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DAEC TM – Dynamic Angle Error Compensation| Heinz
OYRER, ams AG15:00 – 15:25 Uhr
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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
Confidential © ams AG 2015
Page 5
Efficient Motor Commutation through Advanced Position Sensing
EFFICIENCY OF ELECTRICAL MOTORS
MOTOR POSITION SENSOR
DYNAMIC ANGLE ERROR COMPENSATION
TYPICAL APPLICATIONS
BUSINESS DRIVERS
DAEC™
DYNAMIC ANGLE ERROR COMPENSATION
Confidential © ams AG 2015
Page 6
• 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
Confidential © ams AG 2015
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• 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.
Source: CleanTechnica, abb.com/energyefficiency
Majority of electric motors are inefficient
Confidential © ams AG 2015
Page 8
Opportunities for efficiency
• Addressing the efficiency of electric motors is
an important topic that needs to be tackled.
Source: CleanTechnica, abb.com/energyefficiency
Confidential © ams AG 2015
Page 9
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
Confidential © ams AG 2015
Page 10
Efficient Motor Commutation through Advanced Position Sensing
EFFICIENCY OF ELECTRICAL MOTORS
MOTOR POSITION SENSOR
DYNAMIC ANGLE ERROR COMPENSATION
TYPICAL APPLICATIONS
BUSINESS DRIVERS
DAEC™
DYNAMIC ANGLE ERROR COMPENSATION
Confidential © ams AG 2015
Page 11
• 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
Confidential © ams AG 2015
Page 12
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.
Confidential © ams AG 2015
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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.
Confidential © ams AG 2015
Page 14
Efficient Motor Commutation through Advanced Position Sensing
EFFICIENCY OF ELECTRICAL MOTORS
MOTOR POSITION SENSOR
DYNAMIC ANGLE ERROR COMPENSATION
TYPICAL APPLICATIONS
BUSINESS DRIVERS
DAEC™
DYNAMIC ANGLE ERROR COMPENSATION
Confidential © ams AG 2015
Page 15
• 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?
Confidential © ams AG 2015
Page 16
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
Confidential © ams AG 2015
Page 17
• 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
Confidential © ams AG 2015
Page 18
• 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
Confidential © ams AG 2015
Page 19
Efficient Motor Commutation through Advanced Position Sensing
EFFICIENCY OF ELECTRICAL MOTORS
MOTOR POSITION SENSOR
DYNAMIC ANGLE ERROR COMPENSATION
TYPICAL APPLICATIONS
BUSINESS DRIVERS
DAEC™
DYNAMIC ANGLE ERROR COMPENSATION
Confidential © ams AG 2015
Page 20
DAEC™ Video
Confidential © ams AG 2015
Page 25
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]
Confidential © ams AG 2015
Page 26
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.
Confidential © ams AG 2015
Page 27
Integrated Dynamic Angle Error Compensation
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™.
Confidential © ams AG 2015
Page 28
Integrated Dynamic Angle Error Compensation
Dynamic Angle Error
Hardware Compensation integrated!
No Software needed!
External HW + SW compensation needed
Magnetic P
ositio
n S
ensor
Syste
m
Confidential © ams AG 2015
Page 29
Integrated Dynamic Angle Error Compensation
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
Confidential © ams AG 2015
Page 30
• 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
Confidential © ams AG 2015
Page 31
Efficient Motor Commutation through Advanced Position Sensing
EFFICIENCY OF ELECTRICAL MOTORS
MOTOR POSITION SENSOR
DYNAMIC ANGLE ERROR COMPENSATION
TYPICAL APPLICATIONS
BUSINESS DRIVERS
DAEC™
DYNAMIC ANGLE ERROR COMPENSATION
Confidential © ams AG 2015
Page 32
• Electrical power
steering (EPS)
• Dual Clutch
Transmission (DCT)
• Pumps
• Starters
Steering Transmission Miscellaneous Automotive Parts
Typical markets/applications - automotive
• Alternators
• Brake Actuators
Confidential © ams AG 2015
Page 34
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