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If the commutator is not aligned as it should be with the field/excitation the commutation will not be performed at the time when there is a less chance of sparks (lower field value) - it is worth a look.
Regarding drivers for the IGBTs, a good place to start is the IR2110 from International Rectifier: is is quite simple to use, and the datasheet schematics are quite clear. As for the pwm command, instead of the PIC 18f4552, a more suitable would be the dsPIC30F2011, as the latter has dead-time...
I think some more information is needed in order to give you some help. Are you using both IGBTs in a half-bridge or full bridge topology ? If so, the lower IGBT can use the common ground, but the upper one needs a "floating ground", by using a driver like an A3120/A2211 or a half-bridge driver...
In your place I would take the following step: microcontrollers.
Nowadays there are a lot of useful and fun projects regarding arduinos and picaxes, both of which are fun to program and use in a number of applications. Or you can go in a more classical way and program directly PICs, 8051s, and...
Re: single phase motor
Hi
In the first place you need an inverter - an H bridge with MOSFETs or IGBTs that convert the signals from command to the PWM signals to control the motor.
If you want to know which way the drive is rotating, you need an encoder attatched to the shaft of the drive...
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