TIDUBE5A January   2022  – October 2022

 

  1.   Description
  2.   Resources
  3.   Features
  4.   Applications
  5.   5
  6. 1System Description
    1. 1.1 Key System Specifications
  7. 2System Overview
    1. 2.1 Block Diagram
    2. 2.2 Design Considerations
    3. 2.3 Highlighted Products
      1. 2.3.1 TMS320F2800137
      2. 2.3.2 TMS320F280025C
      3. 2.3.3 TMS320F280039C
      4. 2.3.4 UCC28740
      5. 2.3.5 UCC27517
      6. 2.3.6 TLV9062
      7. 2.3.7 TLV76733
    4. 2.4 System Design Theory
      1. 2.4.1 Interleaved PFC
        1. 2.4.1.1 Full Bridge Diode Rectifier Rating
        2. 2.4.1.2 Inductor Ratings
        3. 2.4.1.3 AC Voltage Sensing
        4. 2.4.1.4 DC Link Voltage Sensing
        5. 2.4.1.5 Bus Current Sensing
        6. 2.4.1.6 DC Link Capacitor Rating
        7. 2.4.1.7 MOSFET Ratings
        8. 2.4.1.8 Diode Ratings
      2. 2.4.2 Three-Phase PMSM Drive
        1. 2.4.2.1 Field Oriented Control of PM Synchronous Motor
        2. 2.4.2.2 Sensorless Control of PM Synchronous Motor
          1. 2.4.2.2.1 Enhanced Sliding Mode Observer with Phase Locked Loop
            1. 2.4.2.2.1.1 Mathematical Model and FOC Structure of an IPMSM
            2. 2.4.2.2.1.2 Design of ESMO for the IPMSM
            3. 2.4.2.2.1.3 Rotor Position and Speed Estimation with PLL
        3. 2.4.2.3 Field Weakening (FW) and Maximum Torque Per Ampere (MTPA) Control
        4. 2.4.2.4 Compressor Drive with Automatic Vibration Compensation
        5. 2.4.2.5 Fan Drive with Flying Start
        6. 2.4.2.6 Hardware Prerequisites for Motor Drive
          1. 2.4.2.6.1 Motor Current Feedback
            1. 2.4.2.6.1.1 Current Sensing with Three-Shunt
            2. 2.4.2.6.1.2 Current Sensing with Single-Shunt
          2. 2.4.2.6.2 Motor Voltage Feedback
  8. 3Hardware, Software, Testing Requirements, and Test Results
    1. 3.1 Getting Started Hardware
      1. 3.1.1 Hardware Board Overview
      2. 3.1.2 Test Conditions
      3. 3.1.3 Test Equipment Required for Board Validation
      4. 3.1.4 Test Setup
    2. 3.2 Getting Started Firmware
      1. 3.2.1 Download and Install Software Required for Board Test
      2. 3.2.2 Opening Project Inside CCS
      3. 3.2.3 Project Structure
    3. 3.3 Test Procedure
      1. 3.3.1 Build Level 1: CPU and Board Setup
        1. 3.3.1.1 Start CCS and Open Project
        2. 3.3.1.2 Build and Load Project
        3. 3.3.1.3 Setup Debug Environment Windows
        4. 3.3.1.4 Run the Code
      2. 3.3.2 Build Level 2: Open Loop Check with ADC Feedback
        1. 3.3.2.1 Start CCS and Open Project
        2. 3.3.2.2 Build and Load Project
        3. 3.3.2.3 Setup Debug Environment Windows
        4. 3.3.2.4 Run the Code
      3. 3.3.3 Build Level 3: Closed Current Loop Check
        1. 3.3.3.1 Start CCS and Open Project
        2. 3.3.3.2 Build and Load Project
        3. 3.3.3.3 Setup Debug Environment Windows
        4. 3.3.3.4 Run the Code
      4. 3.3.4 Build Level 4: Full PFC and Motor Drive Control
        1. 3.3.4.1  Start CCS and Open Project
        2. 3.3.4.2  Build and Load Project
        3. 3.3.4.3  Setup Debug Environment Windows
        4. 3.3.4.4  Run the Code
        5. 3.3.4.5  Run the System
        6. 3.3.4.6  Tuning Motor Drive FOC Parameters
        7. 3.3.4.7  Tuning PFC Parameters
        8. 3.3.4.8  Tuning Field Weakening and MTPA Control Parameters
        9. 3.3.4.9  Tuning Flying Start Control Parameters
        10. 3.3.4.10 Tuning Vibration Compensation Parameters
        11. 3.3.4.11 Tuning Current Sensing Parameters
    4. 3.4 Test Results
      1. 3.4.1 Performance Data and Curves
      2. 3.4.2 Functional Waveforms
      3. 3.4.3 Transient Waveforms
      4. 3.4.4 MCU CPU Load, Memory and Peripherals Usage
        1. 3.4.4.1 CPU Load for Full Implementation
        2. 3.4.4.2 Memory Usage
        3. 3.4.4.3 Peripherals Usage
    5. 3.5 Migrate Firmware to a New Hardware Board
      1. 3.5.1 Configure the PWM, CMPSS, and ADC Modules
      2. 3.5.2 Setup Hardware Board Parameters
      3. 3.5.3 Configure Faults Protection Parameters
      4. 3.5.4 Setup Motor Electrical Parameters
      5. 3.5.5 Setup PFC Control Parameters
  9. 4Design and Documentation Support
    1. 4.1 Design Files
      1. 4.1.1 Schematics
      2. 4.1.2 Bill of Materials
      3. 4.1.3 Altium Project
      4. 4.1.4 Gerber Files
      5. 4.1.5 PCB Layout Guidelines
    2. 4.2 Software Files
    3. 4.3 Documentation Support
    4. 4.4 Support Resources
    5. 4.5 Trademarks
  10. 5Terminology
  11. 6Revision History

3.4.1 Performance Data and Curves

Table 3-2 shows the Fan motor testing data at various speed with different load, the motor is coupled to the HD-705-6N dynamometer to add the load.

Table 3-2 Fan Motor and Inverter Power, Efficiency at Different Speed with Load
SPEEDref

(rpm)

SPEEDerror

(rpm)

Tload

(N.m)

Po_motor

(W)

Po_inverter

(W)

ηmotor

(%)

Pin_inverter

(W)

ηinverter

(%)

7503

0.7863

61.8041

89.2126

69.28

95.5376

93.38

15003

0.8386

131.8089

168.3758

78.28

182.5367

92.24

2250

4

0.8907

210.0507

256.1420

82.01

276.9516

92.49

1500

3

0.8456

132.8883

168.9123

78.67

183.0125

92.30

2250

4

0.8952

211.1273

256.1164

82.44

275.9552

92.81

3000

3

0.9482

298.1318

352.3146

84.62

368.9679

95.49

2250

4

0.9037

213.0801

257.8850

82.63

277.8515

92.81

1500

4

0.8542

134.2593

169.7001

79.12

183.6163

92.42

750

2

0.8035

63.1298

90.2685

69.94

98.2091

91.91

Table 3-3 shows the Compressor motor testing data at various speed with different load, the motor is coupled to the HD-815-6N dynamometer to add the load.

Table 3-3 Compressor Motor and Inverter Power, Efficient at Different Speed with Load
Speedref

(rpm)

Speederror

(rpm)

Tload

(N.m)

Po_motor

(W)

Po_inverter

(W)

ηmotor

(%)

Pin_inverter

(W)

ηinverter

(%)

750

2

1.9845

155.8340

229.9068

67.74

251.6578

91.36

1500

4

2.3945

376.1113

521.2635

72.15

569.9387

0.91

2250

5

4.5485

1071.9087

1346.4348

79.61

1372.200

98.12

1500

5

4.2020

660.0950

864.5136

76.36

903.3708

95.70

750

3

5.3235

417.9971

586.1813

71.31

642.0582

91.30

1500

6

5.6984

895.2029

1153.2485

77.63

1212.664

95.10

750

2

5.2779

414.3357

582.2262

71.17

636.5326

91.47

Figure 3-27 shows the measured fan motor drive efficiency at different speed in the system with loading torque variation.

Figure 3-27 Fan Motor Output Power and Efficiency at Various Speed and Load

Figure 3-28 shows the measured fan motor drive efficiency at different speed in the system with loading torque variation.

Figure 3-28 Compressor Motor Output Power and Efficiency at Various Speed and Load

Table 3-4, Table 3-5, and Table 3-6 show the PFC performance data at inputs of 165-VAC, 220-VAC, and 265-VAC input with different load.

Table 3-4 PFC Performance Data Under 165 VAC Input

VINAC (V)

 IINAC (A) PINAC (W)

PF

THDi (%)

 VOUT (V) IOUT (A)

POUT (W)

EFFICIENCY (%)

165.0

0.89

145.6

0.982

13.29

376.8

0.363

137

94.1

165.0

1.75

287.6

0.987

11.69

376.5

0.729

275

95.6

165.0

2.62

430.9

0.992

8.57

376.1

1.101

415

96.3

165.0

3.49

572.9

0.991

9.65

376.4

1.465

552

96.4

165.0

4.38

715.9

0.989

9.15

376.5

2.194

827

96.5

165.0

5.22

857.3

0.991

7.76

376.5

2.194

827

96.5

165.0

6.11

1002.5

0.992

6.39

376.8

2.559

966

96.4

165.0

6.99

1146.1

0.993

5.49

377.3

2.926

1106

96.5

165.0

7.87

1295.5

0.994

4.97

377.5

3.301

1248

96.3

165.0

8.96

1465.5

0.995

3.75

380.2

3.715

1457

99.4

165.0

9.98

1642.4

0.996

3.39

380.3

4.097

1629

99.18

165.0

10.67

1757.6

0.997

3.12

380.4

4.427

1747

99.39
Table 3-5 PFC Performance Data Under 220 VAC Input

VINAC (V)

 IINAC (A) PINAC (W)

PF

THDi (%)

 VOUT (V) IOUT (A)

POUT (W)

EFFICIENCY (%)

220.1

0.686

149.2

0.982

14.9

376.9

0.368

139

93.2

220.1

1.329

287.5

0.982

14.29

377.2

0.731

276

96.0

220.1

1.94

427.0

0.982

9.25

377.1

1.096

414

96.9
220.1

2.626

572.8

0.992

8.01

377

1.47

555

97.1
220.1

3.24

709.5

0.989

7.285

376.9

1.827

689

97.4
220.1

3.86

848.3

0.991

5.958

376.8

2.191

827

97.3
220.1

4.52

990.5

0.993

6.79

376.7

2.556

965

97.4
220.1

5.21

1138.5

0.992

6.4

376.6

2.938

1108

97.4
220.1

5.8

1271.5

0.993

5.98

376.6

3.283

1238

97.4
220.1

6.45

1416.5

0.994

5.35

376.6

3.656

1379

97.4

220.1

7.07

1549.5

0.994

4.93

376.6

4.003

1510

97.5

220.1

7.77

1709.8

0.995

4.29

376.6

4.404

1661

97.22
Table 3-6 PFC Performance Data Under 265 VAC Input

VINAC (V)

 IINAC (A) PINAC (W)

PF

THDi (%)

 VOUT (V) IOUT (A)

POUT (W)

EFFICIENCY (%)

250.0

0.61

148.7

0.965

12.6

385.9

0.368

142

95.5

250.0

1.24

298.9

0.959

8.65

385.9

0.751

290

97.0

250.0

1.81

447.5

0.977

9.97

385.8

1.124

434

97.0

250.0

2.42

595.8

0.979

8.82

385.7

1.499

579

97.2
250.0

3.02

744.3

0.981

11.65

385.7

1.876

724

97.3
250.0

3.62

889.6

0.979

12.03

385.7

2.246

868

97.6
250.0

4.21

1034.9

0.982

10.95

385.6

2.619

1012

97.8
250.0

4.79

1183.7

0.985

9.75

385.6

2.993

1156

97.7
250.0

5.39

1335.2

0.988

7.39

385.6

3.374

1303

97.6
250.0

5.99

1488.9

0.991

5.93

385.8

3.759

1452

97.5
250.0

6.59

1640.1

0.992

5.12

385.9

4.137

1600

97.6
250.0

7.09

1768.6

0.993

4.79

384.9

4.478

1727

97.6