Motor control design for white goods
The trend in the white goods industry is to replace induction motors with permanent magnet synchronous motors (PMSM). In recent years, the price of induction motors has been rising, in part because of rising global steel and copper costs, while PMSM prices have risen more slowly. In addition to price advantages, PMSMs offer lower conduction losses, good low speed torque, simple speed control and compact size, making them attractive.
From the perspective of motor control, PMSM has no core and no hysteresis and saturation problems, so it is simpler to design. Their speed depends only on the switching frequency. In addition, the PMSM does not require the controller to process signals from the Hall effect sensor to monitor the phase current, and the sense resistors embedded in the controller can be simply used to sample the driver currents at different phases.
In the white goods market in different countries and regions, cultural and economic differences have a great impact on motor control design, which will affect the type of air-conditioning compressors that each market admires, and thus affect the design of motor controllers. To help air conditioner OEMs cut overall material and assembly costs while adapting to cultural differences in different market segments, International Rectifier (IR) introduced the iMoTIon controller IC in 2006. In addition to handling the stable torque load of the reel compressor, the iMoTIon controller IC can create a more complex drive function than the three phases of a simple sinusoid, making it easy to solve potential problems caused by vibrations and varying loads from the rotary compressor.
Again, these products can be applied to fan control. If the air conditioner is to efficiently adjust the output to match the environmental conditions and maintain a stable temperature, the fan needs to have variable speed control like a compressor. Studies have shown that allowing fans and compressors to operate at variable speeds can increase the efficiency of the system by up to 40%. In addition, the controller must provide power factor correction (PFC) to meet the institutional requirements of different countries.
The iMoTIon "Integrated Design Platform" consists of a digital control IC and driver IC that integrates the IGBTs and FETs required for power switching. The control IC is a multi-core design with one side built around the 8051 microcontroller, which handles the user interface. The other side is built around a patented Motion Control Engine (MCE) that implements a complex, sensorless PMSM-control algorithm in hardware.
The cores communicate through RAM register blocks that provide setpoints for the MCE and provide diagnostic feedback to the MCU. Although the MCU is still programmed in the traditional way, the MCE algorithm is implemented by using a graphical drag-and-drop method of the simulation function library.
In addition to the MCE, the chip also integrates a mixed-signal module called the Embedded Analog Signal Engine (ASE). This module combines signal conditioning and sensorless motor control using these built-in shunt circuits. Implementing MCE in hardware provides a faster loop response than the DSP, which is sufficient for simultaneous control of the fan and compressor motors.
IR has been continuously updating the iMoTIon product line. The company recently introduced the IRMCK171 controller for electrical motor control and the IRAM336 integrated power module (see figure). The IRMCK171 is a motor controller on a chip. Its MCE side consists of a control unit, a motion peripheral, a motion control sequencer, and a dual-port RAM that maps internal signal nodes. The IRMCK171 includes a unique single-channel shunt reconfiguration circuit and a two-leg shunt detection circuit that supports direct shunt resistor connection ICs.
Motion control can be programmed with iMotion's graphics compiler, which has been integrated into the Matlab/Simulink development environment. On the control side, sequencing, user interface, host communication, and upper layer control tasks are implemented on the 8051. The IRMCK171 provides a 32kB one-time programmable (OTP) program ROM. The IRMCF171 development chip contains 64kB of flash memory. These chips are all available in a 48-pin quad flat package (QFP).
The IRAM336-025SB integrated power module for electrical motor control is a multi-chip hybrid device consisting of a high voltage MOSFET and a three-phase driver in a thermally enhanced package. The bootstrap power supply for high-end drivers can be generated using an internal bootstrap diode, eliminating the need for an isolated power supply. The module can handle motors up to 250W and AC voltages ranging from 85V to 253V. The reference design uses both IRMCK171 and IRAM336 devices.
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