Fairchild solving design problems in motion control

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1

Solving Design Challenges in Motion ControlEuropean Sales & Marketing

PCIM May 2013

Marketing and Applications Team

2

Motor Efficiency for Energy Conservation

• Motors represent as much as 60~70% of the industrial energy used in developing countries.

• The motor drive appliances (washing machines, air-conditioners, fans…etc.) represent around 70% of total household power consumption.

• Reducing the amount of energy used by motors in electronic systems has become a priority worldwide.

3

Three-Phase Motor Solutions

AuxiliaryPowerSupply

Micro-controller

or DSP

Current Sense

Amplifiers

Rectifieror

PFC Stage

Three-phase Inverter

MotorAC

4

LVICHVICs

IGBTs/MOSFETs

Peripherals-Bootstrap diodes

-NTC thermistor

SPM® Modules for InvertersReliable integration of power and driver products

5

6 X IGBT

HVICShunt

Using Discrete

Using SPM® Modules

SPM® Module Advantages:

• Reduced EMI• More compact design • Reduced BOM cost• Simplified design• Reduced assembly costs• Increased reliability

Benefits Of Using SPM® Modules

6

FRDIGBT

Ceramic (Isolation material)

IC

EMC(Epoxy Molding Compound)

Al WiringCu Wiring Lead Frame

Adhesive

B/D

Copper Wire

BSD

Lead Frame

Power Line

Signal Line

IGBT-Based SPM Modules

MOSFET-Based SPM Modules

SPM® Package TechnologyImproved reliability using transfer-moulded modules

7

Motion Control Design ToolReliability assessment from estimation of temperature ripple

8

Three-Phase Motor Solutions

AuxiliaryPowerSupply

Micro-controller

or DSP

Current Sense

Amplifiers

Rectifieror

PFC Stage

Three-phase Inverter

MotorAC

9

PFC-Solutions(10) VTH

(1) VCC

COM

VCC

IN(S)

VFO

CSC

OUT

CFOD

NTCThermistor

(2~4) COM

(5) IN

(13~16) N

(17~20) NR

(6) VFO

(7) CFOD

(8) CSC

(9) RTH (21)(22) P

(24) L

(25) PR

(26) R

(27) S

Q1

D3 D4

D1 D2

D5

(20) VTH

(1) VCC

COM

VCC

IN(R)

VFO

CSC

OUT(S)

CFOD

NTCThermistor

(2) COM

(4) IN(R)

(6) VFO

(7) CFOD

(8) CSC

(19) RTH

(27) PR

(24) N

(26) S

(25) R

IN(S)(5) IN(S)

OUT(R)(23) NC

(22) NSENSE

(21) VAC-

Q1D3

Q2D4

D1 D2Boost-PFC

Bridgeless-PFC

Interleaved Boost-PFC

10

PFC SPM® Modules in SPM 3 package Boost PFC: Standard PFC solution

44mm x 26.8mm

Output power up to 3kW

2.5kV isolation voltage

optimized thermal management with DBC substrate

typ. switching frequency <40kHz

adjustable SCP with soft shut- down control

Built-in Thermistor

Fault Output for UVLP, SCP

Package compatible to Motion Modules

Current rating Tc = 25 °C Voltage rating x10

FPAB20BH60BFPAB30BH60B

(10) VTH

(1) VCC

COM

VCC

IN(S)

VFO

CSC

OUT

CFOD

NTCThermistor

(2~4) COM

(5) IN

(13~16) N

(17~20) NR

(6) VFO

(7) CFOD

(8) CSC

(9) RTH (21)(22) P

(24) L

(25) PR

(26) R

(27) S

Q1

D3 D4

D1 D2

D5

FBA42060 in SPM 45 Package for Lower PowerNew

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PFC SPM® Modules in SPM 3 package Bridgeless PFC: More compact solution

44mm x 26.8mm

Output power up to 6kW

2.5kV isolation voltage

optimized thermal management with DBC substrate

typ. switching frequency <40kHz

adjustable SCP with soft shut- down control

Built-in Thermistor and Shunt

Fault Output for UVLP, SCP

Package compatible to Motion Modules

FPDB30PH60 FPDB40PH60BFPDB50PH60 FPDB60PH60B

(20) VTH

(1) VCC

COM

VCC

IN(R)

VFO

CSC

OUT(S)

CFOD

NTCThermistor

(2) COM

(4) IN(R)

(6) VFO

(7) CFOD

(8) CSC

(19) RTH

(27) PR

(24) N

(26) S

(25) R

IN(S)(5) IN(S)

OUT(R)(23) NC

(22) NSENSE

(21) VAC-

Q1D3

Q2D4

D1 D2

Current rating Tc = 25 °C Voltage rating x10

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FAN9611 Interleaved Dual BCM PFC Controller• Efficiency

– Interleaved Lower Turn-off Losses– Phase Management– Valley Switching Minimize COSS losses– Strong gate drive reduce switching losses– Adjust Bulk Output Voltage at Light Load

• Protection– Closed-loop soft-start w/ Prog. Ramp Time– Current Limit per Channel– Power Limit per Channel– Input Voltage Feed-forward– Secondary Latched OVP– Input Brown-out Protection– Internal maximum fSW clamp limit

• Ease of Design & Solution Size– Easy Valley Detection Implementation– Easy Loop Compensation

(constant BW and PWM Gain)– Integrated +1A/-2A Gate Drivers– Works with DC, 50 Hz to 400 Hz

AC Inputs

VOUTD2

D1

FAN96111

2

3

4

5

6

7

8 9

10

11

12

13

14

15

16

CS2

CS1

VDD

DRV1

DRV2

PGND

VIN

OVPFB

COMP

SS

AGND

MOT

5VB

ZCD2

ZCD1

L2a

AC IN

CIN L1a

RZCD2

RZCD1

C5VB

RMOT

CSS

RCOMP

CCOMP,HF

Q2

RCS1 RCS2

COUT

Q1

VBIAS

RFB1

RFB2

ROV1

ROV2

RIN1

RIN2

RG2

RG1RINHYST

VIN

VLINE

EMI Filter

CCOMP,LF

L1b

L2b

CVDD1 CVDD2

CINF

13

Three-Phase Motor Solutions

AuxiliaryPowerSupply

Micro-controller

or DSP

Current Sense

Amplifiers

Rectifieror

PFC Stage

Three-phase Inverter

MotorAC

14

Pow

er

8W

14W

17W

20W

5W

No bias winding needed Bias winding needed in isolated application

FSL116HR/LR650V, 7.3Ω, DIP

FSL106HR/MR650V, 11.5Ω, DIP

FSL126HR/MR650V, 4.9Ω, DIP

FSL136HR/MR 650V, 3.5Ω,DIP/SO

FSL206MR650V, 14Ω, DIP/SO

Non-self supply Self-supply FSL3 Series

FSL306HR/UR650V, 14Ω

FSL336LR/HR/UR650V, 4Ω

Buck, Buck-Boost & Non-Isolated flyback

25W

30W

Released

Sampling

Development

FSL326LR/HR/UR650V, 6Ω

FSL117MRIN700V, 8.8Ω, DIP

FSL146MR650V, 2.1Ω, DIP

FSL156MRIN650V, 1.8Ω, DIP

FSL137MRIN700V, 4Ω, DIP

FSL4 SeriesIndustrial Flyback

FPS™ AC Regulators < 30W Pin to Pin*

FSQ500/H/X700V 30Ω/SOT223

FSD156MRBN650V, 1.8Ω, DIP

FSL117H700V, 8.8Ω, DIP

FSB147H700V, 2.3Ω, DIP

FSB127H700V, 6Ω, DIP

FSL4110HR/UR1000V 9Ω

FSL4516HR1600V, 10W~30W

Input OVP

Brown-out,AxCap™ discharge,

current limit pin

Pin 4 open

Current limit pin

Monolithic

2 chip.Current limit pin

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FPS™ AC Regulators: FSB1 Series

High Robustness• Internal Avalanche Rugged 700V SenseFET• Accurate Brownout protection with hysteresis• Constant Power Limit (Full AC Input Range)

Improved Light Load Efficiency• No-load power consumption of less

than 55mW at 16W from AxCap™ discharge circuit• Green-mode: PWM freq linearly decreasing

at light-load with burst mode at ve

Ease of Design• Adjustable peak current limit• Slope compensation

FPS Family Features• Peak current-mode control• 100kHz version• Frequency modulation for reducing EMI• Built-in soft start function• VDD Under-voltage Lockout (UVLO)• VDD OVP, OTP, OLP (Auto Restart)• High-voltage Start-up

Brown-out and AxCap™ discharge

L

N

EMIFilter + +

HV

VDD

+

GNDFB

IPK

Drain

PWM

+

230Vac 240Vac 265Vac0

10

20

30

40

50

Standby Power mW (for 16W/5V supply)

16

FPS™AC Regulators: FSL3 Series

High Robustness• Internal Avalanche Rugged 650V SenseFET• OLP, OVP in Auto Restart mode (650ms sleep time)

Improved Light Load Efficiency• Green Mode Function in Light Load Range• 25mW no-load power with bias winding • 125mW no-load power with self supply

Ease of Design• Options to work with and without bias winding• Integrated error amplifier for low component count• Adjustable current limit simplifies OCP and magnetics• Multi level TSD for flexible load response

FPS Family Features• Peak current-mode control• 100kHz version• Frequency modulation for reducing EMI• Built-in soft start function• VDD Under-voltage Lockout (UVLO)• VDD OVP, OTP, OLP (Auto Restart)• High-voltage Start-up

Low component count feedback circuit for non-isolated supplies

DIP7 PowerMLP

DC OUT

D

+

_

+

_

HV-DCIN

GN

D

VC

C

Vco

mp

ILIM

IT

VF

B

D D

Non-isolated flyback

Buck

GND

VCC

Vcomp

ILIMIT

VFB

D

D

DC OUT

HV-DC INPUT

LSOP7

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Reliability and SafetyProtection against component open or short circuit failures

Abnormal OCP or OLP

Over voltage Protection (OVP)

Possibility of failed parts

Output short Protection (OSP)

Thermal shutdown protectionor

Over current protection

ESD

High ESDimmunity ESD

Relatively Rugged parts

Over load protection (OLP)

Over voltage Protection (OVP)

Protected by OCP, OLP, OVP, AOCP, OSP, TSD

18

100V-1000V Input ESBC™ Transistor Power Supplies

Wide Input Range Solutions

19

Three-phase Motor Solutions

AuxiliaryPowerSupply

Micro-controller

or DSP

Current Sense

Amplifiers

Rectifieror

PFC Stage

Three-phase Inverter

MotorAC

20

FCM8531 Hybrid Motor Controller• Fairchild has explored the need of motor engineers and

developed a new hybrid controller – FCM8531• Easy to use and fully integrated solution with completed

developing tools and advanced motor control libraries allows very fast time to market

21

New Architecture for BLDC Motor Control

Advanced Motor ControllerA hardware-based motor controller plus configurable processing core which can be configured to several kinds of specific motor control algorithm.

Embedded MCUA MCS®51-compatible MCU processor provides motor control commands to the AMC to perform motor control activities, and manage external communication interfaces

GPIOUART

I2CSPI

FOC

DQ

Sinusoidal

Integration of Analog and Digital IC

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Benefits of the Hybrid Architecture• Minimum Software Effort

– The AMC performs powerful algorithms such as FOC and DQ control by using Fairchild’s libraries that can be configured and stored in AMC. Only simple system control software program needed in MCU.

• Reliability– AMC and MCU work independently to avoid system hang-ups.

• Robust Performance– Real-time cycle-by-cycle current protections in the hardware

based AMC detect and turn off PWM signals in μs to prevent system damage.

23

Easy-to-Use Development Tool • Fairchild provides the Motor Control Development System

(MCDS) IDE and MCDS Programming Kit for users to develop software, compile programs, and perform online debugging.

• User-friendly interface that reduces the time and effort required for studying datasheets and coding.– Visual setting options to replace complex

software coding.– Motor design configurations by simple

step-by-step clicking and selecting.– Support real time motor tuning.

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Fairchild’s Three-phase Motor Solutions• Fairchild provides key functional building blocks for motor

control systems

• These include:– SPM® smart power modules– PFC controllers– Integrated PWM controllers– BLDC controller– Discrete Components

• IGBT/MOSFETs• HV gate drivers

– Optocouplers

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APPENDIX

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Motion SPM® 5 V2 Series Modules

MOSFET modules with integrated bootstrap diodes & temp sense

29mm x 12mm

high power density (up to 200W)

1.5kV isolation voltage

optimized thermal management

Temperature sensing unit for HVIC

3 N-terminals for low-cost current sensing

high ruggedness

increased creepage distances (only T)

Built-in UVLP & Bootstrap Diodes (incl. 15Ohm)

low conducted and radiated EMI

Voltage rating x10S=SMD, T=Double DIP

FSB50250A(S/T)FSB50450A(S/T)FSB50550A(S/T)FSB50825A(S/T)

(1) COM

(2) VB(U)

(3) VCC(U)

(4) IN (UH)

(5) IN (UL)

(6) N.C

(7) VB(V)

(8) VCC(V)

(9) IN (VH)

(10) IN (VL)

(11) Vts

(12) V B(W)

(13) VCC(W)

(14) IN (WH)

(15) IN (WL)

(16)

(17) P

(18) U, VS(U)

(19) NU

(20) NV

(21) V, VS(V)

(22) N W

(23) W, VS(W)

COM

VCC

LIN

HIN

VB

HO

VS

LO

COM

VCC

LIN

HIN

VB

HO

VS

LO

Vts

COM

VCC

LIN

HIN

VB

HO

VS

LO

N.C

600V SuperFET® II MOSFETs for Higher Power: FSB50660SF (0.70Ωmax) & FSB50760SF (0.53Ωmax)New

27

Motion SPM® 5 V2 Series ModulesMeasurable temperature allows for power reduction at high temperature

- Voltage Output of HVIC temperature- Linear characteristic : VTSU=0.02*TIC+0.3V

[ Simulation data ]

Slope: 20mV/oC

Boundary (0oC, 150oC): 0.3V, 3.3V

Temperature sensing point

[ Internal Structure ]

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MOSFET-Based SPM® Modules have long short circuit times

Advanced & Rugged Silicon Technology

PRODUCT NAME IMAX IMIN TSCW

#1 @ VCC=15.0V, VDS=400V 16.20 [A] 13.60 [A] 44.2 [μsec]

#2 @ VCC=15.0V, VDS=400V 17.15 [A] 13.85 [A] 43.1 [μsec]

Competitor#1 @ VCC=15.0V, VCE=400V 6.80 [A] 6.20 [A] 7.57 [μsec]

#2 @ VCC=15.0V, VCE=400V 6.96 [A] 6.38 [A] 7.18 [μsec]

T=[10μs/div]

Vdc=[100V/div]

Ic=5.0[A/div]

Vin=5.0[V/div]

T=[2μs/div]

Vdc=[100V/div]

Ic=5.0[A/div]

Vin=5.0[V/div]

Short Circuit Test Waveform of FSB50450 Short Circuit Test Waveform of Competitor part

Tscwt =

44[usec]

Tscwt =

7.5[usec]

29

FSL Family(FSL1/2 Series)

Competitor

Manufacture In-house Own FAB & Assembly Plants Outsource FAB & Assembly Plants

BreakdownAvalanche

Energy

Two Chip (PWM/MOSFET)VDMOS General Vertical Structure

Very High Avalanche Energy Guaranteed [ EAS=400.0 mJ ]

One Chip(PWM+MOSFET) for easy sourcingLDMOS General Lateral Structure

Very Low Avalanche Energy[ EAS= 4.0 mJ ]

Secondary Protections

Output Short ProtectionAbnormal OCP Protection

N/A

Power Loss Standby Power at No Load 25~ 50mW Standby Power at No Load 50mW – 200mW

Low Voltage MemoryLogic

High VoltageDevices

General StructureInformation

General StructureInformation

FSL Family Versus Competitor

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