Click to add presentation title Click to edit Master subtitle Click to add date 1 Solving Design Challenges in Motion Control European Sales & Marketing PCIM May 2013 Marketing and Applications Team
Jun 20, 2015
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1
Solving Design Challenges in Motion ControlEuropean Sales & Marketing
PCIM May 2013
Marketing and Applications Team
2
Motor Efficiency for Energy Conservation
• Motors represent as much as 60~70% of the industrial energy used in developing countries.
• The motor drive appliances (washing machines, air-conditioners, fans…etc.) represent around 70% of total household power consumption.
• Reducing the amount of energy used by motors in electronic systems has become a priority worldwide.
3
Three-Phase Motor Solutions
AuxiliaryPowerSupply
Micro-controller
or DSP
Current Sense
Amplifiers
Rectifieror
PFC Stage
Three-phase Inverter
MotorAC
4
LVICHVICs
IGBTs/MOSFETs
Peripherals-Bootstrap diodes
-NTC thermistor
SPM® Modules for InvertersReliable integration of power and driver products
5
6 X IGBT
HVICShunt
Using Discrete
Using SPM® Modules
SPM® Module Advantages:
• Reduced EMI• More compact design • Reduced BOM cost• Simplified design• Reduced assembly costs• Increased reliability
Benefits Of Using SPM® Modules
6
FRDIGBT
Ceramic (Isolation material)
IC
EMC(Epoxy Molding Compound)
Al WiringCu Wiring Lead Frame
Adhesive
B/D
Copper Wire
BSD
Lead Frame
Power Line
Signal Line
IGBT-Based SPM Modules
MOSFET-Based SPM Modules
SPM® Package TechnologyImproved reliability using transfer-moulded modules
7
Motion Control Design ToolReliability assessment from estimation of temperature ripple
8
Three-Phase Motor Solutions
AuxiliaryPowerSupply
Micro-controller
or DSP
Current Sense
Amplifiers
Rectifieror
PFC Stage
Three-phase Inverter
MotorAC
9
PFC-Solutions(10) VTH
(1) VCC
COM
VCC
IN(S)
VFO
CSC
OUT
CFOD
NTCThermistor
(2~4) COM
(5) IN
(13~16) N
(17~20) NR
(6) VFO
(7) CFOD
(8) CSC
(9) RTH (21)(22) P
(24) L
(25) PR
(26) R
(27) S
Q1
D3 D4
D1 D2
D5
(20) VTH
(1) VCC
COM
VCC
IN(R)
VFO
CSC
OUT(S)
CFOD
NTCThermistor
(2) COM
(4) IN(R)
(6) VFO
(7) CFOD
(8) CSC
(19) RTH
(27) PR
(24) N
(26) S
(25) R
IN(S)(5) IN(S)
OUT(R)(23) NC
(22) NSENSE
(21) VAC-
Q1D3
Q2D4
D1 D2Boost-PFC
Bridgeless-PFC
Interleaved Boost-PFC
10
PFC SPM® Modules in SPM 3 package Boost PFC: Standard PFC solution
44mm x 26.8mm
Output power up to 3kW
2.5kV isolation voltage
optimized thermal management with DBC substrate
typ. switching frequency <40kHz
adjustable SCP with soft shut- down control
Built-in Thermistor
Fault Output for UVLP, SCP
Package compatible to Motion Modules
Current rating Tc = 25 °C Voltage rating x10
FPAB20BH60BFPAB30BH60B
(10) VTH
(1) VCC
COM
VCC
IN(S)
VFO
CSC
OUT
CFOD
NTCThermistor
(2~4) COM
(5) IN
(13~16) N
(17~20) NR
(6) VFO
(7) CFOD
(8) CSC
(9) RTH (21)(22) P
(24) L
(25) PR
(26) R
(27) S
Q1
D3 D4
D1 D2
D5
FBA42060 in SPM 45 Package for Lower PowerNew
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PFC SPM® Modules in SPM 3 package Bridgeless PFC: More compact solution
44mm x 26.8mm
Output power up to 6kW
2.5kV isolation voltage
optimized thermal management with DBC substrate
typ. switching frequency <40kHz
adjustable SCP with soft shut- down control
Built-in Thermistor and Shunt
Fault Output for UVLP, SCP
Package compatible to Motion Modules
FPDB30PH60 FPDB40PH60BFPDB50PH60 FPDB60PH60B
(20) VTH
(1) VCC
COM
VCC
IN(R)
VFO
CSC
OUT(S)
CFOD
NTCThermistor
(2) COM
(4) IN(R)
(6) VFO
(7) CFOD
(8) CSC
(19) RTH
(27) PR
(24) N
(26) S
(25) R
IN(S)(5) IN(S)
OUT(R)(23) NC
(22) NSENSE
(21) VAC-
Q1D3
Q2D4
D1 D2
Current rating Tc = 25 °C Voltage rating x10
12
FAN9611 Interleaved Dual BCM PFC Controller• Efficiency
– Interleaved Lower Turn-off Losses– Phase Management– Valley Switching Minimize COSS losses– Strong gate drive reduce switching losses– Adjust Bulk Output Voltage at Light Load
• Protection– Closed-loop soft-start w/ Prog. Ramp Time– Current Limit per Channel– Power Limit per Channel– Input Voltage Feed-forward– Secondary Latched OVP– Input Brown-out Protection– Internal maximum fSW clamp limit
• Ease of Design & Solution Size– Easy Valley Detection Implementation– Easy Loop Compensation
(constant BW and PWM Gain)– Integrated +1A/-2A Gate Drivers– Works with DC, 50 Hz to 400 Hz
AC Inputs
VOUTD2
D1
FAN96111
2
3
4
5
6
7
8 9
10
11
12
13
14
15
16
CS2
CS1
VDD
DRV1
DRV2
PGND
VIN
OVPFB
COMP
SS
AGND
MOT
5VB
ZCD2
ZCD1
L2a
AC IN
CIN L1a
RZCD2
RZCD1
C5VB
RMOT
CSS
RCOMP
CCOMP,HF
Q2
RCS1 RCS2
COUT
Q1
VBIAS
RFB1
RFB2
ROV1
ROV2
RIN1
RIN2
RG2
RG1RINHYST
VIN
VLINE
EMI Filter
CCOMP,LF
L1b
L2b
CVDD1 CVDD2
CINF
13
Three-Phase Motor Solutions
AuxiliaryPowerSupply
Micro-controller
or DSP
Current Sense
Amplifiers
Rectifieror
PFC Stage
Three-phase Inverter
MotorAC
14
Pow
er
8W
14W
17W
20W
5W
No bias winding needed Bias winding needed in isolated application
FSL116HR/LR650V, 7.3Ω, DIP
FSL106HR/MR650V, 11.5Ω, DIP
FSL126HR/MR650V, 4.9Ω, DIP
FSL136HR/MR 650V, 3.5Ω,DIP/SO
FSL206MR650V, 14Ω, DIP/SO
Non-self supply Self-supply FSL3 Series
FSL306HR/UR650V, 14Ω
FSL336LR/HR/UR650V, 4Ω
Buck, Buck-Boost & Non-Isolated flyback
25W
30W
Released
Sampling
Development
FSL326LR/HR/UR650V, 6Ω
FSL117MRIN700V, 8.8Ω, DIP
FSL146MR650V, 2.1Ω, DIP
FSL156MRIN650V, 1.8Ω, DIP
FSL137MRIN700V, 4Ω, DIP
FSL4 SeriesIndustrial Flyback
FPS™ AC Regulators < 30W Pin to Pin*
FSQ500/H/X700V 30Ω/SOT223
FSD156MRBN650V, 1.8Ω, DIP
FSL117H700V, 8.8Ω, DIP
FSB147H700V, 2.3Ω, DIP
FSB127H700V, 6Ω, DIP
FSL4110HR/UR1000V 9Ω
FSL4516HR1600V, 10W~30W
Input OVP
Brown-out,AxCap™ discharge,
current limit pin
Pin 4 open
Current limit pin
Monolithic
2 chip.Current limit pin
15
FPS™ AC Regulators: FSB1 Series
High Robustness• Internal Avalanche Rugged 700V SenseFET• Accurate Brownout protection with hysteresis• Constant Power Limit (Full AC Input Range)
Improved Light Load Efficiency• No-load power consumption of less
than 55mW at 16W from AxCap™ discharge circuit• Green-mode: PWM freq linearly decreasing
at light-load with burst mode at ve
Ease of Design• Adjustable peak current limit• Slope compensation
FPS Family Features• Peak current-mode control• 100kHz version• Frequency modulation for reducing EMI• Built-in soft start function• VDD Under-voltage Lockout (UVLO)• VDD OVP, OTP, OLP (Auto Restart)• High-voltage Start-up
Brown-out and AxCap™ discharge
L
N
EMIFilter + +
HV
VDD
+
GNDFB
IPK
Drain
PWM
+
230Vac 240Vac 265Vac0
10
20
30
40
50
Standby Power mW (for 16W/5V supply)
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FPS™AC Regulators: FSL3 Series
High Robustness• Internal Avalanche Rugged 650V SenseFET• OLP, OVP in Auto Restart mode (650ms sleep time)
Improved Light Load Efficiency• Green Mode Function in Light Load Range• 25mW no-load power with bias winding • 125mW no-load power with self supply
Ease of Design• Options to work with and without bias winding• Integrated error amplifier for low component count• Adjustable current limit simplifies OCP and magnetics• Multi level TSD for flexible load response
FPS Family Features• Peak current-mode control• 100kHz version• Frequency modulation for reducing EMI• Built-in soft start function• VDD Under-voltage Lockout (UVLO)• VDD OVP, OTP, OLP (Auto Restart)• High-voltage Start-up
Low component count feedback circuit for non-isolated supplies
DIP7 PowerMLP
DC OUT
D
+
_
+
_
HV-DCIN
GN
D
VC
C
Vco
mp
ILIM
IT
VF
B
D D
Non-isolated flyback
Buck
GND
VCC
Vcomp
ILIMIT
VFB
D
D
DC OUT
HV-DC INPUT
LSOP7
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Reliability and SafetyProtection against component open or short circuit failures
Abnormal OCP or OLP
Over voltage Protection (OVP)
Possibility of failed parts
Output short Protection (OSP)
Thermal shutdown protectionor
Over current protection
ESD
High ESDimmunity ESD
Relatively Rugged parts
Over load protection (OLP)
Over voltage Protection (OVP)
Protected by OCP, OLP, OVP, AOCP, OSP, TSD
18
100V-1000V Input ESBC™ Transistor Power Supplies
Wide Input Range Solutions
19
Three-phase Motor Solutions
AuxiliaryPowerSupply
Micro-controller
or DSP
Current Sense
Amplifiers
Rectifieror
PFC Stage
Three-phase Inverter
MotorAC
20
FCM8531 Hybrid Motor Controller• Fairchild has explored the need of motor engineers and
developed a new hybrid controller – FCM8531• Easy to use and fully integrated solution with completed
developing tools and advanced motor control libraries allows very fast time to market
21
New Architecture for BLDC Motor Control
Advanced Motor ControllerA hardware-based motor controller plus configurable processing core which can be configured to several kinds of specific motor control algorithm.
Embedded MCUA MCS®51-compatible MCU processor provides motor control commands to the AMC to perform motor control activities, and manage external communication interfaces
GPIOUART
I2CSPI
FOC
DQ
Sinusoidal
Integration of Analog and Digital IC
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Benefits of the Hybrid Architecture• Minimum Software Effort
– The AMC performs powerful algorithms such as FOC and DQ control by using Fairchild’s libraries that can be configured and stored in AMC. Only simple system control software program needed in MCU.
• Reliability– AMC and MCU work independently to avoid system hang-ups.
• Robust Performance– Real-time cycle-by-cycle current protections in the hardware
based AMC detect and turn off PWM signals in μs to prevent system damage.
23
Easy-to-Use Development Tool • Fairchild provides the Motor Control Development System
(MCDS) IDE and MCDS Programming Kit for users to develop software, compile programs, and perform online debugging.
• User-friendly interface that reduces the time and effort required for studying datasheets and coding.– Visual setting options to replace complex
software coding.– Motor design configurations by simple
step-by-step clicking and selecting.– Support real time motor tuning.
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Fairchild’s Three-phase Motor Solutions• Fairchild provides key functional building blocks for motor
control systems
• These include:– SPM® smart power modules– PFC controllers– Integrated PWM controllers– BLDC controller– Discrete Components
• IGBT/MOSFETs• HV gate drivers
– Optocouplers
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APPENDIX
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Motion SPM® 5 V2 Series Modules
MOSFET modules with integrated bootstrap diodes & temp sense
29mm x 12mm
high power density (up to 200W)
1.5kV isolation voltage
optimized thermal management
Temperature sensing unit for HVIC
3 N-terminals for low-cost current sensing
high ruggedness
increased creepage distances (only T)
Built-in UVLP & Bootstrap Diodes (incl. 15Ohm)
low conducted and radiated EMI
Voltage rating x10S=SMD, T=Double DIP
FSB50250A(S/T)FSB50450A(S/T)FSB50550A(S/T)FSB50825A(S/T)
(1) COM
(2) VB(U)
(3) VCC(U)
(4) IN (UH)
(5) IN (UL)
(6) N.C
(7) VB(V)
(8) VCC(V)
(9) IN (VH)
(10) IN (VL)
(11) Vts
(12) V B(W)
(13) VCC(W)
(14) IN (WH)
(15) IN (WL)
(16)
(17) P
(18) U, VS(U)
(19) NU
(20) NV
(21) V, VS(V)
(22) N W
(23) W, VS(W)
COM
VCC
LIN
HIN
VB
HO
VS
LO
COM
VCC
LIN
HIN
VB
HO
VS
LO
Vts
COM
VCC
LIN
HIN
VB
HO
VS
LO
N.C
600V SuperFET® II MOSFETs for Higher Power: FSB50660SF (0.70Ωmax) & FSB50760SF (0.53Ωmax)New
27
Motion SPM® 5 V2 Series ModulesMeasurable temperature allows for power reduction at high temperature
- Voltage Output of HVIC temperature- Linear characteristic : VTSU=0.02*TIC+0.3V
[ Simulation data ]
Slope: 20mV/oC
Boundary (0oC, 150oC): 0.3V, 3.3V
Temperature sensing point
[ Internal Structure ]
28
MOSFET-Based SPM® Modules have long short circuit times
Advanced & Rugged Silicon Technology
PRODUCT NAME IMAX IMIN TSCW
#1 @ VCC=15.0V, VDS=400V 16.20 [A] 13.60 [A] 44.2 [μsec]
#2 @ VCC=15.0V, VDS=400V 17.15 [A] 13.85 [A] 43.1 [μsec]
Competitor#1 @ VCC=15.0V, VCE=400V 6.80 [A] 6.20 [A] 7.57 [μsec]
#2 @ VCC=15.0V, VCE=400V 6.96 [A] 6.38 [A] 7.18 [μsec]
T=[10μs/div]
Vdc=[100V/div]
Ic=5.0[A/div]
Vin=5.0[V/div]
T=[2μs/div]
Vdc=[100V/div]
Ic=5.0[A/div]
Vin=5.0[V/div]
Short Circuit Test Waveform of FSB50450 Short Circuit Test Waveform of Competitor part
Tscwt =
44[usec]
Tscwt =
7.5[usec]
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FSL Family(FSL1/2 Series)
Competitor
Manufacture In-house Own FAB & Assembly Plants Outsource FAB & Assembly Plants
BreakdownAvalanche
Energy
Two Chip (PWM/MOSFET)VDMOS General Vertical Structure
Very High Avalanche Energy Guaranteed [ EAS=400.0 mJ ]
One Chip(PWM+MOSFET) for easy sourcingLDMOS General Lateral Structure
Very Low Avalanche Energy[ EAS= 4.0 mJ ]
Secondary Protections
Output Short ProtectionAbnormal OCP Protection
N/A
Power Loss Standby Power at No Load 25~ 50mW Standby Power at No Load 50mW – 200mW
Low Voltage MemoryLogic
High VoltageDevices
General StructureInformation
General StructureInformation
FSL Family Versus Competitor
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