Energy. Don’t loose itREUSE it! - NXP · PDF fileOne Third of Kinetic Energy ... Dave...

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Energy.Don’t loose it…REUSE it!

Freescale 2008 Motor Control Seminar Series

9.98°

A

B

C

i b

i a

i c

i q

i d θd

d axis

q axis


Three-Phase Line Regeneration

Single-Phase Line Regeneration

Motor Regeneration

Introduction to 4-Quadrant Systems

Freescale Solutions for Regeneration

For Today’s Webinar…


Slide 3Dave Wilson

Second Quadrantnegative speed-positive torque

“reverse-braking”

Generating

Fourth QuadrantPositive speed - negative torque

“forward-braking”

GeneratingThird Quadrant

negative speed - negative torque“reverse-accelerating”

Motoring

First Quadrantpositive speed-positive torque

“forward-accelerating”

Motoring

Tor

que

SpeedIIIIII IV

Quadrants of Operation


Slide 4Dave Wilson

Example 4-Quadrant SystemV+

1

2

3

4

M


Slide 5Dave Wilson

1

2

3

4+ -

MotorBack emf

Q1(Forward)

MotorVoltage

MotorCurrent

DC BusCurrent

1

2

3

4+ -

MotorBack emf

Q4(Forward)

MotorVoltage

MotorCurrent

DC BusCurrent

Motoring GeneratingDC Motor Regeneration

a b a ab ba b a ab

a b a b

Positive average implies motoring

Applied average PWM

voltage greater than back EMF

voltage

Applied average PWM voltage less than back

EMF voltage

Negative average implies generating


Slide 6Dave Wilson

Applied Voltage

Back EMF

Bus regen. can only occur when applied voltage is smaller in magnitude than the motor back-EMF, and of the same polarity.

Plugging

Plugging

Motoring

Motoring

Regeneration

Regeneration

Conditions for DC Motor Regeneration


Slide 7Dave Wilson

96ms 98ms 100ms 102ms 104ms 106ms 108ms 110ms 112ms 114ms-40V

-30V

-20V

-10V

0V

10V

20V

30V

40V

-10A

-8A

-6A

-4A

-2A

0A

2A

4A

6A

8A

10A0.0V

0.1V

0.2V

0.3V

0.4V

0.5V

0.6V

0.7V

0.8V

0.9V

1.0V-10V

-8V

-6V

-4V

-2V

0V

2V

4V

6V

8V

10V

V(zero) V(N017,N023) I(L1)

V(n022) V(n012) V(n013)

V(zero) V(bus_current)

IBUS

VMod

Vemf IL

VemfIL

AC Motor RegenerationMOTORING(unity PF)

GENERATING(unity PF)

V+

+_

A

B

A

BVemf

IL

CarrierMod

IBUS

+ -

VModVemf

VL

IL

VModVemf

VL

IL

96ms 98ms 100ms 102ms 104ms 106ms 108ms 110ms 112ms 114ms-40V

-30V

-20V

-10V

0V

10V

20V

30V

40V

-10A

-8A

-6A

-4A

-2A

0A

2A

4A

6A

8A

10A

0.0V

0.1V

0.2V

0.3V

0.4V

0.5V

0.6V

0.7V

0.8V

0.9V

1.0V

-10V

-6V

-2V

2V

6V

10V

V(zero) V(N017,N023) I(L1)

V(n022) V(n012) V(n013)

V(zero) V(bus_current)

IBUS

Vemf IL

VMod

P=½Vemf ILcos(θ)θ

SPICE SIMULATION


Slide 8Dave Wilson

RegenerativeBoost Converter

PanasonicNi-MH battery stack

200 - 500 V

8100 uF

1 kWBuck

Converter

System 12V

Freescale

Dave’sMost Excellent

MotorController T

M

50 kW3-phase

Traction Motor

Freescale


MotorController

TM

1.2 kWVariable SpeedAC Compressor

Freescale


MotorController T

M

30 kW10k RPM3-phase

Starter/Alternator

Freescale


MotorController

TM

Brush DCEPS Motor

Regeneration in Toyota Prius

7.2V x 28 = 202V6.5 amp-hours

12V

One Thirdof Kinetic Energy

Recaptured!


Slide 9Dave Wilson

S08or

DSC

PWM1PWM2PWM3PWM4PWM5PWM6

VBus

Rectifiers block current flow back on to AC line from the dc bus, thus preventing line regeneration.All motor energy gets dumped in the bus capacitor.

Deceleration

Energy Flow

AC In

V o l t a g e

ADC

Fault1

Port Pinor PWM

Brake

VoltageProcessing

Options-Limit deceleration rate- Bigger capacitor- Turn PWMs off and coast-Brake resistor- Dump energy onto AC line input

Freescale

Dave’sControlCenter

Where Does the Energy Go?


Slide 10Dave Wilson

Energy Flow

Regeneration to a Single Phase AC Line

AC In

Energy Flow


Slide 11Dave Wilson

Single PhaseAC Line Regeneration

VAC

Vbus

VoltageRegulator

(PI)

+

-

Vref

Vbus

VAC

Current ReferenceWaveform

+

-

iL

iL

CurrentRegulator(P or PI)

Vbus

+

+

Vq

Vd

PWM

÷

PWM

PWM PWM

PWM

PWM Module

N

DCarrier

Energy Flow


Slide 12Dave Wilson

Simulation Results of Single-Phase Regenerative System


Slide 13Dave Wilson

PWM 1

PWM 2

PWM 3

PWM 4

PWM 5

PWM 6

VBus

vavbvc

PWM 7

PWM 8

PWM 9

PWM 10

PWM 11

PWM 12

M

Motorola

Dave’sControlCenter

PWM Module A PWM Module B

Freescale offers several controller solutions with the required MIPS and peripherals for this application.

Freescale offers several controller solutions with the required MIPS and peripherals for this application.

MotorDecelerating

Energy FlowEnergy Flow

2E72G56F8346

SSAC0116-A

Regeneration to a 3-Phase AC Line Energy FlowEnergy Flow


Slide 14Dave Wilson

D and Q Axes Representation

α

β

Field Oriented Techniques applied to three-phase systemA B C

t=now

Put current vector on this axis for unity PF.

θDirect Axis

Quadrature Axis

Power Factor = Cos(φ)

RotatingAC Line Voltage

Space Vector

RotatingAC Line Current

Space Vector

Where φ is the angle between the voltage and current space vectors


Slide 15Dave Wilson

Measure the instantaneous AC line voltages. These scalar values represent

the instantaneous magnitudes of the vectors along the A, B, C axes.

AB

C

Three PhaseConverter

A B C

t=now

A

B

C

Phasor Diagram

aVbV

cV

rotating voltage space vector

Power Flow

dθ

Assuming equal phase voltages,-vc = va + vb

FreescaleADC

Step 1: Voltage Measurement


Slide 16Dave Wilson

cb

a

VVV

VV

23

23

23

−=

=

β

α

A

B

C

Phasor Diagram

α

β

αV

βV

This is sometimes referred to as the FORWARD CLARK transformation

Step 2: 3-phase to 2-phase transformation

rotating voltage space vector


Slide 17Dave Wilson

βV

Phasor Diagramα

β

AngleDemodulator

αVdθ

dθ

⎟⎟⎠

⎞⎜⎜⎝

⎛= −

α

βθVV

d1tan

Difficult to evaluate, especially on a fixed-

point machine

Step 3: Angle Demodulation


Slide 18Dave Wilson

Σ Σ Σ

Z-1 Z-1

αβ

++

+ ++

( )nd

∧

θ

( )nd

∧

Δθ

( ) ( ))(ˆ)(sin nnnerror θθ −=

Integrator Integrator

+

cos sin

X

X

Σ+

-[ ])(nCos θ

[ ])(nSin θ

( ) ( ) ( ) ( ) ( ))(ˆsin)(cos)(ˆcos)(sin)(ˆ)(sin nnnnnn θθθθθθ −=−

βV

αV

Tracking Filter Used for Angle Demodulation


Slide 19Dave Wilson

(commanded) +

-

error(t)Bus voltage

(measured)Bus voltage

VBus

PIRegulator

3-Phase AC supply

Step 4: Bus Voltage Regulator


Slide 20Dave Wilson

id = sqrt(2/3) * (cos(θ)*ia + cos(θ - 2*π/3)*ib + cos(θ - 4*π/3)*ic)iq = sqrt(2/3) * (-sin(θ)*ia - sin(θ - 2*π/3)*ib - sin(θ - 4*π/3)*ic)

Forward Clark-Park Transformation

θdd axis

q axis

i q

i d

Step 5. Establish id and iq1mH Vbus

abc

θ q

d

iq

id

6 transistor converter

θAngleDemodulator

-ic = ia + ib

A

B

C

si

i c

i b

i a

3-PhaseAC supply


Slide 21Dave Wilson

i d

∫ I

P+ +

+-

error(t)

∫ I

P+ +

+-

error(t)

(commanded)

i d (measured)

i q

i q (commanded)

(measured)

vd

vq(0 amps)

Output from bus voltage regulator

P or PI regulators work well.

Step 6. Synchronous Frame Current Regulation


Slide 22Dave Wilson

V1 = sqrt(2/3)*(cos(θ)*Vd - sin(θ)*Vq)

V2 = sqrt(2/3)*(cos(θ - 2*π/3)*Vd - sin(θ - 2*π/3)*Vq)

V3 = sqrt(2/3)*(cos(θ - 4*π/3)*Vd - sin(θ - 4*π/3)*Vq)

Reverse Clark-Park Transformation

v1v2v3

d axis

q axis

θd

vd

vq

a

b

cθ

q

dvq

vd

θAngle

Demodulator

A

B

C

v 1

v 3

v 2

Step 7: Synchronous to Stationary Frame Transformation


Slide 23Dave Wilson

Vbus

6 transistor converter

AC Line

v1 v2 v3

VaVbVc

PW

M1

PW

M2

PW

M3

V1 amplified

V3 amplifiedV2 amplified

Step 8. Output Voltage Modulation


Slide 24Dave Wilson

abc

q

d

PWM APWM BPWM C

Vbus

6 transistor converterAC Line

Three-Phase System Overview

θ

PWM

A

PWM

B

PWM

C

+-

P+

-

Desired Bus Voltage PI

Vbus

vd

θ

a b c

AngleDemodulator

+-

P vq

iqabc

q

didθ


Slide 25Dave Wilson

Simulation Results of 3-Phase Regenerative System

Bus Load CurrentD-axis Current

Q-axis Current

Phase A VoltagePhase A Current

Bus Voltage


Slide 26Dave Wilson

ApplicationsStandby Power Supplies

Connecting asynchronous power sources

Hybrid vehicles

Combined starter/alternator

Elevator Drives

Driving high inertial loads

Power Processing

Unit

Variable Speed

Generator

Variable Frequency AC

AC Utility

High-Performance Power Architecture sockets

50 or 60 HzWind Energy

Inverter Load

StaticDisconnect

Switch

Energy Flow

AC Utility

Battery


Slide 27Dave Wilson

Bidirectional control of power

Unity Power Factor (or ANY Power Factor for that matter)

Since Vbus is regulated, and currents are sinusoidal,the semiconductor volt-amp ratings are reduced

Vbus is less sensitive to AC line fluctuations

For three-phase AC systems, FOC algorithms can be used for both converter and inverter control

System Benefits

Sinusoidal Currents


Slide 28Dave Wilson

Matrix Converters

Inherent regeneration to input supply

Sinusoidal line currents possible

Unity (or any) power factor is possible

Direct AC to AC waveform conversion

No energy storage elements required


Slide 29Dave Wilson

Inputs

Outputs

Matrix Converter Topology


Slide 30Dave Wilson

Unfiltered

Filtered

Matrix Converter Output Waveform Example


Slide 31Dave Wilson

Dual Converter-Inverter DSC Solutions

All devices are 60 MHz, (-40, +125)°C

56F8345 56F8346 56F8347 56F8355 56F8356 56F8357 56F8365 56F8366 56F8367

Voltage (Core / I/O) 2.5/3.3V 2.5/3.3V 2.5/3.3V 2.5/3.3V 2.5/3.3V 2.5/3.3V 2.5/3.3V 2.5/3.3V 2.5/3.3VOn-Chip Flash 144KB 144KB 144KB 280KB 280KB 280KB 560KB 560KB 560KBProgram Flash 128KB 128KB 128KB 256KB 256KB 256KB 512KB 512KB 512KBData Flash 8KB 8KB 8KB 8KB 8KB 8KB 32KB 32KB 32KBBoot Flash 8KB 8KB 8KB 16KB 16KB 16KB 32KB 32KB 32KBOn-Chip RAM 12KB 12KB 12KB 20KB 20KB 20KB 36KB 36KB 36KBProgram RAM 4KB 4KB 4KB 4KB 4KB 4KB 4KB 4KB 4KBData RAM 8KB 8KB 8KB 16KB 16KB 16KB 32KB 32KB 32KBFlash security Yes Yes Yes Yes Yes Yes Yes Yes Yes

Ext. Memory Interface - Yes Yes - Yes Yes - Yes Yes

On-Chip Relax. Osc. No No No No No No No No No16-bit Timers 16 16 16 16 16 16 16 16 16Quadrature Decoder 2 x 4ch 2 x 4ch 2 x 4ch 2 x 4ch 2 x 4ch 2 x 4ch 2 x 4ch 2 x 4ch 2 x 4chPWM 2 x 6ch 2 x 6ch 2 x 6ch 2 x 6ch 2 x 6ch 2 x 6ch 2 x 6ch 2 x 6ch 2 x 6chPWM Fault Input 4 + 4 3 + 4 3 + 4 4 + 4 3 + 4 3 + 4 4 + 4 3 + 4 4 + 4PWM Current Sense 3 + 3 3 + 3 3 + 3 3 + 3 3 + 3 3 + 3 3 + 3 3 + 3 3 + 312-bit ADC 4 x 4 ch 4 x 4 ch 4 x 4 ch 4 x 4ch 4 x 4ch 4 x 4ch 4 x 4 ch 4 x 4ch 4 x 4chTemperature Sensor Optional Optional Optional Optional Optional Optional Optional Optional OptionalCAN FlexCAN FlexCAN FlexCAN FlexCAN FlexCAN FlexCAN FlexCAN (2) FlexCAN (2) FlexCAN (2)SCI (UART) 2 2 2 2 2 2 2 2 2SPI (Synchronous) 2 2 2 2 2 2 2 2 2GPIO (Ded./Shrd/Tot) 21/ 28 / 49 0 / 62 / 62 0 / 76 / 76 21 / 28 / 49 0 / 62 / 62 0 / 76 / 76 21 / 28 / 49 0 / 62 / 62 0 / 76 / 76JTAG/EOnCE Yes Yes Yes Yes Yes Yes Yes Yes YesPackage 128LQFP 144LQFP 160LQFP 128LQFP 144LQFP 160LQFP 128LQFP 144LQFP 160LQFP

2.5/3.3V80KB64KB8KB8KB

12KB4KB

8KBYes

-

Yes16

2 x 4ch2 x 6ch4 + 43 + 3

4 x 4chOptionalFlexCAN

22

21 / 28 / 49Yes

128LQFP

56F8335


Slide 32Dave Wilson

Per

iphe

ral I

nteg

ratio

n56F8300 Pin Compatibility

Pin compatible

56F8x46

56F8x45

144 LQFP

128 LQFP

56F8357

280KB(56F835x)

272KB(56F815x)144KB

(56F834x)136KB

(56F814x)

56F8x56

560KB(56F836x)

528KB(56F816x)

128LQFP

144LQFP

160 LQFP

144LQFP

160 LQFP

128LQFP

56F8x65

128 LQFP

80KB(56F833x)

72KB(56F813x)

160 LQFP

56F8x66

56F8x67

56F8x57

56F8x35

56F8x47

56F8x55

56F8x67

56F8x57

56F8x47

160 BGA

160 BGA

160 BGA


Slide 33Dave Wilson

Cost Effective 56F8000 Solutions 56F8011/56F8013/56F8014

32 MIPS Performance 16 K Bytes Program FLASH 4 K Bytes Program/Data RAM Tunable Internal Relaxation OscillatorSoftware Programmable Phase Locked LoopUp to 96 MHz Peripherals – Timers and PWMsUp to 6-Output PWM Module with up to 4 Programmable Fault Inputs

• Selectable PWM frequency for each complementary PWM signal pairTwo 12-bit ADCs with up to 8 Inputs , 1.125us conversion rateSynchronization between PWM and ADCFour 16-bit General Purpose Programmable TimersComputer Operating Properly TimerSerial Ports: SCI, SPI, I2CUp to 26 GPIOs – Versatile pin usageLow Power Consumption – 59mA Max and .026mA MinJTAG/EOnCE™ Debug PortMSRP starting at $2.92 for 1K units•Packages:

32LQFP

System Clock ControlSystem Clock Control(PLL, Osc)(PLL, Osc)

6 Output6 OutputPWMPWM

4 164 16--Bit Bit TimersTimers

66--8 Input8 Input1212--bit ADC bit ADC

SCISCI

Voltage Voltage RegulatorsRegulators

COPCOP

JTAG/JTAG/EOnCEEOnCE

InterruptInterruptControllerController

PowerPowerSupervisorSupervisor

SPISPIIICIIC

56800E 56800E CoreCore

32 MIPS32 MIPS32 MHz32 MHz

FlashFlash RAMRAM

Key Control Peripherals

System Integration System Integration Module (SIM)Module (SIM)


Slide 34Dave Wilson

• 32 MHz/32 MIPS 56800E Core• 3.0-3.6V Operation• 32K-64K Bytes Program FLASH• 4K-8K Bytes Program/Data RAM • Flash security• Tunable Internal Relaxation Oscillator• Software Programmable Phase Locked Loop• Up to 96 MHz Peripherals – Timers and PWMs• 6 Output PWM Module with 4 Programmable Fault

Inputs• 2-12-bit ADCs for 6-8 Inputs w/ Int. or External Vref• Up to 2 12-bit Digital to Analog Converters• 2 - Analog Comparators• Synchronization between PWM and ADC• 4 or 8 16-bit General Purpose Programmable Timers• 1 or 3 Programmable Interval Timers• Computer Operating Properly Timer• 2-Queued Serial Communications Interface • 2-Queued Serial Peripheral Interface• Optional MSCAN• I2C Communications Interface• Up to 53 GPIOs• JTAG/EOnCE™ Debug Port• 4 Lead Free Packages• Up to -40 to 125C temperature range• MSRP starting at $3.30 for 1K units

•32 LQFP 44QFP•48LQFP 64LQFP

Voltage Voltage RegulatorsRegulators

COPCOP

JTAG/EOnCEJTAG/EOnCE™

InterruptInterruptControllerController

PowerPowerSupervisorSupervisor

64KB Flash64KB Flash 8KB RAM8KB RAM

MSCANMSCAN

System Clock ControlSystem Clock Control(PLL, SIM, (PLL, SIM, OscOsc))

33--PITPIT

56800E 56800E CoreCore

32 MIPS32 MIPS32 MHz32 MHz

6 Output6 OutputPWMPWM

8 16bit Timers8 16bit Timers

22--QSCIQSCI22--QSPIQSPI

II22CC22--12bit DACs12bit DACs

22--AnalogAnalogComparatorsComparators

Two 12bit ADCsTwo 12bit ADCsUp to 2x8 InputUp to 2x8 Input

New or Improved New or Improved

56F8000 Family Expansion56F8023/56F8025/56F8036/56F8037 Features


Slide 35Dave Wilson

Anguilla White : Ultra Low cost Product: 56F8002, 56F8006

32 MHz/32 MIPS 56800E Core1.8-3.6V Operation12K - 16K Bytes Program FLASH with Flash security2K Bytes Program/Data RAM Tunable Internal Relaxation Oscillator and 32KHz clockPhase Locked Loop (PLL)Up to 96 MHz Peripherals – Timers, PWM & Hi-SCI6 Output PWM Module with 4 Programmable Fault Inputs

Programmable Dead timer insertionProgrammable PWM generation for Power supply appsMultiple PWM Frequency outputs

Two Programmable Gain Amplifiers with x2, x4, x8, x16 gains (Clocked in order to cancel input offset)Two 12-bit ADCs with up to 24 Inputs , 2.5us Per conversionProgrammable Delay Block provides precise control of ADC/PGA sample times relative to PWM reload cyclesThree High Speed Analog Comparators2 multiple function Programmable TimersComputer Operating Properly TimerOne Periodic Interval Timer (PIT)1 High Speed Serial Communication Interface (Hi-SCI)1 Serial Peripheral Interface (SPI)I2C Communications InterfaceUp to 40 GPIOs – Versatile pin usageJTAG/EOnCE™ Debug PortLead Free “Green” PackagesIndustrial temp: -40C – 105C

Sampling Now!MSRP is $1.50 in 10K quantities!

56800E Core

32MHzPower-On-Reset

Power Supervisor

COP

12-16KB Program

Flash

6-ch PWM Output

System Integration Module (SIM) 1 SCI

1 SPI1 IIC

JTAG/EOnCE

2KB Program/Data RAM

Voltage Regulator

PLL

Interrupt Controller

Relaxation OSC

2 x ProgrammableGain Amplifiers

56F8002, 56F8006Up to 40 GPIOs

ProgrammableDelay Block

Synch

2 x 16bit Timers

Crystal OSC3 x Analog

Comparators

1 Period Int Timer

12ch 12bit ADC12ch 12bit ADC

•28SOIC, 32SDIP , 32LQFP, 48 LQFP


Slide 36Dave Wilson

Pictus: MPC560xPCore• up to 60 MHz PowerPC ISA e200 zen0h core

(64MHz at 105oC)

Memory• 192k to 512k byte Program Flash with ECC• 4x16k byte Data Flash with ECC• 12k to 40k byte SRAM with ECC

I/O• 1 x FlexCAN with 32MB• 1 x Safety port (can be used as additional FlexCAN - 32MB)• 1 x FlexRay Dual Channel with 32MB• 2 x LinFlex• 4 x DSPI (4 independent chip selects each)• 1 x FlexPWM (4x3 channels with 4 Fault Inputs)• 1 x eTimer (6 channels incl. quad decode)• 1 x eTimer (6 channels for general purpose)• 2 x ADC

• 2x13 Ch.(4 shared channels), 10bit, conversion time 760 nsec (2x6ch, 4shared on 100 pin package)

• 1 x ADC triggering unit: 8 events

System• 2 x PLL (one FM-PLL, one for Flexray) • 16Ch eDMA• Fault Collection Unit• 16MHz internal RC OSC• Junction Temperature Sensor• JTAG (2 pin or 5 pin) / Nexus Class 2+• 3.3V single supply (5V mask option) with external ballast

transistor100 and 144 pins TQFP package

• 145oC ambient temperature option with Slugdown package

NexusIEEE-ISTO 5001-2003

Interrupt Controller

Crossbar Switch

I/OBridge SIU 512K

Program FLASH

40KSRAM

DSPI

LinFlex

FlexCA

N

PowerPC™e200z0

VLE

FlexPWM

Safety Port

DSPI

ADC I/F

10 bit

S&H S&HMux Mux

4+1 Ch.PIT

eTimer(6Ch)

eDMA

(c)JTAG

FlexRayFault Collection unit

Boot Assist Module

DSPI

LinFlex

eTimer(6Ch)

10 bit

4x16K Data

FLASH

DSPI


Slide 37Dave Wilson

www.freescale.com/[email protected]

Energy. Don’t loose itREUSE it! - NXP · PDF fileOne Third of Kinetic Energy ... Dave...

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