Demystifying BLDC motor commutation:

Trap, Sine, & FOC

Matt Hein
Applications manager, brushless-DC motor drives
Agenda
• Introduction

• BLDC motor basics

• Basic commutation (trap)

• Sensored & sensorless

• Advanced commutation (Sine & FOC)

• Summary
Matt Hein introduction
• Work
– Applications engineer in motor drives (4 months)
– Systems engineer in motor drives (3.5 years)
– Product marketing engineer in motor drives (3 years)
– Product marketing manager in motor drives (1 year)
– Applications manager in motor drives (1 year)

• Personal
– Rollerblading
– Travel (not so much right now)
– 11-month-old son at home Some of my writings:
• Seven things that only an analog
engineer would understand – e2e.ti.com
• Brushless-DC motor systems for the
uninitiated – Planet Analog
Agenda
• Introduction

• BLDC motor basics

• Basic commutation (trap)

• Sensored & sensorless

• Advanced commutation (Sine & FOC)

• Summary
Motor operation
VS

Mechanical
Driver M
Load

PIN = VS*IM POUT = τ*ω

• Electrical power is converted

into mechanical power
 Motor operation

(1)

• Commutation is mechanical • Commutation is electrical

• Advantage: Easy to drive • Advantage: Efficiency, power
• Downside: efficiency, power, • Downside: System needs to apply
wear-out, sparking signal to commutate motor
Image credit:
(1) Morai Motion, Brushed vs Brushless DC Motors, https://microlinearactuator.com/brushed-vs-brushless-dc-motors/
Motor construction
Sinusoidal motors Trapezoidal motors

BEMF waveform
Motor construction
Sinusoidal motors Trapezoidal motors

Need a way to tell them apart?

Hook up a scope probe between
two outputs and spin it with your
fingers!
Motor construction
Sinusoidal motors Trapezoidal motors

Ideally driven with a sinusoidal current Ideally driven with a trapezoidal current

More on this later!

Agenda
• Introduction

• BLDC motor basics

• Basic commutation (trap)

• Sensored & sensorless

• Advanced commutation (Sine & FOC)

• Summary
Motor operation

Rotation position
defines the
direction of
current!

(1)
• Commutator reverses flow of current to
make sure that the magnetic field
generated on the rotor is always opposed
by the field on the stator
Image credit:
(1) Morai Motion, Brushed vs Brushless DC Motors, https://microlinearactuator.com/brushed-vs-brushless-dc-motors/
Motor operation

Need to
generate a
Rotation position South pole
defines the to attract
direction of the north
current! pole on the
stator

(1)
• Commutator reverses flow of current to • Step 1: Figure out where the rotor is
make sure that the magnetic field
generated on the rotor is always opposed • Step 2: Apply a magnetic field to move
by the field on the stator the rotor
Image credit:
(1) Morai Motion, Brushed vs Brushless DC Motors, https://microlinearactuator.com/brushed-vs-brushless-dc-motors/
Motor operation

Rotation position
defines the
direction of
current!

• Commutator reverses flow of current to • Step 1: Figure out where the rotor is
make sure that the magnetic field
generated on the rotor is always opposed • Step 2: Apply a magnetic field to move
by the field on the stator the rotor
Sensored brushless-DC motor control

Hall-effect Sensor

• Step 1: Figure out where the rotor is

Figure out where the motor • Step 2: Apply a magnetic field to move
is through a position sensor the rotor
 N=H
Sensored motor control S=L
U
Hall A
Hall C Hall A
Hall B

Hall C

1 2 3 4 5 6
W

V
Hall B
 N=H
Sensored trapezoidal motor control S=L
U
Hall A L L H H H L S
N
Hall C Hall A
Hall B H L L L H H

Hall C H H H L L L

1 2 3 4 5 6 N
S S
N

W
Phase U + + Z - - Z
V
Hall B
Phase V - Z + + Z -

Phase W Z - - Z + +
Trapezoidal control (Trap)
Also called: 6-step, block commutation, 120°, 150°

Advantages Disadvantages
• Highest maximum speed • Not great noise performance
• Great for delivering maximum torque • Efficiency not the best
• Lowest switching losses
• Easiest implementation
Brushed-DC vs. sensored brushless-DC

(Optional)

(Optional)
Agenda
• Introduction

• BLDC motor basics

• Basic commutation (trap)

• Sensored & sensorless

• Advanced commutation (Sine & FOC)

• Summary
Sensored brushless-DC motor control

Hall-effect Sensor

• Step 1: Figure out where the rotor is

Figure out where the motor • Step 2: apply a magnetic field to move
is through a position sensor the rotor
Disadvantage: increased cost
Sensorless brushless-DC motor control
Back-EMF

• Step 1: Figure out where the rotor is

Figure out where the motor • Step 2: apply a magnetic field to move
is through Back-EMF the rotor
What is Back-EMF?
Spin the motor with
your fingers to create
Back-EMF a back-EMF signal

Back-EMF is a sinusoidal or
trapezoidal voltage generated
on the motor while it is spinning
Sensorless brushless-DC motor control
Back-EMF “zero crossing”
Back-EMF can be used as a
commutation signal U
S
BEMF

W This coil is not

V
being driven
Sensorless brushless-DC motor control
Back-EMF Detecting Back-EMF:

1) Measurement
Advantage: Simplicity

I Disadvantage: Performance,
BEMF comparator
need to have open window on
+
- phase to measure

Back-EMF measurement does

not allow for sinusoidal or FOC
control
Sensorless brushless-DC motor control
Back-EMF Detecting Back-EMF:

2) Estimation & Calculation

Advantage: Performance, can
achieve sine/FOC

Disadvantage: Complexity,
calculation, need to know
motor parameters
Disadvantages of sensorless?
Back-EMF Where is Back-EMF (sensorless techniques)
not going to work?

Applications that require torque at zero speed

Servo applications  always sensored!

How do we start a motor sensorlessly*?
*not a real word, but it should be

U Starting a motor:

• We need to figure out where the

rotor is so that we can apply a
magnetic field to move it

?
W
V
 How do we start a motor sensorlessly*?
*not a real word, but it should be

Align / Blind Start Initial Position / Speed Detect

• Force a magnetic field on the motor, • Measure position through high

the motor will align to this field frequency pulses or speed through
• The motor may spin backwards back-EMF detection
• Drive motor given initial condition
Agenda
• Introduction

• BLDC motor basics

• Basic commutation (trap)

• Sensored & sensorless

• Advanced commutation (Sine & FOC)

• Summary
 Motor performance

(1)
• Commutation is mechanical
• Commutation is electrical
• Can’t adjust drive method beyond 100%
• Can drive motor with trapezoidal
ON/OFF
(100% ON/OFF) or a smoother
Image credit:
sinusoidal waveform
(1) Morai Motion, Brushed vs Brushless DC Motors, https://microlinearactuator.com/brushed-vs-brushless-dc-motors/
 DRV5013 N=H
Sensored trapezoidal S=L
U
1 2 3 4 5 6
Hall C Hall A
Phase U + + Z - - Z

Phase V - Z + + Z -

Phase W Z - - Z + + S N

Current U + + Z - - Z W

V
Current V - Z + + Z - Hall B

Current W Z - - Z + +
 N=H
Sensored sinusoidal DRV5013
S=L
U
1 2 3 4 5 6
Hall C Hall A
Phase U

Phase V

Phase W S N

Current U W

V
Current V Hall B

Current W
Sinusoidal control (Sine)
Also called: 180° - always ask if your sine control is really 180°!

Advantages Disadvantages
• Low noise • Switching losses
• Easier to implement than FOC • Not great dynamic load performance
• Lower maximum speed
Field-oriented control (FOC)
Also called: vector control, “why is this so complicated”

Advantages Disadvantages
• Highest power output • Computation complexity (especially
• Lowest noise when sensorless)
• Best torque ripple • Coding experience needed
• High motor speed (field weakening) • Switching losses
• Maximum motor efficiency (MTPA)
Field-oriented control (FOC)

FOC applies all motor torque

perpendicular to the rotor
Field-oriented control (FOC)
FOC applies all motor torque perpendicular to the rotor
Field-oriented control (FOC)
FOC applies all motor torque perpendicular to the rotor
Gate
Driver
Field-oriented control (FOC)
FOC applies all motor torque perpendicular to the rotor
Field-oriented control (FOC)
FOC applies all motor torque perpendicular to the rotor
Field-oriented control (FOC)
FOC applies all motor torque perpendicular to the rotor
Field-oriented control (FOC)
FOC applies all motor torque perpendicular to the rotor
 Field-oriented control (FOC)
FOC applies all motor torque perpendicular to the rotor

+ Id PI Torque Vd d,q Vα α,β PWM Vu

0 +
Controller
- PWM Vv
Inverse
Inverse Park
Clarke
Inverter M
Target + PI Speed Iq + Iq PI Torque Vq Vβ PWM Vw
+ +
speed Controller Controller α,β u,v,w
- -
θ Encoder
Id α,β Iα u,v,w Iu

Iv
Park Clarke
Iq Iβ Iw
d,q α,β

Rotor speed Rotor position - θ

d/dt
 Id α,β Iα u,v,w Iu

Clarke transform Park Clarke

Iv

Iq Iβ Iw
d,q α,β

Rotor position - θ

α = 𝑈 + 𝑉α + 𝑊α β = 𝑉β + 𝑊β
α = 𝑈 + 𝑉 cos 120° + 𝑊 cos 240° β = 𝑉 sin 120° + 𝑊 sin 240°
1 1 3 3
α=𝑈− 𝑉− 𝑊 β = 𝑉 − 𝑊
2 2 2 2
 Id α,β Iα u,v,w Iu

Park transform Park Clarke

Iv

Iq Iβ Iw
d,q α,β

Rotor position - θ

d = α𝑑 + β𝑑 𝑞 = α𝑞 + β𝑞
d = α cos θ + β sin θ 𝑞 = −α sin θ + 𝑞 cos θ
Field-oriented control (FOC)
v FOC applies all motor torque perpendicular to the rotor
β

α u

d,q α,β u,v,w

+ Id PI Torque Vd d,q Vα α,β PWM Vu
0 +
w -
Controller
Inverse PWM Vv
Inverse Park
Clarke
Inverter M
Iq + Iq PI Torque Vq Vβ PWM Vw
+
Controller α,β u,v,w
-
θ Encoder
Id α,β Iα u,v,w Iu

Iv
Park Clarke
Iq Iβ Iw
d,q α,β

Rotor position - θ
Agenda
• Introduction

• BLDC motor basics

• Basic commutation (trap)

• Sensored & sensorless

• Advanced commutation (Sine & FOC)

• Summary
Summary
• Think of a brushless-DC motors like a brushed-DC motor without the brushes
– Brushed-DC motor: mechanical commutation, brushless-DC motor: electrical commutation

• Sensored versus sensorless

– Sensored requires additional components but control is easier
– Sensorless requires fewer components but control is harder
– Don’t ask to do a sensorless servo

• Comparison of commutation methods (Trap, Sine, FOC)

Implementation Switching Audible Comments
Loss Noise
Trap Easy look-up table Low High Best for high torque or high speed
Sine Complex look-up table High Low Not the best for dynamic torque
FOC Complex real-time calculation High Lowest Highest efficiency, dynamics
SLYP711
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