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High performance torque control of Brushless DC motor drive based on

TMS320LF2407 DSP controller

Article in International Review of Electrical Engineering (IREE) · May 2007

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 International Review of Electrical Engineering (I.R.E.E.), Vol. xx, n. x

High Performance Torque Control of Brushless DC Motor Drive

based on TMS320LF2407 DSP Controller

A. Vahedi1 H. Moghbeli 2, and A. Halvaei Niasar3

Abstract – Brushless DC (BLDC) motor is attracting much interest due to its high efficiency,
good performance and ease of control for many applications. This paper presents the design and
implementation of a torque controller for a Brushless DC motor drive using the TMS320LF2407A
digital signal processor (DSP) produced by Texas Instruments. Firstly, a theoretical analysis of a
BLDC motor drive is presented and the validity of the proposed analysis is verified by simulation.
The torque is controlled via current regulation directly. Then, hardware and software details of
the system are explored. Finally, an experimental system included by a BLDC motor, DSP control
board, inverters, rectifier is set up to validate the theoretical ones.

Keywords: Brushless DC Motor, TMS320LF2407A DSP, Torque Control.

Nomenclature I. Introduction
B: Damping
ea : Back-EMF voltage of phase A Recent development in permanent magnet (PM)
materials, power electronics, fast digital signal
eb : Back- emf voltage of phase B processors (DSPs) and modern control technologies
ec : Back- emf voltage of phase C have significantly influenced the wide spread use of
E: Magnitude of phase back- emf voltage permanent magnet brushless (PMBL) motor drives in
ia : Current of phase A order to meet the competitive worldwide market
ib : Current of phase B demands of devices, products and processors. The
ic :
availability of smart power electronics devices and their
Current of phase C
optimal topologies has accelerated the growth of cost
idc : DC-link current effective and reliable inverter systems. Software
iref : DC-link reference current controlled on-line implementation of optimal controllers
J: Moment inertia has advanced the art of digital control of PMBL motor
Ke : Back-EMF voltage constant drives [1].
Kt : Motor drives are traditionally designed with
Torque constant
relatively inexpensive analog components. The
L: Phase inductance
weakness of analog systems is their susceptibility to
M: Mutual inductance
temperature variations and component aging. Another
R: Phase resistance
drawback is the difficulty of upgrading these systems.
Te : Electromagnetic torque Digital control structures eliminate drifts and, by using
Ta : Developed electromagnetic torque of phase a programmable processor, the upgrades can be easily
A accomplished by software. The high performance of
Tb : Developed electromagnetic torque of phase digital signal processors (DSPs) allows them to perform
B high resolution control and minimize control loop
Tc : Developed electromagnetic torque of phase delays. These efficient controls make it possible to
C reduce torque ripple, harmonics and improve dynamic
TL : Load torque behavior in all speed ranges. Overall, these
TRef : Torque reference improvements result in a reduction of system cost and
va : Terminal voltage of phase A better reliability [2].
High efficiency due to reduced losses, low
vb : Terminal voltage of phase B maintenance and low rotor inertia of PM brushless
vc : Terminal voltage of phase C motors have increased the demand of these motors in
vdc : DC-link voltage high performance applications such as aerospace,
ωr : Rotor speed transportations and robotics. PM brushless motors are
SF1_x: Switching function of phase x (x=a,b,c) categorized into two groups: sinusoidal flux waveform

Manuscript received January 2007, revised January 2007, accepted February 2007 Copyright © 2007 Praise Worthy Prize - All rights reserved
 H. Moghbeli, A. Vahedi and A. Halvaei Niasar

named PMSM or BLAC and trapezoidal flux waveform

named brushless DC (BLDC). Brushless DC (BLDC)
motor with trapezoidal flux utilizes the trapezoidal
back-EMF with square wave currents to generate
constant torque. It enjoys some advantages rather than
BLAC motor as followings: higher torque for same
motor density, lower and simpler manufacturing cost,
Simple controller, very simple and cheap position
sensors for commutations (3 Hall Effect sensors). The
BLDC motor is inherently electronically controlled and
requires rotor position information for proper
commutation of currents [3]-[4]. On the other hand,
DSP chips become popular for research on digital
control for AC drives due to their high-speed
performance, simple circuitry, and on-chip peripherals
of a micro-controller into a single chip solution.
Especially the new generation DSP controller
TMS320LF2407A produced by Texas Instrument,
which has the advantages of high speed (MIPS)
performance, 2 set (12 outputs) of PWM output, 2 set of Fig. 1. Signal waveforms of a BLDC motor
QEP (Quadrature Encoder Pulse) input, 16 channels 10-
bit A/D converter bits, General Purpose Input/Output,
(GPIO), is very suitable to develop a fully digital Ta = ea ia , Tb = e bi b , Tc = ecic (3)
controller and a complicated intelligent control
algorithm in servo motor drives [5]. The interaction of Te with the load torque determines
This paper presents the modeling and hardware how the motor speed builds up:
implementation of BLDC motor drive. The basic
analysis of BLDC motor drive is described. The drive dω r
system implementation and major part of control is Te = TL + J + Bω r (4)
dt
realized through software.
The magnitude of back-EMF voltage (E) depends on
II. Analysis of Brushless DC Motor Drive the speed and is calculated from

E = K e ⋅ ωr (5)
II.1. Modeling of Three-Phase BLDC Motor
Brushless DC motor is controlled as easy as a separate-
BLDC motor has characteristics as like as a DC exited DC motor. Reference current is related to desired
motor, whereas it is controlled the same as AC motors. torque as:
Fig. 1 shows the three phase currents waveforms with
the trapezoidal back-EMF voltages of a BLDC motor TRe f = K t ⋅ I ref (6)
[6]. As shown, to generate constant output torque,
BLDC motor needs quasi square current waveforms,
which are synchronized with the back-EMF. The typical It means that the electromagnetic torque is controlled by
mathematical model of a three-phase BLDC motor is regulating the DC-link current.
described by the following equations:
a

⎡va ⎤ ⎡R 0 0⎤ ⎡ia ⎤ ⎡L − M 0 0 ⎤ ⎡ia ⎤ ⎡ea ⎤

⎢ ⎥ ⎢
v = 0 R 0 ⎥ × ⎢i ⎥ + ⎢ 0 L − M 0 ⎥ d ⎢i ⎥ + ⎢e ⎥ R
⎢ b⎥ ⎢ ⎥ ⎢ b⎥ ⎢ ⎥ dt ⎢ b ⎥ ⎢ b ⎥ (1)
⎢⎣vc ⎥⎦ ⎢⎣0 0 R⎥⎦ ⎢⎣ic ⎥⎦ ⎢⎣ 0 0 L − M⎥⎦ ⎢⎣ic ⎥⎦ ⎢⎣ec ⎥⎦ L
ea
The electromagnetic torque is expressed as: eb
n
ec
L
1
Te = (Ta + Tb + Tc ) (2) R L
ωm
R
b c
which the developed electromagnetic torque of each
phase is obtained by: Fig. 2. Equivalent circuit of the three- phase BLDC motor

Copyright © 2007 Praise Worthy Prize - All rights reserved International Review of Electrical Engineering, Vol. xx, n. x
 H. Moghbeli, A. Vahedi and A. Halvaei Niasar

II.2. BLDC Motor Drive Simulation 10

ia
Fig. 3 shows the overall system configuration of the

[A]
0
three-phase BLDC motor drive. The inverter topology
is six-switch voltage-source configuration with constant -10
0 0.02 0.04 0.06 0.08 0.1

DC-link voltage (Vdc). The PWM three-phase inverter 10

ib
operation can be divided into six modes according to

[A]
0
the current conduction states as shown in Fig. 1. The
three phase currents are controlled to take a form of -10
0 0.02 0.04 0.06 0.08 0.1

quasi-square waveform. For this motor, in each time 10

ic
only two phases are excited through the conduction

[A]
0

operating modes and the third phase is silent. So, we

-10
can use just one current sensor located in the DC-link 0 0.02 0.04 0.06 0.08 0.1
time (Sec)
[7]. Fig. 4 shows the implementation of the BLDC (a) Phase Currents
motor drive in Matlab/Simulink software. As shown, in
Back-EMF generator block, based on the rotor position, 50
Vab
the numerical expression of back-EMF can be obtained.

[V]
0

In Current Control block, phase current are regulated -50

via hysteresis current controller. This block out the 0 0.02 0.04 0.06 0.08 0.1
50
switching functions (SF1_a,b,c) that are applied to Vbc
power switches. Line voltages are calculated in the

[V]
0

voltage Inverter block using DC-link voltage and -50

0 0.02 0.04 0.06 0.08 0.1
switching functions signals. Developed line voltages are 50
applied to motor and in the BLDC Motor Model block, [V] Vca
0
phase currents are calculated from Eq. (1). Fig. 5 shows
some simulation results. -50
0 0.02 0.04 0.06 0.08 0.1
time (Sec)

(b) Filtered stator line voltages

2
SF1a

-2
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
2
SF1b

-2
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
2
SF1c

-2
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
time (Sec)

(c) Switching function signals

Fig. 3. Basic configuration of trapezoidal BLDC motor drives with Fig. 5. Simulation results of brushless DC motor drive
DC-link current controlled

III. System Hardware Structure

Fig. 6 shows a schematic of the hardware system
that composes of the following parts: DSP board, switch
drive circuits, current and voltage sensing circuits,
IGBT modules, BLDC motor with three Hall Effect
position sensor mounted on it and DC-link part
including rectifier, capacitor and brake resistor. As
following, the main parts are described briefly.

Fig. 4. Implementation of the Brushless DC motor drive in III.1. DSP Controller

Matlab/Simulink
An eZdsp board of TMS320LF2407A DSP acts as
controller to control the whole of the system [8]-[9].

Copyright © 2007 Praise Worthy Prize - All rights reserved International Review of Electrical Engineering, Vol. xx, n. x
 H. Moghbeli, A. Vahedi and A. Halvaei Niasar

Using resistors causes additional power losses and

also has low accuracy. So, we have used isolated
current and voltage transducers LA-55P and LV-25P
made by LEM, and design conditioning board to apply
their output to ADC channel of DSP board.
Conditioner, amplify and add DC offset to make the
signal between 0~3.3V. Fig. 8 shows the schematic of
the current sensing board. Voltage sensing is the same.

Fig. 6. Hardware structure of BLDC motor drive base on

TMS320LF2407A
Fig. 8. Circuit schematic of current sensing board
It reads the current and position feedback, implements
the torque control algorithm and finally generates the
gate signals. DSP can take the command torque or
current from remote via its CAN, SPI, SCI ports or from
an external potentiometer into its ADC units or from its
IV. Software Design of the Control System
data memory. Voltage and current signals after pre-
conditioning circuits come into ADC modules to
convert to digital signals. At the end of each cycle, DSP
generate six independent PWM signals, and outs to IV.1. Software Organization
opto-isolated switch drivers. The switch drivers isolate
This section presents the overall software structure
and amplify the DSP commands and send to IGBT
and the Interrupt subroutine flowcharts. As shown in
modules.
Fig. 9, the software is based on three modules: System
initialization, Protection and the Run module. The first
III.2. Switch Driver Circuit step for development of the software is to initialize all
peripherals on the DSP board, which includes
The output pulses from TMS320LF2407A DSP are initialization of the PWM ports, timer interrupt, Analog-
not capable of directly driving the IGBTs of higher to-Digital (A/D) converters. Also, the needed variables
ratings. Hence device drivers HCPL A316J are used. must be defined in the initialization. The second module
Six driver circuits are used to drive the IGBTs. Fig. 7 checks the healthy of the drive includes power module,
shows the schematic of each A316J drive board. DC-link over current/voltage or other favorite
conditions. The third one is the BLDC control dedicated
III.3. Current and Voltage Sensing Circuits software. It is based on a waiting loop interrupted by
both the Timer 2 unit (INT2) and the Capture unit
Torque control needs to know the current value. (INT4) of Event Manager A (EVA).
Also o protect the circuit from over voltage and over
current conditions or rotor stall condition, some current
and voltage sensing is required. IV.2. General Interrupt Service Routines
i) GISR2 Service Routine
This interrupt is belonged to INT2 level and its
request is generated every current loop period with T1
timer period interrupt. As shown in Fig. 10, before
running the instructions, drive healthy is checked
through protection subroutine. Interrupt operations
performed inside are: Start of Conversion (measuring
the variables that come into ADC unit), current/torque
regulation, updating the duty cycle, load the compare
Fig. 7. Circuit schematic of each switch driver board

Copyright © 2007 Praise Worthy Prize - All rights reserved International Review of Electrical Engineering, Vol. xx, n. x
 H. Moghbeli, A. Vahedi and A. Halvaei Niasar

registers and finally outing the commands to switch

T1PR Interrupt
drivers through SEQUENCE subroutine. T1PR register (PIVR=27h)
is set to 500 to have 10 kHz current loop frequency and
for current regulation, a PI controller is used. At the end
of GISR2, program jumps to infinite loop and waits for Save Status Registers
next interrupts.
Protection
Subroutine
ii) GISR4 Service Routine
This interrupt is belonged to INT4 level and its Read Current & Voltage via
request is generated whenever a pulse level change ADC Subroutine
occurs on the each input pins of Capture unit 1 (CAP1,
CAP2, CAP3). As shown in Fig. 11, firstly the drive
CURRENT_CONTROL
healthy is checked. GP Timer 2 is the time base of
Subroutine
Capture unit. The value of the GP timer 2 is counted
and stored in the corresponding registers when a
specified transition is detected on a capture input pin Update Compare Registers via
SEQUENCE Subroutine
(CAPx). After transition detection, capture pins are
configured as GPIO functionality to read the hall
sensors states and the motor position is determined. 1- Reload Status Registers
GISR2 also may calculate the speed via a fixed point 2- Clear INTM bit
3- Clear EVAIFRA register
division.

Return
Start
Fig. 10. GISR2 Interrupt service routine flowchart

System
Initialization

Protection
Subroutine V. Experimental Results
The experimental test bed as shown in Fig. 12 has
Read Initial Position: been designed and developed in the laboratory. The
1- Disable Capture unit functionality experimental setup consists of a 300 [W] Brushless DC
2- Set Capture pins as GPIO pins motor loaded with a Permanent Magnet DC generator.
3- Read Hall sensors states The rated parameters of the BLDC motor are
4- Enable Capture unit functionality
summarized in table I. The load is adjusted by the
resistor that is connected to the DC generator. The
IGBT switches are used for inverter where the
Waiting for
INT2 & INT4 Interrupts
switching frequency is 10 kHz. All waveforms are
captured via a storage digital oscilloscope. Fig. 13
shows the phase current waveforms and hall sensor of
N
INT2 ? phase A, when the motor operates at stable state and
Y maximum duty cycle. It coincide theoretical waveforms
Run GISR2
shown in Fig. 4. In Fig. 14, switching command of S1
IGBT, current of phase A and line voltage Vab are
shown at duty cycle 100%. Fig. 15 shows the line
N
INT4 ? voltages at duty cycle 100%. They are trapezoidal
Y
waveforms and the same as phase back-EMF voltage
but with constant region 60 degree. Fig. 16 shows the
Run GISR4
switch command of S1 and S2 IGBTs line voltage at
Run duty cycle 50%. The line voltages are as PWM
waveforms.
Fig. 9. System software flowchart

Copyright © 2007 Praise Worthy Prize - All rights reserved International Review of Electrical Engineering, Vol. xx, n. x
 H. Moghbeli, A. Vahedi and A. Halvaei Niasar

Capture Interrupt
(PIVR=33h,34h,35h)

Save Status Registers

Protection
Subroutine

Speed Calculation
via saved time by Timer 2

CURRENT_CONTROL (a) Main board of the drive

Subroutine

Update Commutation Code via:

1- Disable Capture unit functionality
2- Set Capture pins as GPIO pins
3- Read Hall sensors states

Update Compare Registeres via

SEQUENCE Subroutine

Enable Capture unit functionality

1- Reload Status Registers

2- Clear INTM bit
3- Clear EVAIFRC register

Return (b) Entire of the drive

Fig. 12. BLDC motor drive system
Fig. 11. GISR4 Interrupt service routine flowchart

5
Ha

-5
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
2
TABLE I: RATED PARAMETERS OF THE BLDC MOTOR
ia [A]

Prated 300 [W] ωrated 500 [RPM]

-2
Trated 5.7 [N.m] Zp 16 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1

Irated 10 [A] Vrated 44 [V] 2

Rline (2R) 1.4 [Ω] Kt 0.57 [N.m/A]

i b [A]

Lline (2*(L-M)) 1 [mH] Ke 0.3 [V/rpm]

-2
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
2
ic [A]

-2
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
time (Sec)

Fig. 13. Phase current waveforms and H1 signal at duty cycle 100%

Copyright © 2007 Praise Worthy Prize - All rights reserved International Review of Electrical Engineering, Vol. xx, n. x
 H. Moghbeli, A. Vahedi and A. Halvaei Niasar

5
VI. Conclusion
The torque controller system of BLDC motor
Ha

0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
which can be used in traction applications is studied in
5 this paper. The core of the driving system is the
TMS320F2407A chip. The main advantages are:
S1

0 increased system reliability and cost reduction of the

0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
2 overall system. The switch driver circuit consists of the
driver chip HCPL316 and peripheral circuits. Current
I a [A]

-2
regulation is implemented via hysteresis control strategy
50
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
and sensing DC-link current. The simulated results
conforming the experimental results have validated the
V ab [V]

-50
models and algorithms developed in this research. The
0 0.01 0.02 0.03 0.04 0.05
Time (sec)
0.06 0.07 0.08 0.09 0.1
implementation through assembly language
programming of DSP has resulted in reduced hardware
Fig. 14. H1 signal, S1 switch command, phase A current and Vab voltage
at duty cycle 100% and fast response of the controller.
The proposed software is flexible and further
modifications in control structure are also possible by
changing the software. For example, implementing the
5
sensorless control of brushless DC motor drive can be
accomplished by capturing the zero crossing points of
Ha

line voltages instead of capturing the Hall Effect

0
0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 0.04 0.045 0.05 sensors signals.
100
V ab [V]

-100

100
0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 0.04 0.045 0.05
References
V bc [V]

0 [1] T J E Miller, Brushless Permanent Magnet and Reluctance

Motor Drives (Oxford Science Publication, UK, 1999)
-100
0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 0.04 0.045 0.05 [2] Yasuhiko Dote, Servo Motor and Motion Control using Digital
100
Signal Processors (Prentice Hall, Eagle Wood, cliffs, New
V ca [V]

0 Jersey, 1990)
[3] P. Pillay, R. Krishnan, Modeling, simulation, and analysis of
-100
0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 0.04 0.045 0.05 permanent-magnet motor drives. I: The permanent-magnet
Time (Sec) synchronous Motor Drive, IEEE Transactions on Industry
Applications, vol. 25, No. 2, March/April 1989, pp. 265-273.
Fig. 15. H1 signal, line voltages at duty cycle 100%
[4] P. Pillay, R. Krishnan, Modeling, simulation, and analysis of
permanent-magnet motor drives. II: The Brushless DC Motor
Drive, IEEE Transactions on Industry. Applications, vol. 25, No.
2, March/April 1989, pp. 274-279.
[5] TMS320LFLC240xA DSP Controllers Reference Guide--
5 System and Peripherals, Literature Number: SPRU357B, (Texas
Instruments, Revised December 2001).
S1

[6] A. Halvaei Niasar, H. Moghbelli, A. Vahedi, Modeling and

0 Simulation Methods for Brushless DC Motor Drives, Proceeding
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
5
of the First International Conference on Modeling, Simulation
and Applied Optimization (ICMSAO'05), pp.05-7/05-6,
February 2005, Sharjah, U.A.E.
S3

[7] B.K. Lee and M. Ehsani Advanced BLDC Motor Drive for Low
0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 Cost and High Performance Propulsion System in Electric and
100 Hybrid Vehicles, IEEE 2001 International Electric Machines
V ab [V]

and Drives Conference, 2001, Cambridge, MA, June 2001, pp.

0
246-251.
-100 [8] TMS320C24x DSP Controllers Reference Set, Volume 1: CPU,
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
100
System, and Instruction Set, Literature Number: SPRU160B,
(Texas Instruments, Revised September 1997).
V ab [V]

0 [9] TMS320C24x DSP Controllers, Volume 2: Peripheral Library

and Specific Devices, Literature Number: SPRU161B, (Texas
-100
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 Instruments, Revised September 1997).
Time (Sec)

Fig. 16. S1 and S3 switches command, Vab and Vbc voltages

at duty cycle 50%

Copyright © 2007 Praise Worthy Prize - All rights reserved International Review of Electrical Engineering, Vol. xx, n. x
 H. Moghbeli, A. Vahedi and A. Halvaei Niasar

Authors’ information

Abolfazl Vahedi, Associate Professor,

Department of Electrical Engineering, Iran
University of Science & Technology,
Narmak, Tehran, Iran, Postal code: 16846-
13114, Tel: +98 21 73912619, FAX: +98
21 77240490, EML: [email protected]
He received his B.S., M.S. and Ph.D. in
1989, 1992 and 1996 from Ferdowsi
Mashhad University, Institut nationale
polytechnique de Lorraine (INPL-
FRANCE) and INPL all in electrical engineering respectively. He has
directed several projects in the area of conventional and special
electric machines and drives. His research interests are mainly design,
implementation and optimization of electric machines including
traction motors and drives. He is a member of Center of excellence for
power system automation and operation at Iran university of Science
and technology. He is also member of IEE and SEE.

Hassan Moghbeli, Associate Professor,

Qatar Department of Mathematics, Texas
A&M University, Po. Box 23874, Doha,
Qatar and Department of Electrical &
Computer Engineering, Isfahan University
of Technology, Isfahan, Iran. Tel: +98
218054034,
EML: [email protected].
He received his B.S., M.S. and Ph.D. in
1973, 1978 and 1989 from Iran University
of Science and Technology (IUST), Oklahoma State University and
University of Missouri-Columbia (UMC) all in electrical engineering
respectively. He has directed several projects in the area of electric
vehicles, hybrid electric and fuel cell vehicles and railway
electrification. His research interests are mainly the control, electric
drive train, power electronic design of electric vehicles, hybrid electric
vehicles, and electric railroads. He is a member of IEEE, ASME, and
SAE.

Abolfazl Halvaei Niasar, Ph.D. Student,

Department of Electrical Engineering, Iran
University of Science & Technology, Narmak,
Tehran, Iran. Tel: +98 913 1635923, Fax: +98
21 77240490, EML: [email protected]
He received his B.S. and M.S. in 1998 and
2000 from Isfahan University of technology
(IUT) and university of Tehran (UT) both in
electrical engineering respectively. He is now
studying in Iran University of science &
technology (IUST) for Ph.D. His research interests are mainly the
control systems & instrumentation, DSP based control, electric drives,
PM Brushless DC motor drives, sensorless drives. He is a student
member of IEEE.

Copyright © 2007 Praise Worthy Prize - All rights reserved International Review of Electrical Engineering, Vol. xx, n. x

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