Moving Forward Efficiently HEV/EV Traction Motor Lab

Transcription

1 Moving Forward Efficiently HEV/EV Traction Motor Lab A traction motor is an electric motor providing the primary rotational torque of a machine, usually for conversion into linear motion (traction). Renesas Electronics America Inc.

2 Renesas Technology & Solution Portfolio 2

3 Microcontroller and Microprocessor Line-up bit 8/16-bit 1200 DMIPS, Superscalar Automotive & Industrial, 65nm 600µA/MHz, 1.5µA standby 500 DMIPS, Low Power Automotive & Industrial, 90nm 600µA/MHz, 1.5µA standby 165 DMIPS, FPU, DSC Industrial, 90nm 242µA/MHz, 0.2µA standby 25 DMIPS, Low Power Industrial & Automotive, 150nm 190µA/MHz, 0.3µA standby 10 DMIPS, Capacitive Touch Industrial & Automotive, 130nm Wide Format LCDs 350µA/MHz, 1µA standby 1200 DMIPS, Performance Automotive, 40nm 500µA/MHz, 35µA deep standby 165 DMIPS, FPU, DSC Industrial, 40nm 242µA/MHz, 0.2µA standby Embedded Security, ASSP Industrial, 90nm 1mA/MHz, 100µA standby 44 DMIPS, True Low Power Industrial & Automotive, 130nm 144µA/MHz, 0.2µA standby 3

4 Microcontroller and Microprocessor Line-up bit 1200 DMIPS, Superscalar Automotive & Industrial, 65nm 600µA/MHz, 1.5µA standby 500 DMIPS, Low Power Automotive & Industrial, 90nm 600µA/MHz, 1.5µA standby 165 DMIPS, FPU, DSC 32-Bit High Performance, High Efficiency & Integration 1200 DMIPS, Performance Automotive, 40nm 500µA/MHz, 35µA deep standby 165 DMIPS, FPU, DSC Industrial, 40nm 242µA/MHz, 0.2µA standby 8/16-bit Industrial, 90nm 242µA/MHz, 0.2µA standby 25 DMIPS, Low Power Industrial & Automotive, 150nm 190µA/MHz, 0.3µA standby 10 DMIPS, Capacitive Touch Industrial & Automotive, 130nm Wide Format LCDs 350µA/MHz, 1µA standby Embedded Security, ASSP Industrial, 90nm 1mA/MHz, 100µA standby 44 DMIPS, True Low Power Industrial & Automotive, 130nm 144µA/MHz, 0.2µA standby 4

5 Production Vehicles with Traction Motors Hybrids - Millions MY = Model Year of Introduction Source: Total U.S. Vehicle Sales Mitsubishi I MiEV Cadillac Escalade Lincoln MKZ BMW X6 Kia Optima Porsche Cayenne Infiniti M VW Touareg BMW 750i Honda CR-Z Hyundai Sonata Renault Fluence Smart ED Total - Millions 18 Honda Toyota Chevy Ford Nissan BYD 0.1 Accord Highlndr Silverado Fusion Leaf e6 3 Toyota Prius Drivetrain Toyota Honda Ford Lexus Nissan Chevy Dodge Mercedes Chevy Tesla Ford Prius Civic Escape RX400 Altima Tahoe Durango ML450 Volt S Focus

6 Traction Motor Efficiency HEV/EV overall efficiency is a key metric. (35kWh / 100mi) HEV/EV all electric range is a key metric. (38 miles using pure electric) Traction motors are ~70-90% efficient Depending on RPM, other factors Convert electrical energy to mechanical energy Traction motor efficiency is a primary factor in HEV/EV performance Electrical energy storage/retrieval are ~70-80% efficient Convert electrical energy to chemical energy, and then back See DevCon presentation about battery management 6

7 Renesas Smart Society Traction Motor Control Industry s Only Integrated Algorithm Hardware Park/Clarke transformations, PI controller, Duty Cycle Calculation Completely coherent angle and current samples Industry s Only Integrated RDC Hardware Industry leading Tamagawa resolver-to-digital converter (RDC) Optimized, Flexible PWM Generation Peripheral 2 Motor Control with Single Micro Full hardware & RDC support for 2 motors on next gen micro Software Driver Generation using QuantiPhi Less Expense & Faster Development 7

8 Agenda Typical Traction Motor Subsystem Renesas Smart Society Solution IRIS Evaluation Platform Resolver & RDC Lab Software & External RDC Motor Control Lab EMU & Integrated RDC Motor Control Lab Conclusion 8

9 Typical Traction Motor Subsystem 9

10 Typical Hardware Architecture Micro 6 aligned, continuously changing PWMs (5V digital outputs) 3 x IGBT module (6 x IGBT) 3 sinusoidal current waveforms Motor Position Motor Position digital angle RDC Motor Position Resolver output: Sin/Cos depending on motor position Motor with resolver 10

11 Resolver Operation Absolute angle sensor Resolves (modulates) angle into orthogonal pieces: sine & cosine signals Essentially a rotating transformer with specifically positioned secondaries Every angle has unique combination of sine & cosine, yielding an absolute angle Excitation input: V sin ωt Cosine output: kv cos θ sin ωt k = transformation ratio Sine output: kv sin θ sin ωt Sources: Tamagawa Seiki & admotec 11

12 Resolver History $ and # mm Price ($) # Components Width (mm) Source: Tamagawa Seiki, for 52mm diameter resolver 12

13 RDC Operation Performs implicit arctangent Uses trigonometry identity: sin(θ φ) = sinθ cosφ cosθ sinφ Uses approximation: sin(θ φ) θ φ, for θ φ < ±30 To generate difference error, ε, between actual motor angle, θ, and RDC digital angle, φ ε kv (θ φ) sinωt As the difference error, ε, approaches 0, θ = φ and digital angle equals actual motor angle Provides resolution better than 0.1 Analog kv sin θ sin ωt resolver θ Vsinωt buffer kv cos θ sin ωt buffer amp * D/A * D/A + - ε cos ROM cmp Sync compare counter detection sin ROM exc. sig. generator RDC Digital φ 13

14 Motor Timer Peripheral Phase Counting The MTU-III A multi-function timer pulse unit with eight 16-bit channels Phase counting mode is used for an RDC s quadrature encoded angle signal Ch 0 Ch 1 Ch 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7 RDC RDC Motor 1 Motor 2 14

15 Motor Timer Peripheral - PWM Generation Generate a periodic time interval Trigger interrupts for A/D Conversion, Angle Sample Given 3 duty cycles generate 6 PWM signals Coordination of several up/down counters and thresholds Enforce dead time to prevent shoot-through current 15

16 Motor Timer Peripheral PWM Generation The MTU-III A multi-function timer pulse unit with eight 16-bit channels Complementary PWM mode is used for motor control Ch 0 Ch 1 Ch 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7 Motor 1 Motor 2 PWM Carrier Cycle Reg s MTU Comparator Ch 6, 7 Timers Comparator Match Signals Match Signals Output Controller PWM Carrier Output PWM1 H/L PWM2 H/L PWM3 H/L Coil Duty Cycle Reg s 16

17 Software Responsibilities - Traditional Trough ADC Trigger Carrier Trough ISR Motor Algo. ADC Complete ISR Angle count from MTU Current to Amps Voltage Bounds Check Call Motor Algorithm Re-Arm ADC Return from ISR Calculate Elec. Angle Return from ISR Clarke & Park Transforms Q Vector PI Control Loop D Vector PI Control Loop Inverse Transforms Duty Cycle Calculation Timer Match Calculation Write match values to Timer Return 17

18 Renesas Smart Society Solution 18

19 Renesas Smart Architecture 6 aligned, continuously changing PWMs (5V digital outputs) 1 Micro with 2 RDCs Motor 1 See DevCon presentation about IGBTs 3 x IGBT module (6 x IGBT) Motor 1 3 sinusoidal current waveforms Motor 1 Motor 2 Motor 2 Motor 2 Motor Position Motor Position Motor 1 Motor 1 No external RDCs Motor 2 Motor Position Resolver output: Sin/Cos depending on motor position 2 motors with resolvers Motor 2 19

20 Integrated RDC Performs same arctangent operation To generate difference same difference ε To make the digital angle equal actual motor angle Still provides resolution better than 0.1 Analog kv sin θ sin ωt resolver buffer kv cos θ sin ωt buffer θ Vsinωt amp * D/A * D/A + - ε cos ROM cmp Sync compare counter detection sin ROM exc. sig. generator Micro Digital φ 20

21 EMU Peripheral (Enhanced Motor Control Unit) Application Id & Iq Request Data Transfer Section Motor Control Section 3-Phase Waveform Output Section Data from ADC Data from RDC Current and Angle Manipulation Feedback Vector Transforms Duty Cycle Calculation EMU PI Control Loop Inverse Vector Transforms Conversion to Timer Counts Timer Unit PWM Outputs Carrier Timing PWMs to Motor SH72AY Trigger to ADC 21

22 Software Responsibilities Renesas Solution ADC Trigger Carrier Trough ISR Motor Algo. ADC Complete ISR Angle count from MTU EMU Complete ISR Current to Amps Voltage Bounds Check Call Motor Algorithm Re-Arm ADC Return from ISR Calculate Elec. Angle Return from ISR Re-Arm ADC Return from ISR Clarke & Park Transforms Q Vector PI Control Loop D Vector PI Control Loop Inverse Transforms Duty Cycle Calculation Timer Match Calculation Write match values to Timer Return 22

23 IRIS Evaluation Platform 23

24 IRIS Goals Provide investigation system of Renesas solution to OEMs and Tier 1s Encourage use within OEM and Tier 1 development systems Show efficiencies of Renesas integrated RDC Show performance advantages of Renesas Enhanced Motor control timer Unit (EMU) Highlight cost savings & better performance Evaluate RDC vs. resolver inter-operation Evaluate RDC performance with injected noise 24

25 IRIS Capabilities Support for 2 motors Software selectable RDC per motor 4 different external RDCs 1 internal RDC 1 FPGA simulated RDC Software selectable resolver per motor Motor resolver FPGA simulated resolver Resolver Flexibility Excitation voltage of 5V to 15V Practically any transformation ratio 2 FPGA simulated motors and resolvers, including current and voltage feedbacks Isolated, low skew (< 10ns) motor PWMs and control/status 2 x CAN, 1 x RS-232, 1 x isolated USB Robust inputs Automotive capable 6V 30V supply Most inputs protected for short to power/ground 25

26 Simplified IRIS Diagram USB USB micro debug port Control software ATI A7 Drivers Data Acq. & Micro D board Calibration Tool Micro Daughterboard Current, voltage, temp inputs Multiple RDCs & resolver circuits FPGA motor simulator CAN x 2 Power supplies LEDs, switches Control Board (ECU) harness CAN x 2 IGBTs/MOSFETs Gate drivers Volt, current sensors Temp sensors Inverter Board IGBTs/MOSFETs Gate drivers Volt, current sensors Temp sensors Motor & resolver 1 sin, cos, exc Motor & resolver 2 Inverter Board Power Supply 26

27 IRIS Control Board Block Diagram USB ATI A7 Data Acq. & Calibration Tool SH72AY micro Debug port Micro Daughterboard CAN x 2 CAN Txcvr Micro socket Motor Control Motor Control FPGA Motor Simulator Motor Feedback PWM PWM current, voltage, temp Motor Feedback current, voltage, temp Power Supply Analog Muxes AU6802 RDC AU6803 RDC AD2S1205 RDC AD2S1210 RDC Analog Muxes sin, cos exc Analog Muxes AU6802 RDC AU6803 RDC AD2S1205 RDC AD2S1210 RDC Analog Muxes sin, cos exc Control Board (ECU) 27

28 IRIS Software Architecture Motor 1 Control via EMU Motor 2 Control via Software Configuration SW Speed Control App Configuration SW Speed Control App Ext RDC ADC EMU RDC ISR1 ISR2 ADC Input Processing Coordinate Transforms PI Controller Duty Cycle Calculation IGBTs Registers MTU-III IGBTs Motor Resolver Motor Resolver User interface through AUD connection 28

29 Resolver & RDC Lab 29

30 Resolver & RDC Lab 50W motor motor coils connector resolver resolver connector sine wave excitation signal sine/cosine resolver signals Do not connect motor coils Turn motor shaft by hand Watch resolver response oscilloscope 30

31 Software & External RDC Motor Control Lab 31

32 Software & External RDC Motor Control Lab AUD resolver sine/cosine resolver signals Motor PWMs excitation signal resolver connector 50W motor Motor connector Motor Coils Inverter Board ATI VISION & A7E 32

33 EMU & Integrated RDC Motor Control Lab 33

34 EMU & Integrated RDC Motor Control Lab resolver 50W motor AUD sine/cosine resolver signals resolver connector Motor PWMs excitation signal motor connector Motor Coils Inverter Board ATI VISION & A7E 34

35 Conclusion 35

36 Smart Society Traction Motor Control Resolver-to-Digital Converters (RDCs) provide accuracy for high traction motor efficiency Integrated algorithm hardware allows for control of 2 traction motors with 1 micro Significant cost savings can be gained by RDC integration and elimination of 2 nd micro for 2 nd motor Driver generation is real, efficient, practical and even fun Renesas Electronics has a really smart, integrated solution for traction motor control It can be evaluated today 36

37 Questions? 37

38 Renesas Electronics America Inc.