Development of High-Efficiency Low-Cost Drive System of Small-Size Electric Vehicles

Brushless Direct Current (BLDC) motor is superior to carbon brushed DC motors, such as high efficiency, more speed range, less maintenance, longer life etc. This is because BLDC motor has electronic commutation and thus, does not have to overcome friction unlike the brushed DC motor. Thus, they find application in many areas such as Electric Vehicles and Robotics. However, a disadvantage of BLDC motor is that it requires a controller for electronic commutation which can be expensive and also increases the complexity of the implementation. The BLDC motors which are controlled by classical controllers suffer from problems of parametric variation during commutation and torque ripple in the output. The project aims to design a Robust controller for BLDC motor speed control so as to improve the output of BLDC motor.

- This project presents the design and development of a Battery and Super-capacitor Fed Brushless DC (BLDC) Motor Drive System tailored for Electric Vehicle (EV) applications. The objective is to enhance the efficiency, dynamic performance, and reliability of EV powertrains by integrating a hybrid energy storage system comprising a battery and a super-capacitor. In this setup, the battery serves as the primary energy source, providing steady power during normal driving conditions, while the super-capacitor assists in handling transient load demands, such as rapid acceleration or hill climbing, and also absorbs energy during regenerative braking. This hybrid approach reduces stress on the battery, extends its lifespan, and improves overall system responsiveness. To further enhance energy utilization, the system can be integrated with a solar photovoltaic (PV) source, regulated using a Maximum Power Point Tracking (MPPT) algorithm. The MPPT controller ensures that the PV panel operates at its optimal power point under varying solar irradiance conditions, contributing to battery charging and reducing dependency on grid power. Keywords—Brush Less DC Motor, Super-capacitor, Motor Drive System, Hybrid Energy Storage System, Battery, Maximum Power Point Tracking, Photo Voltaic Cell.

DC motors are simple choice for drive systems having very easy speed control techniques. DC motors are used where DC supply is available. Commutation in the conventional DC motors is carried out by commutator which is rotating part placed on the rotor and brushes. Due to these mechanical parts, conventional DC motor consist high amount of losses. Brushless DC (BLDC) Motors are very extensively used motors these days because of its advantages over conventional DC motors. Commutation is carried out with the help of solid-state switches in BLDC motor instead of mechanical commutator as in conventional DC motor. This improves the performance of the motor. BLDC motor shows good speed control characteristics especially in low power applications like hard-disk drives, laser printers and many more. BLDC with current control scheme was discussed in this paper. BLDC drive with fixed speed and variable speeds are developed using Matlab/Simulink and results were shown for both fixed and variable speed applications. Basic operation of BLDC motor was explained with open loop and closed loop speed control. Matlab results were shown for BLDC motor with open loop speed control, BLDC motor for fixed speed closed loop control and BLDC motor with variable speed closed loop control.

Electric vehicles (EVs) have emerged as a promising solution for reducing carbon emissions. The performance of an EV is highly influenced by the control method of the Brushless DC (BLDC) motor. The main challenges in EV applications include the motor stability at low speeds and the power consumption during high acceleration changes. This research proposes a novel BLDC motor control strategy that combines Direct Power Control (DPC) and FieldOriented Control (FOC) to enhance motor efficiency and stability. The DPC method regulates the power consumption of the BLDC motor, whereas FOC ensures stability at low speeds. The proposed hybrid control system was simulated using MATLAB/Simulink on a BLDC motor drive. The simulation results indicate improved motor stability at low speeds and reduced power consumption, confirming the effectiveness of the hybrid DPC-FOC approach for BLDC motor control.

Electric vehicles are currently being developed with the concept of saving energy and environmentally responsible. Electric vehicles use electric motors as the main driving motor. The electric motor which is currently increasingly used is the Brushless Direct Current (BLDC) motor. The BLDC motor controller is more expensive than the price of the BLDC motor itself. The BLDC motor controller has a working temperature range when working. The purpose of this study was to analyze the effect of variations in load values and the speed of electric vehicles on the temperature of the BLDC motor controller. This research was conducted by the experimental method by giving a treatment, then evaluating the effect caused on an object of research. The results showed that there was an influence of load value variations on the BLDC motor controller temperature. Values that look significant are at speeds of 0.5 m/sec and 2.5 m/sec starting from 3 kg to 5 kg. There is no influence on the variation of speed values on the temperature of the BLDC motor controller. The temperature value is stable at 2 kg and 3 kg loads with speed variations from 0.5 m/sec to 2.5 m/sec. Simultaneously variations in load and speed values affect the temperature of the BLDC motor controller by 57.7% with the lowest temperature value at 0.5 m/s and a load of 1 kg with a temperature of 33.34℃ and the highest temperature value at a speed of 2.5 m/sec and a load of 5 kg with a temperature of 37.58℃. Keywords: Electric vehicles, controllers, BLDC motors, temperature.

This paper focus on a novel operation of a brushless dc (BLDC) motor fed by a proportional integral (PI) controlled buck--boost converter supplemented with a battery to provide the required power to drive the BLDC motor. The operational characteristics of the proposed BLDC motor drive system for constant as well as step changes in dc link voltage of a front end converter controlled by a Xilinx System Generator (XSG) based PI controller for two quadrant operations are derived. Thus a field programmable gate array (FPGA) based PI controller manages the energy flow through the battery and the front end converter. Moreover, speed to voltage conversion logic, made to control the BLDC motor through the PI controller, improves the performance and gives optimum control under the unstable driving situation or varying load condition when the complete system becomes a subject of application to electric vehicles (EVs) and hybrid electric vehicles (HEVs). The dual closed loop control implemented for end to end speed control of the proposed drive system facilitates the system with high accuracy integrated with excellent dynamic and steady state performance. In this paper, the proposed controller was designed for a 5 kW/480 V BLDC motor drive system. The feasibility of the proposed dual loop control topology for the BLDC motor drive system is validated and verified with extensive dynamic simulation in MATLAB/SIMULINK and XSG environment.

Electric vehicle is an important component in any smart city and Brushless DC (BLDC) motor is an obvious choice for an electric vehicle. But most of the existing technology of BLDC motor drive suffers from a significant amount of torque ripple. In this paper reduction of torque ripple in Brushless DC motor is studied and a technique has been proposed to minimize it. In a conventional three phase Brushless DC motor with 120° conduction mode torque ripple occurs at 60° interval. i.e. six times in a complete cycle. Torque ripple occurs due to change over of load current from one phase to the other. In this paper an OFF delay has been introduced in the gate firing circuit of the inverter which feeds the brushless DC motor and minimizes the torque ripple. Also this delay has been presented as a function of speed by which the OFF delay can be predetermined to be incorporated in the gate circuit. The propped topology is verified using a suitable computer simulation in MATLAB.

Electric automobiles have lower fuel costs because electric motors are more efficient than internal combustion engines. These automobiles can only drive a certain distance because to insufficient batteries and the lack of charging stations. EVs, on the other hand, lack a short driving distance and require frequent charging and discharging of power batteries. EVs will benefit from the development of energy-saving technologies that will expand their reach and prevent battery damage caused by frequent charging and discharging. The goal is to improve the energy efficiency of braking system and its motor efficiency to generate current, as well as to improve regenerative braking (RB) efficiency in EV’s. Using a Brushless DC (BLDC) motor by adding an LC filter is the method that will be applied. A significant addition of current and less ripple and spike in the torque and a quick dynamic interference is the desired result. The performance of the system optimisation and RB circuit systems by using PI controlling technique. The output from torque produced by a 2200 Rpm is 3 Nm and demonstrates that the BLDC motor is efficient when driven by an LC filter circuit. Finally, using the Matlab/Simulink tool, this research presents a thorough simulation of a BLDC motor’s operation as a motor and a generator with RB to create more current in EVs.

Brushless DC (BLDC) motors are used extensively in the industry for a wide variety of applications. In the Aerospace industry, they are mainly used in the control actuation system in launch vehicles. Different types of faults can develop in a BLDC motor. It is essential to detect these faults in the early stage itself before they develop into system failures. In this paper, fault detection in BLDC motors using parameter estimation technique is presented. Detailed fault diagnosis is subsequently carried out by a fuzzy inference system. Discrete Square Root Filtering in Covariance form (DSFC) algorithm is used initially for estimating the physical parameters of the BLDC motor. These parameters are then passed on to the fuzzy inference system which carries out the detailed diagnosis. Simulation studies carried out indicates that the developed fault detection and isolation scheme is capable of isolating different types of faults like open circuit, short circuit faults, performance degradation of magnets etc. in BLDC motors.

Brushless direct current (BLDC) motors are frequently used in dynamic applications. A Brushless DC Motor is similar to a Brushed DC Motor, except that as the names indicate, they are electronically commutated rather than using brushes for commutation. Brushes are utilized in conventional brushed direct current motors to transmit power to the rotor while they rotate in a fixed magnetic field. Small Brushless DC Motors have flourished as a result of current power electronics and microprocessor technology, both in terms of price and performance. This paper will discuss the history of BLDC motors, their different types, construction, operating principles, and several control mechanisms for driving BLDC motors in various industrial applications. Keywords: BLDC Motor, Pulse Width Modulation (PWM), Hall Effect Sensors, Sensorless control, Rotor, Stator, Back Emf, Trapezoidal Control, Sinusoidal Control, Field Oriented Control

The mechanical commutator of a brushed dc motor can arc, while the electronic commutator of a brushless DC (BLDC) motor is costly and complex. Therefore, this paper presents a novel arcless dc motor based on mechanical-electrical hybrid commutation. The hybrid dc motor is similar to a BLDC motor in that it has permanent magnets and three-phase windings. However, the permanent magnets are on the stator, and the windings are on the rotor. The mechanical component of the hybrid commutating device, which consists of a mechanical commutator and three brushes, is used to generate three square waves with a phase difference of 120°. The electronic component is a freewheeling circuit that consists of a capacitor and four diodes; this component is able to suppress arcing caused by the mechanical component. Simulations and experimental results show that arcing does not occur during the freewheeling process. Moreover, the hybrid dc motor is simple in structure, high in efficiency, and low in cost, and its control is as convenient as that of a brushed dc motor.

A key component of industrial applications is the DC motor. Hence, due to their superior features and performance, Brushless DC (BLDC) motors are more suitable for fractional kilowatt motor’s applications. Albeit, for the purpose of controlling the speed of Brushless DC motor easily, it is quite difficult for obtaining the best controlling performance through the use of the conventional approaches of tuning. In order to search the Proportional – Integral - Derivative (PID) tuning parameters optimally for the different controllers taken into consideration, the use of modern bio-inspired metaheuristic technique called Ant Colony Optimization (ACO) algorithm is employed. This paper particularly discusses and presents on the tunning parameters of . The performance of traditional controller and novel approach is compared, analyzed and presented. Brushless DC motor is buildup in MATLAB and the usage, importance, efficiency and strength of the proposed approach is validated against traditional tunning methods. The obtained result shows better performance of the proposed system with the aid of the proposed controllers for different speed trajectories of the drive when compared with that of the classical Proportional – Integral - Derivative (PID) controllers. Ant Colony Optimization (ACO) seems to be the one of the most effective tuning techniques of Proportional – Integral - Derivative (PID) controllers. This research has significant impact on modern control applications. Received: 9 June 2023 | Revised: 20 September 2023 | Accepted: 10 October 2023 Conflicts of Interest The authors declare that they have no conflicts of interest to this work. Data Availability Statement Data available on request from the corresponding author upon reasonable request.

This paper presents the design and control of a rail guided mover system using a brushless dc (BLDC) motor as traction. In the designed system, the roller on the rail surface is driven by the BLDC motor, and the high-definition camera moves up and down driven by a dc motor. In order to keep the reference position in the low-speed region around the stop position, a modified microstepping method using torque angle is proposed. The proposed microstepping method uses the variable current magnitude according to the estimated torque angle in order to reduce the torque ripple. Then, the actual rotor follows the rotating current vector with the proper torque angle band. Moreover, a smooth deceleration is achieved by a variable gain of the position controller, which is obtained by the deceleration time and position error. Furthermore, the slip effect between the roller and the rail surface is simply compensated by the measured slip coefficient in both forward and backward directions. The proposed position control method is verified by the experiments of the practical rail moving security system.

Nominal voltage of the traction motors being used in electric vehicles is typically higher than the voltage generated by the onboard DC sources. Thus, motors of AC type require boost as well as inversion of available DC voltage. This can be done either by a DC-DC boosted inverter (DBI) or by the recently introduced Z-source inverter (ZSI). Since drives with PM brushless DC (BLDC) motor are largely utilized in the traction of light electric vehicles, it is of interest to carry out a comparative analysis of the two supplies when feeding such kind of motor. In this paper, DBI and ZSI supplies are designed for the study case of an electric city scooter propelled by a PM BLDC motor and powered by a fuel cell with the assistance of a battery. Ratings of the transistors and sizes of the passive components for the two supplies are determined as a function of the fraction of the fuel cell power to the nominal power of the traction motor. The design results are discussed.

Brushless DC (BLDC) Motor is widely used in home appliance, robot, and vehicle industry due to the merits of high power density, low noise, and simple controllability. A demands for the motor, especially slim-type BLDC motor, is expected to increase continuously since the minimizing trend of the actuators is getting attention from various applications. Because a phase inductance of the slim-type BLDC motor is large, it causes a lagging of current compared with back-electromotive force (EMF) in wide range of speed. As a result, there is a problem that reduces the motor efficiency and increases the phase current. Particularly the problem is more serious in high speed range and heavy load condition. This paper proposed control scheme for high efficiency of slim type BLDC motor which can resolve the problems as mentioned above. To synchronize the phase between the current and back-EMF of BLDC motor, it proposed lead angle control method by using current dynamics characteristic. Also, it represented the accurate calculating method of lead angle by using only the maximum value of phase current and information of DC-link voltage. For the verification of the proposed control scheme, various simulations and experiments are employed. As a result, the efficiency improvement of slim type BLDC motor is confirmed.