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01.03.2024 7:15:34
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Power Integrations Bundles New Three-Phase BLDC Control Software into Motor-Expert Suite for BridgeSwitch IC Family
Hardware-Software Solution for Three-Phase BLDC Motor Inverters Enables Greater Than 98 Percent Efficiency, Saves PCB Space and Speeds Time-to-Market

Embedded World – Power Integrations (NASDAQ: POWI), the leader in high-voltage integrated circuits (ICs) for energy-efficient power conversion, today unveiled new control software for three-phase BLDC motor drives. Combined with Power Integrations’ BridgeSwitch™ integrated half-bridge motor driver and easy-to-use Motor-Expert™ configuration and diagnostics tool, this complete hardware-software solution enables 98.2 percent efficiency, reduces board space by more than 70 percent and requires just three components for current feedback circuitry, compared to 30 components in a discrete solution. The solution is ideal for residential and commercial appliances with three-phase motors, such as air conditioner fans, high-speed hair dryers, refrigerator compressors, range hood fans and water pumps.

“Traditional three-shunt field-oriented control (FOC) solutions require expensive and bulky operational amplifiers (op-amps) and matching circuity for motor-current signal conditioning,” states Cristian Ionescu-Catrina, senior product marketing manager for Power Integrations. “Our BridgeSwitch integrated half-bridge ICs provide lossless current feedback for the positive half cycle, and our three-phase FOC software reconstructs the negative half-cycle current information from data present in the other phase current signals. This eliminates the need for costly and inefficient external current sense resistors, op-amps and matching circuitry and the associated complexity.”

Power Integrations’ new software adds three-phase FOC to the existing library of single-phase code. It allows real-time adjustment of motor speed and torque via the Motor-Expert graphical user interface (GUI). The code runs on any Arm® Cortex®-M0 at 48 MHz and does not require a hardware accelerator block. It can also be ported to other equivalent MCUs. The current modeling algorithm is robust and reliable and has passed extensive static and dynamic test conditions, including low latency response to real-time events. The high degree of current accuracy ensures low jitter operation. The new code is MISRA C-compliant (Motor Industry Software Reliability Association), portable, modular and allows the user to modify any of the software layers.

How Three-Phase Motor Control Works with BridgeSwitch ICs

Power Integrations’ BridgeSwitch ICs provide a motor current output signal that maps the current passing through the low-side FREDFET. An internal sense-FET provides lossless current sensing. The sense circuit cannot provide current information when the anti-parallel body diode is conducting during commutation. Built-in gain amplification allows direct connection of the current phase signal to the microcontroller ADC input. The local sense circuit provides an accurate analog of current with a high signal-to-noise ratio and a correspondingly high degree of accuracy. The new software includes a reconstruction algorithm that uses the phase-shifted trigonometric relationship between current signals of all three phases to accurately deduce negative phase-current information.

Updated Motor-Expert Design Tool

Motor-Expert 2.0 is Power Integrations’ easy-to-use motor control configuration and diagnostics tool for the BridgeSwitch IC family. It provides a GUI allowing easy manipulation of input parameters, as well as a terminal emulator for interacting with the motor controller in serial mode. In addition, a motion scope feature displays linear graphs of important controller variables that can be viewed in real time.

Ionescu-Catrina adds: “Precise control, tuning and optimization can take months of software development. Power Integrations created Motor-Expert 2.0 with the design engineer’s needs in mind. The new tool reduces the cost and complexity of BLDC drive design and works with the newly released three-phase motor control software and reference design DER-964 to offer a complete tool for motor drive development.”

Motor and application tuning is performed through the Motor-Expert 2.0 GUI with control loop coefficients being updated in real-time without having to recompile code. The interface also enables users to visualize system operation, displaying the status of data, including current, speed, status, current error, and speed error. A diagnostics field within the software interface provides insight into inverter and motor operation.

Motor-Expert 2.0 supports three-phase and single-phase motor drive design and replaces the previous version of Motor-Expert.

Availability & Resources

A new three-phase inverter reference design employing three BridgeSwitch integrated half-bridge ICs, DER-964, provides up to 300 W output power without requiring a heatsink. It removes the shunts and op-amps seen in conventional feedback measurement and is suitable for a wide range of applications, such as compressors, range hoods, residential and commercial fans and pumps. The design is 98.2% efficient, occupies a 65 mm x 50 mm PCB and can be used with any Cortex-M0 or equivalent microcontroller.

The complete BridgeSwitch, Motor-Expert 2.0 and three-phase motor control software solution is available today and includes a downloadable manual for the software architecture, APIs, functions, calls and variables used in the code.

The new three-phase motor control code and Motor-Expert 2.0 tool are offered as part of the Motor-Expert Suite under a free license for use with BridgeSwitch ICs. BridgeSwitch ICs are priced starting at $1.69 in 10,000-unit quantities of the chipset. For further information, contact a Power Integrations sales representative.

2022062701 / 27.06.2022 / Industry automation / Power Integrations /

Power Integrations Combines Programmability, High Efficiency and Small Form Factor in New Zero-Voltage-Switching Power-Supply ICs
InnoSwitch4-Pro family of flyback switchers enable over 95 percent efficient, compact, USB PD and Universal Fast Charging Specification adapters up to 220 W

Power Integrations Debuts Support for Planar Magnetics in PI Expert Power Supply Design Tool
Software automatically generates a planar transformer design with full electrical specification and build documentation in just five minutes

Power Integrations Launches PowerPros Live Video Application-Engineering Support
Solve design challenges in real-time, 24 hours a day, six days a week

Power Integrations Delivers AEC-Qualified Buck Switcher IC with 850 mA Output for Low-Part-Count Automotive PSUs
LinkSwitch-TN2Q supports 30-550 VDC input with integrated system-level protection

Power Integrations Bundles New Three-Phase BLDC Control Software into Motor-Expert Suite for BridgeSwitch IC Family
Hardware-Software Solution for Three-Phase BLDC Motor Inverters Enables Greater Than 98 Percent Efficiency, Saves PCB Space and Speeds Time-to-Market

Power Integrations Expands InnoSwitch4-CZ Integrated Switcher Family to 220 W
New high-voltage GaN switches boost efficiency to 95 percent, yielding ultra-compact USB PD 3.1 adapters

Power Integrations Launches SCALE EV: Automotive-Qualified IGBT/SiC Module Driver Family; Targets Bus, Truck and Con-Ag EVs
Compact driver board features reinforced isolation, ASIL B/C certification

Power Integrations’ HiperLCS-2 Chipset Boosts LLC Converter Efficiency, Slashes Component Count by 40 Percent
Surface-mount LLC chipset delivers 250 W with over 98 percent efficiency and no heatsink; no-load consumption is less than 50 mW

Power Integrations Introduces Industry’s First Automotive-Qualified High-Voltage Switcher ICs with 1700 V SiC MOSFET
Expanded InnoSwitch3 family slashes component count and boosts efficiency in EV and industrial applications

Power Integrations’ New InnoSwitch3-TN ICs Slash Energy Waste in Appliance Power Supplies by 75%
Beyond the buck regulator: Newest InnoSwitch3 IC family delivers simplicity, flexibility, and industry-leading efficiency in high-output-current designs

Power Integrations Releases InnoSwitch3-PD Reference Design for Ultra-Compact USB Type C, PD + PPS Adapter
DER-937 leverages highly integrated boost PFC and GaN flyback switcher ICs to implement 100 W USB PD charger using only 117 components

Power Integrations Introduces the InnoSwitch3-PD Family of Flyback Switcher ICs with Built-In USB PD Controller
A fully integrated charger solution combines USB PD, PPS, PowiGaN and FluxLink to maximize efficiency and slash component count in adapters and chargers

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