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TT-002100-1005 1
Notor Control Fundamentals
Basic Motor Control Training
Basic Motor Control Training
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Overview
Notor anatomy
What makes a motor spin?
Types of motors
Why do we need electronics in the motor?
System level block diagram
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Anatomy of a Notor
Stator
Rotor
Shaft
Bearings
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Rotor 8 Stator
Rotor
- Rotating part of the Notor
- Precisely balanced against
vibrations
- Special coatings to protect the
windings
- Also called as Armature
Stator
- Stationary part of the Notor
Note: Rotor and Stator can be Nagnets or Electrical Windings
ROTOR
STATOR
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Commutator 8 Brushes
Commutator
- A split-ring rotating device
- Attached to axle of the rotor
Brushes
-The electrical contacts to the
Commutator
- Copper brush contacts or
spring-loaded carbon contacts
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Energizing the coils
DC voltage
- PWN Duty Cycle
AC voltage
-Sinusoidal wave
Commutation
The process of changing the
direction of the current in an
armature (rotor) coil as it moves
under the brushes.
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What makes a Notor Spin?
Transformation of Energy
- Nagneticf Electromagnetic Energy is transformed
into mechanical energy
Electromagnetic Energy
- Generated by passing current through wounded
electric windings
Nagnetic Energy
- Naturally present in all magnets
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Nagnetic Diagram of a Notor
Basics of
(Electro) Nagnets:
- Like Poles repel
- Unlike poles attract
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How is motion in motor produced?
Torque generates motion
- Torque = Force x Distance
- Torque is generated by time varying magnetic field
Electromagnetic Torque
- Conductor in the presence of a time varying magnetic field
- Nagnetic field created in turn by:
Permanent Nagnets
Time varying Current passing through the conductor
Reluctance Torque
- Tendency of the magnetic material aligning itself to the
lowest energy state
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Notor Types
DC Notors (Electromagnetic torque)
- Brushed DC Notors
- Brushless DC Notors
Universal Notors (Electromagnetic torque)
- Runs on AC or DC
- Similar to DC Notors
AC Notors (Electromagnetic torque)
- 1-1 AC !nduction Notor
- 3-1 AC !nduction Notor
- 3-1 Synchronous Notor
Switch Reluctance Notors (Reluctance torque)
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Notor Types: Brushed DC
Brushed DC Notor
Stator: Permanent magnets
Rotor: Windings and Commutator
Stationary Brushes make electrical
connections to the rotor windings
through the Commutator
Rotor winding current produces
torque by interacting with stator
permanent magnets
Stator
Rotor
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Notor Types: Brushless DC
Brushless DC Notor
Stator: Windings
Rotor: Permanent magnets
Stator windings controlled
(commutated) by external
electronics
Stator winding current produces
torque by interacting with rotor
permanent magnets
Stator
Rotor
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Notor Types: Universal Notor
Universal Notor
Stator: Windings
Rotor: Windings and Commutator
Stationary Brushes make electrical
connections to the rotor windings
through the Commutator
Rotor winding current produces torque
by interacting with stator winding
current (electromagnetic field)
Stator
Rotor
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Notor Types: 1-1 AC !nduction Notor
1-1 AC !nduction Notor
Stator: Windings
Rotor: Cast aluminum Windings
(Squirrel cage)
Stator windings are controlled
by the single phase AC line or
external electronics
The interaction of the magnetic
field produced by the stator and
the current carrying conductors
in the rotor causes the rotor to
follow the stator field
Stator
Rotor
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Notor Types: 3 1 AC !nduction Notor
3-1 AC !nduction Notor
Stator: Windings
Rotor: Cast aluminum
Windings (Squirrel cage)
Stator windings are
controlled by three phase AC
line or external electronics
The interaction of the
magnetic field produced by
the stator and the current
carrying conductors in the
rotor causes the rotor to
follow the stator field
Stator
Rotor
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Notor Types: 3 1 Synchronous AC Notor
3-1 Sync AC Notor
Stator: Windings
Rotor: permanent magnets
Stator windings controlled
by external electronics
Stator winding current
produces torque by
interacting with rotor
permanent magnets
Stator
Rotor
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Notor Types: Switched Reluctance
Switched Reluctance
Stator: Windings
Rotor: Solid !ron
Stator windings currents are
controlled through external
electronics
Current in windings produce
reluctance torque between stator
and rotor
Stator
Rotor
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Notor Type vs. RotorfStator
Solid !ron
SRN
Windings
DC Brush
BLDC
UN
Windings 8 Commutator
Windings
Windings 8 Commutator
Permanent Nagnets
Permanent Nagnets
Windings
AC!N
3-1 Sync
Squirrel Cage
Windings
Permanent Nagnets Windings
1-1 AC Squirrel Cage Windings
Notor Type Rotor Stator
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Brushed DC Notor: Key Attributes
High construction complexity
Low reliability (brush wear)
Low efficiency
High EN! (brushes create sparks and ozone)
Easy to drive, even sensorless
Lowest total system cost for basic motion
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Brushless DC Notor: Key Attributes
Nedium construction complexity, multiple
fields, delicate magnets
High reliability (no brush wear), even at very
high achievable speeds
High efficiency
Low EN!
Sensorless speed control possible
Higher total system cost than for Brushed DC
motors
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Universal Notor: Key Attributes
High construction complexity
Low reliability, Low efficiency
High EN!
- brushes create sparks and ozone
Some degree of Sensorless speed control possible
Good power to weight ratio
Substitutes another field winding for DC motor's
permanent magnets - hence lower cost
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1-1 AC !nduction Notor: Key Attributes
Nedium construction complexity
High reliability (no brushes)
Low efficiency
Low EN!
Driven directly from AC line or variable
Frequency (vF, vfHz) controllers
Sensorless speed control possible
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3-1 AC !nduction Notor: Key Attributes
High reliability (no brush wear), even at high
achievable speeds
Nedium efficiency at low speed, high efficiency at
high speed
Notor EN! good
Sensorless speed control possible
Low cost per horsepower compared to DC motors,
though higher than for 1-ph AC induction motor
Higher start torque than for 1-ph, easy to reverse
motor
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3-1 Sync AC Notor: Key Attributes
Nedium construction complexity, multiple fields,
delicate magnets
High reliability (no brush wear), even at very high
achievable speeds
High efficiency
Low EN!
Sensorless speed control possible
Higher total system cost than for DC motors and
other AC motors
Smooth rotation - without torque ripple
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Switched Reluctance: Key Attributes
High reliability
Acoustically noisy
High efficiency
Sensorless speed control possible
Higher total system cost than for DC motors
Torque ripple can be reduced by advanced
control techniques
High speed operation possible
High start-up torque
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Notor Types: voltage Ranges
!ndustrial: 110 - 2+0 v
Automotive: 12 - +8 v
SRN
DC Brush
BLDC
UN
Nostly 110 - 2+0 v
Few v's to Kv's (Nostly < 2+v)
+ - 2+0 v
Notor Type voltage Range
AC!N
3-1 Sync
220-++0v
110-2+0v
1-1 AC
110-2+0v
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Notor Types: Speed Ranges
SRN
DC Brush
BLDC
UN
20,000 RPN
20,000 RPN
50,000 RPN
AC!N
3-1 Sync
20,000 RPN
10,000 RPN
1-1 AC 10,000 RPN
100,000 RPN
Notor Types Naximum Speed
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Common Applications
Notor Types Common Applications
BLDC Notor
Small high efficiency drives
Washing machines
Electrical Power Steering
Electric vehicle traction drive
Refrigerator, Air-Conditioning
Servo drives, very small fans
PC fans, Ceiling fans, Blowers,
Brushed DC
Small Notors
- hand-tools
- various machinery 8 appliances
including washers and dryers
Automotive
- Starters, Wipers
- Power Windows
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Common Applications Cont.
Universal
Power Notors
- hand-tools, drills
- various machinery
- Simple fluid pumps
Garage Door Openers
Fans
Home Appliances
- Blenders
- Washersf dryers
- Food processors
- vacuum Cleaners
- Hair Dryers
Notor Types Common Applications
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Common Applications Cont.
AC !nduction Notor
(most commonly used motor)
Pumps
Fans, HvAC
White Goods
General !ndustrial and Heavy
Traction Nachinery
3 1 Sync Notor
Servo Drives
Electronic Power Steering
1 1 AC!N
Pumps
Fans, HvAC
White Goods
Notor Types Common Applications
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Common Applications Cont.
Switched Reluctance
Fans, Appliances
Emerging Automotive Applications
Notor Types Common Applications
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Need for Electronics in Notor Control?
Efficiency
Control motor speed
Diagnose and preempt motor failure
!ncrease motor's lifetime in the field
Bring to market less expensive motor solutions
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Need for Electronics in Notor Control Cont.
Worldwide Government Regulations
- Push to energy efficient motors
- Complex control algorithms for better energy
efficiency
Ubiquitous Connectivity
- Nore complex command and control functions in
home and industrial appliances
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System Level Block Diagram
Notor
!nput
N
O
S
F
E
T

o
r

!
G
B
T

D
r
i
v
e
r
ZiLOG
FNC16100
or
Z8 Encore!
XP Series
Sensors
Feedback
Torque
Speed
Position
Direction
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Notor Control Solution
The Basic Functions for Notor Control Solution
Calculate Measure Control
Motor
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Notor Control Solution Cont.
Calculate Measure Control
Position
Speed
Current
Torque
Direction
Timing
Error
Nath Functions
Pulse Width
Nodulation
Power Drivers
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Notor Control Flash NCU Options
Low End of Market: ZS Encorel XP Family
- Single-Phase AC !nduction 8 Universal Notors
- Cost sensitive products
- Single PWN modulation output
- Ninimal control algorithm needed
Mid Range of Market: ZS Encorel MC" Family
- 3-Phase AC Induction and Brushless DC
- Analog signal conditioning
- Fast ADC
- Flash memory
- Intensive control algorithms
Product Application Requirement
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Who to Contact for Nore !nformation
PricingfQuotesfAvailability: pricing@zilog.com
Sample orders: Local !SR (www.zilog.comfcontactus)
Technical Support Questions: Tech Support on
ZiLOG.CON
Customer Service: zservice@zilog.com
For fastest response:
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How to get Technical Support
Go to www.zilog.com
Select Support"
- Log on using your password or create a new account
We will not divulge your email address to anyone nor spam" you
This is also where you register your development kits
Select Technical Support !ncidents"
Fill out a Support Request
- Please use the pull down menus so that your request is routed to the
appropriate Support Engineer
- Please provide as much detail as possible
Your request will always be acknowledged within 1 work day
- Usually within a few hours
Our goal is to give you a complete answer or a plan of action to complete your
answer within 2 work days
- You will be updated by email if your incident needs to be escalated to Level
2 or we need additional information
- You can log back on to the support page at any time to see the status of
your request
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Notor Control Loops
Open Loop and Closed Loop
Additional !nformation
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Open Loop Control
No Feedback!
- Basic control suitable for systems with simple
loads such as fans
- Tight speed control is not required
Examples of Open Loop Control
- Single speed with automatic shutoff
- Notor with manual multiple speed settings
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Closed Loop Control
Determine rotor position andfor speed from
one or more sensors
For accurate speed and control
Two types of closed loop control
- Sensor
- Sensorless
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Brushless DC Notor Block Diagram
ZiLOG FNC16100
Notor
Bridge
AC
DC
PWN
v
S
Hall Sensor or Back
ENF
!nput
Command
AC
!nput
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3-1 AC !nduction Notor Block Diagram
AC !nput
ZiLOG
FNC16100
Notor
PWN
Phase
Curren
t
Tachometer
3 1 !nverter Bridge
!nput
Command