Integrated Power Factor Correction (PFC) Sensorless Field Oriented Con
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AN1208
Integrated Power Factor Correction (PFC) Sensorless Field Oriented Control (FOC) System
Author: Vinaya Skanda Microchip Technology Inc. (ADC) Pulse Width Modulator (PWM), enable digital design implementation such complex application simpler easier.
recent years, motor control industry been focusing designing power efficient motor control drives wide variety applications. consumer demand improved power quality standards driving this trend. power quality enhanced implementing Power Factor Correction (PFC), efficient control motor realized using Sensorless Field Oriented Control (FOC) techniques. appliance industry often requires low-cost implementation these algorithms. This achieved integrating Sensorless algorithms single Digital Signal Controller (DSC). This application note describes process integrating complex applications: Sensorless FOC. These applications implemented Permanent Magnet Synchronous Motor (PMSM). addition, this application note also describes integration algorithms, lists necessary hardware requirements, provides guidelines optimize development procedure. integrated solution based these application notes: AN1106, Power Factor Correction Power Conversion Applications Using dsPIC AN1078, Sensorless Field Oriented Control PMSM Motors Using dsPIC30F dsPIC33F Digital Signal Controllers application note AN1106, describes Power Factor Correction (PFC) method. application note AN1078, describes Sensorless Field Oriented Control (FOC) method. detailed digital design implementation techniques provided these application notes. This application note addendum above application notes. integrated application implemented following families dsPIC® devices: dsPIC30F dsPIC33F cost high performance capabilities DSC, combined with wide variety power electronic peripherals such Analog-to-Digital Converter
Digital Motor Control
majority motor control systems often first stage system. Without input stage, current drawn will have significant harmonic content presence switching elements inverter. addition, since motor loads highly inductive, input currents will induce significant reactive power into input system, thereby reducing overall efficiency system. stage which front-end converter motor control application, provides better output voltage regulation reduces harmonic content input current drawn.The standard boost converter topology with average current mode control preferred method implementing digital these applications. dual shunt Sensorless method speed control technique that drives PMSM motor. Sensorless technique overcomes restrictions placed some applications that cannot deploy position speed sensors. speed position PMSM motor estimated measuring phase currents. With constant rotor magnetic field produced permanent magnet rotor, PMSM very efficient when used appliances. When compared with induction motors, PMSM motors more powerful same given size. They also less noisy than motors, since brushes involved. Therefore, PMSM motor chosen this application.
Digital Signal Controller?
dsPIC devices ideal variety complex applications running multiple algorithms different frequencies using multiple peripherals drive various circuits. These applications (e.g., washing machines, refrigerators, conditioners) various motor control peripherals precisely control speed motor various operating loads. integrated Sensorless system uses following peripherals: Pulse Width Modulator (PWM) Analog-to-Digital Converter (ADC) Quadrature Encoder Interface (QEI)
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These peripherals offer following major features: Multiple sources trigger Input Conversion Capability Msps rate Methods simultaneous sample multiple analog channels Fault detection handling capability Comprehensive single-cycle instructions (e.g., MAC) used implement dsPIC device. this control method, output voltage controlled varying average value current amplitude signal. current amplitude signal calculated digitally. third final stage integrated system three-phase inverter stage that converts voltage into three-phase voltage. converted three-phase voltage input PMSM motor. This stage controlled implementing Sensorless strategy dsPIC device. Sensorless controls stator currents flowing into PMSM meet desired speed torque requirements system. position speed information estimated executing mathematical operations dsPIC DSC. integrated system uses five compensators implement Sensorless technique. technique uses compensators control voltage current control loops, Sensorless technique uses three compensators control speed control loop, torque control loop, flux control loop. compensators realized implementing Proportional-Integral (PI) controllers.
SYSTEM OVERVIEW
Figure shows block diagram integrated Sensorless system. first stage rectifier stage that converts input line voltage into rectified voltage. rectified voltage input second stage, which boost converter stage. During second stage, boost converter boosts input voltage shapes inductor current similar that rectified voltage. This achieved implementing digital power factor correction. Average Current Mode Control method
FIGURE
INTEGRATED SENSORLESS SYSTEM BLOCK DIAGRAM
PMSM
Amplifier Gains
Analog-to-Digital Converter
Power Factor Correction
Sensorless Field Oriented Control
Generator
Generator
Duty Cycle Inverter Duty Cycle
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NOVEL APPROACH DIGITAL IMPLEMENTATION SENSORLESS ALGORITHMS
Figure shows block diagram Sensorless control loops implemented digitally using dsPIC device.
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FIGURE
DIGITAL SENSORLESS BLOCK DIAGRAM
Bridge Rectifier Boost Converter Three-Phase Inverter
Control Control
VDCREF Voltage Control VAVG Current Control Speed Control
Estimator
VAVG Rotor System Power Factor Correction (PFC)
Stator System
Stator System
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Sensorless Field Oriented Control (FOC) System
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Digital Power Factor Correction
inductor current (IAC), input rectified voltage (VAC), Output Voltage (VDC) used feedback signals implement digital PFC. These signals scaled hardware gains input analog channels module. algorithm uses three control loops: voltage control loop, current control loop, voltage feed forward control loop. voltage compensator uses reference voltage actual output voltage inputs compute error compensate variations output voltage. output voltage controlled varying average value current amplitude signal. current amplitude signal calculated digitally computing product rectified input voltage, voltage error compensator output, voltage feed-forward compensator output. rectified input voltage multiplied enable current signal have same shape input voltage waveshape. current signal should match rectified voltage closely possible have high power factor. voltage feed-forward compensator essential maintaining constant output power given load because compensates variations input voltage. Once current signal computed, current compensator. output current compensator determines duty cycle pulses. boost converter driven either Output Compare module module. Refer application note AN1106, Power Factor Correction Power Conversion Applications Using dsPIC® (DS01106), information about system design digital implementations this control method. After speed determined mathematical estimation, error between desired speed estimated speed speed compensator. speed compensator produces output that acts reference compensator. permanent magnet motor, reference compensator zero value. controllers compensate errors torque flux, thereby producing output signals respectively. Inverse Park transformation Space Vector Modulation (SVM) techniques applied generate duty cycle Insulated Gate Bipolar Transistors (IGBTs).The motor control module used generate pulses. Refer application note AN1078, Sensorless Field Oriented Control PMSM Motors (DS01078), information about design, implement, tune compensator. implementation details hardware configuration details required develop integrated system discussed following sections.
INTEGRATED SENSORLESS IMPLEMENTATION dsPIC DEVICE
following control parameters routine used, when integrated system implemented using dsPIC30F dsPIC33F device: frequency: frequency: Control loop frequency: Control loop: Point execution routine: Point execution routines: Trigger Source ADC: Timer
Sensorless Field Oriented Control
phase currents, used feedback signals implement Sensorless technique. third phase current, calculated digitally. three-phase currents first converted two-phase stator system using Clarke transformation before being converted two-phase rotor system using Park transformation. This conversion provides computed current components: magnetizing flux function current rotor torque function current position estimator estimates rotor position speed information. motor model uses voltages currents estimate position. motor model essentially position observer indirectly derive rotor position. PMSM model based motor model.
Figure shows timing diagram integrated Sensorless system. Figure through Figure shows state flow diagram integrated system.
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FIGURE TIMING DIAGRAM
PTPER
PTPER
PWM1 Timer PITMR PITMR
PWM2 Timer
Trigger Event
Interrupt Events
PWM1 Interrupt Events
PWM1 Pulses
PWM2 Pulses
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FIGURE STATE FLOW DIAGRAM INTEGRATED SYSTEM
Reset
Initialize Variables
Initialize Parameters
Enable Interrupts
Switch Pressed
Switch Pressed
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FIGURE STATE FLOW DIAGRAM DIGITAL
Switch Pressed
Wait Interrupt
Read
Calculate Sample Count Calculate Sample Count
Interrupt Service Routine
Powe Start
Update PWM2 Duty Cycle
Voltage Control
Dela
Measured Current Control Calculate Reference Current IACREF
Power-on delay
Measured
Measured
Calculate VAVG Voltage Feed-forward Compensate
Measured
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FIGURE STATE FLOW DIAGRAM SENSORLESS
Switch Pressed
Wait Interrupt Measured
Start-up State
Read Reference Torque
Convert Currents
Execute Controllers
Interrupt Motor Running Start-up Duty Cycles using Increment Theta Based Ramp
Start-up Ramp Measured Read Reference Speed from Convert Currents
Sensorless State
Duty Cycles using
Execute Controllers Speed,
Compensate Theta Based Speed
Estimate Theta using Calculate Speed
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IMPLEMENTATION dsPIC30F6010A DEVICE
This section describes following topics: Configuration Details Hardware Setup Hardware Setup System Execution Procedure
Development Resources
develop test integrated algorithm, following software hardware tools required: Hardware Tools: dsPICDEMMC1H 3-Phase High Voltage Power Module (P/N: DM300021) dsPICDEMMC1 Motor Control Development Board (P/N: DM300020) dsPIC30F6010A digital signal controller (P/N: MA300015) PMSM motor MPLAB® REAL ICEDebugger/Programmer 220V, power source power supply Software Tools: MPLAB Version 7.61 later) Compiler Version 3.01 later)
Configuration Details
Figure shows connections between various analog inputs analog channels module. also shows resulting buffer locations where digital results stored.
FIGURE
CONFIGURATION
Result Buffer AN7-POT Speed Ref. ADCBUF0
Phase Current
ADCBUF1
Phase Current ADCBUF2
AN2-POT
Torque Ref.
ADCBUF3
ADCBUF4
ADCBUF5
ADCBUF6
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Hardware Setup
CONFIGURING dsPICDEM MOTOR CONTROL DEVELOPMENT BOARD
following steps outline procedure dsPICDEM Development Board: Remove following components: located line located line located line Connect analog channel analog channel AN6. Connect analog channel analog channel AN11. Connect analog channel connector.
CONFIGURING dsPICDEM MC1H HIGH VOLTAGE POWER MODULE
following steps outline procedure board: Solder high-current jumper wire (AWG minimum) between J13, shown Figure
FIGURE
ESTABLISH COMMON POWER DIGITAL SIGNAL GROUND
Because shunt resistors used sense current from motor, power digital signals must same ground. Solder high-current jumper wire (AWG minimum) between J13. BEFORE
ACCESSING HIGH VOLTAGE POWER MODULE
Before removing lid, following procedure should rigidly followed: Turn power system. Wait minimum minutes that internal discharge circuit reduced voltage safe level. voltage indicator visible through ventilation holes should lit. Verify with voltmeter that discharge taken place checking potential between plus minus terminals 7-pin output connector before proceeding. voltage should less than before proceeding next step. WARNING: voltage more than 10V, repeat steps until voltage level less than 10V. system only safe work voltage less than 10V. Failure heed this warning could result bodily harm. Remove cables from system. Remove screws fixing chassis heat sink bottom. Slide forward while holding unit heat sink. After board housing, modify power module described next section.
AFTER
Jumper Connect LK30 BUS_SENSE terminal using signal wire. Place kOhm resistors links LK20, LK21, LK31, shown Figure
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FIGURE INSTALL FEEDBACK CURRENT SELECTION RESISTORS
System Execution Procedure
Complete following steps execute integrated Sensorless algorithm that controls motor: Launch MPLAB software open program. algorithm. Apply input voltage dsPICDEM MC1H High Voltage Power module. Make sure VR2, Speed Reference POT, minimum position VR1, Initial Torque Reference POT, between position. Start motor pressing switch. motor starts Open Loop mode ramps speed until equal rpm, then makes transition from Open Loop mode Closed Loop mode. When motor enters Closed Loop mode stabilizes, start calculations pressing switch. voltage boosts from initial value based amplitude applied input voltage. Change values operate motor different speed. Stop motor pressing switch.
obtain feedback current, circuit links must completed. activate current feedback this application, populate links LK20, LK21, LK31 with resistors. BEFORE
LK20, LK21, LK31 Links AFTER
Shunt Resistors Remove jumper connection place link jumper LK1. Place jumper position. Place jumpers link through LK12.
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IMPLEMENTATION dsPIC33FJ12MC202 DEVICE
This section describes following topics: Configuration Details dsPIC33FJ12MC202 Allocation Development Resources Hardware Setup Interconnecting Hardware System Execution Procedure
Configuration Details
Figure shows connections between various analog inputs analog channels module. also shows resulting buffer location where digital results stored.
FIGURE
CONFIGURATION
Result Buffer AN5-POT Speed Ref. ADCBUF0
Phase Current
ADCBUF1
Phase Current ADCBUF2
ADCBUF3
ADCBUF4
ADCBUF5
ADCBUF6
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dsPIC33FJ12MC202 Allocation
Since dsPIC33FJ12MC202 device remappable device, functionality each defined user. Table lists different pins functionality assigned pin.
Development Resources
develop test application, following hardware software development tools required: Hardware Tools: dsPICDEM MC1H 3-Phase High Voltage Power Module (P/N: DM300021) Explorer Development Board (P/N: DM240001) Motor Control Interface PICtail Plus Daughter Board (P/N: AC164128) dsPIC33FJ12MC202 Plug-in Module (P/N: MA330014) power supply Variable power supply (0-220V) PMSM motor MPLAB Debugger/Programmer Software Tools: MPLAB Version 8.00.04 later) Version 3.01 later)
TABLE
FUNCTIONALITY
NAME Speed Reference (POT) Ground Primary Oscillator Line Primary Oscillator Line Debug Data Line Debug Clock Line Device Supply Fault Input Signal Switch Motor On/Off Switch On/Off MOSFET Fire Fault Reset/PWM Enable Digital Ground Device Supply Inverter IGBT3 High Fire Inverter IGBT3 Fire Inverter IGBT2 High Fire Inverter IGBT2 Fire Inverter IGBT1 High Fire Inverter IGBT1 Fire Analog Ground Device Supply Reset/Clear Phase Current Phase Current FUNCTIONALITY
PGD/EMUD3 PGC/EMUC3 PWM2H1 VDDCORE PWM1H3 PWM1L3 PWM1H2 PWM1L2 PWM1H1 PWM1L1 AVSS AVDD MCLR
Hardware Setup
ACCESSING HIGH VOLTAGE POWER MODULE
Before removing lid, following procedure should rigidly followed: Turn power system. Wait minimum minutes that internal discharge circuit reduced voltage safe level. voltage indicator visible through ventilation holes should lit. Verify with voltmeter that discharge taken place checking potential between plus minus terminals 7-pin output connector before proceeding. voltage should less than before proceeding next step. WARNING: voltage more than 10V, repeat steps until voltage level less than 10V. system only safe work voltage less than 10V. Failure heed this warning could result bodily harm. Remove cables from system. Remove screws fixing chassis heat sink bottom. Slide forward while holding unit heat sink. After board housing, modify power module described next section.
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MODIFYING dsPICDEM HIGH VOLTAGE POWER MODULE
following steps outline procedure board: Solder high-current jumper wire (AWG minimum) between J13, shown Figure Place kOhm resistors links LK20, LK21, LK31, shown Figure
FIGURE
INSTALL FEEDBACK CURRENT SELECTION RESISTORS
obtain feedback current, circuit links must completed. activate current feedback this application, populate links LK20, LK21, LK31 with resistors. BEFORE
FIGURE
ESTABLISH COMMON POWER DIGITAL SIGNAL GROUND
Because shunt resistors used sense current from motor, power digital signals must same ground. Solder high-current jumper wire (AWG minimum) between J13. BEFORE
LK20, LK21, LK31 Links AFTER
AFTER
Shunt Resistors Jumper Replace resistor with kOhm resistor. Replace resistor with kOhm resistor. Connect LK30 BUS_SENSE terminal using signal wire. Remove jumper connection place link jumper LK1. Place jumper position. Place jumpers link through LK12.
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SETTING EXPLORER BOARD
following steps outline procedure board: Place jumper PIC24 position. Switch position. Remove connections. Some LCDs have internal pull-up resistors; therefore, recommended remove LCD.
Interconnecting Hardware
system, complete following steps: Configure hardware properly. Refer "Hardware Setup" more information hardware modifications. Place dsPIC33FJ12MC202 Explorer Development Board. Connect Explorer Development Board Motor Control Interface PICtail Plus Daughter Board using 120-pin connector. Connect Motor Control Interface PICtail Plus Daughter Board dsPICDEM High Voltage Power Module using 37-pin connector. Connect power supply Explorer Development Board. Connect variable supply dsPICDEM 3-Phase High Voltage Power Module. Power supply. Power input supply.
CONFIGURING SETTING MOTOR CONTROL INTERFACE PICtail PLUS DAUGHTER BOARD
these steps configure board: jumper connect jumper J10, connect jumper J11, connect Place Jumper J27.
CONFIGURING dsPIC33FJ12MC202 PLUG-IN MODULE
following steps outline procedure board: Connect Connect Connect Connect Connect Connect Connect Place following zero resistors: R12, R13, R14, R15, R16, R17, R18, R19, R20, R24, R25. Remove following zero resistors: R10, R11, R21, R22, R23, R26, R27, R28, R29, R30, R31, R32, R33.
System Execution Procedure
Complete following steps execute algorithm dsPIC33F device: Launch MPLAB software open program. Build Flash device. Make sure Debug option selected MPLAB IDE. algorithm. Apply input voltage dsPICDEM 3-Phase High Voltage Power Module. Make sure Speed Reference Explorer Development Board, minimum position (CCW). Start motor pressing switch. motor starts Open Loop mode ramps speed until equal rpm, then makes transition from Open Loop mode Closed Loop mode. When motor enters Closed Loop mode stabilizes, start calculations pressing switch. voltage boosts from initial value based amplitude applied input voltage. Change values operate motor different speed. Stop motor pressing switch.
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LABORATORY TEST RESULTS WAVEFORMS
Figure Figure show waveforms input current, phase current, phase current when executing integrated application. This information aids validating Sensorless implementation dsPIC device.
FIGURE
INPUT CURRENT MOTOR PHASE CURRENT WAVEFORMS
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FIGURE EXPANDED INPUT MOTOR PHASE CURRENT WAVEFORMS
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CONCLUSION
Considering consumer demand increased efficiency growing desires environmental standards, designers always looking algorithms that used develop low-cost, power efficient motor control systems. dsPIC device's high processing power peripheral-rich platform enable implementation complex algorithms single chip. Sensorless process uses three control loops compensate current speed. process uses control loops compensate input current output voltage. these compensators controller compensate variations these parameters, which requires very high processing power finer control system. dsPIC devices best suited handle above requirements because high resolution, good processing speed, availability advanced analog peripherals, variety instructions that support these functions. Microchip various resources assist developing this integrated system. Contact your local Microchip sales office would like further support.
REFERENCES
Several application notes have been published Microchip Technology, which describe dsPIC devices motor control applications. ACIM control see: AN984, Introduction Induction Motor Control Using dsPIC30F (DS00984) AN908, Using dsPIC30F Vector Control ACIM (DS00908) GS004, Driving ACIM with dsPIC MCPWM Module (DS93004) AN1162, Sensorless Field Oriented Control (FOC) Induction Motor (ACIM) (DS01162) AN1206, Sensorless Field Oriented Control (FOC) Induction Motor (ACIM) Using Field Weakening (DS01206) BLDC motor control see: AN901, Using dsPIC30F Sensorless BLDC Control (DS00901) AN957, Sensored BLDC Motor Control Using dsPIC30F2010 (DS00957) AN992, Sensorless BLDC Motor Control Using dsPIC30F2010 (DS00992) AN1083, Sensorless BLDC Control with Back-EMF Filtering (DS01083) AN1160, Sensorless BLDC Control with Back-EMF Filtering Using Majority Function (DS01160) PMSM control see: AN1017, Sinusoidal Control PMSM Motors with dsPIC30F (DS01017) AN1078, Sensorless Field Oriented Control PMSM Motors (DS01078) Power Control see: AN1106, Power Factor Correction Power Conversion Applications Using dsPIC (DS01106) information dsPICDEM Motor Control Development Board see: dsPICDEM Motor Control Development Board User's Guide (DS70098) dsPICDEM MC1H 3-Phase High Voltage Power Module User's Guide (DS70096) dsPICDEM MC1L 3-Phase Voltage Power Module User's Guide (DS70097) Explorer Development Board User's Guide (DS51589) Motor Control Interface PICtail Plus Daughter Board User's Guide (DS51674) These documents available Microchip site (www.microchip.com).
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APPENDIX SOURCE CODE
Software License Agreement
software supplied herewith Microchip Technology Incorporated (the "Company") intended supplied you, Company's customer, solely exclusively with products manufactured Company. software owned Company and/or supplier, protected under applicable copyright laws. rights reserved. violation foregoing restrictions subject user criminal sanctions under applicable laws, well civil liability breach terms conditions this license. THIS SOFTWARE PROVIDED CONDITION. WARRANTIES, WHETHER EXPRESS, IMPLIED STATUTORY, INCLUDING, LIMITED IMPLIED WARRANTIES MERCHANTABILITY FITNESS PARTICULAR PURPOSE APPLY THIS SOFTWARE. COMPANY SHALL NOT, CIRCUMSTANCES, LIABLE SPECIAL, INCIDENTAL CONSEQUENTIAL DAMAGES, REASON WHATSOEVER.
software covered this application note available single WinZip archive file. This archive downloaded from Microchip corporate site www.microchip.com
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NOTES:
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Microchip received ISO/TS-16949:2002 certification worldwide headquarters, design wafer fabrication facilities Chandler Tempe, Arizona; Gresham, Oregon design centers California India. Company's quality system processes procedures PIC® MCUs dsPIC® DSCs, KEELOQ® code hopping devices, Serial EEPROMs, microperipherals, nonvolatile memory analog products. addition, Microchip's quality system design manufacture development systems 9001:2000 certified.
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