Permanent Magnet Optimization Based Design of PMBLDC Motor for Sensorless Single Stage SIWP

A permanent magnet volume optimization based design of brushless DC (BLDC) permanent magnet (PM) motor is presented in this paper. The optimization of permanent magnet reduces its volume which in turn reduces the total cost of the designed brushless DC PM motor. The whole developed system is designed without using any position sensors for position as well as speed estimation, to reduce the cost and complexity, for a robust operating range. The developed system consists of a zero start algorithm controlled mechanical sensorless controller for a brushless DC PM motor operated solar fed irrigation water pump (SIWP) with adaptive commutation error optimization. The maximum power extraction from solar photovoltaic array and the common DC link voltage regulation are done by the voltage source inverter (VSI) alone. A robust speed range parameter, speed independent sensorless commutation and speed control is presented here. A detailed observation on different performance parameters which are effecting the motor's efficiency and cost are presented here. A comparative study between the presented motor and its traditional complement is also given here on the basis of different performance parameter and cost due to optimization of permanent magnet using finite element analysis (FEA). A prototype of the designed motor and the motor controller are manufactured to verify the compatibility and reliability of the designed motor and the controller through different experimental results.