ID630L: Becoming Familiar with Sensorless Vector Control of BLDC Motors Renesas Electronics America Inc. Huangsheng Xu Consumer & Industry BU 14 Octob

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1 ID630L: Becoming Familiar with Sensorless Vector Control of BLDC Motors Renesas Electronics America Inc. Huangsheng Xu Consumer & Industry BU 14 October 2010 Version: 1.0

2 Huangsheng Xu Senior Staff Application Engineer, Primary focus on Motor Control Applications and Customer Supports Ph.D. degree in electrical engineering from Texas A&M University, College Station, Texas, in Twenty years working on motor drives, especially, sensorless vector control of PMSM motors and induction motors. Three U.S. patents Over twenty papers in the IEEE journals and conference proceedings. The third award at IEEE-Industrial Application Society 2006 for sensorless vector control of three-phase induction motors. 2

3 Lab Assistants Gordon Smith & John Pocs Gordon Smith is a Sr. FAE at Renesas, responsible for supporting Customer MCU designs throughout the Greater Chicago Area. He uses his nearly 30 years of Hardware, Software, and System Design experience, to assist Renesas World-class Customers in creating the most rugged, cost-effective, and innovative circuits on the Planet! John Pocs is a motor control expert for MCU motor control applications and customer support. He has 12 year with NEC Electronics, and currently he is a staff application engineer at Renesas, and has over 20 years embedded system development, application and industrial experience. He is very familiar with 8/16/32-bit MCUs. 3

4 Renesas Technology and Solution Portfolio Microcontrollers & Microprocessors #1 Market share worldwide * ASIC, ASSP & Memory Advanced and proven technologies Solutions for Innovation Analog and Power Devices #1 Market share in low-voltage MOSFET** * MCU: 31% revenue basis from Gartner "Semiconductor Applications Worldwide Annual Market Share: Database" 25 March 2010 ** Power MOSFET: 17.1% on unit basis from Marketing Eye 2009 (17.1% on unit basis). 4

in low-voltage MOSFET** * MCU: 31% revenue basis from Gartner "Semiconductor Applications Worldwide Annual Market

5 Renesas Technology and Solution Portfolio Microcontrollers & Microprocessors #1 Market share worldwide * ASIC, ASSP & Memory Advanced and proven technologies Solutions for Innovation Analog and Power Devices #1 Market share in low-voltage MOSFET** * MCU: 31% revenue basis from Gartner "Semiconductor Applications Worldwide Annual Market Share: Database" 25 March 2010 ** Power MOSFET: 17.1% on unit basis from Marketing Eye 2009 (17.1% on unit basis). 5

6 Microcontroller and Microprocessor Line-up Superscalar, MMU, Multimedia Up to 1200 DMIPS, 45, 65 & 90nm process Video and audio processing on Linux Server, Industrial & Automotive High Performance CPU, Low Power Up to 500 DMIPS, 150 & 90nm process 600uA/MHz, 1.5 ua standby Medical, Automotive & Industrial High Performance CPU, FPU, DSC Up to 165 DMIPS, 90nm process 500uA/MHz, 2.5 ua standby Ethernet, CAN, USB, Motor Control, TFT Display Legacy Cores Next-generation migration to RX General Purpose Up to 10 DMIPS, 130nm process 350 ua/mhz, 1uA standby Capacitive touch Ultra Low Power Up to 25 DMIPS, 150nm process 190 ua/mhz, 0.3uA standby Application-specific integration Embedded Security Up to 25 DMIPS, 180, 90nm process 1mA/MHz, 100uA standby Crypto engine, Hardware security 6

Microcontroller and Microprocessor Line-up Superscalar, MMU, Multimedia Up to 1200 DMIPS, 45, 65 & 90nm process Video and audio processing on Linux Server, Industrial & Automotive High Performance

7 Microcontroller and Microprocessor Line-up Superscalar, MMU, Multimedia Up to 1200 DMIPS, 45, 65 & 90nm process Video and audio processing on Linux Server, Industrial & Automotive High Performance CPU, Low Power SuperH Up to 500 DMIPS, 150 & 90nm process 600uA/MHz, 1.5 ua standby Medical, Automotive & Industrial High Performance CPU, FPU, DSC Up to 165 DMIPS, 90nm process 500uA/MHz, 2.5 ua standby Ethernet, CAN, USB, Motor Control, TFT Display Legacy Cores Next-generation migration to RX General Purpose Up to 10 DMIPS, 130nm process 350 ua/mhz, 1uA standby Capacitive touch Ultra Low Power Up to 25 DMIPS, 150nm process 190 ua/mhz, 0.3uA standby Application-specific integration Embedded Security Up to 25 DMIPS, 180, 90nm process 1mA/MHz, 100uA standby Crypto engine, Hardware security 7

8 Sensorless Vector Control Innovation Green Power Home Appliances Sensorless Vector Control Industrial Automation Automotive, Health Medicals 8

9 How much experience do you have with Sensorless Vector Control Design? 1. Extensive 2. Moderate 3. Low 4. None 9

10 How much experience do you have with Renesas Microcontrollers? 1. Extensive 2. Moderate 3. Low 4. None 10

11 Lab Agenda Lab Overview Introducing Sensorless Vector Control Phase 1: Set up Sensorless Vector Control Demo (5 minutes) (15 minutes) (10 minutes) Phase 2: Sample Motor Currents and DC Bus Voltage (15 minutes) Phase 3: Drive the Motor with Open Loop (20 minutes) Phase 4: Understand Sensorless Position and Speed Estimation (20minutes) Phase 5: Drive Motor with Closing Speed using Estimated Speed by GUI (25 minutes) Play time or Q&A (10 minutes) 11

12 Lab Overview Hardware Configuration GUI USB Cable Motor E10A E10A Cable 12

13 Hardware Platform Motor Connector Motor E10A Connector USB Connector SH

14 Renesas Sensorless Vector Control Strategy * ω r ω r Observed actual speed Commanded speed ω r Speed Regulator i d * = 0 i d Current loop * i q i q iq PI Regulator id PI Regulator Inverse park transform * U q * U d d,q to α, β T 1 ( θ) θ * U α * U β Inverse Clarke transform α,β to a, b, c Motor Model Based Flux and Position Observer SIN PWM PWM1~6 DC Bus Voltage Source 3-phase Inverter Clarke transform i q i d α,β to d,q T (θ ) i α i β u,v,w to α,β i u i v Speed loop Park transform ω r Speed Estimation θ 3-phase PMSM 14

15 Motor Startup Procedure Back EMF can t detect at very low speed. Start up with rotor alignment continuing with open loop The startup subroutine provides a constant torque by closing current loop iq = maximum startup torque and id=0. At the given startup time, the software switches over to closed speed loop. Sensorless control takes position and speed from flux and speed observer. 15

16 Software Configuration Sensorless Vector Control Algorithm (Flux observer, speed estimation, PI controller, protection, space vector PWM modulation...) Initialization Parameter Definitions Speed Setting & Ramp Control ADC Sampling Vector Control Transformation PI controller Startup Procedure Current id Regulator Current iq Regulator Flux & Position Observer Speed Estimation Speed Regulator PWM Duty Calculation Space Vector PWM Generation Protections (locked rotor, lost control, overcurrent, POE, watchdog ) Communication Layer WDT IWDT LVD POE 2xADC 12xMTU 512KFlash 96KRAM SCI/CAN/Ethenet SH MHz 32bit FPU 16

17 Sensorless Vector Control Software Workspace All code is written in C, and it is compatible for all Renesas devices. Compiler uses Renesas HEW, which automatically generates the MCU-related definition code. All MCUs have basic ADC, PWM, interrupt, etc, sample codes. For sensorless vector control solution, motor parameters, sensor inputs, ADCs, and control parameters are easily tuned through Renesas Graph Interface (GUI). Real time control parameter changes and track through the watch window. 17

18 High-performance Embedded Workshop (HEW) Project Manager Editor Window Real Time Watch 18

19 Graphic User Interface (GUI) Parameter Setting Speed Setting Variable Display Control Status 19

20 Start Lab Please refer to the lab handout Go ahead and start the lab 1. Done

21 Q & A 21

22 Sensorless Vector Control Innovation Green Power Home Appliances Sensorless Vector Control Industrial Automation Automotive, Health Medicals 22

23 Thank You! 23

24 Renesas Electronics America Inc.

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