Renesas Sensorless Vector Control (Pag 13)

Sensorless Vector Control and
Implementation: Why and How
Renesas Electronics America Inc.

2012 Renesas Electronics America Inc. All rights reserved.
Renesas Technology & Solution Portfolio
Microcontroller and Microprocessor Line-up

2010
2013
1200 DMIPS, Superscalar
32-bit
Automotive & Industrial, 65nm

600A/MHz, 1.5A standby
1200 DMIPS, Performance

Automotive, 40nm
500A/MHz, 35A deep standby
500 DMIPS, Low Power

Automotive & Industrial, 90nm
165 DMIPS, FPU, DSC

Industrial, 40nm
165 DMIPS, FPU, DSC

Industrial, 90nm
8/16-bit
25 DMIPS, Low Power
Industrial, 90nm
1mA/MHz, 100A standby
Industrial & Automotive, 150nm

44 DMIPS, True Low Power
10 DMIPS, Capacitive Touch
Industrial & Automotive, 130nm

Industrial
Automotive, 130nm
Wide
Format&LCDs
350A/MHz, 1A standby
Embedded Security, ASSP
Enabling The Smart Society

Challenge: Sensorless vector control increases the energy
efficiency of motor control systems that drive the smart
society. However, understanding and implementing
sensorless vector control is a herculean task.
MCU
Solution:
This class will help you understand key challenges associated with
sensorless vector control and how to implement it using Renesas
microcontrollers
4
Agenda
Need for vector control
Theory behind vector control
Challenges in implementing sensorless vector control
RX62T MCU family for sensorless vector control
Renesas motor control solutions
Macro Factors Driving Need for Energy Efficiency
Global
Environmental
Concerns
Energy Efficiency
Policies
New Initiatives
Realizing Energy Efficiency in Motor Control

Industrial 44%
Residential 26%
Others 30%
Motors
(45%)
Electronic Control
Energy Efficient
Motors
Variable speed drives
Motor Design
Vector control
Motor Type
Direct torque control

Power factor correction
15%
20%
Up to ~30% savings
7
Sensorless Vector Control Theory
Permanent Magnet AC Motor

Complex Control
Sinusoidal stator current produces rotating field
Rotor mounted magnetic field is rotating
= k .s r
Maintain stator field orthogonal to rotor field
A
X
X
C
A
Vector Control Challenge

Maintain orthogonality
Error correction feedback loop
In-phase current = 0
Orthogonal current set per torque requirements
What parameters to adjust

Voltage magnitude (PWM duty cycle)
Need to transform current vectors to rotor frame

Stator Field
900
Rotor Field
10
Reference Frame Transformation

Vector control advantages
Maximizing torque (efficiency)
Independent control of flux and torque
Snappy torque control for load variation
2-phase Rotor Frame
Three-phase Stator
iu
iq
0
120
11
iv
Mapping
id
Current Transformation to 2-ph Rotor Frame

Step 1 : 3-ph to 2-ph conversion
Step 2 : 2-ph stationary frame to 2-ph rotor frame (rotating)
Rotor position () needed
stationary frame
uvw
stationary frame
iu
dq
rotatory frame
Id
iv
iw
12
Iq
i
d-axis
Clarke Transformation
i
2
i =
3
0
2
qaxis
1 i
a
2 i
3 b
i
2 c
Park Transformation
I d cos sin i
I =
i
sin
cos

q
Sensorless Vector Control

Lower cost but more complex implementation
Current and motor parameters to estimate rotor position

Increased reliability
Reduced cost of sensor ($3-$20)
Less physical space needed
Need to estimate without sensors

Motor
PI
Controller
i*
i
PI
Controller
PWM
Generation
Speed
Calculation
13
Position
Estimation
i
Speed
/position
sensor
Motor Model in Frame

Voltage Equation
Flux Linkage
d
v = Rs i +
dt
d
v = Rs i +
dt
= m cos r + Li
= m sin r + Li
=0
m cos r = Li
m
r
14
m sin r = Li=0
is the rotor flux linked Potential Inaccuracy: If full load or large motor
is the rotor position
Rotor Position and Speed Estimation
m cos r =
m sin r =
r = arctan( )
d
=
dt
Bottleneck: arctan implementation takes several CPU cycles
15
Renesas Flux Observer Model
v , = Rs i , +
d ,
dt
= 0 + (v Rs i )dt
0
Potential inaccuracy: Noise in measuring current and voltage

Potential inaccuracy: Effect of temperature on resistance
16
Flux Observer Implementation

Cascaded low pass filters rather than direct integration
First low pass filter
Derivative
Second low pass filter
Negate the effect of DC offset in measured current/voltage
e ,
yn
yn =
17
Derivative
Low pass filter
1023
yn 1 + e ,
1024
d
dt
d n = yn yn 1
Low pass filter

dn
, ( n )
, ( n )
1023
=
, ( n 1) + d n
1024
Sensorless Vector Control Loop
Park-1
*r
r
Speed
Regulator
Iq*
iq
Regulator
id
Regulator
id*=0
id
dq
To
DC
BUS
Clarke-1
Sine
PWM
to
abc
Flux and Position

Observer
iq
to
dq
abc
to
i
i
Park
Speed
Estimation
18
Clarke
ia
ib
3-ph
Inverter
Implementation Challenges
19
Implementation Challenges
Requirements
1. Computation intensive routines
2. Multiple current/voltage measurement
20
MCU Considerations
High performance CPU, FPU
12Bit Simultaneous Sampling ADC
3. Robust performance
Noise immunity, PWM shut off
4. Cost effective design
On-chip analog, data flash, dual motor
1. Computation Intensive
Clarke/Park Transformations
Flux Estimation
Rotor position and speed
High-performance RX600 Core

100MHz CPU
1-cycle flash access
32x32 H/W multiplier
32/32 H/W divider
32bit Barrel Shifter
Floating point unit
21
Floating Point Unit Advantages

Performance
Wide range and high resolution
No scaling, overflow or saturation
Reduced code size
Ease of Use
Ease of coding, reading, debugging
Compatible with the C/Matlab simulation code
22
Floating Point : Range and Resolution

Single Precision
Floating Point
Fixed Point Q11.21
..0..
..0..
Resolution 10-39
Resolution 2-21
10-7
-210
-103
Range
+210
+103
-1038
23
or
Range
+1038
Fixed-point Calculations Requires Scaling
X(n)
X(n-1)
(32b,Q14.18)
A1
(16b, Q12.4)
E(n)
(16b, Q8.8)
MULT
(32b,Q20.12)
SHIFT
(32b,Q14.18)
(32b,Q14.18)
24
No Scaling Needed
Fixed-Point Implementation
SHIFT
25
FPU Implementation
No Saturation Check
Check for
Saturation
26
Reduced Code Size

FPU instructions make code and the execution time smaller
27
FPU Implementation
Readability
Parameters
Park Transformation Code
28
FPU Implementation
Parameters
Park Transformation Code
FPU Brings Ease of Simulation

Inherently
floating point
Simulation
Platform
Time-consuming
Unidirectional
Fixed Point
Algorithm
Fixed Point
CPU
29
Portable to FPU
Bidirectional
Floating Point
Algorithm
Floating
Point CPU
FPU Implementations
Traditional FPU
Renesas RX FPU
General
Registers
General Registers
No Load/Store
Instructions
Load/Store
Dedicated
Data
Registers
FloatingPoint Unit
30
FloatingPoint Unit
2. Accurate Analog Signal Measurement

Estimates based on current and voltage
Integration for flux estimation
Multiple simultaneous measurements
Simultaneous sampling ADC
4 ADC Samples
Oversampling current waveform

Filtering to mitigate noise
Dual registers for 1-shunt
U
V
W
5us
50us
31
Current Measurement Techniques

1-shunt
3-shunt
1-Shunt Advantages
Cost reduction (Res, PGA)
No need for 3-ph calibration
Reliability
1-shunt Challenges
ADC samples twice quickly
U
V
W
IW,V,U
Reconstruction of current
IW
32
IW+IV
Support for 3-shunt and 1-shunt Detection

12-bit ADCs with 1us conversion time
Double register for 2 samples
3S/H for one-shot sampling of three phase currents
Self-diagnostic capability for UL/IEC safety requirements
ADC Set 1
Double register for 1-shunt
3 S/H for 3 shunt current detection

PGA
S/H
AN1
PGA
S/H
AN2
PGA
S/H
AN03/CVref L
Multiplexer
AN0
ch0
Register 1
Register 2
Register CH1
S/H
A/D
Register CH2
External Reference
Register CH3
CPU Interrupt
Window Comparators
33
PWM Shut off (POE)
3. Robust Performance
Susceptibility to noise
Hardware shut off
Noise immune MCU design

Careful power/ground layout
Pin noise filtering
5V option
On-chip hardware
POE circuit
Fast window comparators
34
4. Cost Effectiveness
On-chip integration
Scalability
Complete solution for driving two 3-ph

motors
6 programmable gain amplifiers
Scalability
6 window comparators
2 x 3ph cPWM timers
2 x quadrature encoder inputs
63TH
32-512KB
Data flash
Scalability
RX6xT package, ROM
RX200 - performance
35
62T
63TL
48-144 pins
Implementing Sensorless Vector Control Using

RX62T
36
RX62T Motor Timer Set (MTU3)

100MHz, 16bit Timers
Protection Features
PWM shut down (Ext, Comparator,
Clock)
Mode registers inaccessible during
operation
ch0
ch1
ch2
ch3
Quadrature Encoder1
A,B,Z
Quadrature Encoder2
A,B,Z
3-phase cPWM O/P

U,V,W
ch4
ch5
ch6
ch7
MTU3
37
3 Input Captures
3-phase cPWM O/P

U,V,W
Hardware Implementation
RX62T
MTU CH3/4
6
PWM Generation
PWM Shut Off
RX600
CORE
Gate Driver
3-phase
inverter
Comparator
x3
3-phase BLDC
Motor
12-bit ADC
S/H
Analog Unit 0
38
PGA
Motor
Current
Software Implementation
Initialization
PWM
Interrupt
VBUS/Current
Measurement
(u,v,w) ->
(,) ->(d,q)
Current
Reconstruction
Last
Actual
Current
Reference
Current
Last &
Reference
Speed PI
Current PI
Voltage (d,q)
New Speed
Estimation
New
Estimation
V(u,v,w) ->
PWM Duty
(d,q) -> (,)

(u,v,w) <Last
39
Fixed point vs. FPU Comparison
Algorithm: Sensor less Vector Control with 1-Shunt Current Detection

PWM Carrier Frequency: 20kHz
Current Loop: 10kHz
RX62T
Starter Kit
40
Renesas
Inverter Board
CPU Bandwidth Usage
Look-up Table
Floating Point
Fixed point
Sine,Cosine,Atan Functions
0%
41
5% 10% 15% 20% 25% 30% 35% 40%
CPU BW
CPU Bandwidth Usage

Floating-point code 40% faster
Overall
Current Measurement
Position Estimation
Floating Point
Fixed point
Clarke and Park

PI Loop
42
10
20
30
40 us
Code Size
Floating-point code size is 45% lower
Current Measurement
Position Estimation
Floating Point
Clarke and Park
Fixed point
PI Loop
B
0
43
50
100 150 200 250
Driving Two 3-Phase BLDC Motors

Sensorless Vector Control
www.renesas.com/rxmotorkit
Floating point math

CPU BW used <50%
Motor #2
External Inverter
44
Motor #1
RX600 Motor Kit
Implementation for Two Motor Control

Control loop executed at Timer underflow interrupt
Both interrupts at same priority level
Alternate Implementations
Control loops at different rates
Interrupt at overflow/underflow
MTU.CH3/4
10KHz
MTU.CH3/4
10KHz
MTU.CH6/7
20KHz
MTU.CH6/7
10KHz
CPU Available
Control
Loop 1
45
Control
Loop 2
Control
Loop 1
Control
Loop 2
Initialization
PWM
Interrupt
VBUS/Current
Measurement
(u,v,w) ->
(,) ->(d,q)
Current
Reconstruction
PWM
Interrupt2
Last
Actual
Current
Reference
Current
Last &
Reference
Speed PI
Current PI
Voltage (d,q)
New Speed
Estimation
New
Estimation
V(u,v,w) ->
PWM Duty
(d,q) -> (,)

(u,v,w) <Last
46
Performance Comparison with a High-end DSP

RX62T offers tremendous value
Comparable performance
Significantly lower cost
System Cost
Code size
+50%
7.8KB
High-end DSP
7.4KB
RX62T
Loop execution
47
16us
18us
Response to Step Change in Load

1050
1040
1030
1020
High-end DSP
Speed (rpm)
1010
RX62T
1000
990
980
970
960
950
0.265
6.343
time
48
22.906
Renesas Motor Control Solutions
49
Motor Control MCUs

RX63TH
Performance
100MHz, 165DMIPs
256KB 512KB
RX62T
100MHz, 165DMIPs
64KB 256KB
RX Core
RX600 Family
-Dual motor vector control
-Floating point
-RX600 Motor Kit
RX63TL
100MHz, 165DMIPs
32KB 64KB
RX220
32MHz,50DMIPs
32KB-256KB
RL78/G14
RX200 Family
-Single motor vector control
-Entry level RX core
RL78/G14
-Scalar control (low-end
vector control)
-RL78 Motor Kit
32MHz, 44DMIPs
32KB 256KB
R8C/3xM
20MHz
8KB 128KB
50
Oct.2012
Timeline
Evaluation Kits for Vector Control

Extensive Code Support
Flexibility to Evaluate and Develop
GUI
External Inverter Connector
RX600 Motor Kit
51
RL78 Motor Kit
High Voltage Demo Platform (2KW)
Line AC
85-265V
AC to DC
rectifier
IGBTs
RJH60D5DPQ-A0
Interleaved PFC
PWM
Set RPM
RPM
Is
Iq
Vdc
Gate
Driver
LCD
CPU Board
Potentiometer and
Push Buttons
In-circuit Scope
52
Current Sense
Hall and Encoder
2KW Inverter Platform
53
Summary
Sensorless vector control improves the motor system
efficiency
Implementing sensorless vector control requires careful
selection of MCU
Renesas provides several motor control MCUs depending on
the application requirements
RX600 and RL78 motor control kits are available for an easy
evaluation of Renesas solutions
High voltage platforms are also available
54
Questions?
55
Enabling The Smart Society

Challenge: Sensorless vector control increases the energy
efficiency of motor control systems that drive the smart
society. However, understanding and implementing
sensorless vector control is a herculean task
MCU
We discussed key challenges associated with sensorless

vector control and how to implement it using Renesas
microcontrollers
Do you agree that we accomplished the above statement?
56
Renesas Electronics America Inc.


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Sensorless Vector Control and

Implementation: Why and How

Renesas Electronics America Inc.

Renesas Technology & Solution Portfolio

2012 Renesas Electronics America Inc. All rights reserved.

Microcontroller and Microprocessor Line-up

1200 DMIPS, Superscalar

Automotive & Industrial, 65nm

1200 DMIPS, Performance

500 DMIPS, Low Power

165 DMIPS, FPU, DSC

165 DMIPS, FPU, DSC

25 DMIPS, Low Power

Industrial & Automotive, 150nm

44 DMIPS, True Low Power

10 DMIPS, Capacitive Touch

Industrial & Automotive, 130nm

Embedded Security, ASSP

2012 Renesas Electronics America Inc. All rights reserved.

Enabling The Smart Society

2012 Renesas Electronics America Inc. All rights reserved.

2012 Renesas Electronics America Inc. All rights reserved.

Macro Factors Driving Need for Energy Efficiency

2012 Renesas Electronics America Inc. All rights reserved.

Realizing Energy Efficiency in Motor Control

Variable speed drives

Direct torque control

2012 Renesas Electronics America Inc. All rights reserved.

Sensorless Vector Control Theory

2012 Renesas Electronics America Inc. All rights reserved.

Permanent Magnet AC Motor

Maintain stator field orthogonal to rotor field

2012 Renesas Electronics America Inc. All rights reserved.

Vector Control Challenge

What parameters to adjust

Need to transform current vectors to rotor frame

2012 Renesas Electronics America Inc. All rights reserved.

Reference Frame Transformation

2-phase Rotor Frame

2012 Renesas Electronics America Inc. All rights reserved.

Current Transformation to 2-ph Rotor Frame

2012 Renesas Electronics America Inc. All rights reserved.

Sensorless Vector Control

Current and motor parameters to estimate rotor position

Need to estimate without sensors

2012 Renesas Electronics America Inc. All rights reserved.

Motor Model in Frame

2012 Renesas Electronics America Inc. All rights reserved.

Rotor Position and Speed Estimation

2012 Renesas Electronics America Inc. All rights reserved.

Renesas Flux Observer Model

Potential inaccuracy: Noise in measuring current and voltage

2012 Renesas Electronics America Inc. All rights reserved.

Flux Observer Implementation

Negate the effect of DC offset in measured current/voltage

Low pass filter

2012 Renesas Electronics America Inc. All rights reserved.

Low pass filter

Sensorless Vector Control Loop

Flux and Position

2012 Renesas Electronics America Inc. All rights reserved.

2012 Renesas Electronics America Inc. All rights reserved.

2. Multiple current/voltage measurement

12Bit Simultaneous Sampling ADC