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Fairchild solving design problems in motion control
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1
Solving Design Challenges
in Motion Control
European Sales & Marketing
PCIM May 2013
Marketing and Applications Team
2. 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.
9. 9
PFC-Solutions
(10) VTH
(1) VCC
COM
VCC
IN(S)
VFO
CSC
OUT
CFOD
NTC
Thermistor
(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
NTC
Thermistor
(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-
Q1
D3
Q2
D4
D1 D2
Boost-PFC
Bridgeless-PFC
Interleaved Boost-PFC
10. 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
FPAB20BH60B
FPAB30BH60B
(10) VTH
(1) VCC
COM
VCC
IN(S)
VFO
CSC
OUT
CFOD
NTC
Thermistor
(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
11. 11
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
FPDB40PH60B
FPDB50PH60
FPDB60PH60B
(20) VTH
(1) VCC
COM
VCC
IN(R)
VFO
CSC
OUT(S)
CFOD
NTC
Thermistor
(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-
Q1
D3
Q2
D4
D1 D2
Current rating Tc = 25 °C Voltage rating x10
12. 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
VOUT
D2
D1
FAN9611
1
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
15. 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
EMI
Filter + +
HV
VDD
+
GNDFB
IPK
Drain
PWM
+
0
10
20
30
40
50
230Vac 240Vac 265Vac
Standby Power mW (for 16W/5V supply)
16. 16
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-DC
IN
GND
VCC
Vcomp
ILIMIT
VFB
D
D
Non-isolated flyback
Buck
GND
VCC
Vcomp
ILIMIT
VFB
D
D
DC
OUT
HV-DC
INPUT
LSOP7
17. 17
Reliability and Safety
Protection 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 protection
or
Over current protection
ESD
High ESD
immunity
ESD
Relatively Rugged
parts
Over load protection (OLP)
Over voltage Protection (OVP)
Protected by OCP, OLP, OVP, AOCP, OSP, TSD
20. 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. 21
New Architecture for BLDC Motor Control
Advanced Motor Controller
A hardware-based motor controller
plus configurable processing core
which can be configured to several
kinds of specific motor control
algorithm.
Embedded MCU
A MCS®51-compatible MCU processor
provides motor control commands to the
AMC to perform motor control
activities, and manage external
communication interfaces
GPIO
UART
I2C
SPI
FOC
DQ
Sinusoidal
Integration of Analog and Digital IC
22. 22
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. 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.
24. 24
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
26. 26
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 x10
S=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) NW
(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. 27
Motion SPM® 5 V2 Series Modules
Measurable 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. 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/di
v]
Vin=5.0[V/div]
T=[2μs/div]
Vdc=[100V/div
]
Ic=5.0[A/di
v]
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]
29. 29
FSL Family
(FSL1/2 Series)
Competitor
Manufacture In-house Own FAB & Assembly Plants Outsource FAB & Assembly Plants
Breakdown
Avalanche
Energy
Two Chip (PWM/MOSFET)
VDMOS General Vertical Structure
Very High Avalanche Energy Guaranteed
[ EAS=400.0 mJ ]
One Chip(PWM+MOSFET) for easy sourcing
LDMOS General Lateral Structure
Very Low Avalanche Energy
[ EAS= 4.0 mJ ]
Secondary
Protections
Output Short Protection
Abnormal OCP Protection
N/A
Power Loss Standby Power at No Load 25~ 50mW Standby Power at No Load 50mW – 200mW
Low Voltage
Memory
Logic
High Voltage
Devices
General
Structure
Information
General
Structure
Information
FSL Family Versus Competitor
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Editor's Notes
You need to put all of these electronics inNow I have to use electronics - softwareIt’s not the technologly but the simplicityCurrent Sensors AmplifiersAC MOTORS - Universal motors - DC Motors – car – constant voltageBrush less motors - carbon brushes that ware outBrushless DC - 3 phase makes the motor go around - Electronics – makes the motor goes aroundPMSM – magnetic field is different – smoother than the brushless – Induction motor – is also 3phase - we can do this as well. Less energy efficientNeed 3 connections to drive them - Automotive slide put in AppendixSomething from Fabio3 phase inverterAPMPower Trench MOSFETsDrivers12V instead of AC
