Download Induction Motor Vector Control.

Induction Motor Vector
Control.
Group F
Group Members and Responsibilities
● Justin Barwick (EE)
○ Control System (Design)
○ Control System
Implementation (Secondary)
● Chris Guido (CpE)
○ Control System
(Implementation)
○ User Interface
● Merritt Robbins (EE)
○ Power System (High
Voltage)
● Will Santos (EE)
○ Power System (Low
Voltage)
Motivation
Electric motors are an already enormous, ever - expanding industry
~45% of the world’s electricity (Waide, 2011) [1]
AC induction motors offer performance benefits vs DC motors
Efficiency
Reliability
Simplicity
Electric transportation systems
Tesla Motors
Variable - speed industrial applications
Machine tools
HVAC
Goals / Objectives
Implement Field Oriented Control (FOC)
Design high voltage power system (325V DC bus)
Low voltage DC bus regulation
15V, 8.5, 4V, 3.6V, 3.3V
Implement two embedded processors
Divide computation to improve performance
High voltage Isolated Measurements
Phase voltage, current
Temperature
Overall Block Diagram
Design Approach
Mathematical Modeling
Numerical Calculation
Schematic Capture
KiCad EDA suite
Power System
Separate high voltage and low voltage boards
High efficiency focus
General Design Decisions
Motor Selection
Reliance Electric ½ HP, 230V/460V fan cooled
Power Output Specification
Don’t trip the breaker
Subsystem Block Diagrams
Space Vector Modulation
Represent three-phase currents in a rotating
reference frame
Alpha-beta-zero transform
Direct-quadrature-zero transform
d-axis control rotor flux linkage
q-axis control motor torque
Machine Equation
Used to recover voltage values in alpha-beta-zero domain
Allows for mapping along inverter states
Calculation of rotor speed
Inverter State Mapping
Inverter
State
Phase C
Activity
Phase B
Activity
Phase A
Activity
000
Inactive
Inactive
Inactive
001
Inactive
Inactive
Active
010
Inactive
Active
Inactive
011
Inactive
Active
Active
100
Active
Inactive
Inactive
101
Active
Inactive
Active
110
Active
Active
Inactive
111
Active
Active
Active
PWM Generation
Zero-sequence transition pulses
Projection time durations
PWM Generation
I/O Peripheral
Algorithm
Algorithm for gathering inputs
from sensors
Data will only be read in if the
sensor data
Display Algorithm
Algorithm driving the LCD
display
Updating on a constant basis
Two view modes
Just determines which
parameters will be
displayed on LCD
PWM Algorithm
Software implementation of Pulse
Width Modulation generation
Synchronous Rectifier Gate Driver
Part Number
IR1167
Emulated ideal diode with a MOSFET
Manufacturer
International Rectifier
Senses V_DS and drives gate accordingly
Input Voltage
12 ~20V
T_on / T_off
40ns / 60ns
Easy package to work with
Trimmable turn off threshold
Maximum Drain Sense
Voltage
200V
Package
8 - SOIC (Standard)
Cost
$2.70 (1 qty)
Synchronous Rectifier Switches (MOSFET)
Part Number
TK62N60X
Low cost for 400V rating
Manufacturer
Vishay / SIliconix
0.3 Ohms * 0.4A^2 = 0.048W
Rated V_DS
400V
Rated I_D
10A
Common Package
10V Gate charge
R_DS (ON)
300 mOhm
Package
TO-247
Cost
$2.70 (1 qty)
DC Link Capacitor
Part Number
C4DEFPQ6380A8TK
Film Capacitor
Manufacturer
Kemet
Small Size
Rated Voltage
400V
Capacitance (tol.)
380uF (10%)
Extremely High Ripple
Non polar
Package
Chassis Mount
Cost
$89.00 (1 qty)
Power Inverter Gate Driver
Part Number
FAN7190M_F085
Low cost
Manufacturer
Fairchild
Standard package
High Side Voltage
650V
Minimum Pulse Width
80ns
High and low side in one chip
Logic level inputs
Package
8 - SOIC (Standard)
Cost
$1.62 (1 qty)
Capable of driving around 0.2 - 99.8% duty
cycle at 20 kHz switching frequency
Power Inverter Switch (IGBT)
Part Number
FGA5065ADF
Small package
Manufacturer
Fairchild
Extremely high current rating
Ratec V_C
650V
Cont. I_C
50A (100A pulses)
Package
TO - 3PN
Cost
$4.79 (1 qty)
Low losses
Current Transformer
Part Number
CR8348-2000-F
High turns ratio for low power sensing
Manufacturer
CR Magnetics Inc.
Frequency Range
20Hz ~ 200kHz
Self isolates eliminating the need for isolation
amplifiers
Current Rating
50A
Decently sized package
Turns Ratio
1:2000
Perfect frequency range for our application
Package
24x11mm Thru-Hole
Cost
$7.05 (1 qty)
Rotary Encoder
Part Number
HEDR-55L2-BY09
Very high resolution
Manufacturer
Broadcom / Avago
Cycles per Revolution
3600
Three channels indicate position, direction of
rotation, and when each full revolution is
completed.
Channels
3 (A,B,I)
Tolerant of high temperatures (100C)
Package
Shaft Mounted (8mm)
Cost
$51.00 (1 qty)
General Purpose Op-Amp
Part Number
OPA2170
Dual Op-Amp, single supply package
Manufacturer
Texas Instruments
Low Cost
Input Voltage
+/- 1.35V ~ 18V
(2.7 ~ 36V)
High Current per channel
GbP
1.2MHz
Low input current
Bias Current (max)
15pA
Small but relatively easily soldered package
Input Offset Voltage
(max)
+/- 1.8mV
Package
8 - VSSOP
Measurement Op_Amp
Part Number
MAX4238ASA+
Extremely low input bias and offset
Manufacturer
Maxim
Ideal for motor voltage sensing
Input Voltage
2.7V ~ 5.5V
GbP
1MHz
Bias Current (max)
1pA
Input Offset Voltage
(max)
0.1uV
Package
8 - SOIC (standard)
Cost
$1.30 (1 qty)
Slightly lower specs in all other areas than
OPA2170
Bigger package but worth it for the bias and
offset.
MSP430
Microcontroller
Purpose
Collect inputs from sensors
Drive LCD Display
Selection Criteria
Manufacturer
Texas Instruments
Part Number
MSP430F5529IPN
I/O Pins
63
Clock Speed
25MHz
Main Memory Size
128KB
Power Supply
1.8V to 3.6V
Price
$8.06
Low Cost
Low Power
Easily programmable
Large number of GPIO pins
Piccolo
Microcontroller
Purpose
Drives the inverter
Manufacturer
Texas Instruments
Part Number
TMS320F28027FPTQ
I/O Pins
Up to 22
High clock speed
Clock Speed
60MHz
Enhanced Control Peripherals
Main Memory Size
64KB
Power Supply
3.3V
Price
$11.11
Implements PWM algorithm to
control the motor
Selection Criteria
4 ePWM Channels
7 ADC Channels with 13-bit
resolution
LCD Display
Purpose
Display information to user
Selection Criteria
Large screen real-estate
Manufacturer
Crystalfontz
Part Number
CFAX1286U-NFH
Power Required
8.5V
InstaSPIN-FOC
•
•
•
TI Software designed for threephase motor systems
Built-in motor parameter
identification
FAST™ Software Encoder
• High flux signal for
applications and stable
monitoring
• High accuracy flux-angle
estimation
• Mechanical, electrical,
and slip speed
estimations
• Accurate rotor shaft
torque signal for
monitoring
Software Tools
controlSUITE™
Set of software infrastructure and tools
Provides datasheets, libraries, and other resources for specific devices
MotorWare™
Provide additional support for InstaSPIN-FOCTM technologies
Modular support for all components (MCU, Power Electronics, Control System
and Techniques)
Enables object oriented software design
Issues
Isolation of High voltage - What is safe?
Mathematical Complexity
Measurement Identification / Accuracy
Budget and Financing
Carey Family Donation ~ $500.00
Self financed
Current Progress
Power System Design: 96%
Mathematical Modeling Research: 90%
Control System Design
Low Voltage Regulation
Regulator Design Considerations
Efficiency/Power Dissipation
Application (Switching Regulation or Linear Regulation)
Switching Regulator Selection:
Texas Instruments TPS54560
Linear Technology LTC 3649
Linear Voltage Regulation
Linear Technology LT3008
Full Wave Schottky Bridge Rectifier
Purpose
Provides the main DC bus for the Low Voltage Electronics
Design Considerations
Diode Type (Schottky)
Low Vf
Good Conduction Characteristics
Smoothing Capacitance
NXP
Manufacturer
DC Forward
Current
3A
Forward Voltage
540 mV
Package
SOD-123
Price
$0.54
Switching Regulator IC Considerations
Losses
Switching loss, gate drive loss, and supply current losses are negligible
Conduction loss provides largest contribution to total power dissipation
Power and Efficiency Characterization
Switching
Regulator
Max Power
Dissipation
Efficiency
Price
TPS54560
1.02 W
85%-90%
$5.65
LTC3649
1.82 W
85%-90%
$12.31
15V Output Switching Regulation
TPS54560
Purpose
● Provides the 15V Rails referenced to DC_Link- for the Inverter
● Provides 4V LV DC Rail for other regulator loads
Selection Criteria
● Low Power Dissipation
● High Efficiency at normal loads
PCB Layout Considerations
● Frequency Dependent Elements
● Catch Diode/Inductor
○ Need to be close to SW pin
Manufacturer
Texas Instruments
Part Number
TPS54560
Power Required
20V
Switching Frequency
100 kHz-2MHz
Output Current (Max)
5A
Package
HSOP(8)
Efficiency
85%-90%
Price
$5.65
Switching Regulator Catch Diode Selection
Purpose
Reverse Polarity Protection
Selection Criteria
Peak Reverse Voltage
Conduction Loss Minimal (1.5W at worst)
Low Vf
Low Reverse Power Dissipation
Manufacturer
NXP
Part Number
PMEG4030ER
Peak Reverse
Voltage
40V
Peak Output Current
3A
Package
SOD-123
Price
$0.41
LT3008 Linear Voltage Regulator
Purpose
Supply the 8.5V, 3.6V, and 3.3V LV DC Rails
Design Considerations
Set I_adj with R1
Setting R2 determines Vout
Low Dropout
Manufacturer
Linear Technology
Dropout Voltage
300mV
Quiescent Current
3 microamps
Package
TSOT-23
Price
$1.46
Works Cited
[1] Waide, Paul, Brunner, Conrad U., et al.: Energy-Efficiency Policy Opportunities
for Electric Motor-Driven Systems. International Energy Agency Working Paper,
Energy Efficiency Series, Paris 2011