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Solutions for Electrical Traction Motor Drive Regenerative Breaking (AA119)
July 16, 2009
Leos Chalupa, Ph.D.Senior System Solution Engineer
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Session Content
►Kinetic Energy Recovery System
►Motor / Generator
►KERS Control Unit
►Energy Storage System
►Freescale Advanced Peripherals
►Motor Control on Freescale Website
TM
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Kinetic Energy Recovery System
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Typical Hybrid System
• High efficiency gas engine• Planetary gear power split device
AC synchronous generator• High voltage AC-DC inverter• Nickel-metal hydride battery• Permanent magnet AC motor
Battery
Inverter
Motor
Drive wheels
Generator
Engine
Power split device
Power circuit
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Hybrid Powertrain Roadmap
Engine Start/Stop
Regenerative Braking
Engine Assist
Full Electric Drive
MicroHybrid
MildHybrid
FullHybrid
SeriesHybrid
Hyb
rid F
unct
ions
2-10k12-42V
10-20k42-100V
20-80k100-300V
80-110k300-600V
Parallel Hybrids
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Driving Hybrid
► Regenerative Braking. The electric motor applies resistance to the drivetrain causing the wheels to slow down. In return, the energy from the wheels turns the motor, which functions as a generator, converting energy normally wasted during coasting and braking into electricity, which is stored in a battery until needed by the electric motor.► Electric Motor Drive/Assist. The electric motor provides additional power to assist the engine in accelerating, passing, or hill climbing. This allows a smaller, more efficient engine to be used. In some vehicles, the motor alone provides power for low-speed driving conditions where internal combustion engines are least efficient.
Source: TOYOTA, Hybrid Synergy Drive, Information Portal
Hybrid strength
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Kinetic Energy Recovery Systems
►Kinetic Energy Recovery Systems (KERS) are currently in use for the motor sport Formula One's 2009 season, and under development for road vehicles.
MotorGenerator
KERS Control Unit
Boost Request(energy to be released)
Driver
Breaking System(energy to be recovered)
Energy Recovery
Energy Release
Energy Storage System
DC
/DC
Battery
Flywheel
TM
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Motor / Generator
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Electric Motor Type Classification
ELECTRIC MOTORS
AC DC
SYNCHRONOUSASYNCHRONOUS
BrushlessInduction Reluctance StepperSinusoidal
Permanent Magnet
Wound Field
Surface PM
Interior PM
• Stator same• Difference in rotor construction
If properly controlled• Provides constant torque• Low torque ripple
SR
VARIABLE RELUCTANCE
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Asynchronous vs. Synchronous
►3-phase winding on the stator – distributed or concentrated
►Assumed sinusoidal flux distribution in air gap►Different rotor construction & consequences
ACIM– Squirrel cage (rugged, reliable, economical)– No brushes, no PM– Low maintenance cost
Synchronous – Rotor with permanent magnet– High efficiency (no rotor loses)
►Synchronous motor rotates at the same frequency as the revolving magnetic field
►Asynchronous means that the mechanical speed of the rotor is generally different from the speed of the revolving magnetic field
ω
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Trapezoidal vs. Sinusoidal PM Machine
►Sinusoidal” or “Sinewave” machine means Synchronous (PMSM)
►Trapezoidal means brushless DC (BLDC) motors
►Differences in flux distribution►Six-Step control vs. Field-Oriented Control►Both requires position information►BLDC motor control
• 2 of the 3 stator phases are excited at any time• 1 unexcited phase used as sensor (BLDC
Sensorless)►Synchronous motor
• All 3 phases persistently excited at any time• Sensorless algorithm becomes complicated
Motor Reversal
Magnetic Flux Linkages of phase A,B,C
Back-EMF voltages of phase A,B,C
Back-EMF phase-to-phase voltages A,B,C
speed
-0,600
-0,400
-0,200
0,000
0,200
0,400
0,600
0,0000 0,0200 0,0400 0,0600 0,0800 0,1000 0,1200 0,1400 0,1600 0,1800 0,2000
Psi_A
Psi_B
Psi_C
-100,000
-80,000
-60,000
-40,000
-20,000
0,000
20,000
40,000
60,000
80,000
100,000
0,0000 0,0200 0,0400 0,0600 0,0800 0,1000 0,1200 0,1400 0,1600 0,1800 0,2000
Ui_A
Ui_B
Ui_C
-200,0
-150,0
-100,0
-50,0
0,0
50,0
100,0
150,0
200,0
0,0000 0,0200 0,0400 0,0600 0,0800 0,1000 0,1200 0,1400 0,1600 0,1800 0,2000
Ui_AB
Ui_BC
Ui_CA
n [rpm]
-1000
-500
0
500
1000
0,0000 0,0200 0,0400 0,0600 0,0800 0,1000 0,1200 0,1400 0,1600 0,1800 0,2000
n [rpm]
Radial PMSM Torque Basics
N·I
N·I
rδ
l
CuCu
iCuCue
CuCump
m
CuCup
p
pp
AIN
rlA
IUAABP
AABP
TP
AABT
IΨINABT
rlINBprFpTlINBF
p
p
p
σ
π
σω
σω
ω
σ
δδ
δδπ
δδπ
δδπ
δδπ
δδδ
δ
⋅=⋅
⋅⋅=
⋅≈⋅⋅⋅⋅⋅≈
⋅⋅⋅⋅⋅≈
⋅=
⋅⋅⋅⋅≈
⋅≈⋅⋅⋅⋅≈
⋅⋅⋅⋅⋅=⋅⋅≈⋅⋅⋅=
Σ
Σ
Σ
Σ
Σ
2where
22
1
Bδ
Aδ
Torque
Power
Radial PMSM Torque Basics
N·I
N·I
rδ
l
CuCu
iCuCue
CuCump
m
CuCup
p
pp
AIN
rlA
IUAABP
AABP
TP
AABT
IΨINABT
rlINBprFpTlINBF
p
p
p
σ
π
σω
σω
ω
σ
δδ
δδπ
δδπ
δδπ
δδπ
δδδ
δ
⋅=⋅
⋅⋅=
⋅≈⋅⋅⋅⋅⋅≈
⋅⋅⋅⋅⋅≈
⋅=
⋅⋅⋅⋅≈
⋅≈⋅⋅⋅⋅≈
⋅⋅⋅⋅⋅=⋅⋅≈⋅⋅⋅=
Σ
Σ
Σ
Σ
Σ
2where
22
1
Bδ
Aδ
Torque
Power
Radial PMSM Torque Basics
N·I
N·I
rδ
l
CuCu
iCuCue
CuCump
m
CuCup
p
pp
AIN
rlA
IUAABP
AABP
TP
AABT
IΨINABT
rlINBprFpTlINBF
p
p
p
σ
π
σω
σω
ω
σ
δδ
δδπ
δδπ
δδπ
δδπ
δδδ
δ
⋅=⋅
⋅⋅=
⋅≈⋅⋅⋅⋅⋅≈
⋅⋅⋅⋅⋅≈
⋅=
⋅⋅⋅⋅≈
⋅≈⋅⋅⋅⋅≈
⋅⋅⋅⋅⋅=⋅⋅≈⋅⋅⋅=
Σ
Σ
Σ
Σ
Σ
2where
22
1
Bδ
Aδ
Torque
Power
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Motor/Generator Key Points
►Motor/Generator is used to boost the car performance and to recover the kinetic energy (peak operation)
►Motor/Generator must be therefore very small and powerful (not to carry unnecessary mass/space). It is designed to work at high electric frequency (~1 kHz) – high number of poles
►Such design requires high resolution PWM, both in time and amplitude
►Thus the advanced PWM peripheral (see further section) is key todesign powerful electric motors
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3-phase PMSM Model
► Considering sinusoidal 3-phase distributed winding and neglecting effect of magnetic saturation and leakage inductances
A
B
C
⎥⎥⎥
⎦
⎤
⎢⎢⎢
⎣
⎡+
⎥⎥⎥
⎦
⎤
⎢⎢⎢
⎣
⎡=
⎥⎥⎥
⎦
⎤
⎢⎢⎢
⎣
⎡
C
B
A
C
B
A
s
C
B
A
dtd
iii
Ruuu
ψψψ
Stator voltage equations
( )
⎥⎥⎥⎥⎥⎥⎥
⎦
⎤
⎢⎢⎢⎢⎢⎢⎢
⎣
⎡
⎟⎠⎞
⎜⎝⎛ +
⎟⎠⎞
⎜⎝⎛ −+
⎥⎥⎥
⎦
⎤
⎢⎢⎢
⎣
⎡
⎥⎥⎥
⎦
⎤
⎢⎢⎢
⎣
⎡=
⎥⎥⎥
⎦
⎤
⎢⎢⎢
⎣
⎡
πθ
πθ
θ
ψψψψ
32cos
32cos
cos
e
e
e
PM
C
B
A
cccbca
bcbbba
acabaa
C
B
A
iii
LLLLLLLLL
Stator linkage fluxψPM
)iuiui(uωp
ωPT CiCBiBAiA
e
p
m
ii ++==
Internal motor torque
π))(θiΨπ)(θiΨ)(θiΨ(pT eCPMeBPMeAPMpi 32
32 sinsinsin +−−−−=
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3-phase PMSM Model
► Considering sinusoidal 3-phase distributed winding and neglecting effect of magnetic saturation and leakage inductances
A
B
C
⎥⎥⎥
⎦
⎤
⎢⎢⎢
⎣
⎡+
⎥⎥⎥
⎦
⎤
⎢⎢⎢
⎣
⎡=
⎥⎥⎥
⎦
⎤
⎢⎢⎢
⎣
⎡
C
B
A
C
B
A
s
C
B
A
dtd
iii
Ruuu
ψψψ
Stator voltage equations
( )
⎥⎥⎥⎥⎥⎥⎥
⎦
⎤
⎢⎢⎢⎢⎢⎢⎢
⎣
⎡
⎟⎠⎞
⎜⎝⎛ +
⎟⎠⎞
⎜⎝⎛ −+
⎥⎥⎥
⎦
⎤
⎢⎢⎢
⎣
⎡
⎥⎥⎥
⎦
⎤
⎢⎢⎢
⎣
⎡=
⎥⎥⎥
⎦
⎤
⎢⎢⎢
⎣
⎡
πθ
πθ
θ
ψψψψ
32cos
32cos
cos
e
e
e
PM
C
B
A
cccbca
bcbbba
acabaa
C
B
A
iii
LLLLLLLLL
Stator linkage fluxψPM
Forward ClarkeForward Clarke
)iuiui(uωp
ωPT CiCBiBAiA
e
p
m
ii ++==
Internal motor torque
π))(θiΨπ)(θiΨ)(θiΨ(pT eCPMeBPMeAPMpi 32
32 sinsinsin +−−−−=
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2-phase PMSM Model
► Considering sinusoidal 2-phase distributed winding and neglecting effect of magnetic saturation and leakage inductances
A
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡
β
α
β
α
β
α
ψψ
dtd
ii
Ruu
s
Stator voltage equations
Stator linkage fluxψPM
α
β
⎥⎦
⎤⎢⎣
⎡⋅Ψ+⎥
⎦
⎤⎢⎣
⎡⋅⎥⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡ΨΨ
=re
reiPM
S
S
S
S
Sdii
LL
θθ
β
α
β
α
sincos
00
0
Internal motor torque
)(23)(
23
αββαββααωiΨiΨpiuiu
pT pii
e
pi −=+=
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2-phase PMSM Model
► Considering sinusoidal 2-phase distributed winding and neglecting effect of magnetic saturation and leakage inductances
A
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡
β
α
β
α
β
α
ψψ
dtd
ii
Ruu
s
Stator voltage equations
Stator linkage fluxψPM
α
β
⎥⎦
⎤⎢⎣
⎡⋅Ψ+⎥
⎦
⎤⎢⎣
⎡⋅⎥⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡ΨΨ
=re
reiPM
S
S
S
S
Sdii
LL
θθ
β
α
β
α
sincos
00
0
Forward ParkForward Park
Internal motor torque
)(23)(
23
αββαββααωiΨiΨpiuiu
pT pii
e
pi −=+=
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Sinusoidal PM Motor Model in dq Synchronous Frame
► Salient machine model in dq synchronous frame aligned with the rotor• Stator Voltage Equations
• Stator Flux Linkages of Salient Machine
• Resulting stator voltage equations
• Internal motor torque
⎥⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−
+⎥⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡
q
d
e
e
q
ds
q
d
ss
ii
Ruu
ψψ
ωω
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡01
00
PMq
d
q
d
q
d
ii
LL
ψψψ
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡10
00
PMed
q
d
qe
q
d
q
d
q
ds
q
d
ii
LL
ii
sLsL
ii
Ruu
ψωω
qPMpdqqdpqiqdide
pi iΨpiΨiΨpiuiu
pT ⋅=−=+=
23)(
23)(
23ω
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Sinusoidal PM Motor Model in dq Synchronous Frame
► Salient machine model in dq synchronous frame aligned with the rotor• Stator Voltage Equations
• Stator Flux Linkages of Salient Machine
• Resulting stator voltage equations
• Internal motor torque
⎥⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−
+⎥⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡
q
d
e
e
q
ds
q
d
ss
ii
Ruu
ψψ
ωω
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡01
00
PMq
d
q
d
q
d
ii
LL
ψψψ
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡10
00
PMed
q
d
qe
q
d
q
d
q
ds
q
d
ii
LL
ii
sLsL
ii
Ruu
ψωω
R-L circuit
qPMpdqqdpqiqdide
pi iΨpiΨiΨpiuiu
pT ⋅=−=+=
23)(
23)(
23ω
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Sinusoidal PM Motor Model in dq Synchronous Frame
► Salient machine model in dq synchronous frame aligned with the rotor• Stator Voltage Equations
• Stator Flux Linkages of Salient Machine
• Resulting stator voltage equations
• Internal motor torque
⎥⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−
+⎥⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡
q
d
e
e
q
ds
q
d
ss
ii
Ruu
ψψ
ωω
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡01
00
PMq
d
q
d
q
d
ii
LL
ψψψ
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡10
00
PMed
q
d
qe
q
d
q
d
q
ds
q
d
ii
LL
ii
sLsL
ii
Ruu
ψωω
R-L circuit cross-coupling
qPMpdqqdpqiqdide
pi iΨpiΨiΨpiuiu
pT ⋅=−=+=
23)(
23)(
23ω
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Sinusoidal PM Motor Model in dq Synchronous Frame
► Salient machine model in dq synchronous frame aligned with the rotor• Stator Voltage Equations
• Stator Flux Linkages of Salient Machine
• Resulting stator voltage equations
• Internal motor torque
⎥⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−
+⎥⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡
q
d
e
e
q
ds
q
d
ss
ii
Ruu
ψψ
ωω
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡01
00
PMq
d
q
d
q
d
ii
LL
ψψψ
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡10
00
PMed
q
d
qe
q
d
q
d
q
ds
q
d
ii
LL
ii
sLsL
ii
Ruu
ψωω
R-L circuit cross-couplingback-EMF
qPMpdqqdpqiqdide
pi iΨpiΨiΨpiuiu
pT ⋅=−=+=
23)(
23)(
23ω
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Field Weakening - Why Is It Needed?
► For given strength of the rotor magnetic field there is point (base speed) where external voltage (Udc) can not “push” any more current “into” the el. motor against the back-EMF (Ui).
► Spinning el. motor above the “base speed” requires to lower the back-EMF (Ui) by weakening the rotor magnetic field.
el. motor speed
Base speed
Stator back-EMF
Maximal voltage
0 3-Phase Power Stage
PMSMUi Ui ≈ k · ω
Udc
Udc
≈ k
RLSimplified
El. Motor Model
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PMSM Field Weakening
► Required to get above motor base speed, where voltage capacity to overcome the back-EMF starts to be limited
► Makes the rotor magnetic field “weaker” in order to lower back-EMF voltage induced in the stator winding
► For PM motors FW means to apply opposite magnetic field to the permanent magnets (since PM rotates this FW field has to rotate as well). Note: the FW changes the angle between the stator and the rotor magnetic fluxes (in d, q rotor related coordinates)
βPMΨ ϑField
αPMΨ
PMΨ
α
βq
d
id
Field weakening range
speedBase speed
Stator voltage
Rotor flux magnitude
Maximal voltage
0
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Br
Φr
HC,FCH�C
Knee
0
Normal load point
Load characteristic
Demagnetization characteristic
Demagnetization effect of external field
Open-circuit operating point
Short-circuit point
BPMB’PM
PM Demagnetization Characteristic
Br
B
HC
HK
H
HC i
Normal
Intrinsic
Model for linear region (0 > H > Hk)
HBB recrPM ⋅+= μ
PM Demagnetization CharacteristicPM -typical hysteresis loop in both normal and intrinsic forms
( )rPMrec
PM BBH −=μ1
PM
Sd
liN ⋅
∑∑∑∑⋅
−⋅−
=⋅
−Φ=Φm
fw
m
PMC
m
fw
m
mPMrPM R
iNRlH
RiN
RR '
Φr
N·iSd
RmPM Rmδ
ΦPMΦr
Magnetic Circuit
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Static Sine PMSM Motor Model
► Static Machine Model in d-q rotating frame• Stator Voltage Equations
• Stator Flux Linkages
• Stator equations for non field weakening (iSd = 0)
• Stator equations for non field weakening (iSd = -ifw)
0==dtds⎥
⎦
⎤⎢⎣
⎡ΨΨ
⋅⎥⎦
⎤⎢⎣
⎡ −+⎥
⎦
⎤⎢⎣
⎡⋅⎥⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡
Sq
Sd
re
re
Sq
Sd
S
S
Sq
Sd
ii
RR
uu
00
00
ωω
⎥⎦
⎤⎢⎣
⎡⋅Ψ+⎥
⎦
⎤⎢⎣
⎡⋅⎥⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡ΨΨ
= 01
00
0SdiPMSq
Sd
S
S
Sq
Sd
ii
LL
0PMreSqSSdreSqSSq
SqSreSqreSdSSd
iRiRu
iLiRu
Ψ⋅+⋅=Ψ⋅+⋅=
⋅⋅−=Ψ⋅−⋅=
ωω
ωω
0PMrefwSreSqSSdreSqSSq
SqSrefwSSqreSdSSd
iLiRiRu
iLiRiRu
Ψ⋅+⋅⋅−⋅=Ψ⋅+⋅=
⋅⋅−⋅−=Ψ⋅−⋅=
ωωω
ωω
reduced Ui by increased ifw
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Torque of PMSM
►Torque Model in d-q rotating frame
qPMpi ipT ⋅Ψ⋅= 023
.0 konstPMd ==ψψBelow nominal speed
Above nominal speedqPMpi ipT ⋅Ψ⋅= 02
3
.0 konstiL SdSPMd ≠⋅−Ψ=ψ
Field weakening range
speedBase speed
Stator voltage
Rotor flux magnitude
Maximal voltage
0
Torque constant is not reduced !
S
N
22max0
22max
23
SdPMpi
SqSd
iIpT
iiI
−⋅Ψ⋅=
+=
Torque (iq) is reduced !
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Natural Limitations of the Control
d
q
u_max
Us
u_d
u_q
Current LimitsCurrent Limits
d
q
i_max
i_d_desired
i_q_limit
►Available voltage amplitude is limited by used type of power stage.
►Phase current amplitude is limited by capabilities of power devices and motor thermal design.
3-Phase Power Stage
PMSMUdc
TM
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KERS Control Unit
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KERS Energy/Power Flow
►Main KCU tasks:• control energy flow in
the system• control eMotor• monitor ESS• command DC/DC
ΔPeMotor ΔPKCU ΔPESS
ΔPeMotor ΔPKCU ΔPESS
Energy Recovery
Energy Release
Drive-train
Battery
Bat
teryD
rive-train
ΔPeMotor ΔPESS
Drive-train
MotorGenerator
KERS Control
UnitEnergy Recovery
Energy Release
Energy Storage System
DC
/DC
ΔPKCU
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Inner Loop (faster) ~100Inner Loop (faster) ~100μμss
Outer Loop (slower) ~ 1Outer Loop (slower) ~ 1--5ms5ms
Fast and Precise Control — FOC► Motor Control – Field Oriented Control (FOC)► The PI controllers operate in the d-q reference frame of the rotor, they are isolated from the sinusoidal variation of motor currents and
voltages and therefore perform equally well at low and high speeds. Iq is made to equal the Torque Command, while Id is equal to zero which allows motors, when operating below base speed, to produce the rated torque at any speed. When Id is not equal to zero then the motor is in Field Weakening, operating above the base speed, where the maximum torque is reduced with increase speed.
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FOC Transformation Sequencing
Phase APhase BPhase C
α
β
Phase APhase BPhase C
d
q
d
q
α
β3-Phase
to2-Phase
Stationaryto
RotatingSVM
3-PhaseSystem
3-PhaseSystem
2-PhaseSystem
AC
Rotatingto
Stationary
ACDCC
ontr
olPr
oces
s
Stationary Reference Frame Stationary Reference FrameRotating Reference Frame
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FOC Transformation Sequencing
Phase APhase BPhase C
α
β
Phase APhase BPhase C
d
q
d
q
α
β3-Phase
to2-Phase
Stationaryto
RotatingSVM
3-PhaseSystem
3-PhaseSystem
2-PhaseSystem
AC
Rotatingto
Stationary
ACDCC
ontr
olPr
oces
s
Stationary Reference Frame Stationary Reference FrameRotating Reference Frame
From measurement
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FOC Transformation Sequencing
Phase APhase BPhase C
α
β
Phase APhase BPhase C
d
q
d
q
α
β3-Phase
to2-Phase
Stationaryto
RotatingSVM
3-PhaseSystem
3-PhaseSystem
2-PhaseSystem
AC
Rotatingto
Stationary
ACDCC
ontr
olPr
oces
s
Stationary Reference Frame Stationary Reference FrameRotating Reference Frame
From measurement ?
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PMSM Current Control
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡10
00
PMed
q
d
qe
q
d
q
d
q
ds
q
d
ii
LL
ii
sLsL
ii
Ruu
ψωω
M
Motorola
Dave’sControlCenter
3ph PMSM
ud
uq
ωe θe
id
iq
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PMSM Current Control
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡10
00
PMed
q
d
qe
q
d
q
d
q
ds
q
d
ii
LL
ii
sLsL
ii
Ruu
ψωω
id*
iq*M
Motorola
Dave’sControlCenter
3ph PMSM
ud
uq
ωe θe
id
iq
Two axis components of required current vector
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PMSM Current Control
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡10
00
PMed
q
d
qe
q
d
q
d
q
ds
q
d
ii
LL
ii
sLsL
ii
Ruu
ψωω
id*
iq*
ωeψPM
M
Motorola
Dave’sControlCenter
3ph PMSM
ud
uq
ωe θe
id
iq
Two axis components of required current vector
back-EMF
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PMSM Current Control
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡10
00
PMed
q
d
qe
q
d
q
d
q
ds
q
d
ii
LL
ii
sLsL
ii
Ruu
ψωω
id*
iq*
ωeψPMωeLdid
−ωeLqiq
M
Motorola
Dave’sControlCenter
3ph PMSM
ud
uq
ωe θe
id
iq
Two axis components of required current vector
cross-couplingback-EMF
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PMSM Current Control
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡10
00
PMed
q
d
qe
q
d
q
d
q
ds
q
d
ii
LL
ii
sLsL
ii
Ruu
ψωω
id*
iq*
Controller
Controller
id
iq
-
-
ωeψPMωeLdid
−ωeLqiq
M
Motorola
Dave’sControlCenter
3ph PMSM
ud
uq
ωe θe
id
iq
Two axis components of required current vector
R-L circuit cross-couplingback-EMF
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PMSM Current Control
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡10
00
PMed
q
d
qe
q
d
q
d
q
ds
q
d
ii
LL
ii
sLsL
ii
Ruu
ψωω
id*
iq*
Controller
Controller
id
iq
-
-
ωeψPMωeLdid
−ωeLqiq
M
Motorola
Dave’sControlCenter
3ph PMSM
ud
uq
ωe θe
id
iq
Two axis components of required current vector
R-L circuit cross-couplingback-EMF
Independent control of DQ currentsIndependent control of DQ currents
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PMSM Current Control
⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡−+⎥
⎦
⎤⎢⎣
⎡⎥⎦
⎤⎢⎣
⎡+⎥
⎦
⎤⎢⎣
⎡=⎥
⎦
⎤⎢⎣
⎡10
00
PMed
q
d
qe
q
d
q
d
q
ds
q
d
ii
LL
ii
sLsL
ii
Ruu
ψωω
id*
iq*
Controller
Controller
id
iq
-
-
ωeψPMωeLdid
−ωeLqiq
M
Motorola
Dave’sControlCenter
3ph PMSM
ud
uq
ωe θe
id
iq
Two axis components of required current vector
R-L circuit cross-couplingback-EMF
Independent control of DQ currentsIndependent control of DQ currents
??????
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PI Controller Gain Calculation
► Implementation of zero Cancellation allows precise matching of characteristic polynomial coefficients
► Enables simple tuning of the current loop bandwidth and attenuation
Controller
Controller
id
iq
-
-
τRL
τRL
uq_RL
ud_RLid_ZCZeroCancellation
id*
iq_ZCZeroCancellation
iq*
LK
RLK
I
P20
02
ω
ξω
=
−=
PI controller gains
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Natural Limitations of the Control
►Available voltage amplitude is limited by used type of power stage
►Phase current amplitude is limited by capabilities of power devices and motor thermal design
d
q
u_max
Us
u_d
u_q
Current LimitsCurrent Limits
d
q
i_max
i_d_desired
i_q_limit
3-Phase Power Stage
PMSMUdc
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UBus
PWM1
PWM4PWM2
PWM3 PWM5
PWM6
Three-phase PWM waveforms and harmonic spectrum.Source: Power Electronics, by Ned Mohan, Tore Undeland, and William Robbins, John Wiley & Sons, 1995
Three Phase Voltage Generation
TMFreescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2009. 47
BC
A
PWM3PWM1
PWM4PWM2
PWM5
PWM6
Sinusoidal Modulation - Limited in Amplitude
► In sinusoidal modulation the amplitude is limited to half of the DC-bus voltage
► The phase to phase voltage is then lower then the DC-bus voltage (although such voltage can be generated between the terminals)
Can such a modulation technique be found that wouldgenerate full phase-to-phase voltage?
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UD
C-B
US
Uph
ase-
phas
e BC
A
PWM3PWM1
PWM4PWM2
PWM5
PWM6
Sinusoidal Modulation - Limited in Amplitude
► In sinusoidal modulation the amplitude is limited to half of the DC-bus voltage
► The phase to phase voltage is then lower then the DC-bus voltage (although such voltage can be generated between the terminals)
Can such a modulation technique be found that wouldgenerate full phase-to-phase voltage?
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BC
A
PWM1
PWM4PWM2
PWM3 PWM5
PWM6 Uph
ase-
phas
e BC
A
Full Phase-to-Phase Voltage Generation
► Full phase-to-phase voltage can be generated by continuously shifting the 3-phase voltage system
► The amplitude of the first harmonic can be then increased by 15.5%
15%
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Uph
ase-
phas
e
BC
A
PWM1
PWM4PWM2
PWM3 PWM5
PWM6
BC
A
Full Phase-to-Phase Voltage Generation
► Full phase-to-phase voltage can be generated by continuously shifting the 3-phase voltage system
► The amplitude of the first harmonic can be then increased by 15.5%
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B C
A
How to Increase Modulation Index
► Modulation index is increased by adding the “shifting” voltage u0 to first harmonic
► “Shifting” voltage u0 must be the same for all three phases, thus it can only contain3r harmonics!
15%
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B C
A
How to Increase Modulation Index
► Modulation index is increased by adding the “shifting” voltage u0 to first harmonic
► “Shifting” voltage u0 must be the same for all three phases, thus it can only contain3r harmonics!
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Field Oriented Control Summary
►Using vector control technique, the control process of AC induction and PM synchronous motors is similar to control process of separately excited DC motors
►In special reference frame, the stator currents can be separatedinto:
• Torque-producing component• Flux-producing component
►Wide variety of control options►Better performance
• Full motor torque capability at low speed• Better dynamic behavior• Higher efficiency for each operation point in a wide speed range• Decoupled control of torque and flux• Natural four quadrant operation
TM
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Energy Storage System
TM
55Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2009.
Battery Energy Storage
►Current technology offers:• high power density• flat discharge and regeneration power curves• fast charge capability• low heat content per watt hour of stored energy• wide state of the charge window• low impedance growth over time
Source: EnerDel, A123
TM
56Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2009.
DC/DC Converter Operation
►Operating Modes
Voltage boosting Battery charging
~ 35
0 V
~ 35
0 V
+ Δ
TM
57Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2009.
DC/DC Converter – Advanced Design
►Converter is split into several phases:• Allows for lower current power devices to be used in each phase• Prevents difficult paralleling of the power devices• Enables to reduce battery current ripples by phase shifting the operation
of each individual converter.
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Flywheel Energy Storage - CD DYNASTORE®
►Reluctance motor• high inertia of rotor• homogeneous rotor
no windings, magnets, rotor cage
• no induced voltage during idle operation
Source: Compact Dynamics
bearing of rotor
rotor
stator
stator windings
channel for coolant backflow
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0 30 60 90 120 150 180 210 240 270 300 330 360position
indu
ctan
ce
L_A L_B L_C
0 30 60 90 120 150 180 210 240 270 300 330 360position
indu
ctan
ce
L_A L_B L_C
Motor Mode Generator Mode
SR Motor Control Basics
►The rotor position is needed for proper commutation of motor phasesVDC
C Ph 1
I1
Ph 2
I2
Ph 3
I3V
T1 T3 T5
T6T4T2D2
D1
D4 D6
D3 D5
Phase Inductance
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Sensorless SR Motor ControlBased on Inductance Slope Detection
Block Diagram
alignedposition
L
θon θoff position / time
position / time
iph
-UDC-BusPWM = Speed Controller
Output
uph
“just in touch”position
unalignedposition
SpeedController
PWMGenerator
ωdesired
PWM OutputDuty Cycle
Controller
ωactual
ωerror
Power Stage
θon θoff
-Σ
Timer CapturePeak
DetectorSpeed
calculation
► Inductance slope detection is transformed to the current peak detection
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Sensorless SR Motor Control Based on Flux Linkage Estimation
∫ ⋅−=Ψt
tEst dtiRu
1
* )(
Curve stored in memory
• Flux linkage is calculated in real time and compared to curve stored in memory
Position = 10°
Power StageDC Bus Voltage
Actual phase current
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On-Fly Phase Resistance EstimationFreescale Patent
θon~ t1 θoff
Liph
U A
timeposition
timeposition
Ψest for ΔR=0
Ψest for ΔR<0
Ψest for ΔR>0 ΨError for ΔR<0
ΨError for ΔR>0
t2
{ )2(_
0flux magnetic real
)2()2( tErrorEstttEst Ψ+Ψ=Ψ=
• Calculation of the flux estimation error at the time point (t2) when phase current falls to the zero level ∫
Ψ−=Δ 2
1
)2(_
t
t
tErrorEst
dtiR • Calculation of the
resistance error for resistance slow rate of change (temperature drift )
∫ ⋅Δ+−=Ψ2
1)2( ))((
t
ttEst dtiRRu
)2(_
2
1)2( tErrorEst
t
ttEst dtiR Ψ=⋅Δ−=Ψ ∫
∫∫ ⋅Δ−⋅−=Ψ2
1
2
1)2( )(
t
t
t
ttEst dtiRdtiRu
resistance error
TM
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Freescale Advanced Peripherals
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MC Peripherals System Diagram
► Advanced peripherals (like flexPWM, fast ADC and Cross Triggering Unit) enable efficient and cost effective control of the main KERS components - eMotor, DC/DC convertor and battery pack or flywheel energy storage
MCU
CTU
eTimer(Pos Counter)
PWM Reload
Timer/ Pos. decoder compare
External Signal
External Trigger
Trig
ger G
ener
ator
eTimer
flexPWM
Sche
dule
r
ADC Cmd
ADC Trig & Ackw
RealPWMs
PWMs
PWM Triggers
Real PWMs ADC Inputs
AD
C1
SHA
RE
D
AD
C2
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Timer Module:• Six Ch IC/OC• Double buffered registers for
detecting two edges in a row• eDMA supported• Integrated quad decoder support• 2 x BUS frequency high resolution
MCU
CTU
eTimer(Pos Counter)
PWM Reload
Timer/ Pos. decoder compare
External Signal
External Trigger
Trig
ger G
ener
ator
eTimer
flexPWM
Sch
edul
er
ADC Cmd
ADC Trig & Ackw
RealPWM’s
PWM’s
PWM Triggers
Real PWM’sADC Inputs
AD
C 1
SHAR
ED
AD
C 2
Electric Motor Control Peripherals
FlexPWM• Optimized for 3ph motor control• One „extra“ pair of PWM integrated• Includes dead time insertion, fault channels,
center/edge alignment, Distortion correction, …
• Register protections• Double buffered registers• eDMA supported• 2 x BUS frequency high resolution
2x ADC• Up to 24channels, with 4 shared. • 10-bit• 760 nsec conversion time• Limit checking & zero crossing detect
Cross Triggering Unit• Allows mcTIM, PWM, ATD
to be synchronized• Automatic ADC & eTimer acquisitions • No CPU intervention during the control
cycle
PWM0 Ch0PWM0 Ch1
PWM1 Ch0PWM1 Ch1
PWM2 Ch0PWM2 Ch1
PWM3 Ch0PWM3 Ch1
Con
trol
M
M
DC/DC
8
2
6
10 4 10
12bit
S&HMUX
I/F12bit
S&HMUX
I/F
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Motor Control PWM Peripheral Module
► Main Features► 4 Sub modules, each with complementary PWM generation, Isense
IC/OC and fault input
► 16 bits of resolution for center, edge aligned, and asymmetricalPWMs
► PWM outputs can operate as complimentary pairs or independent channels
► Independent control of both edges of each PWM output
► Independently programmable PWM output polarity
► Separate dead time for rising and falling edges
► Each complementary pair can operate with its own PWM frequency and dead time values
► All outputs can be programmed to change simultaneously via a "Force Out" event
► Double buffered PWM registers• Integral reload rates from 1 to 16• Half cycle reload capability
► Safety► Write protection for critical registers
► Fault inputs can be assigned to control multiple PWM outputs
► Programmable filters for fault inputs
PWM0 Ch0
Con
trol
PWM0 Ch1
PWM1 Ch0
PWM1 Ch1
PWM2 Ch0
PWM2 Ch1
PWM3 Ch0
PWM3 Ch1
Faults
Internal triggers
Complementary Pairs PWM Modes
Independent ChannelPWM Modes
auX
auX
auX
auX
• Permanent magnet synchronous motor (PMSM, PMAC) • Brushless DC motor (BLDC)• Brush DC motor (BDC)• AC induction motor (ACIM) • Switched reluctance motor (SRM) • Variable reluctance motor (VRM) • Stepper motors• DC/DC converters
CMP1CMP2Independent
Edge Control
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Internal counter
Desired PWM
Use Case for Cross Triggering Unit
Overall delay: ~0.4 ÷ 6 us
ADC trigger output event
ADC clock sync. ADC MUX selection S&H
ADC Sample
Trigger advancement to compensate ADC delays
ADC delays
Low pass filter delay + Topto: ~1usReal feedback signal
at ADC pin
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Motor Control eTimer Peripheral Module
► Main Features► Six 16-bit general purpose up/down timer/counter per module
► Powerful multiplexer between external pins and internal signals for external triggers
► Individual channel capability:• Input capture trigger• Output compare• Many counting modes (gating; triggered; one-shot)• Separate prescaler for each counter• Selectable clock source• Rotation direction flag (Quad decoder mode)
Sec.Input
PRIMARY
SECONDARY
PRESCALER
MUX
STATUS & CONTROL
DMA IF
COUNTER
TMRLOAD TMRHOLD
Edge Detect.
CAPTURE CAPTURE
CAP Buf.1 CAP Buf.1
TMRCMP1 TMRCMP2
CMPLD1 CMPLD2
COMP. COMP.
MUX OFLAG
OutputPrim.Input
CONTROL
OUTPUT
DATA BUS
Peripheral Clock
WD Count
UP/DNOutput Disable
OTHER CTNTRS
eTimer Channel
► Dual action capability per channel• PWM measurement 0% to 100%
► Quadrature decoder• rotor position• rotor zero speed detection (position watchdog)
► ADC trigger can also trigger input capture for rotor position measurement (ex: sin/cos sensor)
► Cascade able for higher precision (32 bits)
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IC 1
IC1IC2
Counter
forward forwardjitter jitterbackward
PRESCALER 16-BIT
Trigger/ClockController
Input Capture
ARR16 bit counter
Encoder Interface
IC 2
output trigger
Output Compare
Encoder Index
eTimer — Encoder Interface Mode
► The counter is clocked by each valid transition on IC 1 or IC 2 by incremental encoder
► Depending on the sequence the counter counts, automatically, up or down
► The Output of Encoder Interface can be connected to Encoder Index to reset the counter on zero position detection
► The timer can provide information on encoded position
► To obtain dynamic information (speed, acceleration, deceleration) by measuring the periods between two encoder events using a second timer
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Microcontroller
ADC
TIMER
PWM
Cross Triggering Unit
Resolver Physical LayerResolver Physical LayerUcos
Usin
Resolver θ
GNDUref
Vdc
3-Phase Low Voltage Power Stage
PWM Isa Isc
U_Dc bus
Isb
U_D
c bu
s
Motor
Differential Amplifier + FilterDifferential Amplifier + Filter
3.3V
0V
3.3V
0V
Resolver Ref. DriverResolver Ref. Driver
Resolver Driver and Interface
IRef 20-100 mA
LP
Filte
r
Tracking Observer Algorithm - SW
Tracking Observercomputation
co-sine samplesine sample
position speed # revolutions
Synchronization
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Motor Control on Freescale Website
Reference designs, application notes, …
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Freescale Motor Control Web Pageswww.freescale.com/motorcontrol
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Q&A
►Thank you for attending this presentation. We’ll now take a few moments for the audience’s questions and then we’ll begin the question and answer session.
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