Trends in efficient motor control

market segment

Stello Matteo Billè

Systems Lab

&Technical Marketing

February 14rd 2012

Agenda

Introduction

Market trends in motor control applications

How ST complies with these market trends

2

According to International Energy Agency (IEA) ~46% of 2006 WW

electricity was consumed by electric motors

This approx generated the equivalent of US 2008 CO2 emissions

End‐users now (2011) spend 565 billion $/year in EMDS1

It could rise to almost 900 billion $ in 2030 without effective measures

The global assessment

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Source: IEA, 2011 1 Electric-Motor Driven Systems

Saving energy in EMDS is possible!

4

TWh

Source: IEA estimate, 2011

Reference scenario: current policy situation is maintained and no additional

policy measures are taken

If all countries adopted a rigorous policy package on EMDS (policy scenario), it

would result in -20% annually in 2030

If all EMDS moved toward the least life‐cycle cost level (LLCC scenario) as

rapidly as technically possible, it would result in -30% annually in 2030

Agenda

Introduction

Market trends in motor control arena

Energy efficiency increase

Devices integration

Reduce costs

Increase safety

How ST complies with these market trends

5

Life-cycle cost analysis: 11kW, 15 years life, 4000h/year

Source: De Almeida, EuP Preparatory study

Market trend #1:

Why increasing energy efficiency?

Save money Policy vs Reference scenario energy cost

saving is ~ -2.8 trillion US$

Energy saving come at less cost than

supplying this energy…

Cost of energy consumed by an electric motor is

typically >95% of the total life cycle cost

Small gains in energy efficiency become huge $

saving over lifetime

… and this is perceived by end buyers

Market penetration of high efficient motors

rapidly increasing in last years

Be eco-friendly Policy vs Reference scenario avoid some

16 Gt of CO2 (~ 2009 WW emission)

Required by norms and voluntary

regulation

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Hardware requirements for efficient motor drives

Efficient 3-phase motors control systems are typically composed by

Control stage including

Microcontroller

User interface and connectivity with related conditioning circuitry

Power stage including

Power switches

Drivers

HW protections

Sensors conditioning circuitry

Bus voltage

Motor current

Motor position and/or speed

Temperature

Application related sensors

This could easily reach hundreds of components…

7

Market trends #2:

System integration

More functionalities into one package device:

Simplifies system design & development

Reduce components number and amount of connections

Shorten control systems validation

Increase reliability, reduce EMI

Help extending technology utilization to companies who couldn’t afford learning curve

Enable new features or improve performances

For instance: faster over-current protection

Reduces control system dimensions facilitating integration of electronics within the motor body

Allow 1 to 1 replacement of non-efficient motors

Help reducing the cabling complexity

Enable new features addition (e.g. electronic compensation of motor vibrations)

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Market trends #3

Reduce costs

Higher initial cost of efficient solutions constitutes an entrance barrier for end-users Although it is actually negligible compared to total life-cycle cost

Low development costs and eventually system solution cost Reduce final price for end-user increasing

market penetration

Increase profitability of efficient motor control market segment

Market requests tools to cut down development time and costs Evaluation boards and reference designs

FW libraries

Design tools

Technical support structures

9

Market trend #4:

Increase safety

Programmable replacing electromechanical components in safety-

sensitive systems

Safety of software-dependent controls growing concern

Safety standards require design of automatic electronic controls that

ensure safe operations

For instance establish a set of MCU components

to be periodically tested run-time (IEC 60730,

IEC 60335 for household appliances)

SIL-2, SIL-3 (IEC EN 61508 for industries)

IEC standards are only mandatory in Europe

but WW industries often choose to comply

anyway

Avoid separate designs in different regions

Sell the value added by safety features outside Europe

Support for safety standards products certification

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Agenda

Introduction

Market trends in motor control arena

Energy efficiency increase

Devices integration

Reduce costs

Increase safety

How ST complies with

Energy efficiency increase

Devices integration

Reduce costs

Increase safety

11

ST and efficient motor control:

over 10 years history

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ST’s been focusing on efficient 3-phase motor control since < 2002 10 years experience in scalar drives of AC IM and Permanent Magnet

Synchronous Motors (PMSM)

6 years experience in vector control (FOC) drives of ACIM and PMSM

~50 different motor control product/system evaluation boards available today on www.st.com

Milestones to remember: 2002: 1st OTP microcontrollers targeting 3-phase

motor control applications

2004: 1st Flash memory microcontroller for 3-phase motor control

2006: 1st Vector control FW library on ARM core MCU

2007: 1st 3-phase power module

2009: 1st HV gate driver family optimized for FOC support

2011: 1st FW library addressing multiple simultaneous motor control

2002 ST72141 ST92141

2004 ST7FMC

2007 First 3-ph power module

2009 smartDRIVE HV driver family

2011 STM32 SDK v3.0

Increase in electronics efficiency

VIPer+ family boosted SMPS efficiency in

active mode and shrunk stand-by power

consumption

Losses on power transistor continuously

decreasing

And plausibly further will thanks (also) to SiC

technology

Our SLLIMMTM Nano family allow getting rid of

heat-sink in many applications (dishwasher

and washer pumps, ceiling fans, …)

Cortex-M3 processor delivers leading

power efficiency (12.5 DMIPS/mW on

90nm process)

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* constant silicon area

Systems integration and ST products:

choose your integration level

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Maximum flexibility offered to our customers in terms of

both devices and SW IPs integration

Find your own best compromise between flexibility and

integration

Devices integration and ST products 1/3

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Gate driving section

(+/- HW protections,

+/- op-amp )

Switches

section

Discrete Power transistors: IGBT/MOSFET

Integrated Circuits Sensors conditioning: TSxxx op-amp and comparators; optionally integrated in MCU

or gate drivers

Gate drivers: smartDRIVE, L638x, T3xx families with integrated bootstrap diodes, optional over-current protection

Microcontroller: STM32 integrates some speed/position sensors conditioning circuitry, PWM generator with dead-time insertion;

Sensors conditioning

MCU

(+ sensor conditioning logics)

Devices integration and ST products 2/3

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Power modules: SLLIMM family up to 600V 20A, integrates gate drivers, bootstrap diodes, power

transistors, free-wheeling diodes and - optionally - op-amp, over-current protection, thermal protection

PowerSPIN (L62xx) family: monolithic solutions for up to 48V 1.4A with embedded over-current protection capability

Microcontroller STM32 MCU integrates some speed/position sensor conditioning circuitry, PWM

generator with dead-time insertion

Power modules

(power transistor, gate drivers; +/-

sensor conditioning)

Sensors conditioning

MCU

(+ sensor conditioning logics)

Devices integration and ST products 3/3

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Complete drive modules SPIMD20 Integrated Motor Drive Module

Up to 2 kW power with 800Vdc supply,

On 100°C motor surface can withstand peak of current up to 40 A

Connection via real time ethernet fieldbus, including but not limited to EtherCAT® as per IEC61158.

On board FPGA (Altera Cyclone III type) and two STM32F103 microcontrollers

SPMID20

Thanks to STM32 computational power, efficient motor control leaves room for many other tasks

STM32 FOC SDK v3.0 enable running 2 motors at the same time

Single MCU can handle application + dual motor control

Drastic simplification of schematic (remove 2nd MCU and traces/devices for communication,…)

STM32 FOC SDK v3.0 available for free

Digital PFC IPs can be optionally added to (dual) motor control

No need for analog PFC controller

Simplification of HW design

Improvement of PFC performances vs analog solution (MCU knows what’s instantaneous motor(s) power request)

Thanks to STM32 wide portfolio it’s possible to operate rationalization of product platforms in final application

Same SW can cover different platforms

Software integration

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Reduce development costs

Higher level integration for both devices and SW IPs

>450 evaluation boards available at www.st.com/evalboards >30 evaluation boards for motor control

Motor control FW libraries available for free for both STM8 and STM32 Detailed documentation

PC design tools

Technical support structures Online support and e2e

community

WW distributed support capability

Seminars and Training

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How safety is facilitated by ST products 1/2

1st level ensured by protections circuitries integrated in ICs…

For microcontrollers Motor control specific

Asynchronous emergency stop input disable inverter driving signal even if clock fails

Safety critical registers (e.g. dead-time) protected by accidental writing or software ‘run-away

Can only be written once after reset

Can be “locked” after writing

Common to all MCU powered applications: Back-up clock

Two watchdog, one with independent watchdog clock tree (internal oscillators) and started without SW intervention

32-bit hardware CRC calculation unit (STM32 only)

Dual stack pointer (STM32 only)

For gate drivers/power modules Comparator for fault protections

Smart shut down for immediate outputs turn-off in case of fault

Interlocking function for shout-through prevention and minimum dead-time assurance

Under voltage lock-out turn-off output if driver supply voltage falls

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How safety is facilitated by ST products 2/2

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2nd level, reliable SW operations

IEC60335 safety standards require controls ensuring safe operations for household appliances

“Class B” compliancy is required if SW prevents unsafe operations For instance door locks or motor temperature in laundry equipment

Self diagnostic routines and related AN and UM available for our customers RAM, Flash and core tested at start-up and in run-time

ST’s self-test library modules certified by VDE WW recognized German test house

pioneer in software safety inspection

Motor control library compliant with MISRA C 2004 rules Software development standard aiming

facilitate code safety, portability and reliability for embedded systems

Additional safety ensured by sensors…

ST is the leading supplier of MEMS (Micro-Electro-Mechanical Systems) for consumer and portable applications1

MEMS can be used for Vibration monitoring

Measure frequency, amplitude and spectrum of vibration to alert before machine failure alarms

Alarm Detect movement in any desired

axis in order to take preventive actions (e.g. applications dealing with weights lifting)

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1 IHS iSuppli: H1 2011 Consumer and Mobile MEMS Market Tracker, August 2011