Journal of Computational Analysis and Applications VOL. 33, NO.

5, 2024

CPLD Controller Based Speed Control of BLDC Motor Drive

Sadhak Juli Singh1, Bhusnur Surekha2, Dubey S. P3
1Research Scholar, Department of Electrical Engineering , BIT Durg, CG, India,
Email: [email protected]
2Professor, EEE Department, BIT Durg, CG, India, Email: [email protected]
3Vice-Chancellor, ICFAI University Raipur, CG, India, Email: [email protected]

Received: 17.04.2024 Revised : 19.05.2024 Accepted: 25.05.2024

ABSTRACT
In today's time, to work in all fields, we need a motor with low power consumption and efficient work
that is why BLDC motor is very famous in the new trend. Therefore it is important to understand the
control techniques and have been explored electronic commutation method of BLDC motors. In this, the
combination of traditional method and new method using hybrid commutation is understood. The
traditional method is Zero Cross Detection Back EMF method and the innovative method is based on PID
controller plus CPLD control technique. This paper shows the tabulation of torque and various features of
PID plus CPLD control technique. Using these techniques together greatly improves the performance of
the BLDC motor, discussed in this research work.

Keywords:BLDC-Brushless DC Motor, ECC- Electronic Controller Circuit, PCB- Printed Circuit Board, ZCD-
zero cross detector, PID- Proportional integral and derivative, CPLD-Complex Programmable Logic
Device, PWM- pulse width modulation

1. INTRODUCTION
The current era marks the start of the industrial revolution, which was sparked by the development of the
motor. In industrial applications, two types of DC motors are typically configured. In the first form, the
static pole structure's field coil generates the necessary magnetic flux, whereas in the second type, a
permanent magnet provides the necessary air gap flux [1,2].
A multitude of motor types have been developed throughout the years, but they can be broadly divided
into two categories: AC motors and DC motors. In a DC machine, the commutator and brushes are
essential components. An advantage of utilizing a DC machine is that high speed and high current can
destroy brushes; a brushless DC motor was developed to get around this restriction. The tiny size, higher
efficiency, and large speed range of BLDC motors have made them quite popular in today's world [2].
Here Better speed versus torque characteristics, high efficiency, excellent dynamic response, long
working life, noiseless operation at greater speed ranges, and cheap maintenance are the key benefits of
brushless DC motors (BLDC) over conventional brushed DC motors. Thus, BLDC is becoming more and
more common. BLDC motors are used extensively in many industries, particularly those that produce
appliances, treat patients, fly in airplanes, manufacture medical equipment, work in chemicals,
manufacture automobiles, make textiles, and automate industrial processes. Digital audio recordings,
computer disc drives, tape recorders, and other visual devices frequently use small motors with external
rotors [3].
The speed control is crucial for BLDC motors. Effective controllers for digital control of the BLDC are
necessary to meet a variety of control requirements. The most widely used controllers are fuzzy logic
controllers (FLU controllers), PID controllers, and combinations of these controllers, such as fuzzy-
genetic algorithms, fuzzy-neural networks, and so forth. The PID controller is chosen as the primary
control algorithm based on the requirements of the actual application as well as stability and reliability
principles [1,2,3,4,5].
The designing and implementation of a closed-loop control system for a high power BLDC motor. Using
the Kp, Ki, and Kd parameters of the PID controller, one can adjust the algorithm through tuning. Using this
method, receive a steady and dependable speed. Experiments demonstrate the robustness of the system's
operating performance both before and after adding load, as well as the dependability of the hardware
and software control algorithms. The system has a wide range of potential applications and can be further
expanded to additional application areas [3].

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An ultra-light electric vehicle can utilize the three-phase BLDC motor controller. A Programmable Logic
Device (CPLD) is used to perform the control, and no additional processor is needed. In this manner, a
reliable and simple control is achieved. Additionally, a phase advance circuit is used to increase the
BLDC's speed range. The controller's extremely low power consumption is an intriguing feature for
battery-powered applications [6].

1.1 PID Controller

Fig 1. Schematic diagram of PID controller

A common feedback loop technique in industrial control systems is the PID controller.
-A feedback control technique that modifies motor speed in response to deviations from the set-point and
actual speed.
- To reduce inaccuracy, three properties are used: proportional (P), integral (I), and derivative (D).
- Widely used in numerous applications [1].

Advantages
1. Ease of Implementation: PID controllers are relatively simple to implement and widely understood.
2. Flexibility: They can be tuned for different types of control requirements.
3. Cost-Effective: PID controllers can be implemented using low-cost microcontrollers or digital signal
processors (DSPs).
4. Robust Performance: PID controllers provide stable and accurate control for a wide range of
applications.

Disadvantages
1. Tuning Complexity: Finding the optimal parameters (Kp, Ki, Kd) can be time-consuming and may
require trial and error.
2. Limited Adaptability: PID controllers may not perform well under varying system dynamics or
disturbances.
3. Computational Delay: Depending on the implementation, PID control loops may introduce
computational delays, especially in high-speed applications.

Applications
Widely used in industrial automation, process control and motor control where high precision is not
critically required.

1.2 CPLD Controller

The digital portion is based on the XC2C64 Complex Programmable Logical Device (CPLD), which has 33
I/O that can be rearranged as needed. An essential feature when employing analog produced inputs is the
ability to customize each input with an inbuilt Schmitt trigger. This is fairly simple to accomplish with
Xilinx's Integrated Software Environment (ISE). Because all inputs and outputs are processed in parallel
in a CPLD, there are almost no speed restrictions, allowing one to select a motor with a high number of
poles and rpm. Concentrated pole BLDC motors, which often have a large number of poles and frequency
above 500 Hz, benefit from this [6,7].

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Fig 2. Structure of Complex Programmable Logic Device

As shown in figure 2 the BLDC motor's phase currents, I a and Ib, are measured using the current
measurement. Therefore, two phase currents are corrected and measured. The sum of the negative
currents in the first two phases equals the current in the third phase. The maximum of all absolute
current values is used to generate a signal. To be consistent with the positive set value for drive and
braking torque, the voltage at point A is moved to point B, which is positive [6]. In relation to the rear emf,
the required phase advance on phase current. Without phase advance, the BLDC cannot generate the
same torque at high speeds, resulting in poor acceleration as the vehicle drives quickly. A phase advance
can counteract this phase lagging, increasing torque and efficiency at high speed [6,8].

CPLD MAX-II Block input and output waveform

the control algorithm according to the proposed system. Logic control was then implemented to CPLD
Max II: EPM240T100C5 using JTAG via Quartus software, a 500W, 48V and 13.5 Ampere rated BLDC
motor without gearbox.

Fig 3. CPLD MAX-II Block input waveform

Figure 3 represents input waveform of CPLD Max II and the output of Micro controller. This
programming/code provides a basic implementation of a PWM generator for a three-phase BLDC motor
control. The PWM duty cycle is determined by pwm_input, and the phases are sequentially enabled
according to the phase shift required for BLDC motor operation.

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Fig 4. CPLD MAX-II Block output waveform of Phase R, Y and B is fed to MOSFET

In such a above figure 4 setup, the CPLD would generate three output signals corresponding to the phases
R (Red), Y (Yellow), and B (Blue). These signals would be pulsed in a specific sequence to control the
motor.
In this waveform:
 Each phase signal (R, Y, B) alternates between high and low states.
 The sequence of pulses in each phase determines the rotation direction and speed of the motor.
Figure shows the specifics of waveform, including pulse width, frequency, and duty cycle, would depend
on the motor control algorithm implemented in the CPLD MAX II. This demonstrates CPLD devices like
the MAX II series can indeed be utilized for generating complex waveforms to control electromechanical
systems, including the switching of MOSFETs for driving Brushless DC (BLDC) motors [7].

Advantages
1. High Speed: CPLDs offer faster processing capabilities compared to microcontroller-based PID
controllers, making them suitable for high-speed motor control.
2. Deterministic Performance: CPLDs provide deterministic and predictable timing, which is crucial for
precise control.
3. Parallel Processing: CPLDs can execute multiple control algorithms simultaneously, enhancing
performance.
4. Customization: They can be highly customized for specific control applications, optimizing
performance for particular tasks.

Disadvantages
1. Complexity: Designing and programming CPLDs requires specialized knowledge and tools.
2. Cost: Initial development and programming costs can be higher compared to PID controllers.
3. Flexibility: Once programmed, CPLDs are less flexible to changes compared to software-based
controllers.

Applications
Suitable for applications requiring high-speed and precise control, such as robotics, advanced motor
control systems, and real-time signal processing.

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Table 1. Key Differences in Speed Control of BLDC Motors [1,2,6,9,10,11,12]

S.N. paramet PID Controller CPLD Controller PID + CPLD Controller
ers
1. Speed Appropriate for standard Faster and more Quick response and
and speed control scenarios where deterministic control is processing times from
Responsi a high response speed is not available, making it perfect the PID Plus CPLC
veness essential. for high-speed applications controller. Advanced
The microcontroller's that need quick and accurate logic and decision-
processing speed and tuning reactions. making capabilities.
parameters have an impact on
the response time.
2. Impleme Simpler to use and necessitate Designing and implementing PID + CPLD requires kn
ntation s less specialist knowledge. something more owledge of both PID co
Complex Although difficult at times, tuni complicated calls for ntrol and CPLD progra
ity ng is a manageable process. familiarity with digital mming, making it more
design concepts and difficult to design and i
hardware description mplement.
languages (HDLs).

3. Flexibilit More versatile and adjustable After installation, less More customization an
y and to various control situations. adaptable. Reprogramming d adaptation to shifting
Adaptabi Modifications to software can the hardware is necessary motor circumstances ar
lity be made with reasonable ease for any changes, and it can e possible with PID + C
be a laborious and PLD control algorithms.
complicated process.

4. Cost More economical in general, es More expensive initially beca Compared to basic PID
pecially when needs low to use of programming and dev controllers, PID + CPLD
medium performance are met. elopment, but it performs be solutions are typically
tter in some high- more expensive.
speed applications.

5. Perform Under different system The CPLD controller is Its sophisticated logic
ance dynamics or outside known for its reliable and and processing
Under disturbances, performance steady operation, which capabilities, PID +
Disturba may deteriorate. keeps control precision CPLD provides
nces under all kinds of improved performance,
circumstances. precision, and stability.

BLDC Motor Specifications

 Rated Voltage: 48 Volt DC.
 Supply voltage : 24 V
 Rated Power: 500W.
 No Load Current: 4.0A.
 No Load Speed: 516 RPM.
 Rated Torque: 102Kg-cm. or 10 Nm
 Rated Speed: 450 RPM.
 Rated Current: 13.4A.
 Efficiency: 80%.

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Hardware data tabulation of BLDC motor torque

First, let's convert the motor's power from watts to volts times amps (𝑃=𝑉𝐼). Assuming the motor
operates at its rated power and voltage, we can use Ohm's Law (V = I R) to calculate the current (𝐼) here I
is motor current and it denoted by Imand V is supply voltage given to BLDC motor and its denoted by SV:
𝑃 = SV * Im[8,13,14]
Im =P/ SV
Given:
 Motor power (P) = 500 watts
 Supply voltage (SV) = 48 volts
We calculate:
𝐼m=500/48
Motor rated current 𝐼m ≈10.42 amps
Now, we can use this current (𝐼m) and the motor's power (𝑃) to estimate the back EMF (𝐸).
𝐸 = SV – 𝐼m * 𝑅
Given:
 Rated Supply voltage (SV) = 48 volts
 Rated Current (𝐼m) ≈ 10.42 amps
The BLDC motor proposed in this project is used in electric vehicles, in which the gear box has been
removed because our hardware does not require it. The rating of BLDC motor is 48 volt, 13.4 amp, 500
watt and 450RPM. Due to unavailability of 48 volt source, a 24 volt 10 amp supply has been applied to the
hardware through SMPS of our project.
The torque calculation of BLDC motor at no load condition, Let us assume to be friction and windage
losses and heat losses are negligible, because motor are operating at no load condition.
𝑃∗60
T= [14,15]
2𝜋𝑁
Where,
T= Torque is measured in Newton meter (NM)
P = BLDC Motor Power (SV * Im) measured in Watt (W)

Hybrid techniques used hardware model Results

PID (Proportional-Integral-Derivative) control and CPLD (Complex Programmable Logic Device)
techniques are new methods used for commutating the BLDC (Brushless DC) motors and CPLDs are
programmable logic devices that can be configured to perform specific tasks.
Combining CPLD and PID for Sensor Input Processing in BLDC Motor Commutation to ascertain the
rotor's position, the CPLD receives inputs from position sensors. The CPLD creates the proper
commutation signals to energize the correct motor phases based on the rotor position. It regulates motor
speed and torque, the CPLD can produce PWM signals with different and variable duty cycles according to
load variations. A PID controller receives feedback from the motor's position or speed measurement. The
PWM duty cycle is modified by the PID controller based on its calculation of the error between the
desired and actual values. The control past of CPLD receives the output of the PID controller, such as a
new duty cycle value for variation of speed.

Fig 5. Hardware setup of PID plus CPLD control Technique of BLDC motor Drive

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A BLDC motor can be operated efficiently by combining a Raspberry Pi Pico (RPI2040) microprocessor
circuit with a CPLD MAX II circuit. The RPI2040 serves as the primary controller in this scenario,
generating PWM signals and carrying out motor control algorithm execution. The CPLD MAX II is a helpful
addition to the RPI2040 provides more logic resources for creating custom control logic and
communication with peripherals. Gate drivers facilitate communication between the CPLD MAX II and the
power MOSFETs that control the motor phases. The RPI2040 and CPLD MAX II generate signals that
power MOSFETs use to switch the current passing through the motor phases.
Three PWM signals, one for each of the three motor phases, are produced by the RPI2040 and CPLD MAX
II. The duty cycle of these PWM signals regulates the average voltage applied to each motor phase as well
as the motor speeds. The synchronization and timing of the PWM signals, which switch the MOSFETs at
the proper moments to match the rotor position, guarantee smooth spinning.

Table 2. Hardware Results of PID plus CPLD Control scheme

Supply voltage Sv = 24 Volt for clockwise direction
S.N. USP( MSP (N) Im Ic (Charging Torque
Motor set Motor actual (motor current) in T = 𝑃∗60 (NM)
2𝜋𝑁
speed) in speed in RPM current) Amp
= (24*Im*60)/
RPM in Amp
(2πN)
1. at start 0 0 0 0
2. 50 50 2.1 3.1 9.63
3. 70 62 2.1 3.1 6.88
4. 90 75 2.1 3.1 5.35
5. 100 88 2.1 3.1 4.81
6. 120 112 2.0 3.1 4.09
7. 150 138 2.0 3.1 3.32
8. 170 162 2.0 3.1 2.73
9. 200 188 2.0 3.1 2.44
10. 230 212 1.9 3.1 2.05
11. 250 238 1.9 3.1 1.83
12. 270 262 1.9 3.1 1.66
13. 300 288 1.8 3.1 1.43
14. 350 338 1.8 3.1 1.22
15. 400 388 1.6 3.1 0.95

450
400
350
Speed in RPM

300
250
200
150
100
50
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
Time in sec

Fig 6. Speed verses time

Looking at the waveform given above, we understand that as the Brushless DC motor rotates, the speed of
the motor continues to increase with respect to time. Approximately linear behavior shows the given
BLDC motor of speed with time is seen.

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12

10
Torque in Nm 8

0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
Time in sec.
Fig 7. Torque verses time

Looking at the graph given above, we understand that when a Brushless DC motor starts rotating, the
torque of the motor becomes very high means maximum, as the speed of the motor increases, the torque
of the motor starts decreasing. The given figure shows how the torque changes with time.

2.5

2
Current in Amp

1.5

0.5

0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
Time in sec

Fig 8. Current verses time

By looking at the graph given above, we can understand that when Brushless DC motor is started, it takes
heavy current in motor starting, when the motor reaches the set value then the current of the motor
starts decreasing slowly.

Fig 9. Speed verses Torque

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The relation between torque and speed can be understood in the graph given above. The magnitude of
torque at the time of starting speed is very high, the magnitude of torque decreases as the speed of the
motor reaches its desired value.
The ideal torque versus speed characteristics of the brushless DC motor is as shown. The waveform of the
hardware of our Brushless DC motor has also been improved in the same way. The waveform of the
tabulated torque versus speed characteristics of the motor has been shown in figure 9.

Current in Amp 2.5

2
1.5
1
0.5
0
0 100 200 300 400 500
Speed in RPM

Fig 10. Speed verses current

Similarly, the graph given above shows the relation between speed and current. In starting the motor, the
motor takes 1.4 amp current. At that time, the value of speed becomes 0. As the motor speed increases,
the value of motor current becomes slightly stable or decreases at the same time.

Fig 11. shows the voltage and time waveform of BLDC motor supply voltage at set speed 100 RPM.

A BLDC motor running at 100 RPM is shown in the above picture figure 11 with its voltage and time
waveform. The motor is powered by a trapezoidal commutation technique. With this approach, each
motor phase's applied voltage varies over time in a trapezoidal fashion.
The switching of the voltage received by the BLDC motor is done through the ESC driver circuit so that the
output waveform of the ESC driver circuit will be the input voltage waveform of the brushless dc motor,
which is in trapezoidal form. The motor supply voltages phase of each phase is at a phase difference of
120 degrees from the each other. As the voltage waveform appears, the current waveform will also
appear according to the magnitude of the motor current.

CONCLUSION
The choice between PID and CPLD controllers for speed control of BLDC motors depends on the specific
requirements of the application. For general purpose applications where ease of implementation and cost
are of primary importance, PID controllers are suitable but for specific Brushless DC motor accurate
speed application, PID plus CPLD method is used for better performance, other than PID controller.

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However, for high-speed, high-precision applications requiring deterministic control, CPLD controllers
provide better performance despite their higher complexity and cost. The results of comparing the
performance of brushless DC motor with PID and PID plus CPLD show that the response of PID plus CPLD
controller is much better than that of PID controller. In addition to high power density, minimal
maintenance requirements and low noise compared to other motors, this high efficiency allows the
production of more torque in a lower speed range. This study compares closed-loop speed control of a
BLDC motor drive driven by a PID controller and BLDC motor drive driven by a PID plus CPLD controller.

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