HERZLICH WILLKOMMEN ZUM LIEFERANTEN-INNOVATIONSTAG … · HERZLICH WILLKOMMEN ZUM...

HERZLICH WILLKOMMEN ZUM LIEFERANTEN-INNOVATIONSTAG 2015

TOGETHER WE MOVE

18. November 2015

TECH-SESSION: VERNETZUNG & ASSISTENZ

14:30 – 16:00 Uhr

TOGETHER WE MOVE

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DAEC TM – Dynamic Angle Error Compensation| Heinz

OYRER, ams AG15:00 – 15:25 Uhr

TOGETHER WE MOVE

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Confidential © ams AG 2015

DAEC™ - Dynamic Angle Error

Compensation

Efficient Motor Commutation

through Advanced Position Sensing

Heinz Oyrer, Senior Manager Global Marketing and Strategy

Position Sensors, Sensor and Sensor Interfaces, ams AG

Magna Lieferanten-Innovationstag, November 18, 2015


Efficient Motor Commutation through Advanced Position Sensing

EFFICIENCY OF ELECTRICAL MOTORS

MOTOR POSITION SENSOR

DYNAMIC ANGLE ERROR COMPENSATION

TYPICAL APPLICATIONS

BUSINESS DRIVERS

DAEC™



• Electric motors are the single biggest

consumer of electricity.

• They account for about 2/3 of industrial

power consumption and, about 45% of global

power consumption, according to a new

analysis by the International Energy Agency

Source: CleanTechnica, abb.com/energyefficiency

Electric motors use majority of global electricity


• Thousands of words and column inches are

devoted to topics such as nuclear power,

renewable energy, and electric vehicles

• Rarely discussed is the fact that the majority

of electric motors are inefficient,

oversized, or running when they don’t

need to be running.


Majority of electric motors are inefficient


Opportunities for efficiency

• Addressing the efficiency of electric motors is

an important topic that needs to be tackled.



Brushless Direct Current (BLDC) motors are rapidly gaining popularity

• "Sales volumes of brushless DC motors are forecast to grow much

faster than that of either brushed DC motors or stepper motors. Major

advantages of brushless DC motors include higher efficiency at

converting electricity into mechanical power, reduced noise, longer

lifetime and higher reliability.“, Michael Liu, IMS Research

• E-Motor market is growing 40% from 2012 to 2017

Government regulations worldwide

• Require the industry to implement new efficiency classes IE1, IE2,

IE3, … (IE = International Efficiency to reduce CO2 (higher efficiency

means better motor control)

Key requirements in Automotive market

• Reducing CO2-emissions by saving weight and reducing fuel

consumption

• Improve passenger safety and anti-collision systems and electric

stability program

• Improve passenger comfort to reduce noise and improve handling

The trend towards brushless motors







BUSINESS DRIVERS

DAEC™



• U.S. CAFE standards require OEMs

to raise average fuel efficiency to

56.2 mpg for new vehicles by 2025;

(CAFE – Corporate Average Fuel

Economy)

• Europe CAFÉ standards require

OEM’s to raise average fuel

efficiency to 60.6 mpg ≈ 26 km/l for

new vehicles by 2025. Translates in

CO2 emission reductions to 70 g/km

by 2025.

Business drivers – improved fuel efficiency & emissionsAdvanced Magnetic Position Sensors in Electronic Power Steering Applications

Source: Center for Climate and Energy Solutions


Business drivers – ISO 26262 (Automotive Safety Integrity Level)The Safety Standard for Electrical and/or Electronic systems in Passenger Vehicles

First published in 2011, ISO26262 is:

• Development process and assessment tool for classifying risk and system safety

• Standard framework and vocabulary for hazard elimination

• Defines organizational safety management and safety life cycles for auto systems

Intended to address three important challenges in today’s automotive technologies:

• New electrical/electronic HW and SW safety functionality in passenger vehicles

• Increase in content and complexity of electro-mechanical systems and related software

• Risk from both systematic failure and random hardware failure

ISO26262 is “Technical State of the Art” and sets a Standard for Lawsuits if in Non-

Compliance

• OEMs legally forced to comply with ISO26262 or risk major law suits.


Business drivers - ISO26262 ComplianceThe Safety Standard for Electrical and/or Electronic systems in Passenger Vehicles

Vehicle hazards & operational situations are assessed and safety measures are defined for:

• Avoiding or controlling systematic failures

• Detecting or Controlling random hardware failures

• Reducing effects of hardware failures

ASIL Classification based on three factors to arrive at one of four levels (A, B, C or D)

• Severity (S0..3)

• Exposure (E0..4)

• Controllability (C0..3)

ASIL-D – Highest safety class event; having reasonable possibility of causing a life-

threatening or fatal injury, with the injury being possible in most operating conditions, and

with little chance of driver intervention/prevention.







BUSINESS DRIVERS

DAEC™



• Position sensors measure the distance a body has moved from its reference and the resulting output is given as a feedback to the control system.

• Motion of a body can be rectilinear or curvilinear; accordingly,

position sensors are called linear position sensors or

angular position sensors.

• Position sensors use different sensing principles to sense the displacement of a body. Depending on these different sensing

principles they can be classified contacting or non-contacting position sensors.

• Contacting sensors measure linear or angular position through a

mechanical connection whereas non-contacting position sensors measure the linear or angular position of an object without any physical contact.

What are Position Sensors?


Brushless DC (BLDC) Motor is Preferred Choice as it offers better starting torque and efficiency

Controls commutation of a brushless DC motor employed in the system

Provides fast and accurate measurements

At startup: provides phase coil information via UVW signals

At speed: provides position measurement via SPI or ABI signals

Eliminates need for discrete hall sensors in stator

Motor Position Sensor ICEnables Efficient Motor Commutation


• Ideal for small motor and system designs

• More design freedom - the sensor does not need to reside on

specific positions inside the motor

• Power efficient - no power dissipation that is typically experienced

with sensor-less/shunt

• Easy integration

• High temperature environment

• High start-up torque

• Low torque ripple

• Low audible noise

• Excellent reliability

• High safety levels

• High accuracy

When is a Position Sensor needed?

DAEC™ technology

Extremely accurate position data, maximize

torque even in high-speed applications


• AEC-Q100 Automotive grade qualified

• Safety flow in parallel with product development

process

• Safety manual certification by independent

company

• Safety support and manual to achieve ASIL

value in different applications

• FMEDA, FIT rate, application notes

• Dedicated safety manager

Safety according ISO26262







BUSINESS DRIVERS

DAEC™



DAEC™ Video

http://www.youtube.com/watch?feature=player_embedded&v=bD-mG5B9vvU

http://www.youtube.com/watch?feature=player_embedded&v=bD-mG5B9vvU


Angle Accuracy: Ideal Slope


Angle Accuracy: INL Error


Angle Accuracy: Noise Error / Jitter Effect


Angle Accuracy: System Propagation Delay


DAE – Dynamic Angle ErrorSpeed dependent angle error

Speed: 10 RPM

DAE = 0,12°

Speed: 1.000 RPM

DAE = 1,20°

Speed: 10.000 RPM

DAE = 12,0°

100µs

0,0

2,0

4,0

6,0

8,0

10,0

12,0

14,0

16,0

18,0

20,0

- 5.000 10.000 15.000

Dynamic Angle Error [deg]

Angle Error [deg]


Integrated Dynamic Angle Error Compensation

Dynamic Angle Error

Magnetic P

ositio

n S

ensor

Syste

m

• The problem with the existing magnetic position sensors on the market is a delay

which comes by nature with the signal processing.

• This led to wrong angle position outputs, especially at high rotation speeds.

• The value of the so called dynamic angle error depends on rotation speed.



Dynamic Angle Error

External HW + SW compensation needed

Magnetic P

ositio

n S

ensor

Syste

m

• Additional hardware chips can calculate this error and do a software correction on the

output angle.

• Therefore a huge software development is needed.

• But still this result is not as good as the DAEC™.



Dynamic Angle Error

Hardware Compensation integrated!

No Software needed!

External HW + SW compensation needed

Magnetic P

ositio

n S

ensor

Syste

m



Hardware Compensation integrated!

No Software needed!

Magnetic P

ositio

n S

ensor

Syste

m

• The DAEC™ Dynamic Angle Error Compensation is the unique feature of the new

generation of position sensors.

• It is a single chip solution which reduces the Dynamic Angle Error almost to zero.

• Of course it delivers all the advantages of contactless angle measurement and there is

a much better accuracy over speed.

• By the way it is easy to use, simple to program and reduce development costs as well

as time to market.

Elimination of Angle Measurement Lag and Fast Refresh Rates (1.9μs) at High RPMs


• Hall Sensor front-end samples target

magnetic field every 110usecs

• Four hall sensor elements used to

produce differential analog Sine and

Cosine signals.

• Sin/Cos analog signals converted to

digital via 14-bit A/D

• Digitized Sin/Cos values fed to

Cordic to produce new angle value

measurement.

• Between 110usecs front-end sample

periods Interpolator/DAEC

calculates new angle output every

1.9usecs based upon device’s

calculation of target magnet

rotational rate.

How Dynamic Angle Error Compensation WorksEnables low latency and fast refresh rates

Elimination of Angle Measurement Lag and Fast Refresh Rates (1.9μs) at High RPMs







BUSINESS DRIVERS

DAEC™



• Electrical power

steering (EPS)

• Dual Clutch

Transmission (DCT)

• Pumps

• Starters

Steering Transmission Miscellaneous Automotive Parts

Typical markets/applications - automotive

• Alternators

• Brake Actuators


Application exampleBLDC Motor for EPS


Summary

• Improving the efficiency of electric motors as an important topic at a global level

• Safety asone of the key issues of future automobile development.

• BLDC motors offer many advantages over brushed DC motors and induction motors.

• Magnetic position sensing as a monolithic integrated function becoming the leading technology for motor control applications that demand:

• High accuracy enables better execution of the commutation scheme, resulting in

• DAEC™ technology - Extremely accurate position data, maximize torque even in high-speed applications

• Wide spread adoption in various applications - Automotive, industrial, aerospace, consumer, medical, instrumentation and automation


Thank you for your Attention

Please visit our website at www.ams.com

ACStyria Autocluster

Parkring 1

8074 Raaba-Grambach

AUSTRIA

www.acstyria.com

+43 316 40 96 96 - 0

TOGETHER WE MOVE

HERZLICH WILLKOMMEN ZUM LIEFERANTEN-INNOVATIONSTAG … · HERZLICH WILLKOMMEN ZUM...

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