Miniaturizzazione del controllo motore in alta tensione

Transcription

1 Miniaturizzazione del controllo motore in alta tensione Stefano Ruzza Technical Marketing and Application Engineer

2 Summary imotion 2.0: concept idea and Roadmap Aim of the study: Define and test an algorithm that reduces the acoustic noise of dishwasher and washing machine when outlet water pipe is empty Activities and Results: Pump characterization Defined an algorithm: able to automatically tell between normal condition of operation (suction pipe completely full of water) and particular condition of operation (suction pipe partially empty or completely empty) able to reduce the acoustic noise emitted by the system in these conditions IMM101T-015M thermal characterization of the inverter used to drive the pump motor.

3 What s imotion? imotion Solution Platform Dedicated to Motor Control established in 2006 >30 productive parts High Volume Production Target Applications

4 imotion - Scalable integration of HW and SW MCE 2.0 or & Cortex M0 imotion Controller MCE 2.0 FOC algorithm allows reliable and smooth operation at wide speed ranges. optionally with MCU Cortex M0 allowing customer specific application code imotion SmartDriver Controller + Gate Driver Higher level of integration with flexibility on power stage Market leading 3-phase gate driver Offered with MCE or MCU - turnkey or programmable imotion SmartIPM Controller + Gate Driver + Power MOSFETs or IGBTs Full inverter system in one compact package Offered with MCE or MCU - turnkey or programmable

5 IMC imotion Controller IMD imotion Driver IMM / IMI imotion Smart IPM s imotion - Portfolio and Roadmap QFN32/QFP48/QFP64 IRMC1xx Series Controller Sensorless FOC with optional Boost PFC Turnkey Core Released QFN32 IRMCK099 Turnkey Sensor less FOC Controller Released TSSOP38/QFN48/QFP64 IMC100T Series Single Motor + PFC Controller Sensored / Sensor less FOC Boost + Totem Pole PFC Firmware included Released IMC300A Series QFP64 Single Motor + PFC Controller + Cortex M0 Sensored / Sensor less FOC Boost + Totem Pole PFC Firmware included In Development imotion 2.0 products support functional safety acc. to IEC ( Class B ) CIPOS -Nano IMM001T Series Turnkey Inverter for Single Motor Control Sensor less FOC 6Ohm/500V 1,7Ohm/500V Released CIPOS -Nano IMM100 Series Turnkey or Cortex M0 based Inverter for Motor Control + PFC Sensored / Sensorless FOC Boost PFC Controller 6Ohm/500V 1,4Ohm/600V 0,95Ohm/600V QFP40 IMD110-6 Series Turnkey or Cortex M0 based Motor Controller & 600V Gate Driver for Motor Control + PFC Controller Sensored / Sensorless FOC Boost/Totem Pole PFC In Development In Development 2Q18 3Q18 4Q18 1Q19 2Q19

6 Analog/Digital I/O s Communication imotion Smart IPM Full inverter in a package Rectifier PFC Power Supply 15V / 3,3V MCE2.0 Or CORTEX TM M imotion Smart IPM Benefits Full Inverter System in one Package Multiple Power Stage Options available A- Version: High flexibility Standard Cortex -M0 for customer implementations T-Version: Easy to use with MCE 2.0 (Motion Control Engine) T-Version: Boost PFC algorithm integrated (optional) Reduced System Cost by reducing BOM count and PCB size

7 imotion IMM100 Smart IPM Portfolio Series Device Part number Package Controller Power Class Program Memory Sensorless FOC Hall inputs Boost PFC IMM100A IMM100A-015M QFN12x12 Cortex -M0 1A/500V 128k IMM100A-046M QFN12x12 Cortex -M0 4A/600V 128k IMM100A-056M QFN12x12 Cortex -M0 5A/600V 128k Function depends on customer application software IMM101T-015M QFN12x12 MCE 2.0 1A/500V - 2/3 IMM100 IMM101T IMM101T-046M QFN12x12 MCE 2.0 4A/600V - 2/3 IMM101T-056M QFN12x12 MCE 2.0 4A/600V (LF optim) - 2/3 IMM102T-015M QFN12x12 MCE 2.0 1A/500V - 2/3 IMM102T IMM102T-046M QFN12x12 MCE 2.0 4A/600V - 2/3 IMM102T-056M QFN12x12 MCE 2.0 5A/600V (LF optim) - 2/3

8 DishWasher (and Washer) noise The dishwasher is an appliance used in the living room Acoustic Noise is important factor for marketing Several discussion forums on how to get the quietest Dishwasher

9 Setup Description The thermal characterization has been done on the IMM100-EVAL- R1.0 board: In particular, the study has been done on two boards: IMM100-EVAL-R1.0 => MOSFETs with R DSon =1,4 Ω at 25 C; IMM100-EVAL-R1.0 => MOSFETs with R DSon =6 Ω at 25 C.

10 Pump Characterization The centrifugal pump is moved by a permanent magnet surface mounted sinusoidal brushless motor. The motor is characterized by a power absorption of 25 W at a rotational speed of 3000 rpm. The motor is characterized by the following parameters: Measured Quantity Value Used Instrument R phase [Ω] 44,63 Fluke Multimeter L d-phase [mh] 105,17 Fluke PM6307 L q-phase [mh] 105,17 Fluke PM6307 Poli 2 K bemf [V/krpm] 8,88 Tektronix DPO 4140 Oscilloscope Tektronix DPO 4140 Oscilloscope

11 Setup Description Suction tank Flow tank Removing the boxes under the suction tank, it is possible to vary the drop between suction and flow. Considered drops are: 20 cm, 40 cm and 100 cm. Centrifugal pump restricted Copyright Infineon Technologies AG All rights reserved. 11

12 Phase current in normal operating conditions I U, 200 ma/div I U, 200 ma/div 1000 rpm 2000 rpm I U, 200 ma/div Note: The suction pipe is full of water and the drop is equal to 20 cm rpm 12

13 Reconstructed iq in normal operating conditions 1000 rpm 2000 rpm Note: The suction pipe is full of water and the drop is equal to 20 cm rpm

14 Phase current in particular conditions of operation In the following pictures, the rotational speed is kept constant and equal to 3000 rpm. Partially empty suction pipe Completely empty suction pipe I U, 200 ma/div I U, 200 ma/div

15 Reconstructed iq in particular conditions of operation In the following pictures, the rotational speed is kept constant and equal to 3000 rpm. Partially empty suction pipe Completely empty suction pipe restricted Copyright Infineon Technologies AG All rights reserved. 15

16 iq [cts] Transition from full suction pipe to empty suction pipe From the previous pictures, it is possible to see that the iq reconstructed current is an important variable to detect the condition of operation of the system. So this variable is used to study the transition from full to empty suction pipe Transition Comparison, i q During the transition, the speed is kept constant and equal to 3000 rpm. h =20 cm h=40 cm h=100 cm Trigger Level t [ms] It is possible to identify a unique value of the iq current which allows to detect the transition between normal and particular conditions of operation independently from the drop. 16

17 Acoustic Noise [db] Acoustic noise generated by the system When the system works in particular conditions of operation, it is possible to measure an increase of the acoustic noise: Acoustic Noise [db] Transition from full to empty suction pipe. 0 Number of point A solution to eliminate acoustic noise is to stop the system when the transition between the two conditions of operation is detected. Another studied strategy is to reduce the rotational speed of the motor until the suction pipe is full of water again. 17

18 Water Flow [l/min] iq [cts] iq [cts] iq [cts] Transition from empty to full suction pipe i The minimum speed of the system has to be chose q transition from empty to full, h=20 cm, 1500 rpm properly in order to allow the 600 pump to elaborate the fluid when the suction pipe 590is full again. It is possible to refer to the following experimental curves: 580 6,5 6 5,5 5 4,5 4 3,5 3 2,5 2 1,5 1 0,5 0 Water flow vs rotational speed Rotational Speed [rpm] h=20 cm h=40 cm h=100 cm 570 iq [cts] i 500 q transition from empty to full, h=40 cm, 1750 rpm 690 Trigger Level t [ms] iq [cts] Trgger Level i q transition from empty to full, h=100 cm, 2500 rpm t [ms] iq [cts] Trigger Level t [ms] 18

19 19 Thermal impedance measurement setup The board is set under a plastic casing in order to reduce convection effects, which could significantly affect the measurements. Thermal camera

20 Temperature [ C] Temperature [ C] Temperature Measure Results Hot Spot Temperature vs Rotational Speed, 3phase mod Hot Spot Temperature vs Rotational Speed, 2phase mod , V 6Ω 150 V 1,7Ω 1,4ohm 300 V 6Ω 300 V 1,7Ω 1,4ohm V 6Ω 150 1,4ohm V 1,7Ω 300 V 6Ω 300 1,4ohm V 1,7Ω Rotational Speed [rpm] Rotational Speed [rpm] 1. The module temperature doesn t rise above 100 C, so the PCB temperature doesn t rise above 105 C, which is the maximum recommended temperature for FR4 material. 2. To reduce the R DSon value of the MOSFETs, it is necessary to increase the devices dimensions, however this causes an increase of the parasitic capacitances values and an increase of switching losses (see next slide) 3. The choice of the module depends on the working condition of the system. 20

21 P TOT [mw] Switching losses of the module To verify the second point of the previous slide, the switching losses of the two modules have been measured. In particular the inverter is switching without any motor connected to the output and the power absorbed by the controller, by the gate driver and from the DC BUS are measured as a function of the DC BUS voltage. Red curve is 1,4 ohm MOS --- Gray curve is 6 ohm MOS 1400 P TOT vs DC BUS Voltage ohm 6 ohm Voltage [V] 21

22 Conclusions From the experiments done on the motor-pump system, it is possible to conclude that: The iq reconstructed quadrature current is a fundamental variable to determine the condition of operation of the system; For the transition from normal conditions of operation to particular conditions of operation, it is possible to identify a unique value of the i q current which allows to detect the two conditions of operation independently from the drop. From the thermal point of view, it is possible to conclude that: IMM101T-015M can be used to fed the system; with a 2-phase modulation it is the best fit. IMM101T can be used in environments where the temperature could be greater than 25 C of the lab due to the presence of hot fluid. 22