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  • High Voltage 3 Phase PMSM Motor Control Evaluation Platform

  • Created: Nov 17, 2015

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This Freescale’s high voltage motor control evaluation platform is for 3-phase motor that requires power up to 1000W. It has an on-board power factor correction circuitry that is based on a boost converter and works in the interleaved topology. It has also an inrush current limiter that uses a negative temperature coefficient thermistor and a relay. The communication and debugging circuitry of this development platform is optically isolated from high voltages up to 5kV. This control platform is also equipped with different sensors to prevent damages from overcurrent and overvoltage faults and to sense the behavior of the motor. The main board accepts input voltages ranging from 90 to 240V AC or 110 to 390V DC.

In this reference design, the high voltage motor control platform is used to control and monitor the behavior of a permanent magnet synchronous motor (PMSM). The whole development platform is composed of a main board and a controller card. The main board includes the current inrush EMI filter, interleaved power factor correction (PFC), power supply for the motor and the controller, DCB brake, 3-phase inverter, sensors, and communication or debugging ports. The current inrush EMI filter is used to protect the whole circuit during the powering of high voltage circuits. It is based on a NTC thermistor and a shorting relay. The PFC stage is based on a boost converter and interleaved topology design. The controller measures the currents in both of the PFC legs, input voltage and the DCBus voltage. It maintains a stable level of the DCBus voltage and the sine shape of the input current from the power line. The whole system requires various voltage levels of +15V, +5V, +3.3V and +1.65Vreference. All power supplies are served from the bus voltage. The bus can be supplied from two sources, the line input across the power bridge, or via the PFC converter. The power source is selected automatically according to the output voltage from the PFC. The power source should be able to deliver at least 8 amperes. The main board sensors monitor the voltage, bus current, phase current, and the PFC current temperature. Advance board functionalities include motor and PFC overcurrent protection, overvoltage or undervoltage protection, and temperature sensing. Though the main board consists almost all parts of the development platform, the main board will not be able to operate without the controller card.

The controller card used in this reference design is the HVP-KV31F120M, which is based on Freescale KV31F512VLL12 device. It is attached to the daughter card connector of the high voltage motor control evaluation platform. The controller card controls the behavior of the motor and monitors the condition of the main board. It measures the voltage or current levels of the sensors and activates the protection circuits included in the design of the development platform. The controller card has a programmable OpenSDA debug interface with multiple applications available, including a mass-storage device flash programming interface, a data-logging application, etc.