3-in-1 Air Condition Solution

Transcription

1 3-in-1 Air Condition Solution FTF-IND-F0476 Zhou Xuwei Application Engineer M A Y TM External Use

2 Agenda Abstract Application Development Sensorless PMSM FOC Timing & PFC Timing Start Up Realization of Outdoor Fan General State Machine Motor State Machine PFC State Machine Freescale Support External Use 1

3 Abstract Design HW Blocks Typical requirements System specification External Use 2

4 Design HW Blocks AC Line Interleaved PFC dc bus 3Ph. Inverter Motor 2 PMSM Fan Control Feedback 3Ph. Inverter Motor 1 PMSM Control Control Feedback Feedback Compressor Interleaved PFC Control Sensorless FOC Control Motor 1 Sensorless FOC Control Motor 2 Application Control Application S/W MC56F84xxx External Use 3

5 Hardware Input: V AC / 40 70Hz Motor W Motor 2 500W Interleaved PFC Necessary feedback for 2 PMS or BLDC motors and PFC control Over-current hardware protection PCI Express processor board Isolated communication DC bus brake resistor with an independent comparator External Use 4

6 Typical Requirements Motor 1 & 2 2x 6-channel PWM modules Parallel sampling 9-channel ADC 2x dc bus current fault to PWM modules PFC 2-channel high-precision PWM 2-channel ADC PFC current and dc bus over-voltage fault (comparators) Application 3-channel ADC for temperature measurement UART with DMA for communication Inter-peripheral cross-bar unit signals interconnection External Use 5

7 System specification Controller (DSC): MC56F84789 Motors: PWM 10kHz 10kHz fast control loop (sensorless PMSM FOC) 1kHz slow control loop (speed and ramp control) Compressor: 1500W, RPM Fan: 30W, RPM PFC: PWM 80kHz - interleaved Input V AC, 40 70Hz Output V DC 20kHz fast control loop (current, sine generation phased to input voltage) 500Hz slow control loop (voltage and ramp control) Application: Power up to 2kW Serial communication at 9600B 3 temperatures measurement Intelligent on/off and fault logic Benefits: Cost-effective (single DSC, no position sensor) High-efficiency (PMSM FOC + PFC) Low-noise (PMSM) Variable-power (FOC) External Use 6

8 Application development Field Oriented Control for PMSM Interleaved PFC External Use 7

9 Motor Control Topology Gate Driver with Isolation A B C Motor Current Feedback Position Feedback Speed/Torque Command PWM Generation Control Algorithm Feedback Processing MCU External Use 8

10 Sensorless PMSM FOC Sensorless Vector Control Algorithm External Use 9

11 Interleaved PFC Connection ~V in V out External Use 10 PWM

12 Interleaved PFC Connection External Use 11

13 Sensorless PMSM FOC timing & PFC timing Motor PWM configuration Motor 1&2 synchronization System PWM&ADC timing Motor 1 (Compressor): PWMA sub module0~2 Motor 2 (Fan): PWMB sub module0~2 PFC (interleaved): PWMA sub module3 Phase shift between PWMA and PWMB as well as the synchronization between PWM&ADC has to be carefully designed External Use 12

14 Motor PWM Configuration RELOAD VAL1 ($1387) VAL3 VAL0 ($0000) VAL2 INIT ($EC78) PWM_T PWM_B Trigger output FOC FOC FOC FOC FOC Current offset Current External Use 13

15 180 ship between two Motors PWM INIT VAL1 RELOAD RELOAD Top Motor 1 Bottom RELOAD RELOAD Top Motor 2 Bottom INIT VAL1 INIT External Use 14

16 System synchronization and Timing VAL0 RELOAD INIT RELOAD VAL1 Top Motor 1 Bottom RELOAD RELOAD Top Motor 2 Bottom Ipfc1 INIT M2 current INIT INIT M1 offset M1 current M2 offset RELOAD RELOAD RELOAD RELOAD RELOAD Ipfc1 PWMA_S3A PWMA_S3B Trigger output Ipfc2 Ipfc2 PWM CMP interrupt EOS interrupt ISRs PFC control External Use 15 M2 fast current control M2 PWM update M1 slow speed control M1 fast current control M1 PWM update M2 slow speed control

17 PWMA to ADC Triggers PWMA SM1 PWMA SM2 SM1 Val4 TRG0 TRG1 TRG0 TRG1 XBAR B OR OR AOI AND AND AND OR XBAR A ADC SM2 Val0 SM2 Val4 SM1 Val AND SM2 Val1 SM2 Val5 External Use 16

18 12-bit ADC Configuration DCBus Voltage M1 Current Rectified Voltage M2 Offset Rectified Voltage M2 Current M1 Offset Sample ANA A5 A6 A0 A7 A5 A6 A7 A0 Sync PFC1 Current Sample x x x x x x PFC2 Current PFC1 Current PFC2 Current ANB B5 B6 B0 B2 B5 B6 B2 B0 Trigger output PWM CMP interrupt EOS interrupt ISRs PFC1 calc M1 fast current control M1 PWM update M2 slow speed control PFC2 calc M2 fast current control M2 PWM update M1 slow speed control External Use 17

19 System Control Loop 20kHz PMWA SM1 CMP ISR On Val0 for PFC1 On Val1 for PFC2 10kHz PWMA SM0 CMP on VAL4 ISR 10kHz ADC12 EOS ISR Level 3 Level 2 Level 2 Read PFC two currents, Read input voltage, PFC fast current control loop PFC slow voltage control loop Read M1 phase currents Read M2 current offsets Read DCBus voltage M1 fast current control loop M2 slow speed control loop ADC reconfiguration for M1 Read M2 phase currents Read M1 current offsets Read DCBus voltage M2 fast current control loop M1 Torque self-study M1 slow speed control loop ADC reconfiguration for M2 External Use 18

20 Start up of outdoor fan Anti-wind start up Start up from standstill Start up from high speed due to inertia External Use 19

21 Start Fan in the rotation condition All inverter legs are turned off until the currents are attenuated to zero; All bottom legs of the inverter are turned on ; The legs are kept on and short-circuited for duration ; Repeat above steps after short-circuit interval ; Initial rotor position and speed are estimated by a three-phase short-circuit current vector. T sh External Use 20

22 External Use 21 Start Fan in the rotation condition Stator voltage equations on the d,q-axis coordinates 1 0 f q d q m d q d m q d i i pl R L L pl R v v Assuming and, and all bottom legs are short-circuited sh m q T R L / 0 R m f q d q d q d i i pl L L pl Assuming and is constant. Transform measured 3-phase shortcircuit phase currents into components and the phase angle of is i 0 0) ( sh q f sh d f sh q sh d T T L T L T i T i i sh sin ) cos (1 ) ( ) ( ) (, i i, I i i I arctan ( sh ) T i

23 Speed estimate e T I 2 sh I1 12 (a) First short circuit. (b) Second short circuit. External Use 22

24 External Use 23 Position estimate sh q f sh d f sh q sh d T T L T L T i T i i sh sin ) cos (1 ) ( ) ( ) ( i i I arctan sin tan tan (1 cos ) sin tan (1 cos ) f e sh q q f d e sh d d e sh q e sh T i L i T L L T L T

25 Position estimate (Cont) e I 0 External Use 24

26 Fan Startup from Still or at Low Speed Get initial rotor still position for sensorless PMSM Align to D-axis by applying non-zero Id current with zero Iq Signal Injection Methods Other methods Get initial rotor position at low speed Method discussed in previous slides External Use 25

27 Fan Startup from Still or at Low Speed q q q* ω e θ L =90 i q* q* d i q θ L i q* d ω r θ d* ω e d* d* A-axis Synchronous rotating reference frame d*q* is set to be lagging the real rotor dq frame by 90 electrical degrees. Fixing the i q* Ramping the speed ω e to V, Integrating speed to get the predicted position. Ramping down i q* External Use 26

28 Fan Startup from Still or at Low Speed Current ramp down Max speed Ramp is doubled Speed and position observers enabled Predicted position is close enough to estimated position of observer, switch to speed close loop. External Use 27

29 Start Fan from high Speed All bottom legs of the inverter are turned on ; Measure the short-circuited currents of three-phase; Enable BEMF observer and Tracking Observer for a while to initialize the observers internal states; Switch to the spin state with both close speed control loop and current control loop. External Use 28

30 General state-machine External Use 29

31 State Machine Fault -> Init SM_CTRL_FAULT_CLEAR Init -> Fault INIT SM_CTRL_FAULT RESET SM_CTRL_INIT_DONE Init -> Stop FAULT Run -> Fault SM_CTRL_FAULT SM_CTRL_START STOP Run -> Fault Stop -> Run Run -> Stop SM_CTRL_STOP_ACK SM_CTRL_FAULT SM_CTRL_RUN_ACK RUN SM_CTRL_STOP External Use 30

32 State Machine Functions State machine functions: Fault system faced a fault condition Init variables initialization Stop system initialized, waiting for the Run command Run system is running; this state has user sub-states State machine transition functions: Init -> Stop initialization done, entering the Stop state Stop -> Run the Run command applied, entering the Run state if Run acknowledged Run -> Stop the Stop command applied, entering the Stop state if Stop acknowledged Fault -> Init fault clearance, entering the Init state Init, Stop, Run -> Fault fault condition occurred, entering the Fault state External Use 31

33 Main Application State Machine Functions State machine functions: Fault - system faced a fault condition temperatures and dc bus voltage measured fault flags checked motors and PFC forced to Stop Relay off LED flashing quickly Init variables initialization Stop system initialized, out by the Run command or fault conditions temperatures and dc bus voltage measured fault flags checked motors forced to Stop Relay off LED flashing quickly Run system is running; out by the Stop command or fault conditions PFC voltage command set; PFC running Motor 1 and 2 are run if the conditions are accomplished temperatures and dc bus voltage measured fault flags checked Relay on LED flashing the Smoke on the Water main riff External Use 32

34 Main Application State Machine Stop/Run States Init -> Stop Switch ON STOP Relay off Relay on Turn on PFC PFC voltage command Relay OFF PFC OFF Motors OFF PFC not running Run -> Stop Stop -> Run Turn off PFC PFC output voltage good Turn off Motor 2 M1 not running M2 not running RUN Relay ON PFC ON Motors ON External Use 33 Switch OFF Turn off Motor 1 Hot-side temperature good

35 Main Application State Machine Run/Fault States Stop -> Run FAULT Relay off Run -> Fault RUN PFC not running Fault condition Turn off Motor 1 Hot-side temperature good Turn off Motor 2 M1 not running M2 not running Turn off PFC External Use 34

36 Motor sub state-machine External Use 35

37 Motors State Machine Run Sub-States Stop -> Run CALIB Calibration time passed Calib -> Ready READY FREEWHEEL Spin -> Freewheel Speed command == 0 & Speed < min speed Speed command == 0 Speed command!= 0 Startup -> Freewheel Freewheel -> Ready Align -> Ready Freewheel -> Align Speed command == 0 Speed command!= 0 Ready -> Align ALIGN SPIN Startup fail Alignment time passed Startup -> Spin Startup ok STARTUP Align -> Startup External Use 36

38 Motors Run Sub-State Functions Run Sub-State functions: Calib ADC offset calibration; entered when switched from Stop to Run Ready motor is ready to run; entered when the calibration time passed Align motor is aligned; entered when applied a non-zero speed command Startup motor is started up in open-loop; entered when the alignment time passed Spin motor is running; entered when the start-up was successful Freewheel rotor is rotating by inertia, PWM is tri-stated; entered when zero-speed command applied in Spin, or if the start-up failed; if start-up failed many times the fault flag is generated and the application goes from Run to Fault Run Sub-State transition functions: Calib -> Ready calibration done, entering the Ready state Ready -> Align non-zero speed command; entering the Align state Align -> Ready zero speed command; entering the Ready state Align -> Startup alignment done; entering the Startup state Startup -> Spin start-up successful; entering the Spin state Startup -> Freewheel start-up failed; entering the Freewheel state Spin -> Freewheel zero speed command; entering the Freewheel state Freewheel -> Ready zero-speed command; entering the Ready state Freewheel -> Align non-zero speed command; entering the Align state External Use 37

39 PFC sub state-machine External Use 38

40 PFC State Machine Run Sub-States Stop -> Run CALIB Calibration time passed Calib -> Ready READY Voltage command!= 0 Run -> Ready Voltage command == 0 Ready -> Run RUN External Use 39

41 PFC Run Sub-State Functions Run Sub-State functions: Calib phasing to power line voltage; entered when switched from Stop to Run Ready PFC is phased and ready to run; entered when the phasing time passed Run PFC is running; entered when applied a non-zero voltage command Run Sub-State transition functions: Calib -> Ready phasing done, entering the Ready state Ready -> Run non-zero voltage command; entering the Run state Run -> Ready zero voltage command; entering the Ready state External Use 40

42 Freescale support Dual PMSM Vector Control Demo with PFC Application based on C-callable library functions (GFLIB, MCLIB, GDFLIB, ACLIB) Application software in C (CodeWarrior ) FreeMASTER visualization tool 3-in-1 high voltage power stage Application support from Freescale motor control experts External Use 41

43 Designing with Freescale Tailored live, hands-on training in a city near you 2014 seminar topics include QorIQ product family update Kinetis K, L, E, V series MCU product training freescale.com/dwf External Use 42

44 Freescale Semiconductor, Inc. External Use