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Induction Motor Vector Control. Induction Motor Vector Control.

Induction Motor Vector Control. - PowerPoint Presentation

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Induction Motor Vector Control. - PPT Presentation

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 ID: 773118

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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 motorsEfficiencyReliabilitySimplicityElectric transportation systemsTesla 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 regulation15V, 8.5, 4V, 3.6V, 3.3VImplement two embedded processorsDivide computation to improve performanceHigh voltage Isolated MeasurementsPhase voltage, current Temperature

Overall Block Diagram

Design Approach Mathematical Modeling Numerical Calculation Schematic CaptureKiCad EDA suitePower SystemSeparate high voltage and low voltage boardsHigh efficiency focus

General Design Decisions Motor Selection Reliance Electric ½ HP, 230V/460V fan cooled Power Output SpecificationDon’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 transformd-axis control rotor flux linkageq-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

Zero-sequence transition pulses Projection time durations PWM Generation 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 modesJust determines which parameters will be displayed on LCD

PWM Algorithm Software implementation of Pulse Width Modulation generation

Synchronous Rectifier Gate Driver Emulated ideal diode with a MOSFET Senses V_DS and drives gate accordingly Easy package to work withTrimmable turn off threshold Part Number IR1167 Manufacturer International Rectifier Input Voltage 12 ~20V T_on / T_off 40ns / 60ns Maximum Drain Sense Voltage 200V Package 8 - SOIC (Standard) Cost $2.70 (1 qty)

Synchronous Rectifier Switches (MOSFET) Low cost for 400V rating 0.3 Ohms * 0.4A^2 = 0.048W Common Package10V Gate charge Part Number TK62N60X Manufacturer Vishay / SIliconix Rated V_DS 400V Rated I_D 10A R_DS (ON) 300 mOhm Package TO-247 Cost $2.70 (1 qty)

DC Link Capacitor Film Capacitor Small Size Extremely High RippleNon polar Part Number C4DEFPQ6380A8TK Manufacturer Kemet Rated Voltage 400V Capacitance (tol.) 380uF (10%) Package Chassis Mount Cost $89.00 (1 qty)

Power Inverter Gate Driver Low cost Standard package High and low side in one chipLogic level inputsCapable of driving around 0.2 - 99.8% duty cycle at 20 kHz switching frequency Part Number FAN7190M_F085 Manufacturer Fairchild High Side Voltage 650V Minimum Pulse Width 80ns Package 8 - SOIC (Standard) Cost $1.62 (1 qty)

Power Inverter Switch (IGBT) Small package Extremely high current rating Low losses Part Number FGA5065ADF Manufacturer Fairchild Ratec V_C 650V Cont. I_C 50A (100A pulses) Package TO - 3PN Cost $4.79 (1 qty)

Current Transformer High turns ratio for low power sensing Self isolates eliminating the need for isolation amplifiers Decently sized packagePerfect frequency range for our application Part Number CR8348-2000-F Manufacturer CR Magnetics Inc. Frequency Range 20Hz ~ 200kHz Current Rating 50A Turns Ratio 1:2000 Package 24x11mm Thru-Hole Cost $7.05 (1 qty)

Rotary Encoder Very high resolution Three channels indicate position, direction of rotation, and when each full revolution is completed. Tolerant of high temperatures (100C) Part Number HEDR-55L2-BY09 Manufacturer Broadcom / Avago Cycles per Revolution 3600 Channels 3 (A,B,I) Package Shaft Mounted (8mm) Cost $51.00 (1 qty)

General Purpose Op-Amp Dual Op-Amp, single supply package Low Cost High Current per channelLow input currentSmall but relatively easily soldered package Part Number OPA2170 Manufacturer Texas Instruments Input Voltage +/- 1.35V ~ 18V (2.7 ~ 36V) GbP 1.2MHz Bias Current (max) 15pA Input Offset Voltage (max) +/- 1.8mV Package 8 - VSSOP

Measurement Op_Amp Extremely low input bias and offset Ideal for motor voltage sensing Slightly lower specs in all other areas than OPA2170Bigger package but worth it for the bias and offset. Part Number MAX4238ASA+ Manufacturer Maxim 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)

MSP430 Microcontroller Purpose Collect inputs from sensors Drive LCD DisplaySelection CriteriaLow CostLow PowerEasily programmableLarge number of GPIO pins 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

Piccolo Microcontroller Purpose Drives the inverter Implements PWM algorithm to control the motorSelection CriteriaHigh clock speedEnhanced Control Peripherals4 ePWM Channels7 ADC Channels with 13-bit resolutionInstaspin-FOC software programmed into ROM Manufacturer Texas Instruments Part Number TMS320F28027FPTQ I/O Pins Up to 22 Clock Speed 60MHz Main Memory Size 64KB Power Supply 3.3V Price $11.11

LCD Display Purpose Display information to user Selection CriteriaLarge screen real-estate Manufacturer Crystalfontz Part Number CFAX1286U-NFH Power Required 8.5V

InstaSPIN-FOC TI Software designed for three-phase motor systems Built-in motor parameter identification FAST™ Software EncoderHigh 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 devicesMotorWare™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 TPS54560Linear 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 ConsiderationsDiode Type (Schottky) Low Vf Good Conduction Characteristics Smoothing Capacitance Manufacturer NXP 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 dissipationPower 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 loadsSelection CriteriaLow Power DissipationHigh 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 CriteriaPeak Reverse VoltageConduction 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 ConsiderationsSet I_adj with R1Setting R2 determines VoutLow 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