AN885
AN885
AN885
INTRODUCTION
Most domestic appliances are driven by an electric motor; for the most part, these motors are
controlled in a simple and rudimentary fashion, and electronics is only now beginning to be applied. This article describes the three main motor families Universal, Induction and Electronically Commutated as well as the relevant electronic control techniques, now possible
thanks to the intrinsic characteristics of STMicroelectronics ST62 Family of microcontrollers.
ST62 MCUs, with their wide range of on-chip peripherals, their wide supply voltage range,
their built-in ruggedness and their legendary noise immunity allow truly low total system cost,
thus favouring the technological advancement of electrical motor design.
Basic electrical topologies are described, together with their associated power and signal
electronics. The relative strengths and weaknesses are explored, using practical examples, in
order to illustrate the advantages of electronic control using ST62 MCUs.
AN885/1196
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Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 ELECTRIC MOTORS IN DOMESTIC APPLIANCES . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 THE RIGHT MOTOR FOR THE JOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 CONVENTIONAL ELECTRIC MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 UNIVERSAL MOTOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 PHASE ANGLE CONTROL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 CHOPPER CONTROL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 HARMONICS AND POWER DRAWN FROM THE MAINS . . . . . . . . . . . . . . . . . 9
4 INDUCTION MOTOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 INDUCTION MOTOR SUPPLIED BY MONOPHASE AC . . . . . . . . . . . . . . . . . . 10
4.2 VARIABLE SPEED CONTROL FOR MONOPHASE INDUCTION MOTORS . . 11
5 ELECTRONIC MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 PERMANENT MAGNET SYNCHRONOUS MOTOR (PMDC) . . . . . . . . . . . . . . 13
5.2 SWITCHED RELUCTANCE MOTOR (SRM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3 SIMPLIFIED TOPOLOGY FOR SWITCHED RELUCTANCE MOTORS . . . . . . 15
5.4 ST6260 OFFERS THE SIMPLEST SRM DRIVER . . . . . . . . . . . . . . . . . . . . . . . 17
5.5 ST62: LOWEST TOTAL SYSTEM COST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6 STMICROELECTRONICS APPLICATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . 18
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BRUSHLESS
UNIVERSAL
INDUCTION
BRUSHLESS ELECTRONIC
COMMUTATION
AUTOCOMMUTATED
Perm. Magnet or Var. Reluctance
FEATURES
AC or DC supplied
AC supplied
Robust
APPLICATIONS FIELDS
Washing machine
Hand tools
Heating-Ventilation-Air
conditioning
H.V.A.C.
Pump / Fan
Vacuum cleaner
Freezer / Refrigerator
Vacuum cleaner
Freezer / Refrigerator
Universal (Brush) Motors are used in applications where high torque and/or variable speed
are required (e.g. drills, food-processors, hand-tools, vacuum cleaners, etc.). They can be
powered either by an AC or DC supply, and are currently the most popular motors in appliances. Due to their poor efficiency and relatively limited life, universal motors are tending to
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be replaced by newer types when the cost of the necessary electronic control systems drops
to sufficiently low levels.
Induction (Brushless) Motors are mainly used in applications requiring silent operation, long
life and high safety levels (i.e. pumps, compressors, refrigerators, fans, etc.). These motors
are AC supplied and rotational speed does not vary easily, since it is synchronised with the
electrical mains frequency.
In the third family, electronic acts as an electronic commutator and takes the place of brushes.
These Electronically Commutated Brushless Motors include Permanent Magnet Synchronous Motors and Switched Reluctance Motors. Both types are controlled by electronically switching the current in the windings. Electronically Commutated Brushless Motors
combine the high torque and variable speed performance of the universal motor with the absence of brushes and the intrinsic ruggedness of the induction motor.
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Umot
ST6210 MCU
t
Imot
t
TRIAC
strength
6/18
weakness
In the example of a washing machine motor controller (Figure 3.), the gate of the TRIAC is directly controlled by a low-cost ST6210 microcontroller. Each high current I/O pin on ST62
Family devices can drive 20 mA, thus one or more pins may be paralleled, depending on the
TRIACs gate drive requirements.
The ST62 Family microcontroller, thanks to its wide voltage supply range and built-in noise immunity, can be directly supplied from the 220V mains using only a few low-cost external components, as illustrated in Figure 3. The ST6210 manages the various washing cycles, the
man-machine interfaces and motor speed control. Motor speed regulation can make use of a
tacho-generator, or can be sensorless [4].
The ST62 controlled solution is extremely economical, while providing maximum flexibility:
changes are simply, rapidly and economically implemented by modifying the ST62 control
program.
Figure 3. Speed regulation using ST6210 MCU driven TRIAC in a washing machine
application
+5V
FUSE
LINE
1
19
18
17
16
47
TRIAC
INVERSION
BTA 16-600CW
+5V
230 V
0V
10 PB5
10K
220nF
LOAD
0V
M
0V
NEUTRAL
220nF/400V
6
2
1
0
PB1 14
PB6 9
PB7 8
NMI 5
TEST 6
VSS 20
TEMPERATURE
0V
SPIN
WASH
0V
+5V
3 PIEZO 4
100F
6V
0V
0V
0V
RAMP
DURATION
RAMP
LIMIT
+5V
OSCIN OSCOUT
0V
+5V
5V6
820-1/2W
13 PB2
12 PB3
11 PB4
10K
+5V
VDD RESET
PA0
PA1
PB0 15
PA2 S
PA3 T
0V
0V
0V
1M
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Umot
TURBOSWITCH
M
5 V
SUPPLY
0 V
15 V
Vdd
230 V
Ud
Imot
USER
Power
MOS
BUFFER
PWM
MCU
ST6265
Vss
INTERFACE
Ic
PEAK CURRENT
DETECTOR
TD300
strength
weakness
20 kHz switching
Need RFI filtering
The mains current waveform is sinusoidal and thus does not generate low frequency harmonics.
Chopper control mode is an efficient means of complying with the IEC 1000-2-3 harmonics
standard. The pulsed current at the chopper frequency must be filtered to remove components
at the switching frequency and above, but the filtering inductance need only be small, and
therefore low-cost, since the chopper frequency can be high (5 - 20kHz).
The chopper circuit comprises a power MOS transistor and a fast Turboswitch TM freewheeling
diode. The pulse width modulated (PWM) drive signal is generated by the ST62 microcontroller, via the STMicroelectronics TD300 MOS driver IC, which level shifts the 5V microcontroller output to the 15V level needed to drive the gate of the power MOS device. The MOS
driver IC also affords protection against short-circuits and over current. The ST62 microcontroller monitors the mains voltage and manages the user interfaces (signals and control).
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= Standard limit
PHASE CONTROL
4
1000 W
M
3
2
1
5 A/[]
2 ms
5 Harmonics #
= Standard limit
Amps
5
CHOPPER CONTROL
600 W
3
2
1
5 A/[]
2 ms
5 Harmonics #
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direct rotating
TRIAC
TRIAC
ST62xx
MCU
strength
10/18
ST62xx
MCU
weakness
L6380
T3
S
T
6
2
6
5
PWM
T1
T2
L6380
T3
T4
Motor
TD 300
T4
Variable speed
Standard MCU
Common induction motor technology
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5 ELECTRONIC MOTORS
Electronic motors have no brushes and are electronically commutated (electronics replacing
brushes). They offer the advantages of both variable speed and high starting torque of the universal motor, together with the absence of brushes, silence and long lifetime of the induction
motor. Nevertheless, electronically commutated motors require sophisticated electronics to
ensure commutation in the windings; they also require a rotor position detector.
Two basic types exist (Figure 8.):
Figure 8. Two types of electronically controlled motors which will be increasingly
adopted in home appliance applications
S
N
S
N
S
S
Switched Reluctance
high speed (50 000 rpm)
emerging technology
Synchronous motors with permanent magnet (PMDC). This technology is already used in
the appliance field for fans and air-conditioners, mainly in the USA. Several manufacturers are
planning to use this motor type for other appliance applications.
Switched reluctance motors (SRM). Switched reluctance technology is currently reemerging in appliance applications thanks to the rapidly falling cost of electronic control solutions. Many appliance manufacturers and research organisations are presently evaluating
feasibility, characteristics and total system cost in order to define acceptable solutions.
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L6380
1
S
T
6
2
x
x
T1
T3
T5
PWM
L6380
T3
L6380
T5
T2
T4
T6
5
Motor
EN
TD 300
T2
T4
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Figure 10. Common topology for a triple asymmetrical bridge driving a Switched
Reluctance Motor (SRM) using three rotor position sensors.
SWITCHING
LOGIC
POSITION
SENSORS
SPEED
REGULATION
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CURRENT DEMAND
LIMITATION
&
CURRENT
CONTROL
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Figure 11. Simplified low cost ST62 MCU solution driving three phase SRM using a
single rotor position sensor.
PWM
L6380
220uF/385V
TD 300
220V
4.7V
5.1V
2.2K
ST6260
5.1V
22uF
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15K
10K
220uF/25V
POSITION
SENSOR
PWM
ST6260
L6382
230vV
Delay angle
adjustment
POSITION SENSOR
&
SPEED MEASUREMENT
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Ph.RABIER/L.PERIER
A.N 392
P.GUILLEMIN
/J.M CHARRETON
A.N.412
/B.MAURICE
[3] Controlling a brush DC motor with an ST6265
J.NICOLAI/T.CASTAGNET
A.N.414
T.CASTAGNET
A.N.416
P.GUILLEMIN
A.N.419
J.M BOURGEOIS
/J.M.CHARRETON/P.RAULT
AN422
[7] Versatile and Cost effective induction motor drive with B.MAURICE
digital three phase generation
/J.M BOURGEOIS/B.SABY
A.N.424
EPE 95
AN519
PCIM95
J.M BOURGEOIS
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