A BL-CC Converter-Based BLDC Motor Drive for Marine Electric Vehicle Applications

Shukla, Tanmay; Kalla, Ujjwal Kumar

doi:https://doi.org/10.1155/2022/7026462

International Transactions on Electrical Energy Systems

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Abstract Introduction Discussion Conclusion Appendix Data Availability Conflicts of Interest References Copyright Related Articles

Research Article | Open Access

Volume 2022 | Article ID 7026462 | https://doi.org/10.1155/2022/7026462

A BL-CC Converter-Based BLDC Motor Drive for Marine Electric Vehicle Applications

Tanmay Shukla¹and Ujjwal Kumar Kalla¹

Academic Editor: N. Prabaharan

Received23 Jan 2022

Accepted28 Apr 2022

Published01 Jun 2022

Abstract

This article presents a BLDC (permanent magnet brushless DC) motor drive for marine electric vehicle (MEV) application. The presented scheme uses bridgeless canonical cell (BL-CC) converter with center-tapped inductor (shown as two separate inductors for analysis purpose) for source-side power factor correction (PFC); however, the BL-CC converter requires two inductors. In the presented scheme use of one center-tapped inductor eliminates the requirement of one extra inductor. Thus, center-tapped inductor usage in BLDC motor drive results in decrement in components count. The BL-CC converter-based BLDC motor drive scheme do not require extra back-feeding diodes like other bridgeless (BL) schemes, but it uses inbuilt antiparallel diodes of insulated gate bipolar transistor (IGBT) switches for the same purpose this again leads to decrement in required component count. In this work, PFC BL-CC converter is operated in discontinuous inductor current (DIC) mode to attain better power quality. The DIC mode operation requires only one voltage sensor to sense DC-link voltage, whereas in continuous conduction mode (CCM), the sensor requirement increases to three (two voltage sensors and one current sensor). The PFC BL-CC converter also eliminates the diode bridge rectifier stage. The elimination of one extra inductor, two extra back-feeding diodes, DBR stage and also requirement of only one voltage sensor in DIC mode operation instead of three sensors for CCM implies reduction in components count which implies the reduction in cost and also the volume and weight of the BLDC motor drive. The weight reduction for marine (on-board) electric vehicle is very important as this enhances the vehicle performance. This paper also presents the detailed mathematical modeling and stability analysis of presented BL-CC converter using pole zero map and Bode plot. The BL-CC converter-based BLDC motor driving system for MEV application for DIC mode operation has been developed in the laboratory as well as on MATLAB/Simulink platform and simulated MATLAB and real-time experimental results have been presented to validate the presented BLDC motor drive under steady-state and dynamic operating conditions.

1. Introduction

Advantages such as higher reliability, greater efficiency, low EMI (electro-magnetic interference) issue, high ruggedness, and its exceptional performance in comparison with other motors [1] over a wide range of speed control [2, 3] makes BLDC motor an ideal choice for many medium and low-power applications like medical equipments, household appliances, air conditioners, motion controllers, position actuators, and transport sector (vehicle applications) [4–7]. Nowadays the application of BLDC in MEVs has become very common. The marine electric vehicles (MEVs) having diesel engine generators (DEGs) produces AC, and this AC voltage has to be converted into useable form by BLDC motor for MEV applications. BLDC motors are a type of synchronous motors having three-phase concentrated windings on stator and permanent magnets on rotor. Hall-effect sensor-based electronic commutation technique is used in this motor, which diminishes or reduces certain issues associated with traditional DC motors such as maintenance issue, sparking and noise problem, and EMI [8]. Hall-effect sensors are utilized to sense the rotor position. A diode bridge rectifier (DBR), fed voltage source inverter (VSI)-based traditional BLDC motor drive draws a peaky input current [9, 10]. This peaky supply current does not resemble the input AC voltage waveform. This gives rise to serious power quality (PQ) issue. The input current THD (total harmonic distortion) with traditional charger is found approximately equal to 65%, which is not acceptable as per IEC 61000-3-2 standard of PQ [11]. So the inclusion of power factor correction (PFC) power converters in drive becomes must, to increase the supply-side PQ. Many PQ enhancement schemes for BLDC motor drive system using different power converters of different orders have been reported in literature [12–21]. Boost PFC converter-fed BLDC motor drive has been presented by Ho et al. [12]. The main advantage of employing the boost PFC converters is availability of inductance at input side, which lessens the supply current harmonics. However, boost converter suffers a drawback that it can only boost up the voltage level but cannot reduce. The buck-boost second-order PFC converter is given by Aishwarya and Gnana Sheela [13]. The advantages of buck-boost PFC converter over boost converter is that it can step up or step down the voltage levels depending on the duty cycle value, but utilization of buck-boost converter in PFC application requires additional/external filter to improve input side PQ. This requirement of external filter adds extra energy storage elements which increases the order of the system. PFC Cuk converter-based BLDC motor drive is reported by Singh and Singh [14]. The Cuk converter is garnished with output- and input-side inductors, which improves the output current and input current waveforms respectively. No external filters are required with PFC Cuk converters due to the presence of inductors at both the ends. However, fourth-order SEPIC and Zeta power converter-based BLDC motor drive are reported in previous studies [15–17]. Like Cuk converter, SEPIC converter is also garnished with output- and input-side inductances. The SEPIC converter also gives noninverted output unlike Cuk converter. A PFC Luo converter-based BLDC motor drive is presented in previous studies [18, 22, 23]. However, PQ-improved canonical cell (CC) converter-based BLDC driver system is reported by Bist and Singh [19]. For EMI problem, various resonant converters have been reported in literature [20, 21, 24, 25]. The soft switching technique to increase the performance from reliability, reduction in switching losses, and EMI interference point of view, is presented by Pahlevani and Jain [26]. Williams [27] presents various types of DC-DC converters. The interleaving of converters provides certain advantages like better power distribution, quicker response to transients, current ripple cancellation, and reduction in passive component size but interleaved arrangement does not have any significant impact on EMI interference [28, 29]. The Interleaved DC-DC converter-based BLDC motor drive configuration also uses DBR which increases the nonlinearity. The answer to DBR-related problem is bridgeless configuration of converter. Various types of bridgeless converter-based BLDC motor drives have been reported in literature [30–39]. The advantage of using such configuration are DBR elimination, simple controlling, and low electrical stress, as the average current across the components conducting during each half cycle of bridgeless PFC converters reduces. Different control schemes for BLDC motor drive are discussed by Ashok and Kumar [40]. The BLDC motor sensorless control schemes are discussed in literature [41, 42]. The speed control scheme of BLDC motor drive with calculation of controller tuning parameters using modified genetic algorithm approach is presented by Vanchinathan et al. [41]. The sensorless fuzzy logic precise commutation control scheme for speed control of BLDC motor drive using equal area criteria approach is presented by Soni and Tripathi [42].This paper presents a BL-CC converter-based reduced component count drive for BLDC motor for MEV application. The presented CC converter-based BLDC motor drive is shown in Figure 1. The BLDC motor drive for MEV application is divided into three parts in addition to two controlling loops. The filter is connected to DEG output, which is input to the BLDC motor drive . The filter is made of filtering inductance (L_f) and capacitance (C_f). Next stage to filter is PF correction stage, which incorporate BL-CC converter. The third stage consists of voltage source converter-fed BLDC motor. The rotor position of BLDC motor is sensed by Hall-effect sensors. These sensed signals are then used to generate the gating pulse of VSI. The gating pulses to switches of BL-CC converter are generated with a simple voltage follower controlling technique using proportional-integral controller.

The contributing and notable features of the presented BL-CC converter-based BLDC motor drive for MEV applications are being listed as follows:(1)The BL-CC converter in BL configuration uses a single-center tapped inductor (shown as two different inductors, i.e., L₁ and L₂ in Figure 1) which conducts partially and fully in different modes of each half cycle of generator output voltage. The usage of this tapped inductance eliminates one extra inductor requirement.(2)BL-CC converter-fed BLDC motor drive uses inbuilt antiparallel diodes of insulated gate bipolar transistor (IGBT) switches for back-feeding during both positive and negative cycle of generator output voltage. So, no separate additional back feeding diodes are required in the presented scheme whereas conventional BL schemes require separate/additional back feeding diodes.(3)The CC converter uses three energy storage elements where as other converters such as Cuk, SEPIC, Zeta, Luo, Landsman, Sheppard Taylor uses more number of energy storage elements as compared to CC converter which witnesses the lower-order of CC converter.(4)PFC is achieved with a simple control (voltage follower) technique as both the switches of the BL-CC converter are needed to be fed with same gate pulse. DIC mode operation reduces the sensors requirement to one which reduces the cost of MEV drive with respect to CCM operation which requires three sensors (two voltage sensors and one current sensor).(5)The presence of inductance in output current loop increases the load current profile and the usage of CC converter for both half cycles of DEG output voltage maintains symmetry of BL-CC converter so analysis of any half cycle (either positive or negative) is sufficient to analyze the operation of PF corrected BL-CC converter. This reduces the calculative as well as analysis burden by 50%.

The presented BL-CC converter operating in DIC mode works as inbuilt PF preregulator of the drive system for obtaining a linear voltage to current profile at generator output voltage (90–260 V). A variable DC-link bus voltage to VSI is used to control the speed of BLDC motor. This reduces the switching losses due to low-frequency electronically commutated switching of VSI. These switching losses at six IGBT switches of VSI shares a significant portion of total losses in BLDC motor drive system.

2. BL-CC Converter Configuration

The CC converter with bridgeless configuration used in BLDC motor drive system with reduced components count has been shown in Figure 2. The converter is symmetrical for both half cycles of input AC voltage. For MEV applications, the input voltage to the BLDC motor drive is output voltage of DEG denoted by . The presented PF-corrected converter uses a single-center tapped inductor (shown as two different inductors i.e. L₁ and L₂ in Figure 1) which conducts partially and fully in different modes of each half cycle of input AC voltage. Also the converter uses the inbuilt antiparallel diodes of IGBT switches which eliminate the usage of extra diodes for completion of conduction loops during different half cycles of input AC voltage.

2.1. Operation of PQ-Enhanced BL-CC AC-DC Converter

In this section, DIC mode operation of BL-CC converter has been described. For DIC mode operation of BL-CC converter, total six possible cases exists-three during positive cycle and other three during negative cycle of input AC voltage. Owing to symmetrical configuration of BL-CC converter, only positive half cycle operation is elaborated in this section. However, the conduction loop during all six possible cases has been depicted in Figures 3(a) to 3(f).

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The six cases/modes arising with BL-CC converter when operated in DIC mode are as follows:(i)Positive half cycle of DEG output voltage.(1)Switch S_P is conducting (supplied with gating pulse).(2)Switch S_P is not conducting (off).(3)Switch S_P is off and also no diode current through diode D₁ vanishes (DIC mode of positive half cycle).(ii)Negative half cycle of DEG output voltage.(4)Switch S_N conducts.(5)Switch S_N is off.(6)Switch S_N is off and also inductor L₂ current vanishes (DIC mode of negative half cycle).

To unfold the CC converter working in BL configuration, different operating modes of presented PF-corrected BL-CC converter, are explicated in present section.(1)Mode-I—The conduction loops during this mode has been shown in Figure 3(a) for more clarity and better understanding. Switch S_P is supplied with gate pulse. The inductor current can be estimated using the following relation: In the ongoing mode, the capacitor C₁ getting discharged through the switch (acting as short circuit for this mode) S_P and the loop getting completed as C₁ − L₁ − Load||C_DC on the other hand another conduction loop during this mode consists of _IN − L_f − L₁ − L₂ and the loops getting completed through antiparallel diode of another switch (S_N). The maximum stress (electric current stress) on switch S_P during mode-1 is given as follows: where, T_S is time interval and d₁ is duty cycle.(2)Mode-II—In this mode, switch S_P is turned off and conduction loops are deployed in Figure 3(b). In this mode, diode D₁ conducts and converter conduction loops consists of C_f − C₁ − L₁ − L₂ and another loop also got completed through diode D₁ consisting of inductor L₁ and DC-link capacitor in parallel with load. Maximum value current through diode D₁ can be evaluated using the following relation: where, . Peak voltage across switch S_P is given as follows: This operating mode also shows the conduction of inbuilt antiparallel diodes of switch S_N.(3)Mode-III—In this mode, the switch S_P remains off, and this mode begins just after the complete vanish of inductor energy where as the capacitor C₁ holds energy and retain its charge; however, the load is supplied with DC-link capacitor and the conduction path for this mode is depicted in Figure 3(c). The diode D₁ also stops conducting so, the current through inductor L₂ and capacitor C₁ is same and the conduction loop during this mode consists of − L₁ − C₁ − L₂ − R||C_DC − C₂. In this mode, capacitor C_DC discharges. The DIC mode can be expressed mathematically as follows: where, d_ON = d₁ and d_OFF = d₂ + d_DICM. Also,

The same operational behavior of the presented BL-CC converter can be realized for other half cycle of input AC voltage due to the presence of symmetry in bridgeless converter configuration.

2.2. Differential Factors of Presented BL-CC Converter

The differential factors with the presented BL-CC converter are PQ improvement, DBR elimination, efficiency enhancement, component count reduction, elimination of back feeding diode, simple control input, and availability of output inductances in output current loop for both half cycles. A brief comparison of various BL converter-based BLDC motor drive is tabulated in Table 1. It shows total components count along with required inductors, capacitors, switches, diodes, and components conducting each half cycle of input voltage.

2.3. Designing and Selection of Components for BL-CC Converter

The presented PF-corrected BL-CC converter is operated in DIC mode such that the energy through the inductor vanishes before completion of cycle and the inductor L₁ and L₂ current becomes discontinuous. However, the voltage across the energy storage capacitor C₁ and C₂ remain continuous throughout the switching period. A 425 W BLDC motor (specification of motor is given in Appendix) is being used in this article to validate the drive system at MATLAB platform. So, a front-end PF-corrected converter with maximum power rating equal to 500 W is designed for BLDC motor drive. For wide range speed variation using DC-link voltage in BLDC motor, the rated value for DC-link voltage is taken as 200 V and minimum value of DC-link voltage is taken as 70 V. The applied input voltage to the PF-corrected converter can be written as follows:where, _max is the peak input voltage and ω_L is the line frequency in radian/second and f_L is the line frequency equal to 50 Hz.

Now, the instantaneous value across the inductor and switch combination can be evaluated as follows:

For CC converter, on applying the voltage-second balance across the inductors, the converter transfer function comes out to be the following:

The duty ratio instantaneous value depends on DC-link capacitor voltage and instantaneous value of input AC voltage.

Since, the BLDC motor speed control is achieved by varying the voltage across DC-link capacitor at the input side of VSI. So, the power at DC link can be taken as a linear function of DC-link capacitor voltage.where represents maximum value of DC-link voltage and P_max represents rated power for PF correction converter. Using relation equation (11), the minimum value of power (P_min) at minimum value of DC-link capacitor voltage, that is, 70 V comes out to be 112.90 W.

The value of CC converter inductance L_CC(L_CC = L₁ + L₂) for operation in DIC mode do require the selection of switching frequency which is one of the critical parameter which decides the switching losses and also the inductor value and size. With higher switching frequency, the inductor size and value reduces but the switching losses across solid-state devices increases and thus require a heat sink of larger size; however, with lower switching frequency, the switching losses reduces significantly, but the value and size of the required inductor increases. Taking both the things into consideration, the switching frequency for this work is taken as 20,000 Hz. The value CC converter inductance L_CC can be calculated using the following formula:

For the calculation of inductance value of CC converter to operate in DCM mode (i.e. inductance value less than critical value), the d₁(t) and R_{IN_min} values are required, which can be calculated as follows:

The inductance value for DIC mode operation can be evaluated as follows:

The inductor, L_CC value chosen as 70 µH. So, the value of inductor L₁ and L₂ comes out to be 35 µH each.

The expression to evaluate energy storage intermediate capacitance in continuous capacitor voltage mode value with allowed 10% of voltage ripple (λ) at maximum AC input voltage value 270 × 1.414 and rated DC-link voltage is given as follows:where, at this instant d₁(t) can be calculated as follows:

The value of capacitor for CC converter C_1,2 is taken as 0.67 µF. The capacitor utilized in the present application must be capable of operating at high frequency and greater surge-current application, so generally polypropylene film energy storage capacitors which have lower series inductance and resistance are used in such applications.

The value of capacitor used at DC-link (C_DC) can be evaluated using the following equation:where, ΔV_DC represents the allowed ripple in voltage across DC-link. The C_DC is needed to be designed at worse case. Which occurs at 70 V (minimum value) DC-link voltage and minimum power is given as follows:

The value of DC-link capacitor is chosen to be 2.1 mF. As the capacitor needs to be used at low switching (due to second harmonic influence in its calculation) and relatively greater value of current and the capacitor is also required to have higher value of capacitance per unit volume due to larger value of capacitance, so electrolytic capacitors could be suited for this application.

2.4. Designing and Selection of Filter Components

As depicted in Figure 1, a low-pass (L-C) filter is used at the input side of BLDC motor drive to avoid the entry of the higher-order harmonics in the input current waveform. The maximum filter capacitance value can be estimated as given as follows:

So, a capacitor of 430 nF is chosen as one of the filter element. The filter inductor value is designed by taking the source input impedance (L_IN) of 3% to 5% of the base impedance value. Therefore, additional inductance required to be used as filter inductance L_f can be calculated as follows:where,

Using equation (18), L_req can be calculated, and its value comes out to be 2.77 mH.

Where, filter cut-off frequency should be in between line frequency and switching frequency. The filter cut-off frequency is taken as 1800 Hz for this work. To withstand current ripples with high frequency switching, the polypropylene film capacitor should be used for this purpose.

3. Controlling of PF-Corrected BL-CC Converter-Fed BLDC Motor Drive

The control scheme for BL-CC AC-DC converter-fed BLDC motor drive for MEV application is explained in this section. The complete BLDC motor driver scheme uses two different controls: one for PF-corrected converter and another for BLDC motor.

3.1. Control Scheme for PF-Corrected BL-CC Converter

A voltage follower (tracking) approach is employed to achieve PF correction at input side using BL-CC converter in DIC mode in this work. For this control technique, only one sensor is needed to control the voltage drop across DC-link capacitor for speed control of BLDC motor. The block diagram of control loop to control DC-link voltage has been depicted in Figure 4. This control technique uses a reference voltage generator (RVG), an error generator (comparator), a pulse width modulation generator (PWMG) and a proportional-integral (P-I) controller. RFG generates reference voltage on multiplying the BLDC motor voltage constant () with reference speed ω and the equation can be expressed as follows:

The resultant reference voltage is applied to error generator along with DC-link-sensed voltage the error generator compares both the DC-link-sensed voltage and RFG output and generate error signal (_err) which is given at jth sample instant as follows:

The generated error signal is applied to P-I controller so that a controlled output voltage () can be generated. The controller output voltage, _C can be expressed as follows:where, K_I and K_P are integral and proportional gains of P-I controllers, respectively. On comparison of with high-frequency saw-tooth wave, Y_ST (from saw-tooth generator) and then using relational operator to get final gate pulse to be fed to switches S_P and S_N of the PF-corrected BL-CC converter. The operation of relational operator is described as follows: For _IN > 0. If Y_ST ≤ _C then switch S_P is “ON.” If Y_ST > _C then switch S_P is “OFF.” For _IN < 0. If Y_ST ≤ _C then switch S_N is “ON” If Y_ST > _C then switch S_N is “OFF.”

3.2. Control Scheme for VSI-Fed BLDC Motor

Electronic commutation technique is used for speed control of BLDC motor. Owing to the usage of electronic commutation circuit, problems such as maintenance issue, sparking and noise problem, and EMI are eliminated or reduced significantly. The rotor positions of BLDC are sensed by Hall-effect (position) sensors. In a BLDC motor at any instant of time, only two stator phases are exited. The information of rotor position (provided by Hall sensors) is being used to decide the state (ON or OFF) of different switches of VSI. This rotor position is helpful to ensure proper current flow direction in different winding of trapezoidal back-electromotive force (B-EMF) BLDC motor at different instant. A conduction loop at instant when VSI switches S₁ and S₅ conduct is shown in Figure 5. At this instant, a current is drawn by VSI-fed BLDC motor from DC-link applied voltage . So the current magnitude and direction both depend on DC-link voltage , mutual inductance (M_AB), and self-inductances (L_A and L_B) of conducting windings, resistances of both windings (R_A and R_B) and also the back EMFs (E_AN and E_BN). Also, the switching states of all six switches of VSI based on all three Hall-sensors (H_A, H_B, and H_C) signals feeding BLDC motor have been shown in Table 2.

4. State-Space Model and Small Signal Analysis of BL-CC Converter

The dynamics of the BL-CC converter can be well understood by resolving the BL-CC converter conduction circuit of each conduction mode into first-order differential equations (FDEs) using basic laws of circuit theory; for stability analysis, these FDEs are expressed in standard state-space form [31]. The standard state-space equations are as follows:where, Q equals F1, F2, and F3 for positive cycle of input AC voltage and for negative cycle of input AC voltage, but due to presence of symmetry in circuit and symmetrical operation in both half cycle cycles of input AC voltage only, the stability analysis of positive cycle converter is done using Bode-plot and Pole-zero map. The BL-CC converter under stability test is shown in Figure 6.

The matrix-vectors for positive cycle of BL-CC converter are follows:

The state-space matrix to incorporate in standard state-space equation for positive cycle converter in DIC mode is obtained using the following relation:

Now the transfer function for positive cycle of BL-CC converter is given as follows:

Calculating the transfer function by entering the values (magnitudes) of components used in BL-CC converter for DIC mode operation lead to transfer function having two zeros and four poles and is given by the following equation:where, a₁ = 109.10, a₂ = 1.818 × 10¹¹, and a₃ = 9.633 × 10¹²

Two zeros and four poles can also be seen in pole zero map of TF_BL-CC,pos, shown in Figure 7(a). In pole zero map, none of the four poles is seen on the right side of the y-axis which witnesses the stability of the positive cycle converter circuit of BL-CC converter. For closed-loop operation, the converter is cascaded with P-I controller and the P-I controller transfer function is given as follows:where, K_P and K_I are proportional and integral tuned parameters and K_I and K_P are selected as 0.05 and 0.001, respectively. Using the BL-CC converter positive-cycle transfer function and TF_ct, bode-plot of complete function is plotted and shown in Figure 7(b). Positive and large values of phase and gain margins are obtained of values 24.3° and 64.2 dB respectively, which confirm good stability of positive half cycle converter. Similarly, the stability for the converter circuit operating in negative half cycle can be seen and due to symmetry in BL configuration exactly same results will be gained after following same method so, in this paper, negative cycle converter is not discussed.

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5. Result and Discussion

Performance of BL-CC AC-DC converter-based drive system for BLDC motor for MEV application is examined in this section with motor specifications as in Appendix using MATLAB/Simulink. The simulated results of drive system are also discussed in this section.

5.1. Simulation Results

In this section, MATLAB simulation results of BL-CC converter-based BLDC motor drive are presented and discussed in detail under steady state as well as dynamic condition.

5.1.1. Performance of Presented BLDC Motor Drive at Steady-State

The steady-state performance of BL-CC converter-based BLDC motor drive with input AC voltage 220 V and DC-link voltage 200 V at rated load is shown in Figure 8. In which Figures 8(a) and 8(b) shows input AC voltage and current, respectively. DC-link voltage and BLDC motor stator current is shown in Figures 8(c) and 8(d), respectively. BLDC motor drive performance with 80 V DC-link voltage and input AC voltage 220 V at rated load is depicted in Figure 9.

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5.1.2. Performance of PF-Corrected BL-CC Converter

The current across both the inductors (L₁ and L₂) of the CC converter in BL configuration is depicted in Figures 10(c) and 10(d), respectively. The DIC mode operation of the PF correction converter can be well seen in Figures 10(c) and 10(d) due to zero inductor current for some instant in current waveforms of both the inductors. The voltages across the intermediate energy storage capacitors C₁ and C₂ are depicted in Figure 11 along with input AC voltage and current. Voltages and current across both the switches of BL-CC converter is depicted in Figure 12. The voltage and current across positive cycle switch SP is shown in Figures 12(a) and 12(b); however, the voltage and current through negative cycle switch is shown in Figures 12(c) and 12(d). The conduction operation of inbuilt antiparallel diode can be clearly seen in Figures 12(b) and 12(d). The current and voltage across switch, S_P of BLDC motor drive system is enlarged and shown in Figure 13. The peak values of voltage and current across the switch S_P from the results shown in Figures 13(a) and 13(b) comes out to be 470 V and 43 A, respectively.

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5.1.3. Dynamic-Performance of Presented BL-CC Converter-Based BLDC Motor Drive

The dynamic performance results of presented BL-CC converter-based BLDC motor drive is incorporated in this section. Figure 14(a) shows the decrease in magnitude of supply current with the sudden rise in voltage from 110 V to 220 V. However, initial and final value of DC-link voltage under this step rise in supply voltage is the same. The DC-link voltage is restored to their previous value under varying supply voltage. The stator current and back EMF of BLDC motor are almost unaffected under varying supply voltage. Figure 14(b) also shows the same initial and final value of DC-link voltage with sudden drop in supply voltage from 220 V to 110 V. However, the supply current and back EMF increases. The stator current is unaffected for the step decrease in supply voltage. The BL-CC converter-based drive performance with sudden variation in DC-link voltage can be seen in Figures 14(c) and 14(d). When DC-link voltage is reduced from 220 V to 150 V, the supply current and back EMF got reduced which can be seen in Figure 14(c). If the DC-link voltage is increased from 150 V to 200 V, the increment in current as well as back EMF are observed in Figure 14(d). The dynamic performance of the BL-CC converter-based BLDC drive under variation in load torque can be seen in Figure 14(e) and 14(f). When the load torque is suddenly increased from 1 N m to 1.55 N m, the back EMF decreases with an increase in supply and stator currents. The final and initial value of the DC-link voltage is also maintained at same value which can be seen in Figure 14(e). Figure 14(f) shows the dynamic results with sudden decrement in load. The results clearly show that the supply current and stator current both decreases with decrement in load torque. However, the back EMF increases with dip in load.

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5.2. Hardware Validation of Presented BL-CC Converter-Based BLDC Drive

In this section, steady-state and dynamic performance real-time experimental results of BL-CC converter-based BLDC motor drive are presented and discussed in detail. PQ results are also shown in this section.

5.2.1. Steady-State Results

Figure 15 shows the experimental results of BL-CC converter-based BLDC motor drive under steady-state operation. The supply current seems to follow the supply voltage profile with DC-link voltage of 200 V.

5.2.2. PQ Results

Figure 16 shows the obtained PQ results with unity power factor operation of the presented BLDC motor drive. The performance indices such as supply input voltage (), supply current (I_IN), apparent (S), active (P), and reactive (Q) powers, displacement power factor (DPF), power factor (PF), and THD of supply current are measured on a “Fluke.” The THD of supply current is 2.9%; therefore, the presented system is meeting the IEC standard 61000-3-2 of PQ.

5.2.3. Experimental Dynamic Performance of the Presented System

Hardware validation of dynamic performance results with step change in supply voltage is shown in Figure 17(a). The results show the increment in supply current with same initial and final value of DC-link voltage on sudden decrement in supply voltage. The results with sudden variation in DC-link voltage is shown in Figure 17(b). The results show the increment in supply current and stator current with sudden increment in DC-link voltage.

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5.3. Efficiency Comparison

In conventional converter powered BLDC motor drive, the losses in the VSI are very high due to high-frequency switching operation to generate the PWM pulses for speed control of BLDC motor. The switching frequency is of order of 20 kHz. This high switching frequency causes higher switching losses in VSI and thus, harnesses the efficiency. The conventional PFC converter and DBR + CSC converter-based CSC converter both uses DBR. The maximum efficiency of DBR is 81.2%, so the efficiency of the DBR-based system will be quite less than 81.2%. In the presented scheme, the VSI used to generate the pulses for BLDC motor is switched at fundamental frequency and the speed control of BLDC motor in the presented BL-CC converter-based PFC scheme is done by varying DC-link voltage and thus, the switching losses are significantly reduced. The presented scheme completely eliminates the DBR stage and therefore the losses associated with DBR are also eliminated and the significant increment (6%–8%) in efficiency is achieved with the present configuration.

The comparison in PFC converter efficiency between conventional PFC, DBR + CSC converter-based PFC and presented BL-CC converter-based PFC scheme under varying power levels is presented in Figure 18. The efficiency under varying power level for presented BL-CC converter-based PFC scheme used in this work is greater than both DBR + CSC converter and conventional converter-based PFC scheme as shown in Figure 18.

6. Conclusion

The detailed mathematical and stability analysis of the BL-CC AC-DC converter used in BLDC motor drive system for MEV application has been shown in this paper. Stability of the converter has been studied with the help of Bode plot and pole-zero maps. The simulated model of the scheme on MATLAB platform has been developed and their simulated analysis using simulated results has also been included in the paper along with the experimental results of the developed prototype in the laboratory. A presented BL-CC AC–DC converter having reduced components count, higher efficiency, and enhanced PQ designed in DIC mode of operation has been verified with the help of experimental results as well as MATLAB simulation results. The presented drive system with reduced components count is garnished with advantages like size reduction and simple controlling. Moreover, the input voltage and current seems to be following linear relation resulting in PQ enhancement and the input current THD is found to be 2.58% at rated load with input AC voltage 220 V and DC-link capacitor voltage 300 V and THD found to be 2.87% with 220 V input AC voltage and DC-link voltage 80 V at rated load. The presented BLDC motor drive is validated using the results obtained to justify the satisfactory closed-loop performance of BLDC motor drive system.

Appendix

Four pole, Rated Power (P_Rated) = 426 W, DC-Link Rated Voltage (_Rated) = 200 V, Rated Torque (T_Rated) = 1.55 Nm, Rated Speed (ω) = 2000 rpm, Phase Inductance (L_ph) = 25.50 mH, Phase Resistance (R_ph) = 14.20 Ω, J (Moment of Inertia) = 1.2×10⁻⁴ m/s².

Data Availability

No data were required.

Conflicts of Interest

The authors declare that they have no conflicts of interest.

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Copyright © 2022 Tanmay Shukla and Ujjwal Kumar Kalla. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

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