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“Moving Forward Efficiently” HEV/EV Traction Motor Lab
A traction motor is an electric motor providing the primary rotational torque of a machine, usually for conversion into linear motion (traction).
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Renesas Technology & Solution Portfolio
In the session 110C, Renesas Next Generation Microcontroller and Microprocessor Technology Roadmap, Ritesh Tyagi introduces this high level image of where the Renesas Products fit. The big picture. <Click> NOTE For Reviewer, the below notes are from the 110C presentation so you can better understand this slide ___________________________________________________________________________________________________________________________________ The wealth of technology you see here is a direct result of the fact that Renesas Electronics Corporation was formed on April 1, 2010 as a joint venture between Renesas Technology and NEC Electronics — Renesas Technology having been launched seven years ago by Hitachi, Ltd. and Mitsubishi Electric Corporation. There are four major areas where Renesas offers distinct technology advantage. --The Microcontrollers and Microprocessors are the back bone of the new company. Renesas is the undisputed leader in this area with 31% of W/W market share. --We do have a rich portfolio of Analog and power devices. Renesas has the #1 market share in low voltage MOSFET solutions. --We have a rich portfolio of ASIC solution with an advanced 90nm, 65nm, 40nm and 28nm processes. The key solutions are for the Smart Grid, Integrated Power Management and Networking --ASSP: Industry leader for USB 2.0 and USB 3.0. Solutions for the cell phone market -- Memory: #1 in the Networking Memory market
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Microcontroller and Microprocessor Line-up
2010 2013 1200 DMIPS, Superscalar 1200 DMIPS, Performance Automotive & Industrial, 65nm 600µA/MHz, 1.5µA standby Automotive, 40nm 500µA/MHz, 35µA deep standby 500 DMIPS, Low Power 32-bit 165 DMIPS, FPU, DSC Automotive & Industrial, 90nm 600µA/MHz, 1.5µA standby Industrial, 40nm 242µA/MHz, 0.2µA standby 165 DMIPS, FPU, DSC Industrial, 90nm 242µA/MHz, 0.2µA standby Embedded Security, ASSP Industrial, 90nm 1mA/MHz, 100µA standby 25 DMIPS, Low Power Industrial & Automotive, 150nm 190µA/MHz, 0.3µA standby 44 DMIPS, True Low Power 8/16-bit Industrial & Automotive, 130nm 144µA/MHz, 0.2µA standby 10 DMIPS, Capacitive Touch Industrial & Automotive, 130nm 350µA/MHz, 1µA standby Wide Format LCDs
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Microcontroller and Microprocessor Line-up
2010 2013 1200 DMIPS, Superscalar 1200 DMIPS, Performance Automotive & Industrial, 65nm 600µA/MHz, 1.5µA standby 32-Bit High Performance, High Efficiency & Integration Automotive, 40nm 500µA/MHz, 35µA deep standby 500 DMIPS, Low Power 32-bit 165 DMIPS, FPU, DSC Automotive & Industrial, 90nm 600µA/MHz, 1.5µA standby Industrial, 40nm 242µA/MHz, 0.2µA standby 165 DMIPS, FPU, DSC Industrial, 90nm 242µA/MHz, 0.2µA standby Embedded Security, ASSP Industrial, 90nm 1mA/MHz, 100µA standby 25 DMIPS, Low Power Industrial & Automotive, 150nm 190µA/MHz, 0.3µA standby 44 DMIPS, True Low Power 8/16-bit Industrial & Automotive, 130nm 144µA/MHz, 0.2µA standby 10 DMIPS, Capacitive Touch Industrial & Automotive, 130nm 350µA/MHz, 1µA standby Wide Format LCDs
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Production Vehicles with Traction Motors
MY = Model Year of Introduction Source: Kia Optima Hybrids - Millions Total - Millions Porsche Cayenne Total U.S. Vehicle Sales Infiniti M VW Touareg BMW 750i U.S. Hybrid Sales Mitsubishi I MiEV Lincoln MKZ Honda CR-Z Renault Fluence Cadillac Escalade BMW X6 Hyundai Sonata Smart ED Honda Accord Toyota Highlndr Chevy Silverado Ford Fusion Nissan Leaf BYD e6 Toyota Prius Drivetrain Toyota Prius Honda Civic Ford Escape Lexus RX400 Nissan Altima Chevy Tahoe Dodge Durango Mercedes ML450 Chevy Volt Tesla S Ford Focus 1997 …
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Traction Motor Efficiency
HEV/EV overall efficiency is a key metric. (35kWh / 100mi) HEV/EV “all electric” range is a key metric. (38 miles using pure electric) Traction motors are ~70-90% efficient Depending on RPM, other factors Convert electrical energy to mechanical energy Traction motor efficiency is a primary factor in HEV/EV performance Electrical energy storage/retrieval are ~70-80% efficient Convert electrical energy to chemical energy, and then back See DevCon presentation about battery management
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Renesas ‘Smart Society’ Traction Motor Control
Industry’s Only Integrated Algorithm Hardware Park/Clarke transformations, PI controller, Duty Cycle Calculation Completely coherent angle and current samples Industry’s Only Integrated RDC Hardware Industry leading Tamagawa resolver-to-digital converter (RDC) Optimized, Flexible PWM Generation Peripheral 2 Motor Control with Single Micro Full hardware & RDC support for 2 motors on next gen micro Software Driver Generation using QuantiPhi Less Expense & Faster Development
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Agenda Typical Traction Motor Subsystem
Renesas “Smart Society” Solution IRIS Evaluation Platform Resolver & RDC Lab Software & External RDC Motor Control Lab EMU & Integrated RDC Motor Control Lab Conclusion
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Typical Traction Motor Subsystem
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Typical Hardware Architecture
3 sinusoidal current waveforms 6 aligned, continuously changing PWMs (5V digital outputs) Micro 3 x IGBT module (6 x IGBT) Motor Position Motor Position digital angle RDC Motor Position Motor with resolver Resolver output: Sin/Cos depending on motor position
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k = transformation ratio
Resolver Operation Absolute angle sensor Resolves (modulates) angle into orthogonal pieces: sine & cosine signals Essentially a rotating transformer with specifically positioned secondaries Every angle has unique combination of sine & cosine, yielding an absolute angle Cosine output: kV cos θ sin ωt Excitation input: V sin ωt Sine output: kV sin θ sin ωt k = transformation ratio Sources: Tamagawa Seiki & admotec
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Resolver History Source: Tamagawa Seiki, for 52mm diameter resolver
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RDC Operation RDC ε φ θ Performs implicit arctangent
Uses trigonometry identity: sin(θ – φ) = sinθ cosφ – cosθ sinφ Uses approximation: sin(θ – φ) ≈ θ – φ, for θ – φ < ±30° To generate difference error, ε, between actual motor angle, θ, and RDC digital angle, φ ε ≈ kV (θ – φ) sinωt As the difference error, ε, approaches 0, θ = φ and digital angle equals actual motor angle Provides resolution better than 0.1° RDC Analog Digital kV sin θ sin ωt cos ROM resolver buffer * D/A + ε cmp Sync detection compare counter φ kV cos θ sin ωt - buffer * D/A sin ROM θ amp exc. sig. generator Vsinωt
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Motor Timer Peripheral – Phase Counting
The MTU-III A multi-function timer pulse unit with eight 16-bit channels Phase counting mode is used for an RDC’s quadrature encoded angle signal Ch 0 Ch 1 Ch 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7 RDC Motor 1 Motor 2
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Motor Timer Peripheral - PWM Generation
Generate a periodic time interval Trigger interrupts for A/D Conversion, Angle Sample Given 3 duty cycles generate 6 PWM signals Coordination of several up/down counters and thresholds Enforce dead time to prevent shoot-through current
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Motor Timer Peripheral – PWM Generation
The MTU-III A multi-function timer pulse unit with eight 16-bit channels Complementary PWM mode is used for motor control Ch 0 Ch 1 Ch 2 Ch 3 Ch 4 Ch 5 Ch 6 Ch 7 Motor 1 Motor 2 PWM Carrier Cycle Reg’s PWM Carrier Output Comparator Match Signals MTU Ch 6, 7 Timers Output Controller PWM1 H/L PWM2 H/L PWM3 H/L Comparator Match Signals Coil Duty Cycle Reg’s
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Software Responsibilities - Traditional
Trough ADC Trigger Carrier Trough ISR Motor Algo. ADC Complete ISR Angle count from MTU Current to Amps Voltage Bounds Check Calculate Elec. Angle Clarke & Park Transforms Duty Cycle Calculation Call Motor Algorithm Return from ISR Q Vector PI Control Loop Timer Match Calculation Re-Arm ADC D Vector PI Control Loop Write match values to Timer Return from ISR Inverse Transforms Return
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Renesas “Smart Society” Solution
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Renesas Smart Architecture
See DevCon presentation about IGBTs 6 aligned, continuously changing PWMs (5V digital outputs) 3 sinusoidal current waveforms 3 x IGBT module (6 x IGBT) 1 Micro with 2 RDCs Motor 1 Motor 1 Motor 1 Motor 2 Motor 2 Motor 2 Motor Position Motor Position Motor 1 Motor 1 Motor 2 2 motors with resolvers Motor 2 No external RDCs Motor Position Resolver output: Sin/Cos depending on motor position
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Integrated RDC Micro ε φ θ Performs same arctangent operation
To generate difference same difference ε To make the digital angle equal actual motor angle Still provides resolution better than 0.1° Micro Analog Digital kV sin θ sin ωt cos ROM resolver buffer * D/A + ε cmp Sync detection compare counter φ kV cos θ sin ωt - buffer * D/A sin ROM θ amp exc. sig. generator Vsinωt
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EMU Peripheral (Enhanced Motor Control Unit)
Application Id & Iq Request Data Transfer Section Motor Control Section 3-Phase Waveform Output Section Feedback Vector Transforms Inverse Vector Transforms PI Control Loop Data from ADC Timer Unit PWM Outputs Carrier Timing Current and Angle Manipulation PWMs to Motor Conversion to Timer Counts Duty Cycle Calculation Data from RDC EMU Trigger to ADC SH72AY
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Software Responsibilities – Renesas Solution
ADC Trigger Carrier Trough ISR Motor Algo. EMU Complete ISR ADC Complete ISR Angle count from MTU Current to Amps Voltage Bounds Check Calculate Elec. Angle Clarke & Park Transforms Duty Cycle Calculation Re-Arm ADC Call Motor Algorithm Return from ISR Q Vector PI Control Loop Timer Match Calculation Return from ISR Re-Arm ADC D Vector PI Control Loop Write match values to Timer Return from ISR Inverse Transforms Return
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IRIS Evaluation Platform
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IRIS Goals Provide investigation system of Renesas solution to OEMs and Tier 1s Encourage use within OEM and Tier 1 development systems Show efficiencies of Renesas integrated RDC Show performance advantages of Renesas Enhanced Motor control timer Unit (EMU) Highlight cost savings & better performance Evaluate RDC vs. resolver inter-operation Evaluate RDC performance with injected noise
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IRIS Capabilities Support for 2 motors
Software selectable RDC per motor 4 different external RDCs 1 internal RDC 1 FPGA simulated RDC Software selectable resolver per motor Motor resolver FPGA simulated resolver Resolver Flexibility Excitation voltage of 5V to 15V Practically any transformation ratio 2 FPGA simulated motors and resolvers, including current and voltage feedbacks Isolated, low skew (< 10ns) motor PWMs and control/status 2 x CAN, 1 x RS-232, 1 x isolated USB Robust inputs Automotive capable 6V – 30V supply Most inputs protected for short to power/ground
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Simplified IRIS Diagram
micro debug port Control software Drivers USB ATI A7 Data Acq. & Calibration Tool IGBTs/MOSFETs Gate drivers Volt, current sensors Temp sensors Micro D’board Motor & resolver 1 Micro Daughterboard Current, voltage, temp inputs Multiple RDCs & resolver circuits FPGA motor simulator CAN x 2 Power supplies LEDs, switches USB Inverter Board sin, cos, exc harness IGBTs/MOSFETs Gate drivers Volt, current sensors Temp sensors Motor & resolver 2 Control Board (ECU) CAN x 2 Inverter Board Power Supply
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IRIS Control Board Block Diagram
SH72AY micro Debug port USB ATI A7 Data Acq. & Calibration Tool Micro Daughterboard Motor Control PWM Micro socket FPGA Motor Simulator PWM CAN Txcvr Motor Control CAN x 2 Motor Feedback current, voltage, temp Motor Feedback current, voltage, temp Analog Muxes AU6802 RDC AU6803 RDC AD2S1205 RDC AD2S1210 RDC Analog Muxes sin, cos Power Supply exc Analog Muxes AU6802 RDC AU6803 RDC AD2S1205 RDC AD2S1210 RDC Analog Muxes sin, cos exc Control Board (ECU)
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IRIS Software Architecture
Motor 1 – Control via EMU Motor 2 – Control via Software Ext RDC Configuration SW Speed Control App Configuration SW Speed Control App ADC EMU ADC RDC Input Processing Coordinate Transforms PI Controller Duty Cycle Calculation ISR1 ISR2 MTU-III IGBTs Registers IGBTs Motor Resolver Motor Resolver User interface through AUD connection
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Resolver & RDC Lab
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Resolver & RDC Lab Do not connect motor coils Turn motor shaft by hand
motor coils connector 50W motor sine wave excitation signal resolver connector resolver sine/cosine resolver signals Do not connect motor coils Turn motor shaft by hand Watch resolver response oscilloscope
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Software & External RDC Motor Control Lab
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Software & External RDC Motor Control Lab
resolver sine/cosine resolver signals resolver connector AUD excitation signal Motor PWMs Motor connector Motor Coils Inverter Board ATI VISION & A7E
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EMU & Integrated RDC Motor Control Lab
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EMU & Integrated RDC Motor Control Lab
50W motor resolver sine/cosine resolver signals resolver connector AUD excitation signal motor connector Motor PWMs Motor Coils Inverter Board ATI VISION & A7E
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Conclusion
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‘Smart Society’ Traction Motor Control
Resolver-to-Digital Converters (RDCs) provide accuracy for high traction motor efficiency Integrated algorithm hardware allows for control of 2 traction motors with 1 micro Significant cost savings can be gained by RDC integration and elimination of 2nd micro for 2nd motor Driver generation is real, efficient, practical and even fun Renesas Electronics has a really smart, integrated solution for traction motor control It can be evaluated today
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Questions?
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