In this post we discuss a universal ESC circuit or an electronic speed controller circuit which can be universally applied for controlling any type 3 phase BLDC or even an alternator motor.
What is an ESC
An ESC or electronic speed controller is an electronic circuit which is normally used for operating and controlling a BLDC 3-phase motor.
BLDC motor stands for brushless DC motor which clearly states that such motors are void of brushes, quite opposite to the brushed type of motors which rely on brushes for commutation.
Due to the absence of brushes BLDC motors are able to operate with maximum efficiency since the absence of brushes relieves it from frictions and other related inefficiency.
However BLDC motors have one major downside, these cannot be operated through a single supply like the other brushed motors, instead a BLDC motor requires a 3-phase driver for operating them.
Despite of this technical complexity, BLDC motors become highly preferable compared to their brushed counterpart, because BLDC motors are extremely efficient in terms power consumption and virtually no wear and tear issues.
This is why BLDC motors are today used in electric vehicles, windmills, airplanes, quad copters, and most motor related equipment.
As discussed above operating a BLDC motor looks quite complex, and if you try to look for a driver or an electronic speed controller circuit for BLDC motors you would probably come across circuits which are too complex using MCUs, or employ hard to find components.
In this post we will learn how to make a simple and effective ESC circuit which may be universally applied to operate most BLDC motors through some minor modifications.
Once you learn the details of the circuit, you could use it to build electric vehicles, quad copters, robots, automatic gates, vacuum cleaner and any motor operated product with maximum efficiency.
Three Phase Generator Circuits
Since a BLDC motor requires a 3 phase signal, the first thing that needs to be designed is a 3-phase generator circuit.
The following circuits show how this can be made using a handful of operating parts.The first one uses opamps while the second one makes use of just a few BJTs.
Simple 3 phase Generators
The 3-phase signal output needs to be integrated with a 3-phase mosfet driver circuit for enabling the motor operation.
Therefore the second important element is the 3 phase alternator driver circuit, which is supposed to respond to the above 3 phase generator circuit for operating the connected BLDC motor.
For a 3 phase driver, you could employ any standard 3-phase driver IC, such as a A4915, 6EDL04I06NT, or our old:
- IRS2330(D) (2.5µs deadtime)
- IRS2332(D) (0.8µs deadtime)
In our universal ESC circuit we will use the IRS2330 and see how this can be configured for the intended electronic speed control and implemented for most BLDC motors. The following image shows the entire circuit of the proposed ESC design.
The ESC Schematic
The presented ESC alternator driver circuit looks pretty straightforward and does not seem to employ any complex stages.
The 3 phase signals acquired from the 3 phase generator circuits is applied to the inputs of the NOT gates shown at the top left of the above diagram.
These 3 phase signals are converted into the required HIN, and LIN inputs for the 3 phase MOSFET driver IC IRS2330.
The IC IRS2330 hence process these signals to operate the connected BLDC motor with the correct phase and torque via the associated driver mosfets or IGBTs.
We can also see an IC 555 based PWM stage. This stage is configured with the low side mosfets or IGBTs, for chopping their gate triggers into appropriate sections.
This gate chopping forces the devices to operate at a rate determined by these chopping PWM duty cycle rate. Wider duty cycles enables the motor to rotate faster and narrower duty cycle allows the motor to slow down proportionately.
The PWM rate is controlled through the IC 555 through the indicated PWM pot.
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Just looking at this post again and noticed the mention of the IRS233, looking for that # will take you to U.S.Tax code sites and USC Federal Codes as in law book pertaining to spouses and stuff I didn’t bother to investigate. Perhaps the part # should include a 0 as in IRS2330 which will take you to a PDF data sheet.
Thank you for notifying, I have corrected it now!
This comment is pertaining to the circuit using the 4049 and the BLDC driver. If a method to make the motor reversible were desired, would it be acceptable to install a switch at the outputs of the inverter, 2 phases and simply switch those 2 ? It seems that way to me as that is how it would be done on an AC 3 phase motor. I can construct the circuit later on and find out for myself, I just haven’t taken the time to assemble it on my breadboard on account I don’t have all the components yet.
I think the reversing of the motor could be implemented simply reversing the 3 phase input sequence across HIN LIN inputs of the IC…doing through a switch could be confusing?
Hey my friend, this time I’m writing to you about BLDC control systems, well I think it may be again, I don’t recall. Anyhow, As we both know, there are indefinite ways to do one thing with electronics. Take this subject, it can be done with circuits as simple as a few transistors with a hand full of other common components thrown into the schematic for basic controlling all the way to extremely complicated IC’s and more components, Bridge drivers and H bridges, transistor, FET, and IGBT’s. So I stumbled across an extremely interesting MCU today from a Co. labeled PAC 5232. This chip is unbelievable, it has so much built into that I am overwhelmed for the time. Maybe you would take a look at it and tell me what you think. It is a pretty recently released item. I have lightly investigated the data sheets and looked for more detailed info on it but nothing is showing up as far as basic instruction on how to get it up and working for development, mostly block info. So it would be a high probability that this chip would be way above and beyond what I would in truth want to experiment with, but man, how cool it would be to have a controller with just half of what I think this would do. So if you get to take a look at it and decide to get back with me, send me an email with an opinion and maybe some suggestions, or simply say it’s too deep. After all this thing works with an ARM Cortex and getting into the code to make that fly is for sure going to require some help from someone way above my ED level.
I took a quick look at the datasheet, and found to be an extensive integrated module which will some time to investigate, however I could not find how an H-bridge using N-channel MOSFETs could be configured through this chip?
HOW ARE YOU? I WANT TO DO THIS, CIRCUIT, BUT I’LL USE MOSFETS INSTEAD OF IGBT. WHAT IS THE CRITERION, AND HOW DO I CALCULATE TO KNOW WHICH RESISTOR CAN I USE ON MOSFETS? I WILL USE MOSFET, IRF3710, 100V BREAKAGE VOLTAGE, DRAIN CURRENT 57 AP, THANK YOU.
I am good thanks….Yes you can replace the shown IGBTs with MOSFETs without any changes in the circuit…..
Lins Roberto Pereira, as Swagatam said, MOSFETs will work without any changes. IGBT’s in my opinion would be a bit more efficient without the risk of failing due to inverse voltage spikes or other issues. I just think they are simply more robust.
Bret Tschacher, COMO VAI? ENTENDI, O QUE VOCÊ DISSE, MAS ESTOU PROCURANDO, ALGO MAIS SIMPLES, POISTENHO POUCO CONHECIMENTO, MAS ESTOU PRESCISANDO MONTAR ESTE PROJETO, POIS AQUI TUDO É MUITO CARO PARA COMPRAR UM ESC DESTA POTÊNCIA.
OBRIGADO PELO SEU TRABALHO,EM NOS AJUDAR, PRECISO CONSTRUIR ESTE ESC, POIS AQUI TUDO É MUITO CARO.
TODOS OS SEIS MOSFET DE SAIDA PARA O MOTOR, SÃO IGUAIS?
TENHO QUE USAR ALGUN RESISTOR?
OBRIGADO.
No problem Lin. But please build it stage-wise. First build only the IC and the MOSFET stage with a 3 phase signal input. Proceed to IC 555 control only once the 3 phase working is confirmed.
Use only PCB or veroboard for the assembly….breadboard will not work.
Olá como vai? Por favor, será que posso usar o IC IR2130, neste circuito? Tem um outro circuito, que posso controlar, alternador, motor modificado? obrigado.
Hi, yes you can use any half bridge IC such as IR2130 and configure it in the following manner:
https://www.homemade-circuits.com/wp-content/uploads/2013/10/3phase-driver.jpg
The PWM of the input 3 phase trigger signal could be optimized for the output control
Man, after almost a day and night searching for a circuit like this, I just find this site with this big, big, mega circuit that literally solves all my problem … I will use a microcontroller to generate the pulses of H1, H2, H3, L1, L2, L3 and the BCs’ PWM, therefore, can program a reversal and use the analog input to control the speed, thereby saving on some components. Thank you very much for sharing this knowledge.
Glad you found the concept useful, wish you all the best, and thanks for the feedback!
It’s OK? Today came the ic drive, which I bought, A4915. But I was surprised by the size of the piece as it is tiny 4mm, and I believe it can only be used on industrial plates. Do you have any information about this? thank you.
The modern ICs are mostly SMD types therefore they will be small, you can ask them for a bigger one with vertical pins, and see if it is available or not in this format.
Oi tudo bem? qual IGBT POSSO USAR PARA UM MOTOR 1000 WATS ? OBRIGADO.
Please search for “1000 watt IGBT datasheet” on Google you will get many options.
Sir I want inveter Air conditioner compressor drive circuit.can you help me sir.
Ishara, do you mean a DC to AC inverter which can handle an air conditioner? Please specify more details such as air conditioner wattage, voltage, etc I’ll try to figure out.
BOA TARDE. QUAL É O SUBSTITUTO PARA IRS 233? NÃO ENCONTRO PELO GOOGLE.
You can try this: FAN73893
all mosfet are n-channel? please tell me about this.
yea all are n channel
Boa noite. Tem algum link onde eu possa encontrar este IRS233 ou IRS2330? obrigado.
I think you can get it from any online store or even from amazon, or ebay…you can Google “Buy IRS233”
ohk got it thanks it was on previous
am abit lost in the circuit where it shows N1-N6 = IC U 4049
How are you? Everything ok? please the name of the CI used in the scheme is correct (IC IRS233) because I already searched google and could not find it! Can I replace with another? thanks
Hi, yes that’s correct, if you are using some other variant then you must match the pinouts correctly.
Hi, what is this the IC in the last photo sir?
Hi, the IC is IRS233
I dont fınd this one anywhere for the buy and proteus for the sımulatıon. Can you suggest any another one?
Sorry I do not have any other alternative, but you can try Googling “3 phase BLDC driver IC”
good night mr svagatam.
For the richness of the above comments and their responses I feel encouraged to set up the circuit mentioned for driving a car alternator converted to bldc.
I promise that as soon as I start the tests I will show the results.
I’ll keep in touch .from thanks already.
It’s my pleasure Jose, wish you all the best! Let me know if you have any problems!
ESC necessary for the rotating the motors(using pwm signal) and also a How to calibrate the motors and is it necessary for all the BLDC motors and without ESC can I run a BLDC motor using pwm signal
If possible to rotate the motor, How?
BLDC will require an ESC, it cannot be operated without these devices:
https://www.homemade-circuits.com/?s=BLDC
boa noite. no esquema ESC a saida 15v do BC547 é ligada nas portas not do 4049?
Nos vcc posso ligar 12v ?
sim você pode usar 12V, sem problemas
Perdão por dar trabalho. Mas a saida 15v do bc 547 é ligada no 4049? preciso muito montar este circuito. obrigado.
Sim, você pode usar todos os + 15V em comum para todos os estágios do circuito
Can i used thrid diagram sir..? It can run my dc burshless motor
All these circuits are complex and advised for the experts, if you are confident about it, then you can build it!
Ok sir but fig second where 3 bc547 transistor used can i used it because it is not more complex… And sure it will be work properly na sir..
It’s a 3 phase generator, you will have to use it with the last circuit.
I am not use it without connecting last cricuit design… It can not run the motor without using last cricuit diagram… I give this reason because my dc burshless motor will have three wire comes from the coil and they connected to hall sensor transistor but it ia blow out due to this i want to run this motor without hall sensor transistor because it is not available in my market sir..
No, you cannot use it without the last circuit.
bom dia. Com este circuito, posso controlar um alternador que vou transformar em motor, para uma bicicleta? Obrigado.
Bom Dia. Sim você pode fazer isso. Sem problemas
Hello Sir Mr Swagatam. Please clarify this please; for the NOT gates, does one just use one input terminal and corresponding output, also does the NOT gates need to be powered up(Vcc & Vss)?
Best regards.
Hi Mthokozisi, all ICs which have Vcc/Vss pins will need to be powered through an external power supply across these pinous, otherwise the IC will not respond. so yes the 4049 will also need an external DC across these relevant pinouts
Goodday Sir. I’d like to say thank you again and I guess I cannever say it enough to amount to the kind of work that you do helping electronics hobbyist across the globe. This circuit seems to be the very thing I’ve been looking for. I guess my case has been settled. I’ll let you know the outcome after I’ve built the ESC. Thank you again.
You are most welcome Mthokozisi, wish you all the best!!
Gooday. Thank you Sir again for your response, your work is simply priceless. For my project I have a sensorless motor(no Hall sensors), but I can’t find the chip for the sensorless esc https://homemade-circuits.com/2017/08/high-current-sensorless-bldc-motor.html
I need to know if the circuit for the universal esc can be used on sensorless motors and if yes, how does one configure the NOT gates inputs as there are no Hall sensors for the NOT gates to work with. My kind of motor has only three stator windings connected in delta.
You are welcome Mthokozisi,
the universal ESC can be used for driving any BLDC motor or any 3-phase motor, regardless of whether it has Hall effect sensors or not.
This circuit utilizes an external 3 phase generator for signalling the ESC through the NOT gates to operate the motor with a 3-phase 120 degree shift signals, which is the standard value for driving all 3-phase motors, therefore this circuit dos not depend on any sensor and is able to independently drive any 3-phase motor.
you can simply connect the 3 wires of the motor with the outputs from the IGbTs or mosfets for enabling the operation.
Hi Swagatam, I’m trying to make a controller for 250W bldc motor. What should be the configuration for it? Can you please get in touch on email?
Hi Rishee, the configuration in the above article is the best configuration according to me, because it does not rely on any special ICs.
You can replace the full-bridge IC with any other variant, and use the other mentioned stages with it in the same format and achieve the required results.
You can feel free to discuss through comments, as this will help the other readers also to learn about your experience in the field.
Thank you Mr Swagatam. I’d like to know the value of the 6 MOSFETs used for the bridge and also the value of the diodes. I need to construct an ESC for a project that I’m on. I’ve converted a car alternator to a hybrid bldc motor powered through an ESC for RC hobbies. Unfortunately the motor doesn’t have enough torque as I’d like it to be. I was wondering if this circuit will be powerful enough to run the motor under load.
Thank you, awaiting your response.
Thanks Mthokozisi, the mosfets can be as per the user’s choice, depending on how much power the output load may be rated at. You can use any suitable ones which may be on par with the rating of the motor. It is better to use IGBTs instead of mosfets for better efficiency.
This circuit can be upgraded for any motor, simply by upgrading the IGBTs accordingly.
I had same question on another post today. Will consider swapping two of the hall inputs but seems like hall inputs will track motor direction. May just need to get motor rolling using this approach then switch to hall sensors
OK, you can try that…
Thank you for the response. how about forward and reverse directions. How can this be accomplished?
forward reverse facility is not provided in the IC, however I think it can be implemented by reversing the 3-phase signal input's logic sequence.
Thank you. I was looking at that as an option.
is this for a sensor less motor?
both types can be used
Not sure my last question was posted. Thank you for your answer I really appreciate it. I have another, how can reversing be added to this example?