Different home appliances- full electronics. New trends in appliance market place 2/41

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Jody Parrish
5 years ago
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1 Modern electrical motor drive solutions for washing machine home appliance Savremena resenja elektricnih pogona za kucne aparate

Different home appliances- full electronics WASHING MASHINE Environmental friendly designs - conserves energy and lowers the cost (washing

such as automatic out-of of balance spin protection and leak detection Conserves energy by efficiently controlling the heating element

efficient operation with less vibration Enhances informational display functions DISHWASHERS Measures water temperature, which allows

control alarm Provides automatic machine startup when electricity is least expensive E-Field sensing for touch panel interface, water and

Improves compressor control and brush-less DC motor control while improving energy Monitors moisture levels inside the appliance cavity

2 Different home appliances- full electronics WASHING MASHINE Environmental friendly designs - conserves energy and lowers the cost (washing time and water usage) smart features such as rinse cycle foam detection and six-stage stage spin speed selector Incorporates safety features, such as automatic out-of of balance spin protection and leak detection Conserves energy by efficiently controlling the heating element Enhances informational display functions DRYERS Conserves energy by efficiently controlling the heating element Provides a quieter, power efficient operation with less vibration Enhances informational display functions DISHWASHERS Measures water temperature, which allows efficient control of the heating Enhances informational display functions such as a countdown to completion of the wash Provides an event control alarm Provides automatic machine startup when electricity is least expensive E-Field sensing for touch panel interface, water and water flow detection REFRIGERATORS AND FREEZERS Provides quieter operation with improved power efficiency for refrigerators and freezers Improves compressor control and brush-less DC motor control while improving energy Monitors moisture levels inside the appliance cavity Monitor ice and frost formation with E-Field sensing HVAC Provides quieter operation Conserves energy by efficiently controlling the fan speed New trends in appliance market place 2/41

3 Washing-machine electrical drive system specifications and design challenges

4 Modern washing machine full electronic design Whirlpool Duet Nord america Motor drive system Whirlpool Duet Main system parts New trends in appliance market place 4/41

5 Fully electronic (uc/dsp based) versus purely mechanical more efficient motor control conserves energy/water/detergent (new legislations, enforce environmental friendly designs) Load capacity (9 kg load, 14 pairs of jeans) High spin speeds, 1000, 1200 rpm (on market) and even 2000 rpm Noise reduction safety features (safety approvals -UL agency) out-of of balance spin estimation/protection (100 gr detection) Inertia estimation (100 gr detection) Pressure sensors, leak detection New smart features (different cycle options) Enhances informational display functions Offers an in-home connection, sends machine progress messages to other in-home devices (advantage at market place) New trends in appliance market place 5/41

6 Appliance electrical drive design challenges Cost - The highly competitive, high-volume, and cost-sensitive sensitive market (1 cent reduction of solution price == thousands of dollars/month) - constant increase of the material price (steel price/magnets) - constant pressure from appliance supplier for price reduction Reduced time to market and reduced product life - New models lunched every year - requires faster, more efficient development cycles - FLASH to ROM conversion can hurt. Legislation - Energy regulations combined with consumer demand for efficient appliances consuming less energy, water, and laundry products are forcing manufacturers to meet these requirements. Safety approvals - UL agency (USA only) New trends in appliance market place 6/41

7 Appliance electrical drive design challenges High starting torque and extended speed range Start and wash speed range High load and high starting torque (3Nm, 500 rpm), flux control for optimal motor losses, motor temperature limit Spin speed range Constant (high) power range 0.3Nm, rpm => 800W 1200W, large BEMF -> flux-weakening & over-modulation (specially for PM or IPM) Highest spin speed ( rpm ) 5 tim es nom inal speed Spin cycle (5 min -10 min.) plaster speed (> 100 rpm ) Load distribution and unbalance est. (2-5 min.) W ash cycle 30 min 60 min (40 rpm 50 rpm ) braking tim e axis New trends in appliance market place 7/41

8 Washing mashine electrical motor selection

9 Washing mashine motor selection? 1) Active material price 2) Capital cost / new production line 3) Application needs specified maximum torque and drum speed 4) Control algorithm complexity 5) Customer preference noise/reliability 6) Optimal performance (extra savings in power stage) 2), 4) 2), 6) 3),4), 6), 5)? 1), 2), 3), 4), 5) UM Universal Motor SRM switching reluctance PM permanent magnet IPM IM internal induction per. mag motor New trends in appliance market place 9/41

Low efficiency Some degree of sensorless speed control possible Good power to weight ratio Belt pulley ratio

10 Universal motor drive Very popular in old washing machines Substitutes another field winding for DC motor s permanent magnets Can be driven by AC or DC (hence universal ) High construction complexity Low reliability Low efficiency Some degree of sensorless speed control possible Good power to weight ratio Belt pulley ratio 10:1 maximum speed 800 rpm cheap AC tachometer mounted on the motor New trends in appliance market place 10/41

Switched Reluctance motor Low construction complexity,

multi-phase Inverter controllers Sensorless speed control

Inverter shoot-through through not possible High speed operation

11 Switched Reluctance motor Low construction complexity, concentrated stator windings High efficiency Driven by multi-phase Inverter controllers Sensorless speed control possible Higher total system cost than for universal motors Inverter shoot-through through not possible High speed operation possible, High start-up torque acoustically noisy New trends in appliance market place 11/41

Three-phase induction motor cheep / simple production /efficient High

Speed-Sensorless possible Low cost per horsepower Belt pulley ration 14:1

and complex motor control algorithm vector drive for flux/torque ctr

12 Three-phase induction motor cheep / simple production /efficient High reliability/efficiency, high spin speeds Medium efficiency at low speed Speed-Sensorless possible Low cost per horsepower Belt pulley ration 14:1 Max. spin speed 2000rpm Cheap ac tachometer Needs more expensive drive HW and complex motor control algorithm vector drive for flux/torque ctr shaft-sensorless minimum no of sensors New trends in appliance market place 12/41

13 Three-phase IM control strategy Scalar control : bad dynamics low cost DSP, simple algorithm problem at low speeds. no current control parameter sensitivity sensorless option Vector control: complex algorithm but low cost DSP parameter sensitivity resolved effective in wide speed range current control different speed estimation schemes parameter identification New trends in appliance market place 13/41

14 Shaft- sensorless IM control structures Model reference adaptive system New trends -1 in appliance market +1 place 14/41

15 Shaft- sensorless IM control structures Full order non-linear observer New trends -1 in appliance market +1 place 15/41

torque, 40 N-m peak) Interior mounted permanent magnets (insert or buried) IPM reluctant torque field

16 Three-phase synchronous motor with PM/IPM Surface mounted permanent magnets -PM No reluctant torque No field weakening option outer rotor soultion popular usual used as direct drum drive (no belt) (18 N-m torque, 40 N-m peak) Interior mounted permanent magnets (insert or buried) IPM reluctant torque field weakening option (high speeds) more complex control sensorless option New trends in appliance market place 16/41

17 Optimal IPM control structure Simultaneous use of magnet and reluctant torque (less material but nonlinear control) Large part of BEMF can be suppressed with Id Shaft - sensorless start and run 1) Field weakening 2) Maximum torque/amp ratio L L sd sq 2 i sd ψ f + L sd 2 + i 2 sq ( 2 / π ) New trends -1 in appliance market +1 place 17/41 r V pω L dc sq 2 T e 3 = pψ f 2 [ i + ( L L ) i i ] sq sd sq sd sq

Low speed sensorless IPM control structure Adding additional signal into rotating coordinates excites the motor at low and zero speed and makes the magnetic saliency signature visible.

18 Low speed sensorless IPM control structure Adding additional signal into rotating coordinates excites the motor at low and zero speed and makes the magnetic saliency signature visible. HF Signal Parameters Signal frequency should be chosen sufficiently high so no to interfere with base motor operating frequency. There is a limitation to max. frequency imposed by inverter PWM switching period. Signal Amplitude should be chosen such that the hf currents generated by this signal are measurable with sufficient accuracy. Increasing the amplitude however, creates audible noise and degrades CFOC performance. PWM utilization Strong filtering Q-axis hf current as a function of rotor position when estimated position is kept zero - Saliency Tracking Idea TM New trends -1 in appliance market +1 place 18/41

19 Low speed sensorless IPM control structure Signal processing Signal demodulation Speed Low-Pass filter Transformation into estimated d-q frame HF carrier extraction Removing harmonics at double the carrier frequency PLL PI regulator TM New trends in appliance market place 19/41

20 High speed sensorless IPM control structure Since back EMF is not included in the observer model then the current observer acts as a state filter for Back EMF. State filter bandwidth limits the performance of the method. Inverse tangent function with two inputs of the extended EMF estimates yields unfiltered rotor angle without any speed information Angle tracking observer noise on the position estimate can be filtered out without adding lag to the estimate within its bandwidth TM New trends in appliance market place 20/41

21 High speed sensorless IPM control structure Rotor electrical position extraction by Inverse tangent function with two inputs of extended EMF ( ˆ θ ) ( ˆ θ ) ˆ = E ˆ sin e E α ˆ = E ˆ cos e E β Ê α Ê β atan Ê Ê α β θˆe ˆe θ Angle tracking observer noise on the position estimate can be filtered out without adding lag to the estimate within its bandwidth.0 e sα e sβ ( ˆ ) θ ˆ θ = sin θ θ e e e e + + K s s + Θ(s) K 2 sin ( Θ ) cos( Θ ) TM New trends in appliance market place 21/41

22 Washing mashine three-phase AC motor drive specifications

23 Three-phase AC motor controller blocks Three-phase AC permanent magnet motor (surface or interior permanent magnets) Power converter 1) Three phase inverter: 800W 1000 W 2) Front End: single phase diode bridge, 1000 VA 3) Inductor / PF correction Europe only Measurement system 1) Motor line current measurement one shunt in DC or three in inverter legs (digital processing within one PWM sample but instantaneous fault protection) 2) DC bus voltage measurement (resister divider) Speed / angle sensors 1) Hall sensors 2) Shaft-sensorless 3) Absolute encoder (development only) Command interface 1) Serial link to master controller µc /DSP 1) square wave control/ vector control 2) with/without the speed sensor 3) with/ without current control Three-phase AC induction motor Power converter 1) Three phase inverter: 800W 1000 W 2) Front End: single phase diode bridge, 1000 VA 3) Inductor / PF correction Europe only Measurement system 1) Motor line current measurement one shunt in DC or three in inverter legs (digital processing within one PWM sample but instantaneous fault protection) 2) DC bus voltage measurement (resister divider) Speed / angle sensors 1) AC tachometer 2) Shaft-sensorless 3) Incremental encoder (development only) Command interface 1) Serial link to master controller µc/dsp 1) scalar control/ vector control 2) with/without the speed sensor 3) with/ without current control New trends in appliance market place 23/41

24 Three-phase AC motor controller block diag. 1) Power section - Different output powers - Different input stages - Different current shunts 2) Processing section - The same µc C /DSP - The same user interface - The same config. mem em. - The same analog circuits for signal processing - The same software tools New trends in appliance market place 24/41

25 Three-phase AC motor controller power stage Integrated solution (favorable price), Example: IRAMS10UP60B Different power ranges Integrated IGBT drivers (TTL logic inputs) Version with internal shunt and current protection New trends in appliance market place 25/41

26 Three-phase AC motor controller measurement f Speed- AC tachometar nptg ( Hz) n( rpm) 60 TG = ω TG 1 2 N NF Filter + f TG ~ω T2CLK TMR2-1 2 T CLK dspic W TG W NF 15 0 f (n-1)t nt 2 ftg nptg TMR = = n( ) f 60 f rpm merenja np TG =8 i T=100 ms merenja t t T TG ~ 1/f TG T TMR2 = T TG CLK = f CLK f TG = f CLK np TG 60 np TG =8, T=100 ms f clk =8MHz 1 n( rpm) Brzina TMPR2 Greška brzine 100 rpm rpm 3000 rpm rpm Brzina TMPR2 greška 100 rpm e rpm rpm New trends in appliance market place 26/41

27 Three-phase AC motor controller measurement DC bus voltage V DC (t) 0, V DC MAX DSP R 1 R 2 0, V AD REF AD 0xFFC0 0x0000 Shift >> 1 0x7FE0 V DC (kt) 0x k V VADC _ IN = VDC ( V ) = 442k + 3.7k V VADC _ IN 1 VDC ( broj) = 0xFFC0 = REF V V V DC AD ( broj) = V ( broj) >> 1 V DC ADC VDC ( broj) = V MAX DC REF AD MAX DC REF AD ( V ) Maximum volts? 340V+10%? New trends in appliance market place 27/41 V V V DC REF AD MAX DC V DC V 0xFFC0 = V DC MAX DC 0xFFC0 napon ADC rez. DSP broj Format1.15 +V MAX 0xFFC0 0x7FE0 približno

28 Three-phase AC motor controller measurement DC current I DC Shunt ± I * Rshunt REF AD 5 V AMP _ OFFSET = = 2. 2 VAD AMP _ GAIN = = 5.63 MAX 2 V V OFSET V REF LEM REF 0, V AD OP dspic AD REF V AD 0xFFC0 0x0000 0x7FE0 (OFSET) + - 0x7FE0 0x8020 I(kT) V ADC _ NUMBER = V IN REF AD 0xFFC0 = G [ A] AMP G I A ADC _ NUMBER = I MAX SHUNT Struja ADC rezultat Broj u DSP 1.15 format +I MAX 0xFFC0 0x7FE0 približno +1 -I MAX 0x0000 0x8020 približno -1 New trends in appliance market place 28/41 I A [ A] REF AD V I = REF V AD I A [ A] MAX V REF AD 2 I _ NUMBER = I I REF AD V + 2 A REF VAD [ A] MAX

29 Three-phase AC motor controller measurement DC current sample timing Two samples are needed in one PWM period New trends in appliance market place 29/41

30 Three-phase AC motor controller measurement DC current sample timing problems V 7 V 1 V T 0 /2 T 1 T 0 /2 V 1 V 1 V T 0 /2 T 1 T 0 /2 V 7 V 2 V k+1 V T 0 /2 T 2 T 1 T 0 /2 V 1 V 1 V k+1 V T 0 /2 T 1 T 6 T 0 /2 PWM start PWM middle PWM start PWM middle PWMA LONGEST_SV_TIME LONGEST_SV_TIME PWMA LONGEST_SV_TIME LONGEST_SV_TIME MIDDLE_SV_TIME MIDDLE_SV_TIME MIDDLE_SV_TIME+EXTRA_TIME MIDDLE_SV_TIME-EXTRA_TIME PWMB PWMB EXTRA_TIME PWMC PWMC SHORTEST_SV_TIME SHORTEST_SV_TIME SHORTEST_SV_TIME SHORTEST_SV_TIME I DC I A I A I DC -I C I A I A -I B Timer 1 Timer 2 SHORT+0 (there is no time to read second current) MIDDLE +Ts+Tr Timer 1 Timer 2 SHORT+Ts+Tr MIDDLE +Ts+Tr Short vectors must be extended New trends in appliance market place 30/41

Washing mashine three-phase AC motor drive DSP or micro selection 1) unit price (per units/year, ROM & FLASH transition) 2) power supply/pcb/ extra peripherals price (amplifiers/eeprom/clock, etc.

31 Washing mashine three-phase AC motor drive DSP or micro selection 1) unit price (per units/year, ROM & FLASH transition) 2) power supply/pcb/ extra peripherals price (amplifiers/eeprom/clock, etc..) 3) minimum processor power for application needs (customer specifications, some extra margin is needed) 4) Reliability (supplier reputation is always important) 5) good development tools 6) good processor road map and future support Engineers go with 3) - 6), with the respect of 1) and 2) Management always go with 1) and maybe 2)

32 Minimum DSP requirements for 3f AC control 30 MHz clock minimum, executed from FLASH and PRAM 8 Kw program internal memory 1 Kw data internal memory ADC 10 bits or higher 2 sample & hold modules Synchronization with PWM output signal Event manager 6 PWM outputs with programmable polarity and dead time Digital faults input instantaneous shot down (NOT digitally clocked) Capture unit with 2 / 3 inputs ( encoder, or Halls or ACtacho) 5 6 Digital IO ( input/ output) 1 serial port Watchdog timer POR ( power on reset ) Good development tools and custumer support New trends in appliance market place 32/41

33 Preferable DSP features for 3f AC control Single power supply ( 5 V power better, 3.3 V we can live with ) 60 MHz clock or higher (higher clock goes with Vcc = 3.3 V) Kw program internal memory / 2 Kw or higher data internal memory FLASH unit price equal the price of ROM unit Internal EEPROM or FLASH on-line programming option ADC - 12 bits or higher 3 sample & hold or 200 ns ADC with pipeline S&H in any moment (Sync. with PWM + prog. extra delay with timer) internal voltage reference Internal current signal amplifiers bipolar shunt signal shifted and amplified 3 amplifiers preferable number. Internal oscillator with programmable PLL clock, (+-2 out of the box) 2 serial ports POR ( power on reset) that actually works Minimum pin number (but must have at least 4 5 extra PIO), 32 is good number Two layer PCB that does not cause the noise problems ( usually 4 layer board recommended) New trends in appliance market place 33/41

Three-phase AC motor controller DSP/Freescale Freescale DSP ex Motorola (8013) Up to 32 MIPS at 32MHz core frequency C-efficient architecture 16KB Program Flash 4KB Unified Data/Program RAM One

34 Three-phase AC motor controller DSP/Freescale Freescale DSP ex Motorola (8013) Up to 32 MIPS at 32MHz core frequency C-efficient architecture 16KB Program Flash 4KB Unified Data/Program RAM One 6-channel PWM module One 6-channel 12-bit ADC One Serial Communication Interface (SCI) One Serial Peripheral Interface (SPI) One 16-bit Quad Timer ( encoder input) One Inter-Integrated Circuit (I2C) Port Computer Operating Properly (COP)/Watchdog On-Chip Relaxation Oscillator Integrated Power-On Reset and Low-Voltage Interrupt Module JTAG/Enhanced On-Chip Emulation for real-time debugging Up to 26 GPIO lines 32-pin LQFP Package 1) only 4K words PM, 2) clock only 30 MHz 3) relatively new product 4) no upgrade product available New trends in appliance market place 34/41

35 Three-phase AC motor controller DSP/TI TI DSP solution TMS320F2810(12), TMS320F MHz (6.67-ns Cycle Time) - Low-Power V Flash Voltage, 1.9-V MHz - JTAG Boundary Scan Support - High-Performance 32-Bit CPU (TMS320C28x) - Harvard Bus Architecture - Code-Efficient (in C/C++ and Assembly) - On-Chip Memory Flash ROM - Flash Devices: Up to 128K x 16 - ROM Devices: Up to 128K x 16-1K x 16 OTP ROM - Single-Access RAM (SARAM) - Boot ROM (4K x 16) - Standard Math Tables External Memory Interface up to 1M Total Memory - Dynamic PLL Ratio Changes Supported - On-Chip Oscillator - Watchdog Timer Module Three External Interrupts 128-Bit Security Key/Lock Three 32-Bit CPU-Timers 1) Fast and good, great support, a lot of code written. But 1) FLASH price > ROM, 2) too many pins, 3) no EEPROM, no internal oscillator option New trends in appliance market place 35/41

36 Three-phase AC motor controller DSP/AnalogD Analog Device DSP (ADMC341) 20 MIPS DSP core C-efficient architecture 4KW Program Flash 512 W Program RAM 512 W Data RAM 6-channel PWM module 6-channel singe slope ADC with 3 bipolar current inputs (three S&H amplifiers) One Serial Communication Interface (SCI) One Serial Peripheral Interface (SPI) Two 16-bit Timeres Watchdog timer Integrated Power-On Reset 9 digital PIO 32-pin LQFP Package 1) only 4K words PM, 2) clock only 20 MHz 3) single slope ADC 4) no product upgrade available New trends in appliance market place 36/41

37 Three-phase AC motor controller software Different development tools Most DSP suppliers offer on-line debugging, C complier/linker, FLASH tools 1) Code worrier Motorola (J-TAG, serial link) 2) Code composer - TI (J-TAG, serial link) 3) ADI Motion Control Debugger- Analog Device (serial link) Coding options 1) Assembler 2) C (very code efficient compilers - memory / execution time ) 3) autocoding (Matlab code generator) 4) Goto DSP supplier web site and use existing modules Software modules 1) Motor control module 2) Analog measurement and Estimation module 3) Motor and motor controller protection module (rms current/el. power/el. torque/temperature (heatsink and motor), DC bus voltage (capacitors)) 4) Fault state machine 5) Serial link driver (slave side) New trends in appliance market place 37/41

38 Washing mashine three-phase AC motor drive NEW TRENDS

39 Washing mashine motor controller new trends Most of the research is system cost driven -minimum sensors needed for drive to operate 1. Shaft sensorless 2. One shunt in DC circuit - Motor & motor controller integration IMAC problems: vibration and temperature rise Improvement of system performance - Efficiency - Unbalance (big problem in America / wooden houses ) - Sensorless low and high speed /parameter on line est. Legislation - Energy regulations combined with consumer demand for efficient appliances consuming less energy, water, and laundry products are forcing manufacturers to meet these requirements. Safety approvals - UL agency (USA only) New trends in appliance market place 39/41

) Motor and control together (no need for self commissioning) Cons

40 Washing mashine motor controller new trends IMAC - integrated motor and control Pro No connectors and long wires reduced heatsink (?) Motor and control together (no need for self commissioning) Cons vibration temperature limit 3f PMSM IMAC 3f IM IMAC New trends in appliance market place 40/41

41 Conclusion The overall white appliance and air-conditioner production and consumption is growing relatively flat yet stable at about 4% annually. The penetration rate of the electronic motor drive in appliance segment grows at over 20%, -> a lot of motor drive business in the appliance market New legislations and safety approvals, new features, material cost increases -> complex product, risk involved. The main driven force would be energy saving, government regulation, competition in terms of performances cost and features. New trends in appliance market place 41/41

User Guide IRMCS3041 System Overview/Guide. Aengus Murray. Table of Contents. Introduction

User Guide IRMCS3041 System Overview/Guide. Aengus Murray. Table of Contents. Introduction User Guide 0607 IRMCS3041 System Overview/Guide By Aengus Murray Table of Contents Introduction... 1 IRMCF341 Application Circuit... 2 Sensorless Control Algorithm... 4 Velocity and Current Control...