Sensorless control of ultrahigh-speed PM brushless motor using PLL and third harmonic back EMF

Application-specific integrated circuit (ASIC) ML4425 is often used for sensorless control of permanent-magnet (PM) brushless direct current (BLDC) motor drives. It integrates the terminal voltage of the unenergized winding that contains the back electromotive force (EMF) information and uses a phase-locked loop (PLL) to determine the proper commutation sequence for the BLDC motor. However, even without pulsewidth modulation, the terminal voltage is distorted by voltage pulses due to the freewheel diode conduction. The pulses, which appear very wide in an ultrahigh-speed (120 kr/min) drive, are also integrated by the ASIC. Consequently, the motor commutation is significantly retarded, and the drive performance is deteriorated. In this paper, it is proposed that the ASIC should integrate the third harmonic back EMF instead of the terminal voltage, such that the commutation retarding is largely reduced and the motor performance is improved. Basic principle and implementation of the new ASIC-based sensorless controller will be presented, and experimental results will be given to verify the control strategy. On the other hand, phase delay in the motor currents arises due to the influence of winding inductance, reducing the drive performance. Therefore, a novel circuit with discrete components is proposed. It also uses the integration of third harmonic back EMF and the PLL technique and provides controllable advanced commutation to the BLDC motor.