ECE 445 Senior Design

Design Review

Single-Phase AC Motor Drive Module

Suiping Wu

Isaac Wong

2/23/2015

TA: Cara Yang

Contents
1. Introduction .......................................................................................................................................... 3
1.1. Statement of Purpose ................................................................................................................... 3
1.2. Objectives...................................................................................................................................... 3
1.2.1. Goals...................................................................................................................................... 3
1.2.2. Functions ............................................................................................................................... 3
1.2.3. Benefits ................................................................................................................................. 3
1.2.4. Features ................................................................................................................................ 4
2. Design.................................................................................................................................................... 4
2.1. Block Diagram ............................................................................................................................... 4
2.2. Block Description .......................................................................................................................... 5
2.2.1. H-Bridge Inverter................................................................................................................... 5
2.2.2. Gate Driver ............................................................................................................................ 6
2.2.3. Microcontroller ..................................................................................................................... 7
2.2.4. Voltage/Current Sense Circuit .............................................................................................. 7
2.3 Power Supply ................................................................................................................................ 8
2.3.1 Inverter DC Voltage ............................................................................................................... 8
2.3.2 Auxiliary DC Voltage .............................................................................................................. 8
3. Schematic .............................................................................................................................................. 9
4. Stimulation and Test Load .................................................................................................................. 10
5. Control Flowchart ............................................................................................................................... 12
6. Requirement & Verification ................................................................................................................ 13
7. Tolerance Analysis............................................................................................................................... 14
8. Safety and Ethics ................................................................................................................................. 14
7.1 Safety and Protection ................................................................................................................. 14
7.2 IEEE Code of Ethics ...................................................................................................................... 14
9. Cost Analysis ....................................................................................................................................... 15
9.1. Labor ........................................................................................................................................... 15
9.2. Parts ............................................................................................................................................ 16
9.3. Grand Total ................................................................................................................................. 16
10. Schedule .......................................................................................................................................... 17
1. Introduction

1.1. Statement of Purpose

The project is motivated by current research on electronic pole switching induction

machine in the power and energy group. The number of the phases of the current
motor drive and the performance of the current sensing circuitry were traded off due to
budget and time constraints. Furthermore, commercial motor drive evaluation board
and motor drive IC are either expensive, financially unsustainable for multiphase
machine research in particular, or the motor drive does not meet the voltage and
current requirements for the research project. Hence, there is a demand in economical,
highly flexible, high-voltage, high-current motor drive module.

1.2. Objectives
1.2.1. Goals

- Develop a high-voltage high-current single-phase AC motor drive module

- Build three modules and operate as a three-phase motor drive

1.2.2. Functions

- Convert input DC voltage into AC voltage for multiphase motor applications

1.2.3. Benefits

- Provide a template for fast inverter production or remodeling for multiphase

machine
- Isolate faults onto a single board, reduce replacement cost
- Easy reconfiguration to fit machine that operates at a different number of phase
input
1.2.4. Features

- Highly flexible and configurable

A set of modules can function as multiphase and/or multilevel inverter with multiple
phase-level combinations
- Current feedback control can further expand to more robust vector control if
machine parameters are available

2. Design

2.1. Block Diagram

Control

Microcontroller Gate Driver H-Bridge Inverter

Voltage/Current Sense

Feedback

Figure 1: High Level Block Diagram

2.2. Block Description
2.2.1. H-Bridge Inverter

The H-bridge inverter comprises 4 single power MOSFETs. Each inverter leg will have 2 power
MOSFETs driven by a gate driver to switch the MOSFETs on and off. The inverter is designed to
handle up to an input DC voltage of 300V, and an input current of 10A.

Fairchild Power MOSFET FCB20N60F was chosen to be the inverter gates. The drain to source
breakdown voltage and continuous drain current are twice of the maximum input voltage and
current. This provides headroom for the inverter to handle voltage spike and inrush current during
starting. The low gate charge of 75nC allows a lower gate switching current.

Table 2: FCB20N60F Key Parameters

Key Parameters Values

Drain to Source breakdown Voltage 600V

Vds
Continuous Drain Current I D 20A ( Tc 25C )
12.5A (Tc 100C )
Gate to Source Voltage Vgss 30V

Gate Threshold Voltage Vgs (th ) Max : 5.0V

Min : 3.0V
Static Drain to Source On Resistance Nom : 0.15
Rds ( on ) Max : 0.19
Total Gate Charge Qg (total ) Nom : 75nC
Max : 98nC
 Figure 2: H-bridge Inverter

2.2.2. Gate Driver

Silabs isolated gate driver Si8234AD-C-IS take a single PWM signal and outputs two complementary
gate signals to high and low side. Si8234 also offers protection features such as 5V undervoltage
lockout, 5 kVrms isolation and overlap protection.

The critical parameter, peak current, was calculated as the following using the maximum total gate
charge of FCB20N60F power MOSFET and a switching time of 50ns.

Qg (total )max I ch arg e Tch arg e

98nC I ch arg e 50ns

I ch arg e 1.96 A

The charging current using the above method is an average/constant current. To account for the
nonlinearity of gate charging current, the average value found was doubled (i.e. 4A) to ensure a
sufficient current level to turn the gates on.

List of Key Featuress of Si8234:

- High-Side Low-Side gate driver

- Accepts single PWM signal and outputs two complementary gate signals
- 4.0A peak current
- 5V undervoltage lockout
- 5.0 kVrms isolation
- Overlap protection, Programmable deadtime
2.2.3. Microcontroller

The microcontroller will be responsible for sending PWM signal to the gate driver, receiving
feedback signal of voltage and current and adjust the PWM signal accordingly. TI LAUNCHXL-
F28069M LanuchPad features InstaSPIN-MOTION and InstaSPIN-FOC functions. The two features
provide a robust speed and field-oriented control schemes by replacing the hard-to-tune PID
controllers with simple, single-parameter tuning. The 16 PWM channel with 8 in high resolution
make possible of expanding the project in the future from driving a three-phase motor up to a 18-
phase motor.

2.2.4. Voltage/Current Sense Circuit

The current sense circuit comprises of three components, AD8210, AD8274, and LM4140. AD8210
high voltage, bidirectional current shunt monitor has a common-mode voltage of -2V to +65V with a
gain of 20. LM4140 precision micropower low dropout voltage reference output is connected to the
negative input of AD8274 very low distortion, precision difference amplifier, which ensures that
AD8274 input has the same common mode voltage as the AD8210. The positive input of AD8274 is
connected directly to the output of AD8210. AD8274 is powered from 15 V supplies and is
configured in a non-inverting gain-of-two configuration. The AD8274 takes the difference between
its two inputs and applies a gain of 2. The input-to-output transfer function is determined to be

Vout ( Rshunt I shunt 20) 2

Assuming the shunt peak current is 15 (i.e 1.5 times more than the rated current), the shunt
resistance value is determined by

5 ( Rshunt 15 20) 2

Rshunt 8.33m

Rshunt 10m
2.3 Power Supply
2.3.1 Inverter DC Voltage

The DC voltage supplied to the inverter serves as the source voltage which will be converted to AC
using PWM modulation. The inverter DC voltage will be provided by two sources depending on the
stage of development. For safety purposes in the early stage of development, Kenwood PD56-10AD

DC power supply will be used to have fully control on input voltage and current level. The power
supply can provide up to 56V and 10A. Once the design has been verified at low DC voltage, the DC
supply voltage will be stepped up to 120V or 240V using the three-terminal 120V DC main on the
lab benches in the machinery lab.

2.3.2 Auxiliary DC Voltage

The auxiliary +5V, +12, 15 DC voltages for supplying the gate driver and sense circuit will be
provided by the DC power supplies on lab bench.
3. Schematic

Figure 3: Inverter Bridge and Gate Drive

 Figure 4: Voltage and Current Sense Circuit

4. Stimulation and Test Load

A resistor-inductor load will be connected to the output terminal of the inverter to mimic the
electrical characteristics of an induction motor. For testing purposes and financially reasons, no off-
the-shelf inductor will be purchased. Test load will be using 100 mH toroid and 20 ohm power
resistor from the machinery lab. Stimulation results showed the peak current will not excess 10A
with the maximum voltage input of 300V.
Figure 5: Inverter Voltage (Bottom) and Current (Top) Output Waveform at 300 Vdc, 100mH, 20ohm
5. Control Flowchart
Start of
Conversion

Execute ADC
Conversion

Save Contexts
and Clear
Interrupt Flag

Execute the Park

and Clarke
Transformation

Execute PID
Modules

Execute the ipark

and svgen
Modules

Execute the
Voltage Calc
Module

Execute the
ACI_FE and
ACI_SE Modules

Execute the
PWM drive

Restore Context

Return

Figure 6: Control Flow Chart

 6. Requirement & Verification

Table 3: Requirement and Verification

Description Requirement Verification Points

Blocks a maximum drain-to-source

voltage Vds of 300 5V
Apply Vds voltage of 300 5V across drain
and source terminal. Probe drain current.
Be able to handle a voltage spike up
to 600V
Power MOSFET
30
FCB20N60F
Apply gate voltage of 5V. Use Kenwood DC
Sustain an operational continuous
power supply to apply Vds and inject 10 2A
drain current Id of 10 1A
of current for 5 minutes and 20 1A for 5
Be able to handle an in-rush current seconds across a 100W 1ohm power resistor
of 20 1A
Set up the gate driver and MOSFET on a
breadboard. Use waveform generator to
Gate Driver Output a gate signal to turn on the
produce a PWM signal. Probe the drain 20
Si8234 power MOSFET on
current of MOSFET.

Microcontroller Connect microcontroller to gate driver. Send

Send PWM signal to gate driver
TI LAUNCHXL- PWM signal to gate driver, and probe output
20
F28069M Adjust PWM signal with current signal of the gate driver
feedback
Set up a sense circuit on a breadboard with a
10 mOhm resister. Apply a known current
Sense and level-shift output voltage
Voltage and Current across the resistor. Probe the sensor outputs
and current to microcontroller ADC 20
Sense Circuit and check with the function output
level
equations.
7. Tolerance Analysis

The most vulnerable part of the inverter is the power MOSFET. When both the high-side and low-
side MOSFET of any one inverter leg is switched on, it creates a short to the ground and draws huge
amount of current, and damages the circuit. Therefore, the gate driver has to be thoroughly tested
with the MOSFET before building and controlling the inverter. MOSFET parasitic body diode reverse
recovery occurs during diode switching from the on-state to the off-state. When the MOSFET is off
(gate-source shorted) and no current flow through its body diode, a voltage step with certain dv/dt
is applied across Drain and Source. The result is a displacement current flow through the drain-base
capacitance (CDB), which can turn on the bipolar to result MOSFET failure.

8. Safety and Ethics

7.1 Safety and Protection

This project involves high voltage and high current. All components shall be carefully chosen, and
their maximum ratings shall not be exceeded. All testing shall begin with low voltage and current
level before moving onto high voltage testing. All power supplies must be turned off before making
any changes on the circuit. Exposed conductors shall be shrink-wrapped.

7.2 IEEE Code of Ethics

As a responsible engineer, we oblige to commit ourselves to the highest ethical and professional
conduct and ensure our project will not violate IEEE Code of Ethics. The following is from the IEEE
Policies, Section 7 - Professional Activities (Part A - IEEE Policies).

1. to accept responsibility in making decisions consistent with the safety, health, and welfare of
the public, and to disclose promptly factors that might endanger the public or the
environment;

- The inverter will be thoroughly tested at the maximum rated voltage and current.
High Voltage warning sign will be printed on the circuit.

2. to avoid real or perceived conflicts of interest whenever possible, and to disclose them to
affected parties when they do exist;

- No sponsors nor other affiliated parties are involved in this project.

 3. to be honest and realistic in stating claims or estimates based on available data;

- The readings and findings will be reported and documented as the way they are.

4. to reject bribery in all its forms;

5. to improve the understanding of technology; its appropriate application, and potential

consequences;

6. to maintain and improve our technical competence and to undertake technological tasks for
others only if qualified by training or experience, or after full disclosure of pertinent
limitations;

7. to seek, accept, and offer honest criticism of technical work, to acknowledge and correct
errors, and to credit properly the contributions of others;

- Any literature, resources, and personals consulted will be fully acknowledge in the final
report.

8. to treat fairly all persons and to not engage in acts of discrimination based on race, religion,
gender, disability, age, national origin, sexual orientation, gender identity, or gender
expression;

9. to avoid injuring others, their property, reputation, or employment by false or malicious

action;

10. to assist colleagues and co-workers in their professional development and to support them in
following this code of ethics.

9. Cost Analysis

9.1. Labor

Table 4: Table of Labor Cost

Total Invested Cost per Engineer [$]

Name Hourly Rate [$]
Hours [2.5 x Hourly Rate x Total Hours]
Isaac Wong 30 170 12,750
Suiping Wu 30 170 12,750
Total 340 25,500
9.2. Parts

Table 5: Table of Parts Cost

Total Cost
Item Description Manufacturer Part No Cost [$] Quantity
[$]
Microcontroller TI LAUNCHXL-F28069M 30 1 30.0
Power MOSFET FCB20N60F 5.22 16 83.52
Cartridge Fuse 0326010.MXP 1.69 20 33.8
Non-Inverting Schmitt Trigger SN74LVC1G17 1.0 4 4.0
Inverting Schmitt Trigger SN74LVC1G14 0.49 4 1.96
High and Low Side Gate Driver Si8234AD-C-IS 3.33 6 6.7
AD8210 4.56 8 60.0
AD8274 1.05 8 8.4
Voltage/ Current Sensing IC
AD8479 6.59 8 52.72
LM4140 4.53 8 36.24
4-layer Printed Circuit Board - 66.0 1 66.0
Total: 383.34

9.3. Grand Total

Table 6: Table of Grand Total

Section Total [$]

Labor 25,500
Parts 383.34
Grand Total 25883.34
10. Schedule

Table 7: Table of Schedule

Week Assignment Responsibility

Finalize Proposal Isaac

4 2/9
Research on microcontroller Suiping
Research and choose parts for hardware
Isaac
Prepare design review
5 2/16
Research and choose microcontroller
Suiping
Request/ order parts
Finalize design review
Isaac
PCB Schematic and layout
6 2/23
Familiarize with the operation of microcontroller Suiping

Finalize PCB layout and place order Isaac

7 3/2
Build test circuit and test with microcontroller Suiping

Solder components on PCB Isaac

8 3/9 Continue testing with microcontroller and debugging
Suiping
controller code
Test inverter circuit with microcontroller
Isaac
9 3/16 Revise PCB design and place order
Debug controller code Suiping
Isaac
10 3/23 Spring Break
Suiping
Solder components on revised PCB Isaac
11 3/30
Test and debug inverter circuit with microcontroller Suiping

Built three inverter circuits

Isaac
Prepare for mock presentation
12 4/6
Prepare microcontroller for three phase operation Suiping

Isaac
13 4/13 Testing and debugging
Suiping
Prepare for presentation Isaac
14 4/20
Prepare for demo Suiping
Prepare for final paper Isaac
15 4/27
Prepare for presentation Suiping
Finalize final paper Isaac
16 5/4
Check out Suiping