Analysis of Variable Speed PFC Chopper FED BLDC Motor Drive

International Journal of Power Electronics and Drive System (IJPEDS)
Vol. 5, No. 3, February 2015, pp. 326~335
ISSN: 2088-8694  326
Journal homepage: http://iaesjournal.com/online/index.php/IJPEDS
Analysis of Variable Speed PFC Chopper FED BLDC Motor
Drive
A. Jeya Selvan Renius, K.Vinoth Kumar
Department of Electrical and Electronics Engineering, School of Electrical Sciences,
Karunya Institute of Technology & Sciences University, Coimbatore – 641114, Tamilnadu, India
Article Info ABSTRACT
Article history:
Received Oct 17, 2014
Revised Dec 2, 2014
Accepted Dec 16, 2014
This paper provides the detailed analysis of the DC-DC chopper fed
Brushless DC motor drive used for low-power applications. The various
methods used to improve the power quality at the ac mains with lesser
number of components are discussed. The most effective method of power
quality improvement is also simulated using MATLAB Simulink. Improved
method of speed control by controlling the dc link voltage of Voltage Source
Inverter is also discussed with reduced switching losses. The continuous and
discontinuous modes of operation of the converters are also discussed based
on the improvement in power quality. The performance of the most effective
solution is simulated in MATLAB Simulink environment and the obtained
results are presented.
Keyword:
Bridgeless
Common-mode noise
DC-DC chopper
Power factor correction
Power quality Copyright © 2015 Institute of Advanced Engineering and Science.
All rights reserved.
Corresponding Author:
A. Jeya Selvan Renius,
Department of Electrical and Electronics Engineering,
School of Electrical Sciences, Karunya University,
Coimbatore – 641114, Tamilnadu, India.
Email: renius28@gmail.com
1. INTRODUCTION
Low power motor drives such as fans, water pumps, blowers, mixers, HVAC transmission, motion
control etc. use BLDC motor for their efficient operation. Since BLDC offers high efficiency, low
electromagnetic interference, low maintenance and high flux density per unit volume, we use BLDC for low
power applications. BLDC motors are very popular in a wide variety of applications. Compared with a DC
motor, the BLDC motor uses an electric commutator rather than a mechanical commutator, so it is more
reliable than the DC motor. In a BLDC motor, rotor magnets generate the rotor’s magnetic flux, so BLDC
motors achieve higher efficiency. Therefore, BLDC motors may be used in high-end white goods
(refrigerators, washing machines, dishwashers, etc.), high-end pumps, and fans and in other appliances which
require high reliability and efficiency.
In this respect, the BLDC motor is equivalent to a reversed DC commutator motor, in which the
magnet rotates while the conductors remain stationary. In the DC commutator motor, the current polarity is
altered by the commutator and brushes.
However, in the brushless DC motor, polarity reversal is performed by power transistors switching
in synchronization with the rotor position. Therefore, BLDC motors often incorporate either internal or
external position sensors to sense the actual rotor position, or the position can be detected without sensors.
The choice of mode of operation of a PFC converter is a critical issue because it directly affects the
cost and rating of the components used in the PFC converter. The continuous conduction mode (CCM) and
discontinuous conduction mode (DCM) are the two modes of operation in which a PFC converter is designed
to operate. In CCM, the current in the inductor or the voltage across the intermediate capacitor remains
continuous, but it requires the sensing of two voltages (dc link voltage and supply voltage) and input side

IJPEDS ISSN: 2088-8694 
Analysis of Variable Speed PFC Chopper FED BLDC Motor Drive (A. Jeya Selvan Renius)
327
current for PFC operation, which is not cost-effective. On the other hand, DCM requires a single voltage
sensor for dc link voltage control, and inherent PFC is achieved at the ac mains, but at the cost of higher
stresses on the PFC converter switch; hence, DCM is preferred for low-power applications.
Figure 1. Block diagram of PFC chopper-fed BLDC motor drive
BLDC with diode bridge rectifier with a high value DC link capacitor has a THD (Total Harmonic
Distortion) of 65% and power factor as low as 0.8. So the power factor is corrected using the PFC converters.
Both continuous and discontinuous modes of the converters are discussed and the discontinuous mode of
conduction is best suited for the low power applications. Since the discontinuous conduction requires only a
single voltage sensor for DC link voltage control. But conventional PFC uses more number of components
that increases the cost of the control circuit. Also the conventional PFC used PWM-VSI for speed control
with constant DC link voltage which produces higher switching losses.
Thus the analysis is made for different methods that improve the power quality at the ac mains. For
further improvement in efficiency, bridgeless (BL) converters are used which allow the elimination of DBR
in the front end. A buck–boost converter configuration is best suited among various BL converter topologies
for applications requiring a wide range of dc link voltage control (i.e., bucking and boosting mode). These
can provide the voltage buck or voltage boost which limits the operating range of dc link voltage control. A
new family of BL SEPIC and Cuk converters has been reported but requires a large number of components
and has losses associated with it.
This paper presents a detailed analysis of chopper-fed BLDC motor drive with variable dc link
voltage of VSI for improved power quality at ac mains with reduced components.
2. EXISTING TOPOLOGY
The conventional PFC uses Pulse Width Modulated Voltage Source Inverter (PWM-VSI) for speed
control with constant DC link voltage. This causes higher switching losses. The switching losses in this
conventional approach increases as a square function of switching frequency.
T. Gopalarathnam and H.A. Toliyat [1] in 2003 proposed a Single Ended Primary Inductance
Converter (SEPIC) based BLDC which also has higher losses in the VSI due to conventional PWM switching
and large number of current and voltage sensors are used that additionally adds to the cost of the converter.
S. Singh and B. Singh [2] in 2011 proposed a paper about Buck-Boost converter based on constant
DC link voltage and also use PWM-VSI for speed control which again increases the switching losses.
S. Singh and B. Singh [3] again in 2012 proposed a cuk converter fed BLDC motor with a variable
DC link voltage that reduces the switching losses since it uses only the fundamental switching frequency.
Speed control is performed by controlling the voltage at the DC bus of VSI. In this paper, Continuous
Conduction Mode (CCM) is used. But the major disadvantage is that it requires three sensors. So it is not
encouraged for low-cost and low-power rating applications.
Since only the bridge converters are used in all the above used topologies, it also contributed for the
switching losses. Thus the bridgeless topologies are preferred. The different bridgeless topologies are
analysed based on the power quality of the ac mains.
3. BRIDGELESS CONVERTER TOPOLOGIES

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The bridgeless converters eliminate the use of diode rectifiers. The diode rectifiers cause more
switching stresses. This is not good for the proper functioning of the converter.
3.1. Boost Converters
Y. Jang and M.M. Jovanovic [4] in the year 2011 proposed a concept based on boost converter fed
BLDC motor drive. The basic topology of the bridgeless PFC boost rectifier is shown in Figure 2. Compared
to conventional PFC boost rectifier one diode is eliminated from the line-current path, so that the line current
simultaneously flows through only two semiconductors, resulting in reduced conduction losses. However, the
bridgeless PFC boost rectifier in Figure 2 has significantly larger common-mode noise than the conventional
PFC boost rectifier. In fact, in the conventional PFC boost rectifier, the output ground is always connected to
the ac source through the full-bridge rectifier whereas, in the bridgeless PFC boost rectifier in Fig. 2, the
output ground is connected to the ac source only during a positive half-line cycle, through the body diode of
switch, while during a negative half-line cycle the output ground is pulsating relative to the ac source with a
high frequency (HF) and with an amplitude equal to the output voltage. This HF pulsating voltage source
charges and discharges the equivalent parasitic capacitance between the output ground and the ac line
ground, resulting in a significantly increased common-mode noise.
Figure 2. Bridgeless PFC Boost converter
The bridgeless boost converter provides only voltage boost which limits the operating range of DC
link voltage control. Thus we move for another topology.
3.2. CUK Converters
Figure 3. Modified Cuk converter with Negative output polarity
L. Huber, Y. Jang and M.M. Jovanovic [5] in the year 2008 proposed a paper based on cuk
converter based BLDC. In this section, the topology derivation of the proposed converter is presented. Figure
3 shows a modified Cuk converter also known as a “Self-lift Cuk” converter. Referring to Figure 3, the
converter can be manipulated to produce a positive output voltage from a negative input voltage. Similarly,
for a converter it is possible to produce a negative output voltage from a negative input voltage. Note that the
converters have similar output characteristics and they are identical except for their input voltage polarity and
switch drain-to source connection. Therefore, it is possible to combine the two converters into a single

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bridgeless ac-dc PFC converter containing a bi-directional switch and an alternating input voltage source.
Likewise, the converter can be combined into a single bridgeless ac-dc PFC converter which offers an
inverted output voltage polarity. Unlike the conventional bridgeless PFC converters, all components in the
proposed converter are fully utilized as there are no idle components during both the positive and negative
ac-line cycle. Also, no additional diodes or capacitors are added to the topology to filter out common mode
noise since the output is not floating.
This converter also has a serious disadvantage of switching losses. So this topology is also not used
now.
3.3. Buck-Boost Converter
W. Lei, L. Hongpeng, J. Shigong and X. Dianguo [6] in the year 2008 proposed a scheme with
buck-boost converter fed BLDC . According to the above analysis, Switches and should have a
symmetrical blocking voltage characteristic. So, the RB-IGBT (Reverse Blocking IGBT) is used. It can block
both forward and reverse voltage during its off state. Comparing IGBT with a series connected diode,
elimination of the series diode helps to reduce losses by decreasing the on-state voltage across the switching
element. Comparing with bridge buck boost PFC converter bridgeless buck-boost PFC converter has one
more switch and capacitor, two less slow diodes. However, comparing the conduction path of these two
circuits, at every moment, three semiconductor devices are only conducting for bridgeless buck-boost PFC
converter, but four semiconductors are conducting for bridge buck-boost PFC converter. Therefore,
conduction loss can be reduced, especially in low line voltage.
Figure 4. Bridgeless PFC Buck-Boost converter
The above PFC buck-boost converter uses three switches which is cost effective and also increases
the switching losses. Thus this method of power quality improvement also has some limitations. So we go for
some other topology for better power quality.
3.4. SEPIC PFC Rectifier
A.A. Fardoun, E.H. Ismail, A.J. Sabzali and M.A. Al-Saffar [7] in the year 2012 proposed a method
of SEPIC PFC rectifier for BLDC. Figure 5 shows the power stage of a bridgeless SEPIC PFC rectifier. In
this circuit, the SEPIC converter is combined with the input rectifier and operates like a conventional SEPIC
PFC converter. The operation of this converter is symmetrical in two half-line cycles of input voltage.
Therefore, the converter operation is explained during one switching period in the positive half-line cycle of
the input voltage. It is assumed that the converter operates in DCM. It means that the output diode turns off
before the main switch is turned on. In order to simplify the analysis, it is supposed that the converter is
operating at a steady state, and all circuit elements are ideal. In addition, the output capacitance is assumed
sufficiently large to be considered as an ideal dc voltage source ( ). Also, the input voltage is assumed
constant and equal to Vac ( ) in a switching cycle. Based on the aforementioned assumptions, the circuit
operation in a switching cycle can be divided into three modes.
The circuit diagram gives the Single Ended Primary Inductance Converter (SEPIC) converter fed
BLDC motor for the improvement in the power quality.
Thus the SEPIC converter is efficient but it requires large number of components. So it is not cost
effective.
These are some of the bridgeless PFC converter techniques for the improvement of power quality in
the ac mains. But all these techniques have some limitations. They also cannot be used for low power
applications. So the proposed technique below is designed in such a way that is best suited for low power
applications.

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Figure 5. Bridgeless SEPIC PFC converter
4. PROPOSED TOPOLOGY
Figure 6 shows the proposed BL buck–boost converter-based VSI-fed BLDC motor drives. The
parameters of the BL buck–boost converter are designed such that it operates in discontinuous inductor
current mode (DICM) to achieve an inherent power factor correction at ac mains. The speed control of BLDC
motor is achieved by the dc link voltage control of VSI using a BL buck–boost converter. This reduces the
switching losses in VSI due to the low frequency operation of VSI for the electronic commutation of the
BLDC motor. The performance of the proposed drive is evaluated for a wide range of speed control with
improved power quality at ac mains. Moreover, the effect of supply voltage variation at universal ac mains is
also studied to demonstrate the performance of the drive in practical supply conditions. Voltage and current
stresses on the PFC converter switch are also evaluated for determining the switch rating and heat sink
design.
Finally, a software implementation of the proposed BLDC motor drive is carried out to demonstrate
the feasibility of the proposed drive over a wide range of speed control with improved power quality at ac
mains.
The proposed circuit diagram of the Buck-boost converter fed BLDC motor is shown in the
Figure 6.
Figure 6. Proposed Circuit diagram of the Buck-boost converter fed BLDC
The above circuit is perfectly suitable for the low power applications.
5. OPERATING PRINCIPLE OF THE PROPOSED PFC BL BUCK– BOOST CONVERTER
The operation of the PFC BL buck–boost converter is classified into two parts which include the
operation during the positive and negative half cycles of supply voltage and during the complete switching
cycle.
5.1. Operation during Positive and Negative Half Cycles of Supply Voltage
In the proposed scheme of the BL buck–boost converter, switches and operate for the positive
and negative half cycles of the supply voltage, respectively. During the positive half cycle of the supply
voltage, switch , inductor , and diodes and are operated to transfer energy to dc link capacitor
as shown in Figure 7(a)–(c).

331
Similarly, for the negative half cycle of the supply voltage, switch , inductor , and diodes
and conduct as shown in Figure 8(a)–(c). In the discontinuous mode of operation of the BL buck–boost
converter, the current in inductor becomes discontinuous for certain duration in a switching period.
5.2. Operation during Complete Switching Cycle
Three modes of operation during a complete switching cycle are discussed for the positive half cycle
of supply voltage as shown hereinafter.
Mode I:
In this mode, switch conducts to charge the inductor ; hence, an inductor current increases
in this mode as shown in Figure 7(a). Diode completes the input side circuitry, whereas the dc link
capacitor is discharged by the VSI-fed BLDC motor.
Mode II:
As shown in Figure 7(b), in this mode of operation, switch is turned off, and the stored energy in
inductor is transferred to dc link capacitor until the inductor is completely discharged. The current in
inductor reduces and reaches zero.
Mode III:
In this mode, inductor enters discontinuous conduction, i.e., no energy is left in the inductor;
hence, current becomes zero for the rest of the switching period. As shown in Figure 7(c), none of the
switch or diode is conducting in this mode, and dc link capacitor supplies energy to the load; hence,
voltage across dc link capacitor starts decreasing. The operation is repeated when switch is turned
on again after a complete switching cycle.
(a) Mode 1 (b) Mode 2
(c) Mode 3
Figure 7. Operation of the proposed converter in different modes (a)-(c) for a positive half cycle of the supply
voltage

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(a) Mode 1
(b) Mode 2
(c) Mode 3
Figure 8. Operation of the proposed converter in different modes (a)-(c) for a negative half cycle of the
supply voltage
6. SIMULATION CIRCUIT
The proposed bridgeless buck-boost converter fed BLDC with variable DC link voltage of VSI to
improve the power quality at ac mains with reduced components is simulated in MATLAB and the results are
shown below.
Figure 9. Simulation circuit of Buck-boost converter fed BLDC in MATLAB Simulink

333
The above circuit consists of the main blocks which are used for the BLDC control. The sub-blocks
are presented below. The main sub-block is the buck-boost converter block.
Figure 10. Simulation sub-block of buck-boost converter
The proposed method is simulated in MATLAB as given above and the results are evaluated.
7. SIMULATED RESULTS
The simulated results for various parts of the proposed circuit are shown in Figure 11. The
performance of the proposed BLDC motor drive is simulated in MATLAB/Simulink environment using the
Sim-Power System toolbox. The performance evaluation of the proposed drive is categorized in terms of the
performance of the BLDC motor and BL buck–boost converter and the achieved power quality indices
obtained at ac mains. The parameters associated with the BLDC motor such as speed (N), electromagnetic
torque ( ), and stator current ( ) are analysed for the proper functioning of the BLDC motor. Parameters
such as supply voltage ( ), supply current ( ), dc link voltage ( ), inductor’s currents ( , ,), switch
voltages ( ,, ), and switch currents ( , ) of the PFC BL buck–boost converter are evaluated to
demonstrate its proper functioning.
(a) Stator current and electromotive force output waveform

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(b) Rotor Speed output waveform (c) Electromagnetic Torque output waveform
(d) Variable DC voltage output waveform (e) Voltage across phase a & b
(f) Pulses for VSI
Figure 11. The simulated results for various parts of the proposed circuit
7. CONCLUSION
A PFC BL buck–boost converter-based VSI-fed BLDC motor drive has been proposed targeting low
power applications. A new method of speed control has been utilized by controlling the voltage at dc bus and
operating the VSI at fundamental frequency for the electronic commutation of the BLDC motor for reducing
the switching losses in VSI. The front-end BL buck boost converter has been operated in DICM for achieving
an inherent power factor correction at ac mains. A satisfactory performance has been achieved for speed
control and supply voltage variation with power quality indices. Moreover, voltage and current stresses on
the PFC switch have been evaluated for determining the practical application of the proposed scheme. The
proposed scheme has shown satisfactory performance, and it is a recommended solution applicable to low-
power BLDC motor drives.

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REFERENCES
[1] T Gopalarathnam, HA Toliyat. A new topology for unipolar brushless dc motor drive with high power factor. IEEE
Trans. Power Electron., 2003; 18(6): 1397–1404.
[2] S Singh, B Singh. Power quality improved PMBLDCM drive for adjustable speed application with reduced sensor
buck-boost PFC converter. Proc. 4th ICETET. 2011: 180–184.
[3] S Singh, B Singh. A voltage-controlled PFC Cuk converter based PMBLDCM drive for air conditioners. IEEE
Trans. Ind. Appl., 2012; 48(2): 832–838.
[4] Y Jang, MM Jovanovi´c. Bridgeless high-power-factor buck converter. IEEE Trans. Power Electron., 2011; 26(2):
602–611.
[5] L Huber, Y Jang, MM Jovanovi´c. Performance evaluation of bridgeless PFC boost rectifiers. IEEE Trans. Power
Electron., 2008; 23(3): 1381–1390.
[6] W Wei, L Hongpeng, J Shigong, X Dianguo. A novel bridgeless buck-boost PFC converter. IEEE PESC/IEEE
Power Electron. Spec. Conf., 2008: 1304–1308.
[7] AA Fardoun, EH Ismail, AJ Sabzali, MA Al-Saffar. New efficient bridgeless Cuk rectifiers for PFC applications.
IEEE Trans. Power Electron., 2012; 27(7): 3292–3301.
BIOGRAPHIES OF AUTHORS
Mr. A. Jeya Selvan Renius received his B.Tech. degree in Electronics and Communication
Engineering from Anna University, Tamilnadu, India. Presently he is pursuing M.Tech in Power
Electronics and Drives from Karunya University, Coimbatore, Tamil Nadu, India. His present
research interests are Power converters and inverters, Special machines, Solar and wind
Applications.
Prof. K. Vinoth Kumar received his B.E. degree in Electrical and Electronics Engineering
from Anna University, Chennai, Tamil Nadu, India. He obtained M.Tech in Power Electronics
and Drives from VIT University, Vellore, Tamil Nadu, India. Presently he is working as an
Assistant Professor in the School of Electrical Science, Karunya Institute of Technology and
Sciences (Karunya University), Coimbatore, Tamil Nadu, India. He is pursuing PhD degree in
Karunya University, Coimbatore, India. His present research interests are Condition Monitoring
of Industrial Drives, Neural Networks and Fuzzy Logic, Special machines, Application of Soft
Computing Technique. He has published various papers in international journals and
conferences and also published four textbooks. He is a member of IEEE (USA), MISTE and
also in International association of Electrical Engineers (IAENG).

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