires high numbers
of auxiliary capacitors. For n-level inverter it requires (n-1)
main capacitors and (n-1)*(n-2)/2 auxiliary capacitor. The
main advantages of this converter is it doesn’t require filters
for high level and active and reactive power flow is possible.
But the control of the system is complicated when the output
level is increased. The circuit diagram for single leg is
shown in Fig 6.
C. Cascaded Multilevel Inverter
The series connection of H-bridge inverter with separate
DC sources is termed as cascaded H-bridge multilevel
inverter. It doesn’t requires any clamping diodes and flying
capacitors. For three phase configuration, the cascaded
converters can be connected either in star connection or
delta connection. Compare to other topologies, it uses fewer
components. The control is also simple. But it needs
separate DC sources for the power conversion, which limits
its use. For n-level inverter the number of switching device
required is 2(n-1) per leg. The circuit configuration of single
phase five level inverter and its output voltage waveform is
shown in Fig. 7 and Fig. 8 respectively. Each cell contains
isolated DC source.
1571
Arunkumar and Thangavel
A Review Paper on Torque Ripple Reduction and Power Quality Improvement in Brushless DC Motor Drives
International Electrical Engineering Journal (IEEJ)
Vol. 5 (2014) No.10, pp. 1567-1575
ISSN 2078-2365
http://www.ieejournal.com/
Fig. 7 Cascaded H-bridge multilevel inverter
value of DC link capacitors. This circuit result in highly
distorted supply current with THD of 65% and a poor power
factor of 0.8 which is not accepted by International Power
Quality (PQ) standards such as IEC-61000-3-2 [32]. Hence
a power factor corrected (PFC) frontend rectifiers are
required to improve the power factor in order to improve the
power quality (PQ) at the AC mains.
Two stage PFC converters are in normal practice in which
one PFC converter improves the power quality (PQ) at AC
mains which is typically a boost converter and another one
is for voltage control, which depends upon the choice of
application. Due to more number of components in the
above circuit losses gets increased. A single stage PFC
converters has gained much more attention because the PFC
operation and the DC-link voltage control can be achieved
in a single stage. Also it is more efficient compared to two
stage converters [32-33].
The another critical issue in the BLDC motor is the
choice of mode of operation of a PFC converters, because it
directly affects the cost of the components used in the PFC
converters as well as ratings. The PFC converters are
designed to operate in two basic mode of operation either in
continuous conduction mode (CCM) or discontinuous
conduction mode (DCM) [34-35]. As the name indicates,
the voltage across the intermediate capacitor and current in
the inductor remains constant. But it requires two voltage
sensors (dc link voltage and supply voltage) and one current
sensor (Supply current) for PFC operation. But in DCM
operation single voltage sensor is enough for dc link voltage
control to achieve better PFC is achieved at AC mains [35].
But in DCM operation the stresses across the switch of PFC
converters are high compared to CCM operation. So it is not
preferable for higher power rating applications. Hence the
choice of the mode of operation trade-off between the
stresses and allowable power rating.
Fig. 8 Five level output voltage waveform
Among these three topologies single source, multi DC
link cascaded H-bridge multilevel inverter is the best choice
for torque ripple minimization in the BLDC motor drive.
IV. POWER QUALITY ISSUES
The power quality has become the most important factor
to be considered at the point of BLDC motors. The
international standards such as International Electrotechnical
Commission (IEC) 61000-3-2, recommended such that the
harmonics in the supply current should be within the limit.
For class-A equipment (< 600 W, 16 A per phase) which
includes household appliances, the IEC 61000-3-2 restricts
that the THD of the supply current should be below 19%
[31]. Conventionally diode bridge rectifier (DBR) is used as
a front-end rectifier in VSI fed BLDC motors with high
V. PFC CONVERTERS
In the conventional PFC scheme the speed control can be
achieved by pulsewidth-modulated voltage source inverter
(PWM-VSI) with constant dc link voltage. This results
higher switching losses in the VSI which is the square
function of switching frequency. The speed of the BLDC
motor is directly proportional to the DC link voltage. So the
speed control can be achieved by a variable DC link voltage
of VSI with fundamental frequency switching (electronic
commutation). This offers minimum switching losses.
Singh and Singh [36] have proposed the concept of
buck-boost converter fed BLDC motor with constant DC
link voltage and PWM-VSI for speed control, which offers
high switching losses. The buck-boost converter is replaced
with single-ended primary-inductance converter (SEPIC)
1572
Arunkumar and Thangavel
A Review Paper on Torque Ripple Reduction and Power Quality Improvement in Brushless DC Motor Drives
International Electrical Engineering Journal (IEEJ)
Vol. 5 (2014) No.10, pp. 1567-1575
ISSN 2078-2365
http://www.ieejournal.com/
based VSI fed BLDC motor drive has been proposed by
Gopalarathnam and Taliyat. Due to higher number of
current and voltage sensors restricts its applicability to low
power applications [37].
The switching losses across the switches due to
fundamental frequency switching of VSI for electronic
commutation of BLDC motor can be minimized by Cuk
converter fed BLDC motor drive with a variable DC link
voltage has been proposed by Singh and Singh [32]. But it
needs three voltage control sensors for PFC operation which
is not cost effective and suitable for high power applications
only.
For further improvement in the efficiency and
performance of the BLDC motor the front-end DBR is
replaced with bridgeless (BL) topologies. The BL topology
offers less conduction losses across the switches. Jang and
Jovanovic [38] and Huber et al. [39] have proposed the BL
buck and boost converter for PFC operation. But it limits the
operating range of the dc link voltage control due to separate
buck and boost operation of the converter. Also high starting
inrush current is major drawback of these converters.
Abbas A. Fordoun et al. analyze the Cuk derived
converters from PFC operation in BLDC motors. The Cuk
converter has inherent advantages like natural protection
against inrush current and overload current, lower ripple
content in the current and low electromagnetic interference
(EMI). The equivalent circuit of Cuk derived converters is
shown in Fig.9 (a)-(c).
(a)
(c)
Fig. 9 Equivalent circuits for (a) Type I. (b) Type II and (c) Type III Cuk
derived PFC Converters
Thus the Cuk derived converters do not suffer from
common-mode EMI noise emission problem compared to
conventional
Cuk
converter
topology.
Also
“near-zero-current-ripple” condition at the input and output
port of the converter can be achieved without
compromising the performance. But the component count
gets increased in the Cuk derived converters which
increase the switching losses in the converter [40].
Among the different BL converter topologies, the
bridgeless buck-boost rectifier has less component count.
To achieve inherent power factor correction at AC mains,
the rectifier is operated in a discontinuous inductor current
mode (DICM). This rectifier offers low switching losses in
VSI, because the VSI operates in low frequency for
electronic commutation in BLDC motor [41]. The
equivalent circuit for the BL buck-boost converter is shown
in Fig. 10. The comparative analysis between the different
PFC converter topologies is tabulated in table. 2
Hence the BL buck-boost PFC converter is a best choice
for improving the power factor at the AC mains in order to
obtain the best power quality. Compared to other BL
topologies the buck-boost converter have a minimum
number of components. So the losses associated with the
switches and stress on switches gets reduced.
Table. 2
Comparative Analysis of BL Converter Topologies
Configuration
(b)
SW
No. of Devices
D
L
C TOTAL
Suitability
BL-BUCK
2
4
2
2
10
NO
BL-BOOST
2
2
1
1
6
NO
BL-CUK T-1
2
3
3
3
11
YES
BL-CUK T-2
2
2
3
4
11
YES
BL-CUK T-3
2
4
4
3
13
YES
BL-BUCK-BOOST
2
4
2
1
9
YES
1573
Arunkumar and Thangavel
A Review Paper on Torque Ripple Reduction and Power Quality Improvement in Brushless DC Motor Drives
International Electrical Engineering Journal (IEEJ)
Vol. 5 (2014) No.10, pp. 1567-1575
ISSN 2078-2365
http://www.ieejournal.com/
[7]
[8]
[9]
[10]
[11]
Fig. 10 Equivalent circuit of bridgeless buck-boost converter
[12]
VI. CONCLUSION
An exhaustive overview of torque ripple minimization
and power quality improvement in the brushless dc motors
(BLDC) has been presented in this paper. Among different
torque minimization techniques, the cascaded H-bridge
multilevel inverter gives better performance in the efficiency
as well as smoother distortion less stator current. The
harmonics in the stator current are effectively reduced which
minimize the THD. Also different PFC converters are
analyzed for power quality improvement at AC mains. From
this analysis the BL buck-boost converter provides reduced
switching losses and stresses across the switches. The
BLDC motor has inherent household applications and the
performance of these motors have been improved by BL
buck boost converter as front-end rectifier and cascaded
H-bridge multilevel inverter fed BLDC motor drive.
[13]
[14]
[15]
[16]
[17]
[18]
[19]
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