System purpose
Industrial motor drives are the backbone of today’s global industry. They account for almost two-thirds of energy consumed in the industrial applications today.
With increasing stricter regulations, the need for high energy savings keeps growing for Industrial drives. While BLDC motors can be typically powered from the mains a VFD is required for efficiency and better control.
Industrial drives can be used with either AC motors or Brushless DC (BLDC) motors and onsemi provides a variety of components that can used to create a complete Industrial drive solution that will improve efficiency, reduce the overall system size, reduce BOM, and reduce the time to market for the customer.
Low RDS(on) discrete Si and SiC FETs and integrated modules provide further advantages by reducing the overall system size, heat sink requirements and cost of the end equipment.
AC motor benefits -> Easy to control, low startup power demand, high durability, controllable start-up currents.
BLDC motor benefits -> low maintenance, high startup power, fast response to start and stop, higher efficiency.
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System implementations
Topology for an Industrial drive (BLDC motors)
AC / DC converter
- Solution to convert AC from mains supply to HVDC bus for the whole system.
Power supplies
- Convert HVDC bus to different low voltage DC (SMPS)
- Low voltage DC / DC Auxiliary supply for Control hardware (SMPS, LDO)
- DC / DC Auxiliary supply for Sensing hardware (SMPS, LDO)
Power stage
- Output Inverter stage
- Brake (optional)
- Gate drivers
Sensing hardware
- Current sensing amplifiers
- Voltage sensing
- Temperature sensing products
Control hardware
- Microcontroller
- MCU, ASIC, DSP, FPGA
System description
While On Semiconductor provides a wide variety of discrete products for a complete motor drive solutions, On Semiconductor’s power modules can be used to reduce system size and time to market while increasing efficiency.
There are three types of power modules available in the current portfolio:
- Power integrated Module (PIM) –
- CIB PIM → Converter + Inverter + Brake
- CIP PIM → Converter + Inverter + PFC
- Intelligent Power Module (IPM) → Gate Driver + Inverter + Temperature sensor + Protection
A motor Control system can then be designed with three different approaches:
- Solution using discrete components like IGBTs / MOSFETs / EliteSiC MOSFETs, Diodes, EliteSiC Diodes, gate drivers, PFC controllers, etc.
- Solution using Power integrated modules (PIM) like CIB and CIP modules along with gate drivers.
- Solution using Intelligent Power modules (IPM) along with discrete components for converter and Brake (optional).
Regardless of an approach from the above three, an industrial drive system will consist components described below:
- The controller stage that consists of DSP products, MCUs, ASICs and FPGAs to communicate with the whole system. This stage receives provides input signals to the gate drivers, which drives the output inverter stage and brake (if present).
- Op – Amps / current sense amplifiers that measure voltage across current sense resistors at the inverter stage.
- Temperature sensing products for monitoring output inverter stage temperature.
- DC/DC converter products that provides different DC voltage levels for process control supply (+24V), Gate drivers (+12V / +15V)
- Low voltage DC/DC converters for low voltage (+3.3V) products like MCU, DSP, FPGA and ASIC
- Opto-Isolators for general-purpose I/O and communication ports.
- Low voltage bus protection and eFuse (+24V) for protected loads
Discrete Approach
- In this approach, a motor control solution can be designed using discrete components for AC/DC converter, Brake, Output inverter stage along with gate drivers.
- High voltage (HV) gate drivers to drive Output inverter stage.
- Low voltage (LV) gate drivers to drive the brake and PFC.
- Power Integrated Modules (PIM) Approach
- Intelligent Power Module (IPM) Approach
Power Integrated Modules (PIM) Approach
- In this approach, the discrete output stage and the converter circuit is replaced by a single PIM.
- A single CIB PIM integrates the converter, brake and inverter circuit.
- A CIP PIM integrates the converter, PFC and inverter circuit
- HV gate drivers are still required for the output inverter stage of the PIM
- LV gate drivers are still required for the brake and PFC blocks of the PIM
Intelligent Power Module (IPM) Approach
- IPMs are a great option to reduce the system size, cost and time to market of the system. An IPM module consists of a gate driver along with an output inverter stage.
- IPMs also integrates protection of Power Systems from short circuits, Under voltage lockout (4 per module, one for each high side FET and one for the 3 low side FETs), Temperature monitor
- A 2-in-1 PFC IPM can also be used to replace the gate driver and the PFC controller
- The major applications of intelligent power modules can be observed in inverters, heating, ventilation, and air-conditioning (HVAC), and elevators.
Additional considerations
Motor development kits (MDK)
The MDK power boards are designed using either PIMs, or IPMs, or discrete MOSFETs. Three MDKs have been released by the SEC so far:
- The 1kW power board is designed using a 600V compact IPM
- The 4kW board is designed using the SPM31 intelligent power module
- Series of 4 medium voltage MDK board for 10V to 100V applications
Motor development kit family
Motor development kits available
- 1 kW 600 V based on Compact IPM and Universal Controller Board Kit
- 4 kW 650 V based on SPM31 and Universal Controller Board Kit
- Series of 4 boards for medium voltage MDKs for BLDC motors
- Board A: 10V-16V / 600W max
- Board B: 16V-30V / 960W max
- Board C: 30V-60V / 1.2kW max
- Board D: 60V-100V /1.2kW max
Product choice based on application
Product suggestions will depend on the power levels of the application. While IGBTs, EliteSiC products, IPMs and PIMs make a great choice for applications with bus voltages above 250V such as Industrial drives, HVAC and Building controls.
Gate driver topologies
Different isolation techniques in gate driver play an important role while selecting the correct gate driver. There are isolated gate drivers (Galvanic isolation and Junction Isolation) and non-isolated gate drivers. However, most high-power Industrial drives will use a Junction isolated or galvanic isolated gate driver.
Economical drivers = non isolated
4kW and above systems – isolated drivers as systems are already expensive and need of isolation is realized.
Industry 4.0
Industry 4.0 (or fourth industrial revolution) is the technology revolution where machines will be linked to each other through a communication network. Industrial drives for these applications will use network communication products like Ethernet, Bluetooth, wifi chips and zigbee.
While motor control is one of the crucial part in factory automation, they are often used with onsemi solutions as mentioned below:
- Power conversion, AC/DC and DC/DC converters
- Lidar and imaging solutions
- Battery charging solutions
- Communications
| Suggested Block | Web Part Number (WPN) | Comments | WPN Description |
|---|---|---|---|
| eFuse | NCS32100 position sensor | Dual inductive rotary position sensor with self calibration | |
| ECS640 ecoSpin™ | Configurable motor controllers for reliable operation up to 600 Volts | ||
| NIS5x2x | Electronic fuse (eFuse), 12V, 44 mΩ, 4A, ISENSE | ||
| NIS4461 | +24 VOLT ELECTRONIC FUSE | ||
| IGBTs | FGHL75T65MQDTL4 | 650V, 75A Field Stop Trench IGBT | |
| FGHL50T65SQDT | 650 FS4 HI SPEED 50 A WITH FULL RATING FRD | ||
| AFGHL50T65SQDC | 650V 50A FS4 HYBRID IGBT | ||
| MOSFETs EliteSiC / GaN |
NTBG045N065SC1 | EliteSiC MOS D2PAK-7L 650V | |
| NTH4L045N065SC1 | EliteSiC MOS TO247-4L 650V | ||
| NTBG080N120SC1 | EliteSiC MOS D2PAK-7L 80MOHM 1200V | ||
| NTBG160N120SC1 | EliteSiC MOS D2PAK-7L 160MOHM 1200V | ||
| NTD360N65S3H | SUPERFET® III, FAST, 650 V, 10 A, 360 mΩ, DPAK | ||
| NTMT125N65S3H | SUPERFET® III, FAST, 650 V, 24 A, 125 mΩ, Power88 | ||
| EliteSiC Diodes | FFSP0665B | EliteSiC DIODE TO220 650V | |
| FFSP0865B | EliteSiC DIODE TO220 650V | ||
| NDSH20120C | EliteSiC DIODE GEN2.0 1200V TO247-2L | ||
| PFC modules | NFL25065L4BT | IPMs | IPM, 650 V, 50 A |
| NFP36060L42T | IPMs | IPM, 650 V, 60 A | |
| STK57FU394AG-E | 2-in-1 PFC | 2-in-1 PFC and Inverter, 600 V, 15 A | |
| Gate Drivers | NCD57001 | Isolated high current and high efficiency IGBT gate driver with internal galvanic isolation | |
| NCD57090 | Isolated High Current Gate Driver | ||
| I P M 3-Phase inverter modules |
NFAM0512L5B | SPM31, 1200V, 5A | |
| NFAM0512L5BT | 1200V, 5A (NTC option) | ||
| NFAM2065L4B | SPM31, 650 V, 20 A | ||
| NFAL5012L5B | Intelligent Power Module, SPM49, 1200 V, 50A | ||
| NFAL3512L5B | SPM49, 1200 V, 35 A |
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