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Motor Control Solutions

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Industrial 3-Phase BLDC motors

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System purpose

Industrial motor drives are the backbone of today’s global industry. They account for almost two-thirds of energy consumed in the industrial applications today.

With increasing stricter regulations, the need for high energy savings keeps growing for Industrial drives. While BLDC motors can be typically powered from the mains a VFD is required for efficiency and better control.

Industrial drives can be used with either AC motors or Brushless DC (BLDC) motors and onsemi provides a variety of components that can used to create a complete Industrial drive solution that will improve efficiency, reduce the overall system size, reduce BOM, and reduce the time to market for the customer.

Low R_DS(on) discrete Si and SiC FETs and integrated modules provide further advantages by reducing the overall system size, heat sink requirements and cost of the end equipment.

AC motor benefits -> Easy to control, low startup power demand, high durability, controllable start-up currents.

BLDC motor benefits -> low maintenance, high startup power, fast response to start and stop, higher efficiency.

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System implementations

EBV - onsemi - Motor Control - Topology for an Industrial drive (BLDC motors) - Mixed Media

Topology for an Industrial drive (BLDC motors)

AC / DC converter

Solution to convert AC from mains supply to HVDC bus for the whole system.

Power supplies

Convert HVDC bus to different low voltage DC (SMPS)
Low voltage DC / DC Auxiliary supply for Control hardware (SMPS, LDO)
DC / DC Auxiliary supply for Sensing hardware (SMPS, LDO)

Power stage

Output Inverter stage
Brake (optional)
Gate drivers

Sensing hardware

Current sensing amplifiers
Voltage sensing
Temperature sensing products

Control hardware

Microcontroller
MCU, ASIC, DSP, FPGA

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System description

While On Semiconductor provides a wide variety of discrete products for a complete motor drive solutions, On Semiconductor’s power modules can be used to reduce system size and time to market while increasing efficiency.

There are three types of power modules available in the current portfolio:

Power integrated Module (PIM) –
- CIB PIM → Converter + Inverter + Brake
- CIP PIM → Converter + Inverter + PFC
Intelligent Power Module (IPM) → Gate Driver + Inverter + Temperature sensor + Protection

A motor Control system can then be designed with three different approaches:

Solution using discrete components like IGBTs / MOSFETs / EliteSiC MOSFETs, Diodes, EliteSiC Diodes, gate drivers, PFC controllers, etc.
Solution using Power integrated modules (PIM) like CIB and CIP modules along with gate drivers.
Solution using Intelligent Power modules (IPM) along with discrete components for converter and Brake (optional).

Regardless of an approach from the above three, an industrial drive system will consist components described below:

The controller stage that consists of DSP products, MCUs, ASICs and FPGAs to communicate with the whole system. This stage receives provides input signals to the gate drivers, which drives the output inverter stage and brake (if present).
Op – Amps / current sense amplifiers that measure voltage across current sense resistors at the inverter stage.
Temperature sensing products for monitoring output inverter stage temperature.
DC/DC converter products that provides different DC voltage levels for process control supply (+24V), Gate drivers (+12V / +15V)
Low voltage DC/DC converters for low voltage (+3.3V) products like MCU, DSP, FPGA and ASIC
Opto-Isolators for general-purpose I/O and communication ports.
Low voltage bus protection and eFuse (+24V) for protected loads

Discrete Approach

In this approach, a motor control solution can be designed using discrete components for AC/DC converter, Brake, Output inverter stage along with gate drivers.
High voltage (HV) gate drivers to drive Output inverter stage.
Low voltage (LV) gate drivers to drive the brake and PFC.

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Power Integrated Modules (PIM) Approach
Intelligent Power Module (IPM) Approach

Power Integrated Modules (PIM) Approach

In this approach, the discrete output stage and the converter circuit is replaced by a single PIM.
A single CIB PIM integrates the converter, brake and inverter circuit.
A CIP PIM integrates the converter, PFC and inverter circuit
HV gate drivers are still required for the output inverter stage of the PIM
LV gate drivers are still required for the brake and PFC blocks of the PIM

Intelligent Power Module (IPM) Approach

IPMs are a great option to reduce the system size, cost and time to market of the system. An IPM module consists of a gate driver along with an output inverter stage.
IPMs also integrates protection of Power Systems from short circuits, Under voltage lockout (4 per module, one for each high side FET and one for the 3 low side FETs), Temperature monitor
A 2-in-1 PFC IPM can also be used to replace the gate driver and the PFC controller
The major applications of intelligent power modules can be observed in inverters, heating, ventilation, and air-conditioning (HVAC), and elevators.

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Additional considerations

Motor development kits (MDK)

The MDK power boards are designed using either PIMs, or IPMs, or discrete MOSFETs. Three MDKs have been released by the SEC so far:

The 1kW power board is designed using a 600V compact IPM
The 4kW board is designed using the SPM31 intelligent power module
Series of 4 medium voltage MDK board for 10V to 100V applications

Motor development kit family

Motor development kits available

1 kW 600 V based on Compact IPM and Universal Controller Board Kit
4 kW 650 V based on SPM31 and Universal Controller Board Kit
Series of 4 boards for medium voltage MDKs for BLDC motors
Board A: 10V-16V / 600W max
Board B: 16V-30V / 960W max
Board C: 30V-60V / 1.2kW max
Board D: 60V-100V /1.2kW max

Product choice based on application

Product suggestions will depend on the power levels of the application. While IGBTs, EliteSiC products, IPMs and PIMs make a great choice for applications with bus voltages above 250V such as Industrial drives, HVAC and Building controls.

Gate driver topologies

Different isolation techniques in gate driver play an important role while selecting the correct gate driver. There are isolated gate drivers (Galvanic isolation and Junction Isolation) and non-isolated gate drivers. However, most high-power Industrial drives will use a Junction isolated or galvanic isolated gate driver.

Economical drivers = non isolated

4kW and above systems – isolated drivers as systems are already expensive and need of isolation is realized.

Industry 4.0

Industry 4.0 (or fourth industrial revolution) is the technology revolution where machines will be linked to each other through a communication network. Industrial drives for these applications will use network communication products like Ethernet, Bluetooth, wifi chips and zigbee.

While motor control is one of the crucial part in factory automation, they are often used with onsemi solutions as mentioned below:

Power conversion, AC/DC and DC/DC converters
Lidar and imaging solutions
Battery charging solutions
Communications

Solution block diagram (discrete approach)

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Solution block diagram (PIM approach)

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Solution block diagram (IPM approach)

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AC / DC converter topologies

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Suggested Block	Web Part Number (WPN)	Comments	WPN Description
eFuse	NCS32100 position sensor		Dual inductive rotary position sensor with self calibration
	ECS640 ecoSpin™		Configurable motor controllers for reliable operation up to 600 Volts
	NIS5x2x		Electronic fuse (eFuse), 12V, 44 mΩ, 4A, ISENSE
	NIS4461		+24 VOLT ELECTRONIC FUSE
IGBTs	FGHL75T65MQDTL4		650V, 75A Field Stop Trench IGBT
	FGHL50T65SQDT		650 FS4 HI SPEED 50 A WITH FULL RATING FRD
	AFGHL50T65SQDC		650V 50A FS4 HYBRID IGBT
MOSFETs EliteSiC / GaN	NTBG045N065SC1		EliteSiC MOS D2PAK-7L 650V
	NTH4L045N065SC1		EliteSiC MOS TO247-4L 650V
	NTBG080N120SC1		EliteSiC MOS D2PAK-7L 80MOHM 1200V
	NTBG160N120SC1		EliteSiC MOS D2PAK-7L 160MOHM 1200V
	NTD360N65S3H		SUPERFET^® III, FAST, 650 V, 10 A, 360 mΩ, DPAK
	NTMT125N65S3H		SUPERFET^® III, FAST, 650 V, 24 A, 125 mΩ, Power88
EliteSiC Diodes	FFSP0665B		EliteSiC DIODE TO220 650V
	FFSP0865B		EliteSiC DIODE TO220 650V
	NDSH20120C		EliteSiC DIODE GEN2.0 1200V TO247-2L
PFC modules	NFL25065L4BT	IPMs	IPM, 650 V, 50 A
	NFP36060L42T	IPMs	IPM, 650 V, 60 A
	STK57FU394AG-E	2-in-1 PFC	2-in-1 PFC and Inverter, 600 V, 15 A
Gate Drivers	NCD57001		Isolated high current and high efficiency IGBT gate driver with internal galvanic isolation
Gate Drivers	NCD57090		Isolated High Current Gate Driver
I P M 3-Phase inverter modules	NFAM0512L5B		SPM31, 1200V, 5A
	NFAM0512L5BT		1200V, 5A (NTC option)
	NFAM2065L4B		SPM31, 650 V, 20 A
	NFAL5012L5B		Intelligent Power Module, SPM49, 1200 V, 50A
	NFAL3512L5B		SPM49, 1200 V, 35 A