Emerging Integrated Drive Controller

Transcription

1 Emerging Integrated Drive Controller Ramesh Ramamoorthy - Senior Drive solution Expert & Sam Sabapathy - SMTS (Senior Member of the Technical Staff) C2000 System Solutions Industrial Drives & Functional Safety 1

2 Speaker Bio Ramesh Ramamoorthy M.Tech (EE) Indian Institute of Technology, Madras, India Drive System Solution Expert at Texas Instruments 22 years in Motor Drives and Power Electronics Expertise in Industrial and R&D environments Sam G. Sabapathy B.E (Hons) from Madras University, India MS (EE) Northern Illinois University, USA Senior Member of the Technical Staff at TI Currently leading System solutions In Industrial Drives and Functional Safety at Texas Instruments 35 years in Embedded Systems & Control solutions 2

3 Abstract Modern industrial drives demands flexible feedback sensing technologies, real time connectivity and functional safety to provide superior performance, reliability and accessibility at an optimal cost. With the matured evolution of sigma-delta converters, drive manufacturers see the advantages of moving to isolated sigma-delta sensing for signal quality and performance. For servo control applications, position sensing is a critical requirement, that also demands flexible interface to analog sensors and digital encoders using various protocols. Real time connectivity and functional safety are value added features that are being demanded by end equipment users. This stretches the requirements of the digital controller s capabilities and expects adaptable interfaces to a wide range of feedback devices with high bandwidth. Emerging integrated SoCs offer a cost effective alternative to existing multi-mcu and MCU with FPGA solutions. This paper reviews the need of an integrated development platform that provides the flexibility to explore the emerging hardware and software technologies and modern trends in the development of smart industrial drive. 3

4 Agenda Industrial Drives What and where do they play? Application Sectors & Diversity Drive subsystems & components Challenges Technical/Technological challenges Subsystem integration Drive Controller Trend Programmable Hardware - FPGA for Drives Multi-core processors and multi axis Integrated SOC targeting single chip solution Design platform for DRIVEs Define a Single Platform to show case solutions today and beyond What is coming.. Low cost development platform for Hardware and Software, algorithms 4

5 Agenda Industrial Drives What and where do they play? Application Sectors & Diversity Drive subsystems & components Challenges Technical/Technological challenges Subsystem integration Drive Controller Trend Programmable Hardware - FPGA for Drives Multi-core processors and multi axis Integrated SOC targeting single chip solution Design platform for DRIVEs Define a Single Platform to show case solutions today and beyond What is coming.. Low cost development platform for Hardware and Software, algorithms 5

6 INDUSTRIAL Drive and Applications sectors Ind.Robots Servo Drives AC Drives CNC Elevators Hardware Software FULL SYSTEM D E S I G N E X P E R T I S E 6

7 INDUSTRIAL Drive and Applications sectors Ind.Robots Servo Drives AC Drives CNC Elevators MCUs-SoCs for Real-time control in Drive control Improve overall motor system responsiveness, scalability, and future growth 7

8 Drive Power stage and its subsystems 8

9 Drives Terminologies & Partitioning Power Stage 9

10 Agenda Industrial Drives What and where do they play? Application Sectors & Diversity Drive subsystems & components Challenges Technical/Technological challenges Subsystem integration Drive Controller Trend Programmable Hardware - FPGA for Drives Multi-core processors and multi axis Integrated SOC targeting single chip solution Design platform for DRIVEs Define a Single Platform to show case solutions today and beyond What is coming.. Low cost development platform for Hardware and Software, algorithms 10

11 Drive Subsystem Challenges Functional Safety 11

12 Technical and Technology challenges CPU Processing Control Algorithms : > Analog/Digital Peripheral integration Maintain Real - time control demands Increase performance with less MHz > CPU assisted HW accelerators High precision math > Dedicated Fixed/Float math accelerators Flexible fixed point /integer math 32-bit float/64-bit float Application processing > Motion and motion planning algorithms Motor diagnostics > Adopt emerging tools Multi-axis > Redundant control peripherals & IO Functional safety enablement > Built-in diagnostics and runtime/power up 12

13 Drive Subsystem integration challenges Actuation Flexible PWM actuation Multiple Event triggers for Analog subsystems Cycle by Cycle control, Fast PWM trip and protection Hi resolution PWMs & deadband V/I Feedback sensing Simultaneous sampling Low latency conversions High accuracy with low cost analog Low cost transfer from high voltage to low voltage domain Position sensing Manage multi-protocol standards for rotor position sensing Adapt to long encoder cable (20-100m) Manage analog and digital position sensors Acquire position information greater than 20-bit format Integrated connectivity Add easy connectivity with Ethernet type links Provide a deterministic packet communication on Ethernet links Accommodate existing protocols and emerging standards Migration/Time to market Migrate proprietary control topology to new architecture Reduce cost per axis in terms of HW and SW Common power stage for multi topologies Reduce cost of isolation > Flexible Actuation interfaces > Flexible Sensing interfaces > Configurable HW & protocol > Configurable HW & protocol > Compatible HW & SW tools 13

14 Agenda Industrial Drives What and where do they play? Application Sectors & Diversity Drive subsystems & components Challenges Technical/Technological challenges Subsystem integration Drive Controller Trend Programmable Hardware - FPGA for Drives Multi-core processors and multi axis Integrated SOC targeting single chip solution Design platform for DRIVEs Define a Single Platform to show case solutions today and beyond What is coming.. Low cost development platform for Hardware and Software, algorithms 14

15 Drive Makers Adapt/Adopt New Technologies MCU System Power Supplies FPGA Power Supply Multi Rail Power Supply MCU Monitor ADC FPGA EMIF Port FPGA Code Apps Code O T H E R S P E E D P O S I T I O N MCU Core Control Subsystem 15

16 Drive Integration of Configurable Functions MCU System Power Supplies FPGA Power Supply Multi Rail Power Supply MCU FPGA Code Apps Code O T H + E R Monitor ADC DSP S P E E D MCU MCU Core EMIF P O S I T I O N FPGA Port On-chip Position Encoder s C P U s PWM PWM Protect Sinc Filters IO SPI/ EMIF Control Subsystem 12/ 16-bit ADC MCU on-chip resource 16

17 Integrated SoCs Simplify Drive Designs MCU System Power Supplies FPGA Power Supply Multi Rail Power Supply MCU FPGA Code Apps Code Monitor ADC FPGA EMIF Port O Drive S P Control T P O S H E I E E T R D I O N System on a Chip MCU Core MCUs Control Subsystem MCU-SoC 17

18 Drive architecture & subsystem: Summary/Trends System Characteristics MCU +FPGA FPGA +Analog Integrated MCU Processing power Apps/Control/Comms Single CPU Multi CPU Multi CPU + Accelerators Axis Single Multi Multi Control loops 30-50us Software <5us Hardware Current sensing Int / Ext. ADC Ext ADC Sigma/Delta <5us Software Int ADC & Sigma Delta Position sensing In FPGA In FPGA Internal Power supplies Modest Expensive Modest Simulation Low High High Algorithm flexibility Med High Very High Power stage partitions Limited With no SDFM Limited With SDFM only Flexible System Cost/axis $$ $$$$ $$ Isolation Needed Partial Flexible Industrial Drive - SOC Real estate High Big Optimal 18

19 Agenda Industrial Drives What and where do they play? Application Sectors & Diversity Drive subsystems & components Challenges Technical/Technological challenges Subsystem integration Drive Controller Trend Programmable Hardware - FPGA for Drives Multi-core processors and multi axis Integrated SOC targeting single chip solution Design platform for DRIVEs Define a Single Platform to show case solutions today and beyond What is coming.. Low cost development platform for Hardware and Software, algorithms 19

20 Performance, Integration and Flexibility Focus on differentiation; not table-stakes technologies Investigate combinations of new technology without the need to fabricate new hardware every time Get to market more quickly, delivering higher value Integrated Drive Controller MCUs Processing Processing Actuation Multi-current Multi-current Sensing Sensing 24 ch Flexible PWM High MIPS (Multi- Up to Core) 800 MIPS (Dual Core) Up to 24 ch Flexible PWM Quad 16 bit/12 bit ADCs 3 phase control Multi ADCs16 bit/12 bit Math Accelerators Trigonometric Math Unit 3 phase to multil-level Sinc Filters with compare Multi axis control Sigma Sinc filters Up to >1MB Up flash to 1MB flash Programmable Trip Zones AMC130x, 120x compliant Up to >200KB Up SRAM to 204KB SRAM Programmable protection Hall, Fluxgate, Shunt topologies Safety diagnostics LEMS, Shunt topologies Flexible System Expansion Support Industrial Industrial Connectivity Connectivity FunctionalSafety Position Position Encoder Encoder Feedback Feedback AM335x control card Resolver Integrated CAN included Endat2.2 Expansion for future slots for functional future QEP Expansion slot C2000 for future link via industrial SPI or BiSS safety functional enhancements safety Serial interface encoder like communications McBSP enhancements Resolvers Chipenhancements level and System level EnDAT, BiSS and other protocols Real time connectivity EtherCAT, EthernetIP, Sensorless and more Sensorless and more Profinet, Profibus and more 20

21 Design DRIVE platform- Integrates subsystems and makes exploration easy! BUS voltage Current sensing Sigma/Delta Position Interfaces Encoder/Resolver channels Current sensing Fluxgate/Hall Bias supplies Current sensing Shunt Power stage Bias Supplies for MCUs Isolation - SoC Integrated Control MCU Real Time Ind. Connec ctivity External Fucntioana l Safety 2-channel 21

22 Q&A on Drive & subsystems challenges? What do you see at your customers? 1. What are the challenges to solve in real-time processing performance? 2. What are the challenges to solve in voltage and current sensing? 3. What are the challenges to solve in position feedback? 4. What are the challenges to solve in connectivity? 5. What are the challenges to solve in connectivity protocols? 6. What are the challenges to solve in isolation? 7. What are the challenges to solve in MCU, IGBT, Isolated Bias supplies? 22

23 THANK YOU! C2000 Real-time Microcontrollers Industrial Drives Catalog Motor Digital Power 23