IJSTE - International Journal of Science Technology & Engineering | Volume 2 | Issue 11 | May 2016 ISSN (online): 2349-784X Fuzzy based Power Factor Improvement and Harmonic Reduction with PFC- CUK Converter Fed BLDC Motor Drive T. Sridevi Assistant Professor Sri Sairam Institute of Technology, Chennai, Tamilnadu Abstract This paper deals with a power factor improvement using PFC-based Cuk converter-for speed control of brushless dc motor (BLDC) drive as a cost-effective solution for low-power applications. The speed of the BLDC motor is controlled by varying the dc-bus voltage of a voltage source inverter (VSI) which uses a low frequency switching of VSI (electronic commutation of the BLDC motor) for low switching losses. A diode bridge rectifier followed by a Cuk converter working in a discontinuous conduction mode (DCM) is used for control of dc-link voltage with unity power factor at ac mains using fuzzy controller. The performance of the BLDC motor is simulated in a MATLAB/Simulink environment. Keywords: Brushless dc (BLDC) motor, Cuk Converter, Total Harmonic Distortion, Power Factor improvement, Pulse Width Modulation (PWM), Discontinuous Conduction Mode (DCM), Fuzzy controller ________________________________________________________________________________________________________ I. INTRODUCTION Efficiency and cost would be the major concerns in the development of low-power motor drives targeting household applications such as for example fans, water pumps, blowers, mixers, etc. The utilization of the brushless direct current (BLDC) motor in these applications is becoming very common due to options that come with high efficiency, high flux density per unit volume, low maintenance requirements, and low electromagnetic-interference problems. These BLDC motors are not limited to household applications, but they're ideal for other applications such as for example medical equipment, transportation, HVAC, motion control, and many industrial tools. A BLDC motor has three phase windings on the stator and permanent magnets on the rotor. The BLDC motor can be referred to as an electronically commutated motor because an electronic commutation based on rotor position can be used rather than mechanical commutation which includes disadvantages like sparking and wear and tear of brushes and commutator assembly. Power quality problems have become important issues to be looked at due to the recommended limits of harmonics in supply current by various international power quality standards like the International Electro Technical Commission (IEC) 61000-3-2. For class-A equipment (< 600 W, 16 A per phase) which include household equipment, IEC 61000-3-2restricts the harmonic current of different order such that the full total harmonic distortion (THD) of the supply current must be below 19%. A BLDC motor when fed by way of a diode bridge rectifier (DBR) with a higher value of dc link capacitor draws peaky current which can cause a THD of supply current of the order of 65% and power factor as little as 0.8. Hence, a DBR followed by way of a power factor corrected (PFC) Cuk converter is utilized for improving the power quality at ac mains. The continuous conduction mode (CCM) and discontinuous conduction mode (DCM) are the 2 modes of operation by which a PFC converter is designed to operate. In CCM, the present in the inductor or the voltage over the intermediate capacitor remains continuous, but it needs the sensing of two voltages (dc link voltage and supply voltage) and input side current for PFC operation, that is not cost-effective. On another hand, DCM requires someone 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. The conventional PFC scheme of the BLDC motor drive utilizes a pulse width-modulated voltage source inverter (PWM-VSI) for speed control with a consistent dc link voltage. This offers higher switching losses in VSI while the switching losses increase as a square function of switching frequency. While the speed of the BLDC motor is directly proportional to the applied dc link voltage, hence, the speed control is accomplished by the variable dc link voltage of VSI. This enables the fundamental frequency switching of VSI (i.e., electronic commutation) and offers reduced switching losses. So, here Cuk converter-fed BLDC motor drive has been proposed with the idea of variable dc link voltage. This reduces the switching losses in VSI as a result of fundamental switching frequency operation for the electronic commutation of the BLDC motor and to the variation of the speed by controlling the voltage at the dc bus of VSI. A CCM operation of the Cuk converter has been utilized which requires three sensors and isn't encouraged for cheap and low power rating. So here discontinuous conduction mode has been utilized. All rights reserved by www.ijste.org 1 Fuzzy based Power Factor Improvement and Harmonic Reduction with PFC- CUK Converter Fed BLDC Motor Drive (IJSTE/ Volume 2 / Issue 11 / 001) II. BRUSHLESS DC MOTOR (BLDC) Principle BLDC motors are basically inside-out DC motors. In a DC motor the stator is a permanent magnet. The rotor has the windings, which are excited with a current. The current in the rotor is reversed to create a rotating or moving electric field by means of a split commutator and brushes. On the other hand, in a BLDC motor the windings are on the stator and the rotor is a permanent magnet. Hence the term inside-out DC motor. Many motor types can be considered brushless; including stepper and AC-induction motors, but the term brushless is given to a group of motors that act similarly to DC brush type motors without the limitations of a physical commutator. Fig. 2: Basic operation of BLDC motor To build a brushless motor, the current-carrying coils must be taken off the rotating mechanism. In their place, the permanent magnet will be allowed to rotate within the case. The current still needs to be switched based on rotary position. The torque produced by the rotor varies trapezoidal with respect to the angle of the field. As the angle θ increases, the torque drops to an unusable level. Fig. 2.1: waveform of current and torque Construction Stator The stator of a BLDC motor consists of stacked steel laminations with windings placed in the slots that are axially cut along the inner periphery traditionally, the stator resembles that of an induction motor; however, the windings are distributed in a different manner. Most BLDC motors have three stator windings connected in star fashion. Fig. 2.2: BLDC motor stator All rights reserved by www.ijste.org 2 Fuzzy based Power Factor Improvement and Harmonic Reduction with PFC- CUK Converter Fed BLDC Motor Drive (IJSTE/ Volume 2 / Issue 11 / 001) One or more coils are placed in the slots and they are interconnected to make a winding. Each of these windings is distributed over the stator periphery to form an even numbers of poles. There are two types of stator windings variants: trapezoidal and sinusoidal motors. This differentiation is made on the basis of the interconnection of coils in the stator windings to give the different types of back Electromotive Force (EMF). Rotor Circular core with magnets on the periphery Circular core with rectangular magnets embedded in rotor. Circular core with rectangular magnets inserted into the rotor core. Fig. 2.3: BLDC motor rotor The rotor is made of permanent magnet and can vary from two to eight pole pairs with alternate North (N) and South (S) poles. Based on the required magnetic field density in the rotor, the proper magnetic material is chosen to make the rotor. Ferrite magnets are traditionally used to make permanent magnets. As the technology advances, rare earth alloy magnets are gaining popularity. The ferrite magnets are less expensive but they have the disadvantage of low flux density for a given volume. In contrast, the alloy material has high magnetic density per volume and enables the rotor to compress further for the same torque. Also, these allo y magnets improve the size to-weight ratio and give higher torque for the same size motor using ferrite magnets. III. CUK CONVERTER Circuit Representation Fig. 3: Cuk converter circuit representation The Cuk converter is named for Slobodan Cuk of the California Institute of Technology. It is the result of applying the duality principle to the buck-boost converter to use a capacitor instead of an inductor as the primary energy storage device. As a result, the DC transfer function is nominally the same as that of the Buck-Boost converter, Vo = DVs/ (1-D) Where, D represents the PWM duty cycle of the transistor Q. Vs represents the source voltage. Vo represents the output voltage. All rights reserved by www.ijste.org 3 Fuzzy based Power Factor Improvement and Harmonic Reduction with PFC- CUK Converter Fed BLDC Motor Drive (IJSTE/ Volume 2 / Issue 11 / 001) An advantage of the Cuk converter topology is that the current pulsing occurs within the converter itself and both the input and output currents are not pulsed. Furthermore, if integrated magnetics are used, the input or output current can (theoretically) be nullified as the ripple is transferred to the other side of the converter. Because only one capacitor suffers the losses associated with (internal) current pulsing, the Cuk converter is more efficient than a filtered Buck-Boost converter. Design of PFC Cuk Converter The proposed PFC Cuk converter is designed bldc motor drive with main considerations on the speed control with PQ improvement at ac mains. The dc link voltage of the PFC converter is given as Vdc = Vin D/(1 − D) Where Vin is the average output of the DBR for a given ac input voltage (Vs) related as Vin = 2√2Vs/π. The Cuk converter uses a boost inductor (Li) and a capacitor (C1) for energy transfer. Their values are given as Li =DVin/ {fs(ΔILi)} C1 =DIdc/{fsΔVC1} Where ΔILi is a specified inductor current ripple, ΔVC1 is a specified voltage ripple in the intermediate capacitor (C1), and Idc is the current drawn by the PMBLDCM from the dc link. A ripple filter is designed for ripple-free voltage at the dc link of the Cuk converter. The inductance (Lo) of the ripple filter restricts the inductor peak-to-peak ripple current (ΔILo) within a specified value for the given switching frequency (fs), whereas the capacitance (Cd) is calculated for the allowed ripple in the dc link voltage (ΔVCd). The values of the ripple filter inductor and capacitor are given as Lo = (1 − D)Vdc/ {fs(ΔILo)} Cd =Idc/(2ωΔVCd). IV. CONTROL OF CUK CONVERTER FED BLDC MOTOR DRIVE Fig.4 shows the PFC Cuk converter-based VSI-fed BLDC motor drive using a current multiplier and a voltage follower approach, respectively. A high frequency metal–oxide–semiconductor field-effect transistor (MOSFET) is used in the Cuk converter for PFC and voltage control whereas insulated gate bipolar transistors (IGBTs) are used in the VSI for its low frequency operation. The BLDC motor is commutated electronically to operate the IGBTs of VSI in fundamental frequency switching mode to reduce its switching losses. The current flowing in either of the input or output inductor (Li and Lo) or the voltage across the intermediate capacitor (C1) becomes discontinuous in a switching period for a PFC Cuk converter operating in the DCM. Fig. 4: BLDC motor drive fed by a PFC Cuk converter Operation of Cuk Converter in Discontinuous Conduction Mode(DCM): The DCM operation is further classified into two broad categories of a discontinuous inductor current mode (DICM) and a discontinuous capacitor voltage mode (DCVM). All rights reserved by www.ijste.org 4 Fuzzy based Power Factor Improvement and Harmonic Reduction with PFC- CUK Converter Fed BLDC Motor Drive (IJSTE/ Volume 2 / Issue 11 / 001) In the DICM, the current flowing in inductor Li or Lo becomes discontinuous in their respective modes of operation While in DCVM operation; the voltage appearing across the intermediate capacitor C1 becomes discontinuous in a switching period. Discontinuous Inductor Current Mode (Li)(DICM) The operation of the Cuk converter in the DICM (Li) is described as follows. Fig 4.2 shows the operation of the Cuk converter in three different intervals of a switching period. 1) Interval I: When switch Sw in turned ON, inductor Li stores energy while capacitor C1 discharges through Switch Sw to transfer its energy to the dc-link capacitor Cd as shown in Fig 4(a). Input inductor current i Li increases while the voltage across the capacitor C1 decreases. 2) Interval II: When switch Sw is turned OFF, the energy stored in inductor Li is transferred to intermediate capacitor C1 via diode D, till it is completely discharged to enter DCM operation. 3) Interval III: During this interval, no energy is left in input inductor Li ; hence, current i Li becomes zero. Moreover, inductor Lo operates in continuous conduction to transfer its energy to dc-link capacitor Cd. Fig 4.2. Operation of the Cuk converter in the DICM (Li) Discontinuous Inductor Current Mode (Lo) Operation: The operation of the Cuk converter in the DICM (Lo) is described as follows. Fig 4.3(a)–(c) shows the operation of the Cuk converter in three different intervals of a switching period. Interval I: As shown in Fig 4.3(a), when switch Sw in turned ON, inductor Li stores energy while capacitor C1 discharges through switch S w to transfer its energy to the dc-link capacitor Cd. Interval II: When switch Sw is turned OFF, the energy stored in inductor Li and Lo is transferred to intermediate capacitor C1 and dc-link capacitor Cd, respectively. Interval III: In this mode of operation, the output inductor Lo is completely discharged; hence, its current iLo becomes zero. An inductor Li operates in continuous conduction to transfer its energy to the intermediate capacitor C1 via diode D. Fig. 4.3: Operation of the Cuk converter in DICM (Lo) during (a)–(c) different intervals of switching period All rights reserved by www.ijste.org 5 Fuzzy based Power Factor Improvement and Harmonic Reduction with PFC- CUK Converter Fed BLDC Motor Drive (IJSTE/ Volume 2 / Issue 11 / 001) DCVM (C1) Operation The operation of the Cuk converter in the DCVM (C1) is described as follows. Fig 4.4(a)–(c) shows the operation of the Cuk converter in three different intervals of a switching period. 1) Interval I: When switch Sw in turned ON as shown in Fig 4.4(a), inductor Li stores energy while capacitor C1 discharges through switch Sw to transfer its energy to the dc-link capacitor Cd. 2) Interval II: The switch is in conduction state but intermediate capacitor C1 is completely discharged; hence, the voltage across it becomes zero. Output inductor Lo continues to supply energy to the dc-link capacitor. 3) Interval III: As the switch Sw is turned OFF, input inductor Li starts charging the intermediate capacitor, while the output inductor Lo continues to operate in continuous conduction and supplies energy to the dc-link capacitor. Fig. 4.4: Operation of the Cuk converter in the DCVM (C1) during (a)–(c) different intervals of switching period V. FUZZY CONTROLLER Design of Fuzzy Controller Fig. 5.1: fuzzy l.ogic controller Design of Fuzzy Controller Error (E) and change in error (CE) are the inputs for the fuzzy controller whereas the output of the controller is change in duty cycle (ΔDC). The error is defined as the difference between the ref speed and actual speed, the change in error is defined as the difference between the present error and previous error and the output, change in duty cycle ΔDC is which could be either positive or negative is added with the existing duty-cycle to determine the new duty-cycle (DCnew) Fig. 5.1 shows All rights reserved by www.ijste.org 6 Fuzzy based Power Factor Improvement and Harmonic Reduction with PFC- CUK Converter Fed BLDC Motor Drive (IJSTE/ Volume 2 / Issue 11 / 001) the basic structure of fuzzy logic controller. The fuzzy controller is composed of the following four elements: fuzzification, fuzzy rule-base, fuzzy inference engine and defuzzification. Fuzzification Fuzzy logic uses linguistic variables instead of numerical variables. The process of converting a numerical variable in to a linguistic variable is called fuzzification. The fuzzifier includes two parts: choice of membership function and choice of scaling factor. The fuzzy variables error, change in error and change in duty-cycle are quantized using the linguistic terms NB, NM, NS, Z, PS, PM, and PB (negative big, negative medium, negative small, zero, positive small, positive medium and positive big respectively).. Fig. 5.2: membership functions The motor maximum range of speed is 0-3000 rpm. The possible range of error is -3000 to +3000 rpm. The universe of discourse for error is -3000 rpm to +3000 rpm and for the change in duty cycle, defined as - 100 % and +100 %. In order to achieve faster control action and simplification, the inputs and output are normalized to +/-100 rpm, +/-100 rpm and +/-100 respectively. The membership functions used for inputs and output are given in figure 5.2 Fuzzy Logic Uses Fuzzy logic uses FL offers several unique features that make it a particularly good choice for many control problems. 1) It is inherently robust since it does not require precise, noise-free inputs and can be programmed to fail safely if a feedback sensor quits or is destroyed. The output control is a smooth control function despite a wide range of input variations. 2) Since the FL controller processes user-defined rules governing the target control system, it can be modified and tweaked easily to improve or drastically alter system performance. New sensors can easily be incorporated into the system simply by generating appropriate governing rules. 3) FL is not limited to a few feedback inputs and one or two control outputs, nor is it necessary to measure or compute rate-ofchange parameters in order for it to be implemented. Any sensor data that provides some indication of a system's actions and reactions is sufficient. This allows the sensors to be inexpensive and imprecise thus keeping the overall system cost and complexity low. 4) Because of the rule-based operation, any reasonable number of inputs can be processed and numerous outputs generated. 5) FL can control nonlinear systems that would be difficult or impossible to model mathematically. All rights reserved by www.ijste.org 7 Fuzzy based Power Factor Improvement and Harmonic Reduction with PFC- CUK Converter Fed BLDC Motor Drive (IJSTE/ Volume 2 / Issue 11 / 001) VI. SIMULATION Circuit Diagram Fig. 6.1: simulation diagram Power Factor Fig. 6.2: power factor measurement Input Voltage & Current Fig. 3: Input voltage & current of PFC Cuk Converter-Fed BLDC Motor Drive. All rights reserved by www.ijste.org 8 Fuzzy based Power Factor Improvement and Harmonic Reduction with PFC- CUK Converter Fed BLDC Motor Drive (IJSTE/ Volume 2 / Issue 11 / 001) Gate Pulse Fig. 6.4: Gate pulse of PFC Cuk Converter-Fed BLDC Motor Drive. Phase Voltages Fig. 6.5: The Phase voltages of PFC Cuk Converter-Fed BLDC Motor Drive. Vs, Is, Speed, Torque, Stator Current Fig. 6.6: Vs, Is, speed, torque, stator current of PFC Cuk Converter-Fed BLDC Motor Drive. All rights reserved by www.ijste.org 9 Fuzzy based Power Factor Improvement and Harmonic Reduction with PFC- CUK Converter Fed BLDC Motor Drive (IJSTE/ Volume 2 / Issue 11 / 001) Line Voltages Fig. 6.7: line voltages of PFC Cuk Converter-Fed BLDC Motor Drive. Stator Currents Fig. 8: stator currents of PFC Cuk Converter-Fed BLDC Motor Drive. DC Link Voltage Fig. 6.9: DC link voltage of PFC Cuk Converter-Fed BLDC Motor Drive. All rights reserved by www.ijste.org 10 Fuzzy based Power Factor Improvement and Harmonic Reduction with PFC- CUK Converter Fed BLDC Motor Drive (IJSTE/ Volume 2 / Issue 11 / 001) Motor Output Fig. 6.10: motor output of PFC Cuk Converter-Fed BLDC Motor Drive. VII. FFT ANALYSIS OF PFC CUK CONVERTER IN SIMULINK Fig. 7: FFT analysis VIII. CONCLUSION A Cuk converter for VSI-fed BLDC motor drive has been designed for achieving a unity PF at ac mains for the development of the low-cost PFC motor for numerous low-power equipments such fans, blowers, water pumps, etc. The speed of the BLDC motor drive has been controlled by varying the dc-link voltage of VSI, which allows the VSI to operate in the fundamental frequency switching mode for reduced switching losses. Four different modes of the Cuk converter operating in the CCM and DCM have been explored for the development of the BLDC motor drive with unity PF at ac mains. A detailed comparison of all modes of operation has been presented on the basis of feasibility in design and the cost constraint in the development of such drive for lowpower applications. Finally, a best suited mode of the Cuk converter with output inductor current operating in the DICM has been selected for experimental verifications. The proposed drive system has shown satisfactory results in all aspects and is a recommended solution for low-power BLDC motor drives. All rights reserved by www.ijste.org 11 Fuzzy based Power Factor Improvement and Harmonic Reduction with PFC- CUK Converter Fed BLDC Motor Drive (IJSTE/ Volume 2 / Issue 11 / 001) REFERENCES [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] [23] [24] [25] [26] [27] [28] [29] [30] [31] [32] [33] [34] [35] [36] [37] [38] J. F. Gieras and M.Wing, Permanent Magnet Motor Technology—Design and Application. New York, NY, USA: Marcel Dekker, Inc, 2002. C. L. 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