PROTECTIVE CIRCUITS FOR MOTOR DRIVE

SMPS
DARANI JYOTHI (14E609)
DEEPIKA (14E610)
NILESH RAM BALUSU (14E635)
RAJESH J (14E642)
HARISH V (15R904)

Dissertation submitted in partial fulfillment of the requirements for the degree of

BACHELOR OF ENGINEERING

Branch: ELECTRICAL AND ELECTRONICS ENGINEERING(SW)

of ANNA University

JAN 2018
DEPARTMENT OF

PSG COLLEGE OF TECHNOLOGY

(Autonomous Institution)

COIMBATORE – 641 004

Current sensing:
Current sensing is a fundamental requirement in a wide range of electronic applications.

Applications that uses current sensing are:

 Battery life indicators and chargers

 Overcurrent protection and supervising circuits
 Current and voltage regulators
 Linear and switch mode power supplies
 Control signal
 Diagnostic equipment’s
 Motor speed control and overload protection

There are wide variety of the current sensors and circuits. Among them, one is current sensing
(shunt)resistor.

In this current is converted into voltage by = × .

Advantages:

 Low cost
 High measure accuracy
 Measurable current range is from low to medium.
 Capability to measure DC to AC current.

Disadvantages:

 Power loss given by P= *R. hence cannot be used for high current sensing or measuring.
 Introduces additional resistance into the measured circuit path, which may increase the source
output resistance and undesirable loading effect.

Selection criteria:

 Low value sensing resistor with tight tolerance, compromises losses and accuracy.
 High current capability, high peak power rating to handle short duration and transient peak
current.
 Low inductance to reduce the EMF due to high frequency components.
 Low temperature coefficient, low thermal EMF and high temperature capability, if there is a
wide temperature variation.

Current sensing techniques:

Low side current sensing:

Resistor is connected between load and ground.

Advantages:

 Low input common mode voltage

  Low VDD parts
 Ground reference input and output.
 Simplicity and low cost.

Disadvantages:

 Ground path disturbance

 Load is lifted from system ground since Rsen adds undesirable resistance to the ground path.
 High load current caused by accidental short circuit goes un detected.

High side current sensing:

Used for motor monitoring, control, overcurrent protection and supervising circuits, automotive
safety systems and Battery current monitoring.
 The resistor ratios of R2/R1 and R1*/R2* must be well matched to obtain acceptable CMRRdiff.
Tight tolerance will increase the cost.

Design:

The current sensing circuit consists of two stages.

The first stage is a non-inverting amplifier.
second stage is a non-inverting Schmitt Trigger.
We have used the LM258 op-amp IC in our design for the non-inverting amplifier and
the LM393 dual core comparator IC for the Schmitt Trigger.
For our circuit, we have taken the shunt resistance value to be 0.03Ω.
 We have also taken 10A to be the required current, 12A to be the maximum rated
current and 20A to be the maximum permissible current in the circuit. The currents 10A, 12A
and 20A give potential difference of 0.3V, 0.36V and 0.6V respectively.
We have designed the circuit in such a way that any current flowing at 12A and above is
considered over-current and a signal is detected at that instant and sent to the microcontroller.
The microcontroller is assumed to be of TTL Logic, so we have included a +5V pull-up source at
the end.
The simulated output is given below. For a signal where is voltage varies from 0.3V to
0.36V and then to 0.2V. The blue line is the input and green is the output.

We will be discussing the relevance of the resistors used in the two stages. In the first
stage, for the non-inverting amplifier both the resistors R1 and Rf affect the gain of the
amplifier. The voltage gain formula is so given,

=
1

Fig.1.6. Non-inverting Amplifier

The second stage is the Schmitt Trigger and the resistances here play a major role along
with the reference source used here. The diagram and formula are given below.
 Figure 2
Transition happens only when
Vin >VTU  Vout=VH ; Vin <VTL  Vout=VL

Switching circuit along with the current sensing shunt resistor:

Figure 4
Current sensing circuit:

Figure 5
Design:

(Naming are referred from Figure 5)

Rated current through the DC bus: 10A

Allowable current: 12A

Maximum current that can flow through the DC bus: 20A

Current sensing Shunt resistance value: Rsh= 0.03 ohm

Therefore, the transition voltage at which the relay or the DC bus must be open circuited is
given by, V=I*R.

Vin = 12*0.03 = 0.36 V (Vsh)

Non-inverting amplifier design:

This is used to amplify the input signal to the measurable and comparable level.

LM258 is used as non-inverting amplifier

Vout is given by
 3
= 1+
2

45
= 1+ 0.36
10

= 1.98

Comparator and Schmitt trigger design:

This is used to compare the Vout from non-inverting amplifier and design the threshold for the
transition range(gap).

The output of the comparator is a digital signal which is puller up to the 5V ref.

VON= 5V (VH)

VOFF= 0V (VL)

The current threshold in the DC bus is given as the lower limit 11.5 A and the upper
limit 12.5 A

Their respective output voltage from the non-inverting amplifier output is calculated as

1.8975 V (VTL) and 2.0295 V (VTU)

6
= ( )
7

6
= ( )
7

Transition voltage is Vs =1.98 V

But since VTU=Vs, Vs is considered as 2.0295 V instead of 1.98 V. (to give upper threshold)

VS=2.0295 V

By using VTL equation, we get R6=1k and R7=37.878k.

For LM393 the reference voltage to the non-inverting terminal is given by,
 6
= 1+
7

Vref=1.9773 V

Vref is got by the reference voltage 5v and a voltage divider formed by R4 and R20 given by,

20
=5 ×( )
4 + 20

R4=1.5287k

R20=1k
Back EMF detection:

The maximum square Input voltage to the BLDC motor is the DC bus voltage. The Back-EMF
detection is the most important part of the BLDC motor electronic commutation process. Only
when we detect the back EMF will we know when to turn the current on in the other winding.
At every instant of the BLDC motor operation, two phases are always active in opposite
directions while the other phase is inactive.

When we look at this in terms as windings, the current will not flow through one of the
windings, so it acts as a floating winding.
 =
2

= +
2

Zero crossing detection:

Ec is the varying quantity. It should be detected where it crosses zero. Since, practically it is not

possible to measure the back-emf inside the motor. So, we are detecting the floating terminal

voltage which is given by Vc for the C-phase.

Therefore, at zero crossing the Vc voltage should be equal to half of the Vdc (DC bus voltage)

= 480

480
= = 280
2

= 280 +
Circuit used for the switching:

Figure 6
Back-EMF detection for the three-different phase:

Figure 7

Figure 8
 Figure 9

Design:

480 V DC bus voltage is reduced to 5V for the op-amp operation.

Transition voltage Vs is 2.5 V which is got by reducing the neutral voltage Vn (or junction voltage).

Resistor values are given by,

Same for all the current sensing circuits (except the resistor name changes)
43
= ( )
44

43
= ( )
44

43
= 1+
44

VS=2.5 v ; Vref=2.487 v ; VL=0 v

VTU=2.5 v ; VTL=2.47395 v ; VH=5 v

Fly-back smps:
 Used for low power output and provides isolation from input main supply.
 Output: few watts to 100 W
 Simpler topology
 Input: unregulated dc from rectifier
 Output: multiple isolated outputs and operate on wide range of output variation.
 Less energy- efficient, low cost, used for low output power.
 Used in the range of 100khz, mosfet (single switch topology)

Topology of fly-back converter:

 Ripple will be in low frequency, twice the main frequency
 Due to very high switching frequency of the switches the output voltage is considered constant
magnitude
 Fast switching device along with fast dynamic control over switch (duty cycle), desired output
voltage is maintained.
 Transformer for voltage isolation and better matching between input and output voltage,
currents
 Fly back-transformer is different from normal transformer, 1’ and 2’ winding in fly-back
transformer will not conduct simultaneously.
 Since both windings are not conducting simultaneously they are mostly like magnetically
coupled inductors.
 Also called inductor-transformer. Magnetic circuit design is done like it is done for inductor.
 Output consist of rectifier and filtering circuits.
 SMPS Output voltage is taken across the output capacitor
 Practical circuit consist of the voltage and current feedback and controller for modulating the
duty cycle ratio of the switch.
 Multiple secondary winding is used for generating multiple isolated voltages.
 One is dedicated for the estimating the load voltage and for the power supply (control
power for the circuit).
 Snubber circuit is used to dissipate the power stores as leakage inductance in 1’ winding
when switch is turned ‘off’ .

Assumption made:
 Magnetic circuit is linear, and coupling is ideal. (No leakage inductance)
 Voltage drop on the switches are neglected
 Input dc supply is ripple free
 Winding, transformer core, capacitor- loss less.
 o

Principle of operation:
Mode 1: switch is closed(ON).

Secondary doted terminal is at higher potential.

Diode is reversed biased.

Flux in transformer core is fully due to the primary current.

Continuous flux mode:

Second cycle Turing ‘ON’ is carried before magnetic flux in the transformer core is reset to zero.

Some flux is already present in the core before the switch is turned ON(closed), the primary
winding current abruptly rises to a finite value as the switch is turned ON Magnitude of current step
corresponds to, the primary winding current required to maintain the previous flux in the core.

Energy stored in fly-back inductor transformer, =( )/2

Ip denotes the magnitude of primary current at the end of conduction period.

Capacitor maintains constant voltage (assume C is very high) and supplies current to the load. It also
maintains secondary winding voltage constant, Vsec=Edc * (N2 /N1)

Voltage across diode: Vdiode = Vo + Edc * (N2/N2)

Mode 2: The switch is turned OFF (opened) after conduction.

The voltage polarities across the windings are reversed.

Diode is forward biased.

Discontinuous mode:
Discontinuous mode occurs when whole of the magnetic field energy is stored is transferred to
the load. i,e, when secondary winding diode is not conducting.

However load voltage is supplied by the output capacitor.

Mode 3 – ideal mode:

This mode of the circuit where diode is not conducting and primary switch is open. The load
voltage is supplied by output capacitor is called ideal mode operation. This exist till the
commencement of the next cycle. This is the part of the discontinuous mode.
 Transition mode:
It is the operating mode in which the commencement of the next cycle takes place at an instant
when whole of the stored energy in the magnetic field is transferred to the output. That is, period of
ideal mode of opearation of smps is zero.

Nature of coupled inductors:

 Mmf produces by the winding do not change suddenly.
 Mmf (magneto motiveforce)is responcible for flux production in the core. Mmf is the algebric sum of
the ampere-turnes of the two winding.
 Current entering the doted terminal- positive mmf
 Current leaving the doted termianl – negative mmf
 Mmf is proportional to the flux produced. Flux decides the energyt stored in the magnetic field by
/2 ,
 B – flux per unit area. So it will not change suddenly.
 Flux conduction is not continuous.
 Primary winding and secondary windings do not conduct at the same time.
 Operates at very high frequency in terms of kilo or mega hertz.