HEV/EV HVAC eCompressor Motor Management Reference Design

The reference design used sensorless field-oriented management and not using a place sensor, aiming to scale back growth time and improve system effectivity.

For many years, the interior combustion engine (ICE) has powered not solely automobiles but additionally their heating and cooling programs. Because the automotive business strikes in the direction of electrification, transitioning to hybrid electrical automobiles (HEVs) with smaller combustion engines or totally electrical automobiles (EVs) with out engines, the heating, air flow, and air-conditioning (HVAC) programs are more and more pushed by a PMSM motor that powers the eCompressor utilizing high-voltage electrical energy. This eCompressor is essential for cooling, heating through a warmth pump, and managing the thermal situations of different powertrain programs just like the battery pack and traction drive. In the present day, the eCompressor in HEVs and EVs faces a rising set of necessities, together with decrease prices, smaller measurement, decreased vibration and noise, in addition to larger energy ranges and elevated vitality effectivity. The TIDM-02012, a high-voltage HEV/EV HVAC eCompressor motor management reference design from Texas Devices (TI), demonstrates controlling an eCompressor motor utilizing field-oriented management (FOC) with out requiring a place sensor.

The system is designed to scale back the variety of crucial elements within the invoice of supplies, improve effectivity, and decrease vibration and noise, whereas additionally saving growth time. It’s based mostly on the TMS320F28003x real-time controller sequence and provides scalability with future MCUs within the portfolio utilizing the controlCARD-based kind issue. Moreover, the design accommodates each multi-shunt and single-shunt present sensing modes to cater to numerous design goals. An remoted gate driver is included to help 400V and 800V DC bus voltages, aligning with the business’s shift in the direction of larger voltage ranges.

Within the automotive sector, functions akin to HVAC compressors and Optimistic Temperature Coefficient (PTC) heaters each make the most of excessive voltage and require remoted communication. These elements are essential for guaranteeing efficient local weather management and heating inside automobiles, working beneath stringent security and effectivity requirements to deal with the excessive voltage calls for safely.

The options of this reference design embrace sensorless Discipline-Oriented Management (FOC) using the InstaSPIN FAST observer, which operates on a cost-optimized C2000 real-time microcontroller. The {hardware} and software program supplied with this design have been completely examined and are ready-to-use, considerably accelerating growth time to market. This design helps quite a lot of software program capabilities akin to field-weakening management, Most Torque Per Ampere (MTPA), over modulation, and vibration compensation via incremental software program builds that enable verification of various software program modules step-by-step. It additionally provides operation throughout a large pace vary, ranging from 5 electrical Hz, and contains help for CAN FD and LIN interfaces, together with motor over-current safety utilizing on-chip comparators.

TI has examined this reference design. It comes with a Invoice of Materials (BOM), schematics, meeting drawing, Printed Circuit Board (PCB) structure, and so on. You could find further information concerning the reference design on the corporate’s web site. To learn extra about this reference design, click on right here.