Hall-Sensor-Based Position Detection for Quick Reversal of Speed Control in a BLDC Motor Drive System for Industrial Applications

Abstract

This paper proposes the novel idea of eliminating the front-end converters used indirect current (DC) bus voltage variation, thereby allowing for control of the speed of the brushless direct current (BLDC) motors in the two-quadrant operation of a permanent magnet brushless direct current (PMBLDC) motor, which is required for multiple bi-directional hot roughing steel rolling mills. The first phase of steel rolling, the manufacture of plates, strips etc., using hot slabs from the continuous casting stage, is carried out for thickness reduction, before the same is sent to the finishing mill for further mechanical processing. The hot roughing process involves applying high, compressive pressure, using a hydraulically operated mechanism, through a pair of backup rolls and work rolls for rolling. Overall, the processes consist of multiple passes of forward and reverse rolling at increasing roll speeds. The rolling process was modeled, taking into account parameters like roller dimensions, angle and length of contact, and rolling force, at various temperatures, using actual data obtained from a steel mill. From this data, speed and torque profiles at the motor shaft, covering the entire rolling process, were created. A profile-based feedback controller is proposed for setting the six-pulse inverter frequency and parameters of the pulse width modulated (PWM) waveform for current control, based on Hall sensor position, and the same is implemented for closed loop operation of the brushless direct current motor drive system. The performance enhancement of the two different controllers was also evaluated, during the rolling of 1005 hot rolled (HR) steel, and was taken into consideration in the research analysis. The entire process was simulated in the MATLAB/Simulink platform, and the results verify the suitability of an entire-drive system for industrial steel rolling applications.

Flexible Magnetic Field Nanosensors for Wearable Electronics: A Review

“…Hall sensors, known for their precise position detection and current monitoring capabilities, are widely utilized in automotive and consumer electronics industries. − The sensitivity of Hall sensors, a critical parameter, is contingent upon the charge carrier mobility (μ) and sheet carrier density ( n ), with higher values of μ and lower values of n corresponding to increased sensitivity. − Presently, silicon complementary metal–oxide–semiconductor (CMOS)-based Hall sensors are extensively employed due to their well-established production processes and cost effectiveness. However, with the emergence of novel applications such as wearable electronics, electronic skin, robotics, and prosthetics, there is a growing demand for thin and flexible sensor devices. − The flexibility of these sensors not only bestows operational advantages but also facilitates seamless integration on curved and nonplanar surfaces owing to their slender form factor.…”

Advanced Control for Electric Drives: Current Challenges and Future Perspectives

“…Multiple sensor systems were analyzed based on different influencing factors and performance indicators in the automotive field. In [18], the speed control for brushless direct current (BLDC) motors, in steel rolling applications, was investigated using a cascade control loop. The load torque and the speed reference were calculated from the rolling process.…”

Development and Experimental Implementation of Optimized PI-ANFIS Controller for Speed Control of a Brushless DC Motor in Fuel Cell Electric Vehicles

“…Developing independent energy sources, especially clean and economically viable sources, is one of the significant technological challenges currently being faced. The use of an electric motor, with high energy efficiency and silent and non-polluting operation, seems to be the ideal solution, and many studies have been carried out to study the effect of the load change on a brushless DC motor [8][9][10], while limited studies have investigated the speed regulation of a motor powered by a fuel cell [11][12][13].…”