Renesas Electronics America Inc. © 2012 Renesas Electronics America Inc. All rights reserved. Class ID: “Moving Forward Efficiently” HEV/EV Traction Motor Lab Mark Ramseyer, Staff Technical Application Engineer Terry Downs, Staff Technical Application Engineer A traction motor is an electric motor providing the primary rotational torque of a machine, usually for conversion into linear motion (traction). 0L04A

© 2012 Renesas Electronics America Inc. All rights reserved.2 Mark Ramseyer Staff Technical Application Engineer Digital Circuit Design Resolver/RDC Interfaces Model Based Development (MBD) Virtualization, Co-simulation, HIL simulation 22 Years Embedded Microcontroller Development Microcontroller specification IC design, verification, simulation and timing PCB circuit design and layout Controller system design Software and firmware development Compilers and software tools Calibration and data acquisition tools Ford Motor Co., Ford Microelectronics, Visteon, General Motors BS in Computer & Electrical Engineering from

© 2012 Renesas Electronics America Inc. All rights reserved.3 Terry Downs Technical Application Engineer Embedded Software Digital Circuit Design Motor Control Driver and Algorithm Design 25 Years Embedded Microcontroller Development IC specification and verification – Microcontrollers – Flash Memory IC packaging IC quality Electronic controller manufacturing Electronic module design Software development Ford Electronics, Visteon, General Motors Powertrain BSEE – Lawrence Technological University MSEE – University of Michigan

© 2012 Renesas Electronics America Inc. All rights reserved.4 Renesas Technology & Solution Portfolio

© 2012 Renesas Electronics America Inc. All rights reserved.5 Microcontroller and Microprocessor Line-up Wide Format LCDs  Industrial & Automotive, 130nm  350µA/MHz, 1µA standby 44 DMIPS, True Low Power Embedded Security, ASSP 165 DMIPS, FPU, DSC 1200 DMIPS, Performance 1200 DMIPS, Superscalar 500 DMIPS, Low Power 165 DMIPS, FPU, DSC 25 DMIPS, Low Power 10 DMIPS, Capacitive Touch  Industrial & Automotive, 150nm  190µA/MHz, 0.3µA standby  Industrial, 90nm  242µA/MHz, 0.2µA standby  Automotive & Industrial, 90nm  600µA/MHz, 1.5µA standby  Automotive & Industrial, 65nm  600µA/MHz, 1.5µA standby  Automotive, 40nm  500µA/MHz, 35µA deep standby  Industrial, 40nm  242µA/MHz, 0.2µA standby  Industrial, 90nm  1mA/MHz, 100µA standby  Industrial & Automotive, 130nm  144µA/MHz, 0.2µA standby bit 8/16-bit

© 2012 Renesas Electronics America Inc. All rights reserved.6 Microcontroller and Microprocessor Line-up Wide Format LCDs  Industrial & Automotive, 130nm  350µA/MHz, 1µA standby 44 DMIPS, True Low Power Embedded Security, ASSP 165 DMIPS, FPU, DSC 1200 DMIPS, Performance 1200 DMIPS, Superscalar 500 DMIPS, Low Power 165 DMIPS, FPU, DSC 25 DMIPS, Low Power 10 DMIPS, Capacitive Touch  Industrial & Automotive, 150nm  190µA/MHz, 0.3µA standby  Industrial, 90nm  242µA/MHz, 0.2µA standby  Automotive & Industrial, 90nm  600µA/MHz, 1.5µA standby  Automotive & Industrial, 65nm  600µA/MHz, 1.5µA standby  Automotive, 40nm  500µA/MHz, 35µA deep standby  Industrial, 40nm  242µA/MHz, 0.2µA standby  Industrial, 90nm  1mA/MHz, 100µA standby  Industrial & Automotive, 130nm  144µA/MHz, 0.2µA standby bit 8/16-bit

© 2012 Renesas Electronics America Inc. All rights reserved.7 Production Vehicles with Traction Motors Toyota Prius Drivetrain 1997 … Toyota Prius Honda Civic Ford Escape Honda Accord Lexus RX400 Toyota Highlndr Nissan Altima Chevy Tahoe VW Touareg Infiniti M Porsche Cayenne Kia Optima MY = Model Year of Introduction Source: Dodge Durango Chevy Silverado Cadillac Escalade Mitsubishi I MiEV Mercedes ML450 Ford Fusion BMW X6 Lincoln MKZ Chevy Volt Nissan Leaf Honda CR-Z BMW 750i Hyundai Sonata Tesla S BYD e6 Smart ED Renault Fluence Ford Focus U.S. Hybrid Sales Total U.S. Vehicle Sales Total - Millions Hybrids - Millions

© 2012 Renesas Electronics America Inc. All rights reserved.8 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

© 2012 Renesas Electronics America Inc. All rights reserved.9 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

© 2012 Renesas Electronics America Inc. All rights reserved.10 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

© 2012 Renesas Electronics America Inc. All rights reserved.11 Typical Traction Motor Subsystem

© 2012 Renesas Electronics America Inc. All rights reserved.12 Typical Hardware Architecture 6 aligned, continuously changing PWMs (5V digital outputs) 3 sinusoidal current waveforms Motor with resolver Resolver output: Sin/Cos depending on motor position Motor Position 3 x IGBT module (6 x IGBT) Micro RDC digital angle

© 2012 Renesas Electronics America Inc. All rights reserved.13 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 Excitation input: V sin ωt Sine output: kV sin θ sin ωt Cosine output: kV cos θ sin ωt k = transformation ratio Sources: Tamagawa Seiki & admotec

© 2012 Renesas Electronics America Inc. All rights reserved.14 Resolver History Source: Tamagawa Seiki, for 52mm diameter resolver

© 2012 Renesas Electronics America Inc. All rights reserved.15 RDC Operation 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° * D/A resolver * D/A Sync detection buffer amp + - cmp comparecounter ε θ φ RDC Vsinωt kV cos θ sin ωt kV sin θ sin ωt Analog Digital sin ROM cos ROM exc. sig. generator

© 2012 Renesas Electronics America Inc. All rights reserved.16 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 0Ch 1Ch 2Ch 3Ch 4Ch 5Ch 6Ch 7 RDC Motor 1Motor 2

© 2012 Renesas Electronics America Inc. All rights reserved.17 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

© 2012 Renesas Electronics America Inc. All rights reserved.18 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 0Ch 1Ch 2Ch 3Ch 4Ch 5Ch 6Ch 7 Motor 1Motor 2 Comparator PWM Carrier Cycle Reg’s Ch 6, 7 Timers Coil Duty Cycle Reg’s Output Controller PWM Carrier Output PWM1 H/L PWM2 H/L PWM3 H/L Match Signals Match Signals MTU

© 2012 Renesas Electronics America Inc. All rights reserved.19 Software Responsibilities - Traditional ADC Complete ISR Trough ADC Trigger Carrier Trough ISR Angle count from MTU Calculate Elec. Angle Return from ISR Re-Arm ADC Return from ISR Motor Algo. Call Motor Algorithm Current to Amps Clarke & Park Transforms Q Vector PI Control Loop D Vector PI Control Loop Inverse Transforms Voltage Bounds Check Duty Cycle Calculation Timer Match Calculation Write match values to Timer Return

© 2012 Renesas Electronics America Inc. All rights reserved.20 Renesas “Smart Society” Solution

© 2012 Renesas Electronics America Inc. All rights reserved.21 Renesas Smart Architecture 6 aligned, continuously changing PWMs (5V digital outputs) 3 sinusoidal current waveforms 2 motors with resolvers Resolver output: Sin/Cos depending on motor position Motor Position 3 x IGBT module (6 x IGBT) 1 Micro with 2 RDCs No external RDCs Motor 1 Motor 2 Motor 1 Motor 2 Motor 1 Motor 2 Motor 1 Motor 2 Motor 1 Motor 2 See DevCon presentation about IGBTs

© 2012 Renesas Electronics America Inc. All rights reserved.22 Integrated RDC 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° * D/A resolver * D/A Sync detection buffer amp + - cmp comparecounter ε θ φ Micro Vsinωt kV cos θ sin ωt kV sin θ sin ωt Analog Digital sin ROM cos ROM exc. sig. generator

© 2012 Renesas Electronics America Inc. All rights reserved.23 EMU Peripheral (Enhanced Motor Control Unit) Timer Unit PWM Outputs Carrier Timing 3-Phase Waveform Output Section Motor Control SectionData Transfer Section PWMs to Motor Trigger to ADC Data from ADC Data from RDC Current and Angle Manipulation Feedback Vector Transforms Inverse Vector Transforms Duty Cycle Calculation PI Control Loop Conversion to Timer Counts EMU Application Id & Iq Request SH72AY

© 2012 Renesas Electronics America Inc. All rights reserved.24 Software Responsibilities – Renesas Solution ADC Complete ISR ADC Trigger Carrier Trough ISR Angle count from MTU Calculate Elec. Angle Return from ISR Re-Arm ADC Return from ISR Motor Algo. Call Motor Algorithm Current to Amps Clarke & Park Transforms Q Vector PI Control Loop D Vector PI Control Loop Inverse Transforms Voltage Bounds Check Duty Cycle Calculation Timer Match Calculation Write match values to Timer Return EMU Complete ISR Re-Arm ADC Return from ISR

© 2012 Renesas Electronics America Inc. All rights reserved.25 IRIS Evaluation Platform

© 2012 Renesas Electronics America Inc. All rights reserved.26 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

© 2012 Renesas Electronics America Inc. All rights reserved.27 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

© 2012 Renesas Electronics America Inc. All rights reserved.28 Simplified IRIS Diagram Control Board (ECU) Micro Daughterboard Current, voltage, temp inputs Multiple RDCs & resolver circuits FPGA motor simulator CAN x 2 Power supplies LEDs, switches Power Supply Inverter Board Motor & resolver 1 Motor & resolver 2 IGBTs/MOSFETs Gate drivers Volt, current sensors Temp sensors Inverter Board CAN x 2 harness sin, cos, exc ATI A7 Data Acq. & Calibration Tool USB Micro D’board micro debug port IGBTs/MOSFETs Gate drivers Volt, current sensors Temp sensors USB Control software Drivers

© 2012 Renesas Electronics America Inc. All rights reserved.29 IRIS Control Board Block Diagram CAN Txcvr Micro socket Micro Daughterboard SH72AY micro Debug port CAN x 2 Motor Control PWM Power Supply sin, cos exc current, voltage, temp sin, cos exc Control Board (ECU) PWM Analog Muxes USB AU6803 RDC AD2S1205 RDC AD2S1210 RDC Analog Muxes AU6802 RDC AU6803 RDC AD2S1205 RDC AD2S1210 RDC Analog Muxes AU6802 RDC Motor Feedback ATI A7 Data Acq. & Calibration Tool Motor Control current, voltage, temp Motor Feedback FPGA Motor Simulator

© 2012 Renesas Electronics America Inc. All rights reserved.30 IRIS Software Architecture EMU Registers ADC IGBTs Motor Resolver ISR2 ISR1 Configuration SW Speed Control App IGBTs Motor Resolver ADC Ext RDC Configuration SW Speed Control App MTU-III Input Processing Coordinate Transforms PI Controller Duty Cycle Calculation User interface through AUD connection Motor 1 – Control via EMUMotor 2 – Control via Software RDC

© 2012 Renesas Electronics America Inc. All rights reserved.31 Resolver & RDC Lab

© 2012 Renesas Electronics America Inc. All rights reserved.32 Resolver & RDC Lab 50W motor resolver connector motor coils connector resolver sine wave excitation signal sine/cosine resolver signals oscilloscope Do not connect motor coils Turn motor shaft by hand Watch resolver response

© 2012 Renesas Electronics America Inc. All rights reserved.33 Software & External RDC Motor Control Lab

© 2012 Renesas Electronics America Inc. All rights reserved.34 Software & External RDC Motor Control Lab 50W motor resolver connector Motor connector resolver excitation signal sine/cosine resolver signals Motor Coils AUD ATI VISION & A7E Inverter Board Motor PWMs

© 2012 Renesas Electronics America Inc. All rights reserved.35 EMU & Integrated RDC Motor Control Lab

© 2012 Renesas Electronics America Inc. All rights reserved.36 EMU & Integrated RDC Motor Control Lab 50W motor resolver connector motor connector resolver excitation signal sine/cosine resolver signals Motor PWMs AUD ATI VISION & A7E Inverter Board Motor Coils

© 2012 Renesas Electronics America Inc. All rights reserved.37 Conclusion

© 2012 Renesas Electronics America Inc. All rights reserved.38 ‘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 2 nd micro for 2 nd 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

© 2012 Renesas Electronics America Inc. All rights reserved.39 Questions? Questions?

© 2012 Renesas Electronics America Inc. All rights reserved.40 Please utilize the ‘Guidebook’ application to leave feedback Or, ask for the paper feedback form Please Provide Your Feedback

Renesas Electronics America Inc. © 2012 Renesas Electronics America Inc. All rights reserved.