Development Plan For DC300V Input DLBC Motor Sensorless Control Circuit Using Tpd4164kintroduction

Development plan for DC300V input DLBC motor sensorless control circuit using TPD4164K Introduction

This reference guide explains the specifications and operating procedures of the sensorless control circuit for a brushless DC motor with a DC300V input (referred to as "this reference design"). The fan in indoor air conditioners typically uses a brushless motor that operates at a DC300V level. Previously, motors were mainly driven using square wave excitation with Hall sensors. However, in recent years, in response to the demand for lower system costs, higher efficiency, and quieter motors, motors are now being driven using sinusoidal excitation and vector control without Hall sensors. In this reference design, the microcontroller TMPM374FWUG is used to control the motor and achieve sensorless vector control. The intelligent power device consists of switches for the three-phase inverter and a gate driver, packaged in a compact form for motor driving. This reference design (RD179-2) uses the TPD4164K (IGBT with built-in diode, withstand voltage of 600V, maximum output current of 2.0A, and HDI P30 package). This device helps achieve efficient motor driving with a compact onboard area. This design guide describes the design of the sensorless control circuit for a brushless DC motor with a DC300V input (referred to as "this reference design").

picture of real products

Simple block diagram

Parameter

circuit design

MCU and its peripheral circuits

Motor Control Circuit (TPD4164K)

The scheme also includes shunt current detection circuit, fault detection circuit, motor voltage detection circuit and other protection circuits and protection measures. Design documents, including circuit design formulas, can greatly reduce the development time.

Characteristics

1. Advanced Microcontroller: The design utilizes the Toshiba microcontroller TMPM374FWUG, equipped with a high-speed Arm Cortex-M3 core that supports operating frequencies of up to 80MHz. It has a wide operating temperature range (-40 to 80°C) and is ideal for motor control applications that require high performance and reliability.

2. Sophisticated Motor Control Features: The microcontroller incorporates various functions suitable for motor control, including A/D converters, programmable motor drivers, vector engines, and encoders. These features provide a foundation for precise and flexible motor control.

3. Intelligent Power Device TPD4164K: This device offers a high-voltage (600V withstand voltage), three-phase brushless motor driving solution. It features built-in IGBTs, current sensing with 3 shunt resistors, multiple protection circuits, and shutdown functions, allowing direct motor driving from the microcontroller's control signals.

4. Multiple Protection Mechanisms: The design includes overheat protection, undervoltage protection, overcurrent protection, and shutdown functions to ensure the safety and reliability of the motor drive system.

5. Intuitive Circuit Design: Detailed circuit design and component lists are provided to enable developers to have a clear understanding of every aspect of the design, facilitating implementation and troubleshooting.

6. Integrated Motor Drive Circuit: The design includes MCU peripheral circuits, motor drive circuits, shunt current measurement circuits, error detection circuits, and motor voltage detection circuits, forming a complete solution to support complex motor control requirements.

7. Debugging and Diagnostic Support: The design incorporates error detection circuits and motor voltage detection circuits, allowing the system to monitor performance and diagnose issues quickly during operation, improving maintenance efficiency and system stability.

8. Compact Packaging: The microcontroller is packaged in a small LQFP44 package, and the intelligent power module is packaged in HDI P30, enabling a compact onboard design.

This solution provides an ideal solution for applications that require high efficiency, high performance, and advanced motor control capabilities.

Applications

Based on the technical features of this project, the following are possible application areas and specific uses:

1. Industrial Automation

●  Precision control machines: CNC machine tools, automated assembly lines, robotic arms, etc., which require precise speed and position control.

●  Pump and fan control: Suitable for applications that require flow and pressure regulation, such as HVAC systems, cooling systems, and ventilation equipment.

2. Home Appliances

● Air conditioners: Particularly suitable for the fan and compressor of indoor and outdoor air conditioners due to the noise reduction capabilities of sensorless control.

● controlling fans and compressors in indoor and outdoor air conditioners.

● Washing machines and dishwashers: efficient and low-noise motor control can be achieved in these applications.

3. Electric Transportation

● Electric bicycles and electric motorcycles: provide motor control solutions for electric two-wheelers, enhancing their performance and range.

● Autonomous vehicles: precise drive control is necessary in automated guided vehicles (AGVs) and other automated transportation tools.

4. Consumer Electronics

● Power tools: such as electric drills and saws, which require reliable and efficient motor control.

● Personal care products: such as electric toothbrushes and shavers, which require small and efficient motors.

5. Energy Industry

● Renewable energy systems: for example, wind turbine regulation in wind power generation, requiring precise motor control to optimize power generation efficiency.

● Battery energy storage systems: used to control cooling fans and pumps in battery management systems.

6. Medical Devices

● Diagnostic instruments: such as CT scanners and MRI machines, which require high precision and low vibration motor control.

● Assistive devices: such as electric wheelchairs and rehabilitation equipment.

7. Aerospace

● Aircraft control systems: precise motor control in drones and other aircraft.

● Satellite positioning systems: used for precise positioning of satellite antennas or instruments.

These application fields make use of the high efficiency, low noise, high performance, and multi-functional protection features designed in this project, as well as its ability to operate stably within a wide range of working temperatures.

Critical device

Service and Support

● Overall Solution: Provide a complete DC 300V input brushless DC motor sensorless control circuit solution to meet customer requirements, and customize and optimize according to customer needs.

● PCB: Provide PCB boards, PCB manufacturing files, stencil files, printing files, and layout files. Ensure reasonable layout and stable wiring. Customers can make secondary development and layout adjustments according to their own needs.

● Intelligent Power Device Selection: Provide intelligent power device selection recommendations and assist customers in obtaining product parameters and usage guidelines.

● Related Design Reference Documents: IC-related design documents, circuit topologies, design principle analysis, major component selection rules, and industry-related regulations.

● Bill of Materials (BOM): Provide BOM materials according to customer requirements to ensure reliable component quality.

Component Introduction

Microcontroller TMPM374FWUG

The Toshiba microcontroller TMPM374FWUG is used in this reference design to control the motor.

● Equipped with a high-speed Arm Cortex-M3 processor that can run up to 80MHz (operating temperature range of -40 to 80 degrees Celsius).

● Equipped with features suitable for motor control, such as analog-to-digital converter (A/D converter), programmable motor driver, vector engine, and encoder.

● Supports operation at 5V voltage.

● Compact LQFP44 package.

Intelligent Power Device TPD4164K

The intelligent power device TPD4164K is used in this reference design (RD179-2). The TPD4164K is a high-voltage three-phase brushless motor driver that integrates a rated 600V IGBT and supports 3-shunt resistor current sensing. It also integrates level-shifted high-side drivers, low-side drivers, overheat protection circuit, undervoltage protection circuit, overcurrent protection, and shutdown (SD) function. As a result, a three-phase brushless motor can be directly driven by receiving control signals from the microcontroller.

● Output withstand voltage VBB 600V (Max value)

● Output current Iout 2.0A (Max value)

● HDIP30 package