Design and application of a novel high precision and low cost electronic tachogenerator for sensor-based brushless direct current motor drivers

This study presents a precise speed control method for Brushless Direct Current (BLDC) Motors using an electronic tachogenerator (ETg) instead of an electro-mechanical tachogenerator. Most commonly used three-phase BLDC motors have three position sensors for rotor position data to provide commutation among stator windings. Aforementioned position sensors are usually Hall-effect sensors delivering binary-high and binary-low data as long as the motor rotates. These binary sets from three Hall-effect sensors can be used as an analogue rotor speed signal for closed loop applications. Each position sensor signal is apart from 120 electrical degrees. By using an electronic circuitry, a combination of position sensor signals is converted to the analogue signal providing an input to a PI speed controller. To implement this, a frequency to voltage converter has been used in this study. Then, the analogue speed signal has been evaluated as rotor speed data in comparison with the reference speed. So, an ETg system has been successfully achieved in place of an electro-mechanical tachogenerator for BLDC motor speed control. The proposed ETg has been tested under various speed conditions on an experimental setup. Employed tests and obtained results show that the proposed low-cost speed feedback sub-system can be effectively used in BLDC motor drive systems. Through the proved method and designed sub-system, a new motor controller chip with a speed feedback capability has been aimed.