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Investigation and mitigation of unbalanced hall sensor signal faults in sensored brushless DC motor drives

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Abstract

This paper investigates hall sensor signal unbalancing faults in sensored Brushless Direct Current (BLDC) motor drives and presents a fault effect minimization scheme for implementation in motor controller without any modification in system architecture, or core commutation method. In the proposed scheme detection, classification, and estimation of fault extent are carried out separately at the start of controller itself for subsequent corrections without involving issue of repetitive error estimation and finding valid reference signal separately for correcting inverter switching mistiming, as required in classical methods. The categorization part of scheme maps the faults with corresponding hall sensors. The proposed scheme is validated in MATLAB/Simulink model. It is tested on experimental test bench of controller and 1 kW BLDC motor of an electric rickshaw, along with another technique based on least square method (LSM) for performance comparison. Results show reduction of peak-to-peak value by 30% and ripple content by 50% in phase currents, and peak-to-peak reduction of 47% with 29% lesser ripple content in DC link current by using the presented scheme. The observed increment in efficiency is 0.8% and 2% in nominal torque/ampere at 30% load. At 100% load, increase of 2.2% efficiency and 9% nominal torque/ampere are observed. The increased memory loading of controller is estimated to be 1.25 times as compared to normal run without any correction scheme. Approximately 24% of this additional loading is utilized for repetitive calculations as compared to 63% in the other LSM based scheme, resulting in lesser run time loading of controller. The transient response with sudden load change shows better response with implementation of the proposed scheme in controller.

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Authors and Affiliations

  1. Department of Electrical Engineering, Delhi Technological University, Delhi, India

    Arvind Goswami, Mini Sreejeth & Madhusudan Singh

Authors
  1. Arvind Goswami
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  2. Mini Sreejeth
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  3. Madhusudan Singh
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Contributions

All authors contributed to the concept and manuscript preparation. The first draft of the manuscript was written by AG and all authors contributed to manuscript finalization. Research set up, data collection and analysis were performed by AG and MS. All authors read and approved the final manuscript.

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Correspondence to Arvind Goswami.

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Goswami, A., Sreejeth, M. & Singh, M. Investigation and mitigation of unbalanced hall sensor signal faults in sensored brushless DC motor drives. Electr Eng (2024). https://doi.org/10.1007/s00202-024-02245-7

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