Upload
corino
View
972
Download
19
Tags:
Embed Size (px)
Citation preview
© 2008 Microchip Technology Incorporated. All Rights Reserved. Class Title Slide 1
1253 IMC
Overview of Intelligent Motor Control Solutions
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 2
Class Objectives
When you finish this class you will know:
What electric motors are, and how they operateHow to select the best motor for your application based on the characteristics, and features of the most common electric motor types How to control these electric motors, and the resources available to assist you
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 3
AgendaBasic Motor TheoryOverview of common motor types and applications
DC Brush MotorDC Brushless MotorPermanent Magnet Synchronous MotorAC InductionStepper MotorSwitched Reluctance Motor
Motor control algorithms and resources
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 4
Basic Motor Theory
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 5
Basic Motor Theory
What is a Motor?A Motor Converts Electrical Energy to MechanicalA Motor Converts Electrical Energy to Mechanical
Force is developed when charge moves through a Force is developed when charge moves through a magnetic fieldmagnetic field
How?How?
F = I x BF = I x B
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 6
Left Hand Rule
I
B
F
I
B
F = I x B
N
S
F
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 7
Motor Torque
Torque production
Taking direction of F into account T=Fr sin θ
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 8
Motor Torque
SummaryTorque = Force * Distance
F = I x BT = ( I x B ) * DWhen B and D are constant T = K * I A
When field is wound B = K * I F
In wound DC motors Torque and Flux B can be controlled independently
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 9
Motor Torque
B BSN
I
BF
T=F x D
D
F
F
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 10
Common Motor Typesand Applications
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 11
Motor Classification
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 12
Topics of Discussion:
DC Brush MotorDC Brushless MotorPermanent Magnet Synchronous MotorAC Induction MotorStepper MotorSwitched Reluctance Motor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 13
DC Brush MotorOperating Principle:
Rotor/Armature comprised of wire wound conductive laminates Stator has permanent magnets (or wound field)Commutation is performed through mechanical contact (brushes)Synchronous, internal commutation
Characteristics:Good controllability
On/Off, ProportionalLinear torque/current curveSpeed proportionate to voltage appliedRequires maintenanceLow overloading capabilityLow heat dissipation
PermanentMagnet
Windings
StatorBrushes
Rotor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 14
DC Brush Motor
Application examples:WipersDoor locksWindow liftsAntenna retractorSeat adjustAnti-lock Braking SystemCordless hand drillElectric lawnmower
BrushesPermanentMagnet
Stator CommutatorWindings
Laminate Core
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 15
DC Brushless MotorOperating Principle:
Rotor comprised of permanent magnetsStator has windingsCommutation is performed electronically Operates as an ‘inside-out’ DC motor
Characteristics:No sparks -> safer in explosive environmentsCleaner, faster, more efficientLess noisy, more reliableLinear current/torque relationship -> smoother accelerationGood overloading capability
Rotor
StatorPermanent
Magnet
Windings
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 16
DC Brushless Motor
Application examples:Anti-lock Braking SystemDisk Drive ServoThrottle controlFuel pumpOil pump
Hall sensors
Stator winding
Rotor magnets
Bearings
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 17
Brushed & Brushless DC Motor Construction
PERMANENT MAGNET BRUSHED DC MOTOR
PERMANENT MAGNET BRUSHLESSDC MOTORPermanent
MagnetPermanent
Magnet
Windings
Stator Brushes
Rotor RotorWindings
Stator
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 18
BLDC vs. BDC Motor
Moderate - Due to increases in steel & copper. ( with wound field stator)
Moderate - Since it has permanent magnets, building cost may be higher. However, steel & copper prices are up
Cost of Building
Arcs in the brushes will generate noise causing EMI in the equipment nearby
Low, because it has permanent magnets on the rotor. This improves the dynamic response.
Electric Noise Generation
Lower - Mechanical limitations be the brushesHigher - No mechanical limitation imposed by brushes/commutator
Speed Range
Higher rotor inertia which limits the dynamic characteristics
Low, because it has permanent magnets on the rotor. This improves the dynamic response.
Rotor Inertia
Moderate/Low - The heat produced by the armature is dissipated in the air gap, thus increasing the temperature in the air gap and limiting specs on the output power/frame size
High - Reduced size due to superior thermal characteristics. Because BLDC has the windings on the stator, which is connected to the case, the heat dissipation is better
Output Power/ Frame Size
ModerateHigh - No voltage drop across brushesEfficiency
Moderately flat - At higher speeds, brush friction increases, thus reducing useful torque
Flat - Enables operation on all speeds with rated load
Speed/Torque Characteristics
ShorterLongerLife
Periodic maintenance is requiredLess required due to absence of brushesMaintenance
Brushed commutationElectronic commutation based on Hall position sensors
Commutation
Brushed DC MotorBLDC MotorFeature
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 19
Permanent Magnet Synchronous Motor
Operating Principle:Rotor comprised of permanent magnetsStator has windingsCommutation is performed electronically Sinusoidal Back EMF
Characteristics:No sparks -> safer in explosive environmentsCleaner, faster, more efficientLess noisy, more reliableHigh Efficiency & ReliabilityDesigned for high-performance Servo ApplicationsRuns with/without Position EncodersMore compact, efficient and lighter than ACIMCoupled with FOC control produces optimal torqueSmooth low and high speed performanceLow Audible Noise & EMI
Rotor
StatorPermanent
Magnet
Windings
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 20
PMSM ApplicationsAir Conditioner & Refrigerator (AC) compressorsDirect-drive washing machinesAutomotive Electrical power steeringMachining ToolsTraction controlData Storage
Hall sensors
Stator windingsRotor
Permanentmagnets
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 21
PMSM Construction PMSM is an AC synchronous motor whose field excitation is provided by PMsSimilar to the BLDC but BEMF is sinusoidal The Back EMF ideally contains no harmonicsLeads to a reduction in audible noise Better efficiency
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 22
AC Induction MotorOperating Principle:
Reverse of an alternator (generator)Rotor and stator carry alternating currentConstructed in either 1- to 3- phase Asynchronous motor
Characteristics:Low Cost to manufactureSimple, low-cost design for fixed-speed applicationsLower efficiency than other motor typesSpeed proportionate to line frequency (50 or 60 Hz)Complex control for variable speed and torque
120 * frequency120 * frequencyPolesPoles
Synchronous = Synchronous = SpeedSpeed
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 23
ACIM ApplicationsLarger horsepower motorsAir Conditioner & Refrigerator compressorsWhite good machinesPumpsBlowersAutomationPower Tools
AC Induction motor 90%
Other motors
Bearings
Stator windings
Squirrel Cage Rotor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 24
BLDC vs. AC Motor
The rotor runs at a lower frequency than the stator by slip frequency and slip increases with the load on the motor
No slip is experienced between stator and rotor frequencies
Slip
No Controller is required for fixed speed; a controller is required for variable speed
A controller is always required to keep the motor running. The same controller can be used for variable speed control
Control Requirements
Approximately up to seven times rated - Starter circuit rating should be carefully selected. Normally uses a Star-Delta starter
Rated - No special starter circuit requiredStarting Current
High - Poor dynamic characteristicsLow - Better dynamic characteristicsRotor Inertia
Moderate - Since both stator and rotor have windings, the output power to size is lower than BLDC
High - Since it has permanent magnets on the rotor, smaller size can be achieved for a given output power.
Output Power/ Frame Size
Nonlinear - Lower torque at lower speedsFlat - Enables operation at all speeds with rated load
Speed/Torque Characteristics
AC Induction MotorsBLDC/PMSM MotorsFeatures
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 25
Stepper Motor
Operating Principle:Rotor consists of permanent magnets with many polesStator has two pairs of windings.
Characteristics:Easy to position – moves in steps based on pulses supplied to the stator windingsDirection of rotation is changed by reversing the pulse sequenceSpeed control is by the frequency of pulses or pulse rate
Rotor
StatorPermanentMagnets
N/S Poles
Windings
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 26
Stepper MotorApplication examples:
Idle speed adjustExhaust gas re-circulationDuct airflow vanesMirror controlTelescopesAntennasToysMany others!
BearingsStator windings
Rotor magnets
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 27
Switched Reluctance MotorOperating Principle:
No permanent magnetsRotor consists of iron laminatesStator similar to brushless DC motorTorque produced as a result of attraction between electromagnet and iron rotor
Characteristics:Motor construction is simple and cheapNeeds MCU control to reduce torque ripple and audible noise
Rotor
Stator
Windings
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 28
Switched Reluctance MotorApplication examples:
Fuel pumpThrottle controlOil pumpABSVacuum cleanerLawnmowerWashing machineAutomatic Doors in buildings and vehiclesFans
Rotor
Stator
Windings
© 2008 Microchip Technology Incorporated. All Rights Reserved. Class Title Slide 29
1253 IMC
Motor Drives
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 30
Motor Drives
Direct on line starter – Relay DriveThyristor driveMotor Soft StarterElectronic speed control
Adjustable-speed driveVariable-frequency driveTorque and speed control
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 31
Variable Speed/Frequency Drives
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 32
Need for Variable Speed Drives (VSD)
Electric motors consume 1/3 power in USMotorized Equipment oversized
Exceed maximum torque requirementsMotors oversized
To meet equipment requirementsMotor usually in continuous, full-speed operation
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 33
Variable motor frequency – Energy efficientMany applications (fan, pumps) follow affinity law20% reduction in speed ~ 50% reduction in power
Better performanceApplication specific V/f curvesTorque and slip controlNoise control
Increased motor life spanReduced starting currentProtection against supply disturbances
Other benefitsReduced Volume and Weight ie: Lower PriceFault detection and displayNetworked solutionStandards compatible product
Electrical Motor Drive –Advantages
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 34
Motor and Drive Application Requirement
Constant TorqueMixers, screw feeders, extruders and positive displacement pumps
Constant Power High torque is required at low speedLow torque at high speedMachine tools, tractions
Variable Torque Low torque is required at a low speedHigher torque at high speedCentrifugal loads such as fans, pumps and blowersMost energy savings from variable frequency drive
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 35
Control Technique TypesVector/Field Oriented Control
Indirect control variables are Flux and TorqueScalar Control (V/F control)
Voltage AmplitudeSine PWMSVM PWMSix Step PWM
Rotational FrequencyDirect Torque Control
Direct control variables are Flux and Torque
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 36
Motor
115/230VAC50/60Hz
Rectifier
PIC®
Microcontroller3-Phase Bridge Driver
SMPSMOSFET Driver
IREIF
Active PFC
Computer
Display and
Control Panel
Feedback Devices
VSI
Electrical Motor Drive – Block Diagram
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 37
Electrical Motor DriveInput – Output
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 38
Electrical Motor DriveInput – Output
© 2008 Microchip Technology Incorporated. All Rights Reserved. Class Title Slide 39
1253 IMC
Motor Control Algorithms
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 40
Brush DC Motor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 41
DC MotorRed is North PolarizationBlue is South PolarizationOpposite Polarities attract Rotor will rotate until North is aligned with SouthJust before alignment commutator contacts and energizes next windingSpark is generated when the commutator changes windings
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 42
Closed Loop Control
PID Motor+ -Desired Speed
Measured Speed
Speed Error Voltage
SpeedCalculation
Hall SensorPeriod
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 43
Low Side Drive Configuration for DC Brushed Motor
Desired PIC® MCU or dsPIC® DSC FeaturesCCP, ECCP, MCPWM, SR Latch10 Bit High Speed ADCInternal ComparatorInternal TMRs
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 44
High Side Drive Configuration for DC Brushed Motor
Desired PIC® MCU or dsPIC® DSC FeaturesCCP, ECCP, MCPWM, SR Latch10 Bit High Speed ADCInternal ComparatorInternal TMRs
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 45
H-Bridge Configuration for DC Brushed Motor
Desired PIC® MCU or dsPIC® DSC FeaturesECCP, MCPWM10 Bit High Speed ADCInternal ComparatorChange NotificationQuaduature Encoder Internal TMRs
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 46
Brushed DC Motor Design Flow Chart
VariableSpeedMotor?
Unidirectionalor Bi-directional
Control?
Open Loop orClosed Loop
Control?
SpeedControl?
PositionControl?
Any PIC MCU
No, On/OffControl Only
1 I/O Pin
Yes
No
1 H/W PWM orFirmware (plus 1-4 I/O Pins)
Bi-directional
Closed Loop Control
Open Loop
TachometerADC Input or
Interrupt
1 Shunt Resistor withOpAmp Circuits,or 1 Hall EffectTransducers1 ADC
Yes, FaultShut Down
OnlyTorqueControl?
No
Yes
QuadratureEncoder
Unidirectional
1 H/W PWM orFirmware
MCU orDiscreteSolution?Yes
Yes YesPotentiometerADC Input
QEI Module
ExternalLogic
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 47
Brushed DC Application Resources
The DC Motor Control Tips ‘n Tricks document has lots of information about driving brush DC motors.
DS41233
This app note provides C code for a position servomotor application. Two versions of the code are provided for the PIC16F877 device and PIC18C452, respectively. Position information is obtained from the motor using an incremental quadratureencoder and external decoding logic.
PIC18CXXX/PIC16CXXX DC ServomotorAN696
The PIC16F684 has the Enhanced Capture Compare PWM (ECCP) peripheral for driving a H bridge inverter. This makes the device an excellent choice for low-cost control of a brushed DC motor.
Low-cost Bi-directional Brushed DC Motor Control Using PIC16F684AN893
Start here if you would like to learn more about basic brush motor theory.
Brushed DC Motor FundamentalsAN905
Brushed DC
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 48
Brushless DC Motor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 49
What is Commutation?Revolving Electrical Field GenerationThis Rotating Field is synchronized to the rotor magnet to generate torqueContinuous Torque generation keeps the motor moving
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 50
Six Step for BLDCCommutation – six steps per electrical rev.Phase currents rectangularLess processing power requiredProduces more Torque than PMSMCreates more torque ripple
Rotor position unknown between commutationPosition Information Required
Hall sensors indicate commutation pointBack EMF zero cross for sensorless
Starting ramp tuning for BEMF signal
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 51
Six Step BLDC Control
+TORQUE FIRING
BR G
Q1 Q3Q2
Q4 Q6Q5Green Winding
Q1,Q5 Q1,Q6 Q2,Q6 Q2,Q4 Q3,Q4 Q3,Q5
60o
HALL A
HALL B
HALL C
Q1,Q5 Q1,Q6Q3,Q5
Sector 5
Hall State0 1 2
5 4 6 2
3
34
1
55
04
16
Blue Winding
Red Winding
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 52
Brushless DC Motor Energization
100
N
S
R
G
r
r
bb
g
gB
com
com
com
110
010
011
101
001
R
GB
N
S
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 53
Brushless DC DriveDesired PIC® MCU or
dsPIC® DSC FeaturesMCPWM Fault Shutdown10 Bit High Speed ADCInternal ComparatorChange NotificationQuaduature Encoder Internal TMRs
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 54
BLDC Application Resources
In this class we discuss how a 3-phase brushless motor operates, the drive circuitry required to commutate the motor, and methods for determining the motor position before it starts and as it rotates. Emphasis is on controlling the motor with a low cost PIC16Fxxx Mid-range microcontroller. Code development for motor startup, acceleration, and steady state operation is covered as are techniques for reducing torque ripple and regenerative breaking. Exciting live motor demonstrations are performed.
3-Phase Brushless Motor Control With Low Cost PIC16 Microcontrollers1255 TPM
Masters Class
This application note describes a sensorless BLDC application using the BEMF detection method.
Using the PIC18F2431 for Sensorless BLDC Motor Control AN970
This application note provides a basic solution for driving a BLDC motor with 3 hall sensors.
Brushless DC Motor Control Using PIC18FXX31AN899
This application note presents a software solution that can be implemented using a low-cost 8-bit microcontroller. The software provides sensorless motor commutation and open-loop speed control.
Sensorless Brushless DC Motor Control with PIC16AN1175
Low Cost BLDC Control Solutions
This application note provides a good overview of brushless DC motor characteristics and presents software solutions for the PIC16Fxxx family of devices.
Brushless DC Motor Control Made Easy AN857
If you are not familiar with how a brushless DC motor works, this is a good place to start.
Brushless DC Motor FundamentalsAN885
BLDC
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 55
Sensorless BLDCEliminate Hall-Effect sensors and cabling cost by going sensorless FIR Filtering of the BEMF and or using Majority Detect can help with high-speed
motors or motors with distorted BEMF signalsADC (or comparators) supports the sampling of the motor phase BEMF voltagesFrom the voltages, the CPU determines the rotor position and drives the motor
control PWM module
Phase R
Phase B
Phase G
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 56
BLDC Motor Design Flow Chart
2 Phase or3 PhaseMotor?
Open or ClosedLoop?
Sensored orSensorless
Control?
Analog or DigitalFeedback?
Torque Control?
Any PIC MCU orIntegrated Fan Controler
Firmware Commutation2 I/O Pins
3-Phase
No
Comparators,High Speed ADC,
Filters
PWM or Motor Control PWM,ADC Inputs, I/O Pins
Open LoopSpeed Control
Closed LoopControl
Sensored
Sensorless
MeasureBack EMF
3 Shunt Resistors with OpAmp Circuits,or 3 Hall Effect Transducers & ADC
Yes
Yes, FaultShut Down
Only
OpampsComparitors,I/O Interrupts
Analog
Digital
Speed orPositionControl?
6 I/O Pins2-3 ADC Inputs
PWM, Motor Control PWM,
No YesQuadrature Encoder
Timer, Input Capture,or Interrupt
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 57
Advanced BLDC Application Resources
This updated workshop class provides a detailed overview of BLDC motor theory and control algorithms. The class also provides anintroduction to the dsPIC30F/33F architecture, and motor control peripherals, along with an in depth look at the newest Microchip’s sensorless BLDC Motor Control application (AN1160) and Motor Control Graphical User Interface.
dsPIC® Digital Signal Controllers (DSC) Motor Control Workshop1256 MCW
Masters Class
This application note describes a sensorless BLDC motor control algorithm, implemented using the dsPIC® Digital Signal Controller (DSC). The algorithm works by the use of a majority function for digitally filtering the back-Electromotive Force (BEMF). Each phase of the motor is filtered to determine when to commutate the motor drive voltages. This control technique excludes the need for discrete, low-pass filtering hardware and off-chip comparators.
Sensorless BLDC Control with Back-EMF Filtering Using a Majority FunctionAN1160
This application note uses the dsPIC to operate a 3-phase BLDC motor without position sensors. The application samples the BEMF signals using the high-speed ADC converter and uses DSP filtering to pre-process the signals. This filtering minimizes external components. This application is optimized for high speed motor operation.
Sensorless BLDC Control With Back-EMF FilteringAN1083
For a version of this same application that is optimized for the 28-pin dsPIC30F2010 device, see AN992. This code would also work well with other 28-pin and 40-pin dsPIC30F motor control device variants.
Sensorless BLDC Code for 28-Pin dsPIC30F DevicesAN992
This application note describes a sensorless BLDC control application using the BEMF detection method. The dsPIC DSC ADC is used to detect the BEMF voltage. The application is written in C language for a dsPIC30F6010 or a dsPIC30F6010A device. The source code has parameters to adjust the open loop startup sequence and also the closed loop operation of the motor. A GUI is available in the MPLAB® IDE to help set the parameters. See GS005 for more information about the GUI.
Using the dsPIC30F for Sensorless BLDC ControlAN901
This application note describes a BLDC application using hall effect sensors for motor position feedback. The application source code is written in C and optimized for the dsPIC30F2010 and other 28-pin dsPIC® DSC variants.
Sensored BLDC Motor Control Using dsPIC30F2010AN957
Advanced BLDC Control Solutions
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 58
Permanent Magnet Synchronous Motor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 59
Sine PWM
VSI output is Sine modulated PWMMotor acts as a low pass filter Motor integrates PWM voltage to produce sine currentOutput voltage is proportional to frequency, maintaining constant V/fSpace Vector Modulation allows for 100% line to line modulation
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 60
Six Step Sine Control
Sine Phase
Green Winding
60 120 180 240 300 0
60 o
HALL A
HALL B
HALL C
60 1200
Sector 5Hall States
0 1 2
5 4 6 233
41
55
04
16
Blue Winding
Red Winding
R G
Q1 Q3Q2
Q4 Q6Q5B
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 61
FOC for PMSMV/F Sinusoidal drive produces smooth control at low speed but is inefficient at high speedsFOC provides smooth control at low speeds as well as efficient control at high speedsFOC provides the best of both worldsField Weakening
What happens when the Back EMF approaches the supply voltage?To enable more speed the rotor field must be weakenedThe stator d axis current is set to a negative valueTorque reduces and speed increases with field weakening
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 62
PMSM Operation
S
N
S
N
N
S
N S
θS
N
S
N
N
S
N S
90°
BEMF (V)
Current (I)
BEMF (V)
Current (I)
Without FOC With FOC
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 63
PMS Motor Energization
100
N
S
R
G
r
r
bb
g
gB
com
com
com
110
010
011
101
001
120600Sine Phase
Green Winding
60 120 180 240 300 0
Sector5Hall States
0 1 2
54 6 2
3
341
55
04
16
Blue Winding
Red Winding
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 64
PMSM CharacteristicsTorque/Current
Speed0
Continuous operation
Short time operation VSI voltage line
Demagnetization limit
VSI current/Torque limit
ωr
T0
ωmax
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 65
Permanent Magnet Synchronous Motor Driver
Desired PIC® MCU or dsPIC® DSC FeaturesMCPWM Fault Shutdown10 Bit High Speed ADCInternal ComparatorChange NotificationQuaduature Encoder Internal TMRsHigh Speed Math
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 66
FOC Sensorless PMSMTop of the line dynamic torque response and efficiency and the lowest system cost motor control solution ADC supports sampling the motor voltage and currentsDSP supports Clark and Park transformations transform and two PI loops controlling torque and fluxDSP supports speed and position PI loops as determined by an estimator motor model rotor position outputThe outputs of the PI loops are transformed using Space Vector Modulation to drive the MCPWM outputs to
the motor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 67
PMSM Application Resources
New dsPIC® DSC algorithm has been developed for Sensorless Field Oriented Control for Permanent Magnet Synchronous Motor (PMSM). This algorithm takes advantage of the processing power of the DSP engine present on dsPIC33F DSC.
Sensorless FOC for PMSM with dsPIC® Digital Signal Controller (DSC)1258 FOC
Masters Class
Active power factor correction is often used in electronic motor control applications to improve conversion efficiency. This application note describes a software solution that is designed to operate on Microchip’s motor control development system (P/N DM300021).
Power Factor Correction in Power Conversion Applications Using the dsPIC® DSCAN1106
This application is similar to AN1017, but eliminates the need for rotor position feedback sensors. An estimator algorithm calculates the position of the rotor from measured voltages and currents.
Sensorless Field Oriented Control of Permanent Magnet Synchronous MotorsAN1078
This application note uses a 28-pin dsPIC30F device and the PICDEM™ MCLV Development Board to control a PMSM with hall effect sensors. The application also features a speed control loop that allows 4-quadrant torque control.
Sinusoidal Control of PMSM Motors with dsPIC30F DSCAN1017
PMSM
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 68
AC Induction Motor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 69
AC Induction Motor
Simple Control for Direct On Line or ThyrisistordriveModerate control for Voltage/Frequency driveField Oriented/Vector Control
Smooth control at low speedsEfficient control at high speedsComplex control for variable speed and torque
Must know rotor position (velocity) for slip and vector controlRotor position sensor is eliminated for sensorless vector control strategiesSensorless control does not work at low motor speeds
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 70
Field Weakening
Ψ,U
Speed0Constant
Power Region
Constant Torque Region
ωr ωmax
Ψo
Uo
ACIM Characteristics
Voltage
Torque TmaxTmax
Vrated
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 71
AC Induction Motor DriveDesired PIC® MCU or
dsPIC® DSC FeaturesMCPWM Fault Shutdown10 Bit High Speed ADCInternal ComparatorChange NotificationQuaduature Encoder Internal TMRsHigh Speed Math
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 72
FOC Sensorless ACIMTop of the line dynamic torque response and efficiency and the lowest system cost motor control solution ADC supports sampling the motor voltage and currentsDSP supports Clark and Park transformations transform and two PI loops controlling torque and fluxDSP supports speed and position PI loops as determined by an estimator motor model rotor position outputThe outputs of the PI loops are transformed using Space Vector Modulation to drive the MCPWM outputs to
the motor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 73
AC Induction Motor Design Flow Chart
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 74
ACIM Application Resources
This is an introductory level document to teach the reader about variable speed ACIM control. It also provides simple assembly code example for the dsPIC® DSC that will control a single phase or 3-phase ACIM.
An Introduction to AC Induction Motor Control Using the dsPIC30F MCUAN984
Space Vector Modulation is a special PWM control technique that allows a higher peak voltage to be delivered to the motor from the inverter while producing sinusoidal motor currents. AN955 describes the theory of Space Vector Modulation and presents an assembly code example for the PIC18F architecture.
VF Control of 3-Phase Induction Motor Using Space Vector ModulationAN955
This app note provides a control solution for a 3-phase ACIM using the PIC18Fxx31 series of microcontrollers. These are the preferred devices for ACIM control in the PIC18F family since they have a specialized motor control PWM peripheral that can drive a 3-phase inverter with a minimum amount of external hardware and minimal software overhead.
VF Control of 3-Phase AC Induction Motors Using the PIC18F4431AN900
The PIC16F7x7 series of devices are a good choice for low cost 3-phase ACIM control since they have 3 PWM generators.
VF Control of 3-Phase Induction Motors Using PIC16F7X7 MicrocontrollersAN889
The PIC16F72 provides a low cost solution for variable speed control of a single phase ACIM.
Bi-directional VF Control of Single and 3-Phase Induction Motors Using the PIC16F72AN967
As the name suggests, this app note will teach you the basics of how AC induction motors work.
AC Induction Motor FundamentalsAN887
ACIM
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 75
ACIM Application Resources(Continued)
The dsPIC® DSC family of devices offers DSP performance and peripherals that are well matched for advanced motor control algorithms. This class starts with an introduction to the characteristics of the AC induction motor. An overview of electronic control methods is provided from a historical perspective. Finally, the theory and benefits of Sensorless Field Oriented Control (FOC) are explained. A demo of the Sensorless FOC algorithm will be shown in the class. Hands-on exercises will allow you to experiment with the basic and advanced control methods described in this class.
Sensorless FOC for ACIM with dsPIC® Digital Signal Controller (DSC) 1257 ACI
Masters Class
Active power factor correction is often used in electronic motor control applications to improve conversion efficiency. This application note describes a software solution that is designed to operate on Microchip’s motor control development system (P/N DM300021).
Power Factor Correction in Power Conversion Applications Using the dsPIC® DSCAN1106
This application note presents a solution for sensorless Field Oriented Control (FOC) of induction motors using a dsPIC® Digital Signal Controller (DSC). Position and speed of the motor are estimated using software PLL.
Sensorless Field Oriented Control (FOC) of an AC Induction MotorAN1162A
This app note shows a high-performance control solution for an ACIM. Motor current and velocity are sensed and regulated using a closed-loop control system.
Using the dsPIC30F for Vector Control of an AC Induction MotorAN908
ACIM
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 76
Motor Control Algorithms
Lower NoiseSensored (Hall Effect) (Sinusoidal/180º)BLDC/PMSM
Highest EfficiencyBest Torque
Control
Sensorless (requires advanced tuning)- FOC with single or dual shunt circuits
PMSM
Lower CostSensorless (requires moderate tuning) (Trapezoidal/120º)- Back EMF with A/D- FIR filtered BEMF with A/D- FIR filtered BEMF with A/D and Majority Detect function
BLDC
Better TorqueControl
Sensored (Hall Effect) (Trapezoidal/120º)- High speed operation (5 to 20K RPM)- Rapid load changes requiring fast torque response- Fast or high accuracy on a servo position response
BLDC
Better ControlClosed Loop- Sensored (QEI)- Sensorless FOC (Vector Control/180º) with
single/dual shunts
3-phase ACIM
Low CostOpen Loop (V/F) with variable speed3-phase ACIM
BenefitsControl TechniqueMotor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 77
* dsPIC30F Application Notes or demo code available
** ACIM Sinewave tables stored in program Flash memory ***Depends on motor speed and A/D sampling speed
MCU Requirements
10K Bytes FLASH 256 Bytes RAM
5 -15***
9Back EMF (ADC)LowMedium-HighSensorless Commutation optional current or speed loops
26Back EMF (with external comparators)
Low-Medium
Medium-HighSensorless Commutation
0.51.5-23-Positions (Input Capture)MediumLowCommutation with Hall Effect Sensors
BLDC Motors
252-Phase Currents (ADC) 3-Phase Voltages (ADC)
MediumMedium-HighSensorless Vector Control
7.25 K Bytes FLASH 244 Bytes SRAM*
9Speed (QEI) 2-Phase Currents (ADC)
HighHighVector Control*
610Speed (QEI) 2-Phase Currents (ADC)
HighMediumSlip Frequency Control
57.5Speed (QEI) Bus Current (ADC)
Low-Medium
Low-MediumSlip Optimization
34.5Speed (QEI)LowLowSlip Limit (V/F)
<2 K Bytes Flash 32 Bytes SRAM**
23NoneLowLowVolts/Frequency*
ACIM Motors
dsPIC DSC resources
dsPIC DSC®MIPS
PIC18 MIPS
Sensing RequirementsRelative Cost
Relative Performance
Algorithm Type
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 78
Stepper Motor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 79
Stepping the Motor
Different step modes produce different step angles
Full Step Half Step Microstep
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 80
Microstepping
Increases Step ResolutionDivides a Full Step into sub-steps
Smoother transitions between stepsLimits noiseReduces anti-resonance problems
Maximum torqueLow step ratesHigh step rates
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 81
Microsteps vs. Step Rate
Increasing microsteps will require an increase in step rate
To produce same RPM as Full Step
Step Rate x 32Full Step/32
Step Rate x 16Full Step/16
Step Rate x 8Full Step/ 8
Step Rate x 4Full Step/ 4
Step Rate Factor for Equivalent Full Step RPM
Number of Microsteps
Number of microsteps can be > 32 Practically stepper performance isn’t improved
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 82
Microstep Look-Up Table
100%100%+Sin 90°+115
95.6%100%+Sin 73.1°+11298%100%+Sin 78.75°+113
99.5%100%+Sin 84.35°+114
93%100%+Sin 67.5°+11188%100%+Sin 61.8°+11083%100%+Sin 56.25°+1977%100%+Sin 50.6°+1871%100%+Sin 45°+1763%100%+Sin 39°+1656%100%+Sin 33.75°+1547%100%+Sin 28°+1438%100%+Sin 22.5°+1329%100%+Sin 16.8°+1220%100%+Sin 11.25°+119.8%100%+Sin 5.6°+10
PWM2DC
PWM1 DC
Winding B(current)
Winding A(current)
Microstep
90°/16 Steps= 5.625°/Step
Sin 5.6°= 0.098or
9.8% Duty Cycle
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 83
Microstepping SummaryGradual current change from one winding to anotherImplemented using variable DC PWMRequires more processing powerCode utilizes a LUT based on Sine functionSignificantly reduces anti-resonances
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 84
Stepper Motor DriverDesired PIC® MCU or
dsPIC® DSC FeaturesCCP, ECCP,MCPWM 10 Bit High Speed ADCInternal ComparatorChange NotificationQuaduature Encoder Internal TMRs
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 85
Stepper Motor Design Flow Chart
Motor Phases?
Micro-Stepping(Half-Stepping)
2 Phase (Bi-polar)1 Phase (Uni-polar)
Commutation2 PWMs or Firmware2 H Bridges
Commutation1 PWM/Phase or Firmware1 0r 2 N-FET Driver/Phase
NoFull SteppingMicro-Stepping
(Half Stepping)8 I/O Pins
Yes Yes
Any PIC MCU ordsPIC DSC
1 or 2 I/O Pins/Phase
NoFull Stepping
Any PIC MCU ordsPIC DSC
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 86
Stepper Application Resources
This class is an introduction into stepper motors, how they work, and how to use them in your designs. The anatomy and functional characteristics of the stepper motor will be discussed, along with common drive topologies, basic control circuits and some basic current limiting configurations. In addition, resonant and anti resonant behavior, its root cause, and techniques for dealing with it, will also be discussed. Demonstrations will be used to reinforce topics covered
Stepping Into Stepper Motors1254 STM
Masters Class
Microstepping a stepper motor increases stepping accuracy and reduces resonance in the motor. The two PWMs in the PIC18C452 can be used to control the voltage to the windings of a bipolar stepper motor.
Stepper Motor Microstepping with PIC18C452AN822
If you are not familiar with how a Stepper motor works, this is a good place to start. This application note covers different types of stepping motors: variable reluctance, permanent magnet and hybrid. Single-stepping, halfstepping, microstepping and current limiting.
Stepping Motor FundamentalsAN907
This application note describes how to drive a bipolar stepping motor with the PIC16F684. The Enhanced Capture Compare PWM (ECCP) module is used to implement a microsteppingtechnique known as hightorque microstepping.
Stepper Motor Control using the PIC16F684AN906
Stepper
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 87
Motor Control Development Tools
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 88
Low-Cost BLDC/PMSMHardware Development Tools
The PICDEM™ dsPIC30F MCLV development board (DM183021) is intended for low-voltage (up to 48V), BLDC applications up to 48 Volts at 1 Amp. It provides a low-cost method for users to evaluate and develop motor control applications using 28-pin dsPIC30F motor control products.
The PICDEM dsPIC33F MCLV development board (DM330021) is intended for low-voltage BLDC applications up to 48 Volts at 10 Amps. It provides a low-cost method for users to evaluate and develop motor control applications using dsPIC30F or dsPIC33F motor control products via a PIM or 28-pin SOIC socket. Serial interfaces include: RS232C, CAN, LIN and USB (for RTDM). Feedback support includes: Hall-Effect Sensors, Shaft Encoder and 3 shunt resistors.
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 89
Advanced Motor Control Development System
• Our advanced motor control development systems use a modular approach. Start with either the dsPIC30F MC1 development board or the dsPIC33F Explorer 16 development board with PICtail™ Plus Motor Control Interface board. Then add either the High- or Low-Voltage Power Module and optionally a BLDC or ACIM motor.
• Shown here is the system for dsPIC33F based development, using the Explorer16, the PICtail Plus Motor Control Interface Board, the Low-Voltage Power Module and a BLDC motor (Part #AC300020)
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 90
Data Monitor and Control Interface
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 91
SummaryToday we covered:
The characteristics, features and, applications of the most popular electric motor types including:
DC Brush MotorDC Brushless MotorPermanent Magnet SynchronousAC Induction MotorStepper MotorSwitched Reluctance Motor
The control algorithms and resources available
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 92
Microchip Improves Motor Efficiency
DSP Resource On-ChipNoise Profile Diagnostics
Free SoftwareMigrate from Brushed to Brushless Motors
Improve Reliability
Multiple S&H ADCBetter Loop Response
Free SoftwareIncorporate Field Oriented ControlBetter Torque Control
1% Internal OscillatorRemove Crystal
Optimized Feature SetEasily Migrate to other DSC’s in Portfolio
6 x 6 mm small packagesIntegrate controller on motorCost Reduction
PWM with 2 Time basesIntegrate PFC + Motor Control
Free Software, 4 S&H ADCRemove Expensive Sensors
Free SoftwareIncorporate Sinusoidal ControlNoise Reduction
Free SoftwareIncorporate Field-Oriented Control
PWM with 2 Time basesAdd Power Factor CorrectionEnergy Savings
Microchip has the solution!MethodNeed
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 93
• For resources and information for motor-control applications, visit Microchip’s Motor Control Design Center at: www.microchip.com/motor• Microchip Application Notes for Motor-Control Applications:
Using the dsPIC30F for Sensorless BLDC Control AN901Using the dsPIC30F for Vector Control of an ACIM AN908Sensored BLDC Motor Control Using dsPIC30F2010 AN957An Introduction to ACIM Control Using the dsPIC30F AN984Using the dsPIC30F2010 for Sensorless BLDC Control AN992Sinusoidal Control of PMSM Motors with dsPIC30F AN1017Sensorless FOC for PMSM using dsPIC AN1078Sensorless BLDC using BEMF IIR Filtering AN1083Sensorless BLDC Control with Back-EMF Filtering AN1160Using a Majority FunctionGetting Started with the BLDC Motors and dsPIC30F GS001Measuring Speed and Position with the QEI Module GS002Driving ACIM with the dsPIC® DSC MCPWM Module GS004Using the dsPIC30F Sensorless Motor Tuning Interface GS005
Resources
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 94
Microchip Motor Control Web Site
• For more information, check out the Microchip Motor Control web site at http://www.microchip.com/motors
• Investigate applications by motor type
• Download a web seminar
• Sign up for a training class
• Get answers to technical questions
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 95
ReferencesFitzgerald, Kingley, Kusko, Electric Machinery, 1971, McGraw Hill R. Krishnan, Electric Motor Drives, 2001, Prentice HallDC Motors, Speed Controls, and Servo Systems, 1980 Electrocraft CorporationNovotny, Lipo, Vector Control and Dynamics of AC Drives, 2003, Oxford PressBose, Modern Power Electronics and AC Drives, 2002, Prentice HallHanselman, Duane C., Brushless Permanent-Magnet Motor Design, 1994, McGraw-Hill
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 96
Thank You for Attending!
© 2008 Microchip Technology Incorporated. All Rights Reserved. Class Title Slide 97
1253 IMC
Appendix
© 2008 Microchip Technology Incorporated. All Rights Reserved. Class Title Slide 98
1253 IMC
Motor Interface/Driver
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 99
Position Sensing
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 100
ResolverHigher Resolution. (i.e. 1024 Different States per Rev)A/D Module + Processing PowerResolver Externally Mounted (More Expensive)Provides Absolute position feedback Cosine
Sine
Resolver Output
Rotor Angular Position
0º
180º
360º
Sensing Position of a BLDC
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 101
Optical EncoderHigh Resolution. (i.e. 500 Interrupts per Rev)Special QEI Module + Some MathOptical Encoder Externally Mounted (Expensive)Useful for servo applications due to resolution
INDEX
QEB
QEA
0º
180º
360º
Optical Encoder Output
Rotor Angular Position
Sensing Position of a BLDC
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 102
Hall EffectLow Resolution (i.e. 30 Interrupts per Rev)Simple External Interrupt I/Os1 to 3 Hall effect sensors (Less Expensive)Standard position sensing for low-cost applications
Hall A
0º
180º
360º
Hall B
Hall C
Hall Effect Sensors
Rotor Angular Position
Sensing Position of a BLDC
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 103
Position Sensing InterfaceQEI Module senses motor speed and positionThree Input Quadrature Encoder
Phase APhase BINDEX signals
16-bit position counterChange NotificationInput Capture
3-phInverter
VBUS
AN6AN0QEAQEB
INDEX
AN7
PWM3HPWM3LPWM2HPWM2LPWM1HPWM1L
FLTA Fault
IBUSAN1
120 - 240VAC
BLDC Motor
IncrementalEncoder
PIC
®M
CU
or d
sPIC
®D
SC
Rectifier
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 104
Sensorless Position Detection
Reliability – especially aerospace, militaryPhysical space restrictions – axial lengthIssues surrounding sealing of connectionsApplications where rotor runs “flooded”Manufacturability – alignment and duty cycle toleranceCost – especially on low power systems
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 105
What is BEMF?When a DC motor spins, the PM rotor, moving past the stator coils induces a electrical potential in the coils called Back EMFBEMF is directly proportional to speedBEMF = RPM/KvIn order to sense BEMF we have to spin the motor
BEMF
Motor
R L
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 106
BEMF Motor Speed Sensing
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 107
BLDC Motor Back EMF
A
C B
DC+
DC-
Back EMF
Phase A and C are energizedInactive Phase B has induced Back EMFNormally the phase which is not energized, is monitored for Back EMFImportant: Motor has to be spinning
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 108
Comparing the BEMF Voltage to Half the DC Bus Voltage
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 109
Comparator ModuleDual comparators with fast 20 ns response timeEach comparator has 3 selectable inputs (Cx+, Cx-and voltage reference) for its two pinsProgrammable voltage reference (16 stage resistor ladder network and dual voltage ranges)Programmable output polarityOptional output pin and interrupt on changeOptional wake up from Sleep Mode
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 110
Current Sensing
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 111
Resistive Low Side Current Sensing
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 112
Resistive High Side Current Sensing
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 113
Magnetic Current Sensing
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 114
ADC ModuleUp to 16 analog inputs (up to 32 on dsPIC33E) 10-bit Resolution with < +1 LSB/ > -1 LSB DNL error (dsPIC30E)10-bit/12-bit Resolution with < +1 LSB/ > -1 LSB DNL error (dsPIC33F/33E)Sample time - 154 nS1 us conversion time (1.1 Msps) 10-bit mode2 us conversion time (500 ksps) 12-bit mode4 Sample and Hold circuits 10-bit mode (1 S&H in 12-bit mode)External VREF+ and VREF-Programmable sampling sequence
16-sample, dual-ported result bufferScan modeAlternate sample mode
Multiple conversion trigger sourcesSelectable result formatsConversions in Sleep and Idle
3-phInverter
VBUS
AN6AN0QEAQEB
INDEX
AN7
PWM3HPWM3LPWM2HPWM2LPWM1HPWM1L
FLTA Fault
IBUSAN1
BLDC Motor
IncrementalEncoder
PIC
®M
CU
or d
sPIC
®D
SC
120 - 240VAC
Rectifier
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 115
Motor Driver or Inverter
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 116
High Frequency CarrierDuty Cycle Varied Over Time to Generate a Lower Frequency Signal
+V
PWM1H
PWM1L
3 PhaseBLDC
PWM2H
PWM2L
PWM3H
PWM3L
PWM with Inverter
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 117
Motor Control PWM ModulePWM Module drives motorUp to Four PWM generatorsSeveral options allow PWM to drive many circuit types
AC MotorsDC motorsPower supplies
High frequency @ more bits = better control of motor operationFault detection for safe operation
3-phInverter
VBUS
AN6AN0QEAQEB
INDEX
AN7
PWM3HPWM3LPWM2HPWM2LPWM1HPWM1L
FLTA Fault
IBUSAN1
BLDC Motor
IncrementalEncoder
PIC
®M
CU
or d
sPIC
®D
SC
120 - 240VAC
Rectifier
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 118
Transistor Considerations
Winding
Vsupply
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 119
Transistor Considerations
Winding
Vsupply
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 120
Transistor Considerations
Winding
Vsupply
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 121
Transistor Considerations
Winding
Vsupply
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 122
Transistor Considerations
Winding
Vsupply
P-Channel
N-Channel
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 123
Transistor Considerations
Winding
Vsupply
N-Channel
N-Channel
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 124
Other Considerations
Choosing a Power Switching Element:Based on applicationMotor specifications
VoltageCurrentPower ratings
Current limiting required if driving the motor at higher than rated voltages
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 125
Selecting The Inverter SwitchElement
PLOSS = Irms * 2 * RDS-ON
where:RDS-ON = drain-to-source
on-state resistanceIrms = drain-to-source rms current
PLOSS = Iave * VCE-SAT
Where:VCE-SAT = collector-to-emitter
saturation voltageIave = collector-to-emitter average current
MOSFETMOSFET IGBTIGBT
NN--ChannelChannel NN--ChannelChannel
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 126
Gate Charge
Vdrv CGS
Rdrv
on
off
turn-on turn-off
t1 t2t3
t1t2t3
VthVpl
VDR
VGS
VDS
IG
0
0
0
2 2 Crss(VDS(t)- VDS(t-1))
2Ciss(VDR)
2PDRIVE - +[ ]fSW
The gate drive current must not only overcome the Ciss=Cgs+Cds, but also the energy injected into the gate from the Crss = Cds.
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 127
MOSFET or IGBTMOSFETs for application voltages < 250V
The selection of IGBTs with rated voltages below 600V is very small.
IGBTs for application voltages > 1000VAs the voltage rating of the MOSFET increases, so does the RDS-ON and size of the device. Above 1000V, the RDS-ON of the MOSFET can no longer compete with the saturated junction of the IGBT.
Application-specific between the 250V and 1000V Factors power dissipation, switching frequency and cost of the device.
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 128
Hints for Design and De-rating
Voltage rating of the device is de-rated to 80% of its valueThe maximum junction temperature of the device should not exceed 120ºC at maximum load and maximum ambientMinimize trace inductance going to the leads of the motor from the drive circuitryThe current rating for the switching element must also be able to withstand short circuit and start-up conditions
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 129
Gate Driver Functions
Minimizes turn-on and off timesProvides power to keep the power switch onProvides reverse bias in order to ensure the switching device remains in the off-stateAmplifies the control signalProvides protection from over current
Feedback would be requiredProvides a large current for initiating turn-on, then large gate voltage at low current levels for the duration of the turn-on periodMay provide electrical isolation where requiredMay provide deadtime (blanking time)
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 130
High Voltage FloatingMOS Gate Driver
Block Diagram
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 131
Gate Drive Requirements Of High-side Devices
Gate voltage must be 10 V to 15 V higher than the drain voltageThe gate voltage must be controllable from the logic, which is normally referenced to ground The power absorbed by the gate drive circuitry should not significantly affect the overall efficiency
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 132
Power Dissipation in a HVICLow voltage static losses (PD,q(LV)) are due to the quiescent currents from the low voltage supplies
(e.g., VDD, VCC and VSS). In a typical 15 V application these losses amount to approximately 3.5 mW at 25°C and increase to approximately 5 mW at TJ = 125°C
Low voltage dynamic losses (PD,SW(LV)) on the VCC supply are due to
Capacitor is charging or discharging through a resistor, half of the energy that goes into charging the capacitance is dissipated in the resistorDynamic losses associated with the switching of the internal CMOS circuitry
High voltage static losses (PD,Q(HV)) are mainly due to the leakage currents in the level shifting stage.High voltage switching losses (PD,SW(HV))
Due to the level shifting circuitDue to the charging and discharging of the capacitance of the high-side p-well
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 133
High Voltage Integrated Circuits
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 134
High Voltage Integrated Motor Drivers
Configurable phase commutation delay
Current monitoring
Miniature TSSOP20
PWM output to drive H-bridgeVariable or fixed speed control of single-phase brushless dc fans, blowers and pumps
ZXBM1015 single-phase motor predriver
Zetex Semi-conductors
Phase sequence generator
PWM controllerSmart motor drivers6208/6228/ 6235/6229
Dual DMOS full bridge6226/6207/ 6227/
PowerDIP24, PowerSO36 and SO24
Two-phase stepper motor driver has:
Dual dc or bipolar stepper motors and BLDC motors
L6205/6225/6206/STMicro-electronics
600-V ac 3-phase systems2114SS/21141SS
(IR21381Q /2177S/21771S/
400-V ac 3-phase systems
1200-V rating on current-sensing ICs
BLDC and ac motor drives2214SS/22141SS
64-lead MQFP,16-lead SOIC, and 24-lead SSOP
1200-V IGBT gate driver ICs protect against ground faults, shoot-through, and short to supply rails
AC induction motor drives up to 15 hp
IR22381Q /2277S/22771S/
International Rectifier
Needs no heatsink for motor drives up to 180 W
11-pin mini SIPHalf-bridge FredFET with gate driver
Two- and three-phase half-bridge inverter motor drives for ac induction and BLDC motors
IR3103 motor drive ICInternational Rectifier
29 mm × 12 mm, 23-lead Tiny-DIP
Modules combine six fast-recovery MOSFETs and three half-bridge, high-voltage ICs
BLDC motors in home appliances (below 100 W)
FSB50250 and FSB50450 Motion-Smart Power Modules
Fairchild Semi-conductor
PackageFeaturesApplicationsModelVendor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 135
Power Electronics Gate Drive Stages
Fault detection circuitry
Conditioning of Feedback Signals
Optocouplers Drive Isolated Hall-EffectCurrent Transducer
Signals from/to dsPIC® DSC
Fault signals
Currents measured
IsolatedSwitchingSignals
Switchingsignals
Phase voltagesPhase voltages
Isolated Three Phase Inverter
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 136
Driver Application Resources
Driving ACIM with the dsPIC® DSC MCPWM ModuleGS004
Measuring Speed and Position with the QEI Module GS002
The DC Motor Control Tips ‘n Tricks document has lots of information about driving brush DC motors.
DS41233
Electronic motor control for various types of motors represents one of the main applications for MOSFET drivers today. This application note discusses some of the fundamental concepts needed to obtain the proper MOSFET driver for your application.
Determining MOSFET Driver Needs for Motor Drive ApplicationsAN898a
Sensors are a critical component in a motor control system. They are used to sense the current, position, speed and direction of the rotating motor. In most motor control systems, several sensors are used to provide feedback information on the motor. These sensors are used in the control loop and to improve the reliability by detecting fault conditions that may damage the motor.
Motor Control Sensor Feedback CircuitsAN894
Motor Interface/Driver
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 137
Motor Control Vocabulary
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 138
Motor Control VocabularyMost Commonly found Motor Types
DC BrushDC BrushlessPMSMAC inductionStepper MotorSwitched Reluctance
General Functions for Motor ControlTimerAnalog to Digital ConverterPulse Width Modulation
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 139
Motor Control Vocabulary
Electricity BasicsAC is Alternating Current
Think of the wall socketIt is how electricity is generated!Motor is a reverse of a generator!
DC is Direct CurrentThink of a batteryArmature is energized in a DC motor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 140
Motor Control Vocabulary
Motor Structure Armature
Device that turns in a motorSometimes called “rotor”Energized in a DC motor
StatorThe “outside” caseEnergized in an AC motor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 141
Motor Control Vocabulary
Motor Structure (continued)Commutator
Only found in DC motorsPermits generation of direct current in a rotating machine
TorqueApplication of force“Think of turning a bolt”
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 142
Motor Control Vocabulary
Motor Structure (continued)Poles
AC Induction motorNumber of magnetic on poles stator winding See Synchronous speed
PMS MotorNumber of PM poles on the rotorMechanical vs. Electrical revolutions
Brush DC MotorStronger magnetic field (torque)Poles do not determine speed
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 143
Motor Control Vocabulary
Torque RippleVariation in torque (Commutation)Expressed as a percentage of torque
SlipRotor unable keep up with stator fieldCaused by load
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 144
Motor Control Vocabulary
Field WeakeningDecrease strength of the magnetic fieldIncreases motor speedDecreases torque
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 145
Motor Control Vocabulary
InverterElectronic deviceConverts fixed frequency and fixed voltages to variable frequency and voltageElectronic speed control of an AC motor
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 146
Motor Control Vocabulary
Synchronous Speed (ACIM)Speed of the rotating magnetic field in stator winding Rotor moves with the rotating stator fieldSpeed = 120 * freq
Poles
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 147
Motor Control Vocabulary
Electrical Revolution (BLDC)Rotor moves with the rotating stator fieldSix Steps per Rotor pole pairElectrical RPS = Mechanical RPS
Rotor Pole Pairs
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 148
Motor Control Vocabulary
DynamometerCalibrated dynamic loadMeasures motor
Output torque Speed Efficiency
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 149
Motor Control Vocabulary
Open Loop ControlNo feedback – basic control suitable for systems with simple loads such as fansTimer based solutionMay have current sense for overload / stall conditions
Closed loop controlPosition / speed feedback from sensor(s)Used for accurate speed and control
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 150
Motor Control Vocabulary
Two Types of Closed loop control
With SensorHall Effect, Resolvers, QuadratureEncoders
Without Sensor (“sensorless”)Measures the current flowing in the motor
Measure back EMF for motors with magnetsMeasure inductance (L) in switched reluctance motors
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 151
Motor Control VocabularyEmbedded Control Algorithms (examples)
More complex than using timersEmployed in closed loop systems
PI - Proportional IntegrativePID - Proportional Integrative DifferentialAlgorithms require
MeasurementCalculationControl
Requires microcontroller performance
© 2008 Microchip Technology Incorporated. All Rights Reserved. 1253 IMC Slide 152
TrademarksThe Microchip name and logo, the Microchip logo, Accuron, dsPIC, KeeLoq, KeeLoq logo, MPLAB, PIC, PICmicro, PICSTART, PRO MATE, rfPIC and SmartShunt are registered trademarks of Microchip Technology Incorporated in the U.S.A. and other countries.FilterLab, Linear Active Thermistor, MXDEV, MXLAB, SEEVAL, SmartSensorand The Embedded Control Solutions Company are registered trademarks of Microchip Technology Incorporated in the U.S.A.Analog-for-the-Digital Age, Application Maestro, CodeGuard, dsPICDEM, dsPICDEM.net, dsPICworks, dsSPEAK, ECAN, ECONOMONITOR, FanSense, In-Circuit Serial Programming, ICSP, ICEPIC, Mindi, MiWi, MPASM, MPLAB Certified logo, MPLIB, MPLINK, mTouch, PICkit, PICDEM, PICDEM.net, PICtail, PIC32 logo, PowerCal, PowerInfo, PowerMate, PowerTool, REAL ICE, rfLAB, Select Mode, Total Endurance, UNI/O, WiperLock and ZENA are trademarks of Microchip Technology Incorporated in the U.S.A. and other countries.SQTP is a service mark of Microchip Technology Incorporated in the U.S.A.All other trademarks mentioned herein are property of their respective companies.© 2008, Microchip Technology Incorporated. All Rights Reserved.