2012 Texas Instruments Motor Control Training

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Dave Wilson
Team Lead, Motor Solutions Group
2012 Texas Instruments Motor Control Training
In Today’s Exciting Episode…
Motor Topologies and Operation

Digital Control Techniques

Power Modulation and Regeneration

TI Motor Control Solutions

 Control Partitioning
2012 Texas Instruments Motor Control Training

Intelligence Power Conversion Motor

Feedback vs. Feedforward

Digital Control Space Vector Modulation Brushless DC
PI(D) controllers Power Regeneration ACIM
Observers PMSM
Field Oriented Control Stepper
Sensorless FOC
2012 Texas Instruments Motor Control Training

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 Torque in a BLDC Motor

Clockwise
N

Torque
θ
Stable Point 360°

Counter-Clockwise
S

TI Spins Motors…Smarter, Safer, Greener.

 A Torque = ( 4 NBlr ) ( I )
= (kT ) ( I )

0°
C
B

Torque
N B

Current
B
C B

A 0°

TI Spins Motors…Smarter, Safer, Greener.

Control of a Brushless D.C. Motor

2
A

Controller
B 12 zones in 360 degrees
s of mechanical rotation
3

4 C r
t

5
120 0 hall spacing is
6 preferred over 60 0
spacing since
1 unpowered or
1 unconnected sensors
0 produce 111 or 000
codes, which can be
used for fault
Source: Eastern Air Devices, Inc. Brushless DC Motor Brochure detection.

TI Spins Motors…Smarter, Safer, Greener.

 BLDC Commutation
Q1
Q2
Q3
Q4

Q5
Q6

Hall A
Hall B

Hall C

Fault input signal

TI Spins Motors…Smarter, Safer, Greener.

 Commutation of a Brushless DC Motor
C C C
A B A B A B
N N N
B A B N A B S S N A
N S
S S S N
S N
C S S C C S S C C N N C
S S N S N S
N S S
A N B A N B A N S B
N N

B C A B C A B C A
n o p
C C C
A B A B A B
S S S N S
B S A B A B N A
S N
N N N S
N S
C N N C C N N C C S S C
N S S
N N N
S N N
A S B A S B A S N B
S S

B C A B C A B C A

q r s
TI Spins Motors…Smarter, Safer, Greener.
 Spoke Design BLDC Motor

TI Spins Motors…Smarter, Safer, Greener.

 Disk Drive BLDC Motor

TI Spins Motors…Smarter, Safer, Greener.

 96% BLDC Motor Efficiency
≈ 100W

Using iron based amorphous

core material, Japanese
researchers at Tokai University
break 96% efficiency barrier!

TI Spins Motors…Smarter, Safer, Greener.

 BLDC Control

Controller
Conditioning

Source: Eastern Air Devices, Inc. Brushless DC Motor Brochure

TI Spins Motors…Smarter, Safer, Greener.

Traditional Sensorless Commutation
Rotor Electrical Position (Degrees)
0 60 120 180 240 300 360

Phase A

Phase B

Phase C

Zero
crossings

PWM 1

PWM 3

PWM 5

PWM 2

PWM 4

PWM 6

TI Spins Motors…Smarter, Safer, Greener.

Introducing InstaSPIN – BLDC!
What is InstaSPIN - BLDC?
MCU
PWM0
PWM1
Gate Power BLDC
PWM2
ADC0 PWM3 Drivers Inverter Motor
ADC1 PWM4
ADC2 PWM5

InstaSPIN - BLDC
Software

Phase A
Phase B
Phase C

InstaSPIN - BLDC is a method to perform

sensorless commutation on three-phase
BLDC motors which enables quick
commissioning, robust control (even at
low speeds), and exceptional adaptation
to velocity perturbations.

TI Spins Motors…Smarter, Safer, Greener.

The InstaSPIN Advantage
Extremely robust! (InstaSPIN has currently been tested on about 80
different motors. In each case, the motor was running in under 30
seconds, and suitably tuned in under two minutes.)

Extremely simple! Only one parameter needs to be adjusted to tune

the commutation process.

Commutation advance easily accomplished at high speed by

dynamically lowering the threshold level.

Back-EMF integration creates a less noisy signal for commutation

control. This results in more reliable low speed operation.

InstaSPIN immediately adapts to acceleration changes (unlike the

zero-cross timing technique).

TI Spins Motors…Smarter, Safer, Greener.

InstaSPIN - BLDC…A Peek Under the Hood

Rotor Electrical Position (Degrees)

0 60 120 180 240 300 360

Phase A

Phase B

Phase C

Vth

-Vth

Commutate

TI Spins Motors…Smarter, Safer, Greener.

Speed Invariant Performance

1/6 Amplitude
Zero-crossing line

Commutate Commutate

Zero

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Start Integrating

dλ ∂λ dθ ∂λ
voltage = = ⋅ = ⋅ ωm
dt ∂θ dt ∂θ
TI Spins Motors…Smarter, Safer, Greener.
Current Mode Control Topology

Kp
+
+ PWM Value Commutation
Commanded current (torque)
- +
Engine

Ki ∫
Bus Current
(from shunt resistor)

Controls current only. Velocity is out of control.

TI Spins Motors…Smarter, Safer, Greener.

Velocity Mode Control Topology

Commanded Kp
Rotor
+
Speed + PWM Value Commutation
+
Engine
-

Ki ∫
Commutation Times

Rotor Speed Estimate Velocity

Calculation

Controls velocity only. Current is out of control.

TI Spins Motors…Smarter, Safer, Greener.

 Cascade Mode Control Topology

Commanded current (torque)

Velocity Loop
PWM Value
Commanded Kp Limit Kp
Rotor
+ +
Speed + + Commutation
+ - +
Engine
-

Ki ∫ - Velocity Loop
Limit
Ki ∫
Commutation Times
Bus Current
(from shunt resistor)

Rotor Speed Estimate Velocity

Calculation

Controls both velocity and current.

TI Spins Motors…Smarter, Safer, Greener.

 DRV8312 Board

TI Spins Motors…Smarter, Safer, Greener.

 DRV8301 Board

TI Spins Motors…Smarter, Safer, Greener.

 User Interface

TI Spins Motors…Smarter, Safer, Greener.

 Brushless DC Motor Summary
Advantages
High power output per frame size
Easy to control with trapezoidal commutation
High efficiency due to small rotor losses
Low profile designs possible
Excellent high speed performance
Structure inherently allows heat to be easily removed

Disadvantages
Slightly more torque ripple than PMAC motors
Uniform airgap flux density required for trapezoidal back-
EMF is difficult to achieve
Field weakening requires additional current
Permanent magnetic field causes viscous drag
Permanent magnets can be demagnetized at high temp.

TI Spins Motors…Smarter, Safer, Greener.