Motor Control Electronic Systems
Motor Drive/Control Solutions
Motor drivers cover a wide range of applications, each with different power requirements and characteristics to fulfill, such as speed, transmission, torque control, and adjustments in position or speed. To meet these market demands, developers face increasing pressure to improve design efficiency further to stand out in a competitive market. For example, high design efficiency can be achieved by reducing total energy consumption and optimizing thermal management. The main function of motors is switching, which involves applying current to the motor windings at precisely the right time. Switching is controlled by algorithms on microcontrollers or digital signal processors (DSP). Motor control algorithms are typically very complex as they must make accurate switching decisions under various engine load conditions.
Brushless DC (BLDC) and Servo Motors
Brushless DC (BLDC) motors, known for their simple and durable structure, are widely used in the field of automation technology. These motors, without brushes and commutators, adjust stator current based on the rotor's permanent magnet position to generate torque. On the other hand, a servo motor is an electromechanical system equipped with mechanical components and feedback electronics for driving. It requires an appropriate control system to perform specific operations.
High Reliability:
To protect motor driver ICs from abnormal voltage and current, motor drivers must have comprehensive protection features, such as preventing malfunction caused by reduced power supply voltage. Additionally, they must have current limiting functions to control motor current during start-up, forced stop, or lock-up, as well as functions to output fault status to an external host processor to ensure safety.
Low Power, High Efficiency:
To reduce motor power consumption, low-power components and driving technologies are required. For example, using automatic advance angle adjustment functions can achieve very high efficiency across a wide range of rotational speeds from low to high.
Quiet, Low Vibration:
Optimizing driving waveforms is crucial for reducing noise and vibration during motor operation. This requires selecting the most suitable motor excitation driving technology for various fields of application. For example, the optimal excitation mode for BLDC motor drivers (120 degrees, 150 degrees, sine wave), soft start technology for fan motor drivers, and current decay methods for stepper motor drivers.
Control and Convenience:
Through motor digital rotation control technologies such as FLL (speed control) and PLL (phase control), and high-precision positioning control technologies required by actuators, efficient driving control algorithms can be implemented. By applying control algorithms processed through hardware logic to driver ICs, these algorithms are made user-friendly for designers. Additionally, compatibility between driver ICs improves convenience. During development, if specifications change, replacement can occur without modifying the motor drive control circuit board layout.
Motor Drive Control Systems
The development of motor drive control systems is typically categorized into two methods: Scalar Control and Vector Control.
Traditional Scalar Control, such as Voltage-Frequency Control (V/F or VVVF), adjusts motor frequency and voltage to maintain magnetic flux for efficiency. However, it has limitations, including low starting torque, slow response, poor accuracy, and sensitivity to load variations.
Vector Control, particularly Field-Oriented Control (FOC), overcomes these drawbacks by offering precise and efficient motor control. This approach enables AC motors to operate with the simplicity and precision of DC motors. Advances in power electronics and integrated circuits have further enhanced the performance of motor servo systems.
Wellysun has long specialized in developing motor drive controllers and application solutions, providing comprehensive software and hardware reference designs. These accelerate customer development cycles and speed up product launches. Current offerings for motor drive and control development include:
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Motor Drive System Design:
Using a Top-down design approach, along with computer simulation tools, to optimize motor, power electronic circuits, and driving software for motor drive systems. Design the most advanced motor control algorithms tailored to customer needs and applications, selecting the most suitable high-efficiency, low-cost single-phase/three-phase BLDC motor driver design solutions.
Power Electronics System Optimization:
The trial-and-error method remains a common approach among many manufacturers. However, Wellysun offers a Top-down design method, providing modeling and comprehensive system analysis services for existing customer products. This helps customers use systematic methods to design circuit systems with high reliability and energy efficiency performance.
Electromechanical Integration System Design:
Typical electromechanical integration systems, such as pumps (oil pumps, air pumps, or water pumps), combine motors and fluid machinery. Wellysun uses theoretical tools and computer simulation software to design pumps comprehensively. With prototype testing, pump products can achieve optimized design in cost, performance, and efficiency.
Algorithm Design:
Wellysun provides motor control algorithm design services, such as six-step square wave, sine wave, and vector control driving algorithms. Drive designs include permanent magnet motor speed estimation technology (PM Sensorless) or reluctance motor speed control algorithm design, or optimizing existing control algorithms for customers.