應用於DVD主軸馬達無刷直流馬達無感測控制IC之研製 

Design and Implementation of a Sensorless BLDC Spindle Motor Control IC for DVD-RAM Players

[研究成果]

中文摘要


關鍵詞:無刷直流馬達、機電積體馬達、智慧型馬達、無感測控制、適應控制、DSP馬達控制、馬達控制晶片、馬達驅動功率模組、即時網路通訊、電腦輔助設計

本計畫是一個為期三年的『產學合作整合性研究計畫』,擬發展應用於未來資訊家電與工業自動化的智慧型機電積體馬達(integrated electromechanical motor, IEMM)。微小馬達一般系指功率低於3W的馬達,本計畫將以微小無刷直流馬達為目標,發展與整合無感測控制技術、DSP馬達控制、混合式馬達控制晶片設計、馬達驅動IC設計、即時網路通訊、數位伺服控制晶片設計等技術,研製一個可程式之無感測無刷直流馬達控制晶片,發展下一代智慧型積體馬達之關鍵技術。本計畫將發展網路控制智慧型馬達的整合技術,研製一個具有網路介面的智慧型馬達驅動系統,所發展之技術可應用於光碟機主軸驅動系統、資訊家電產品、電動車輛等領域。擬發展之關鍵技術包含:無刷直流馬達控制IC設計技術。無刷直流馬達之無感測控制技術、混合式無刷直流馬達控制晶片設計技術、微小馬達伺服控制晶片設計技術。本計畫為期三年,各階段之研究摘要分述於后:

第一年:無刷直流馬達無感測控制技術之發展
針對微小型之無刷直流馬達,提出新型的無感測控制架構,發展結合類比數位控制的混合式無刷直流馬達無感測控制技術。本階段主要的研究目標在於發展出一種適合混合式IC設計的無感測控制架構,研究高轉速(>10,000rpm)的轉速估測與弱磁控制方法,並發展無感測控制法則的定點運算方法,探討量化誤差所造成的換相誤差,研究計畫將採用單晶片DSP進行控制架構的實作驗證,並結合類比電路設計,完成一個微小馬達測試平台,藉此評估所提出之混合式無感測控制架構的性能,並以此為基礎進行下階段無感測控制IC設計之研究。本階段同時亦將針對馬達控制IC設計,發展可共用與重複使用的IC設計架構與方法,發展可組合式的數位馬達控制晶片架構,做為未來設計微小馬達控制控制晶片的基礎。

第二年:混合式無刷直流馬達無感測控制IC之研製
本階段以精密小型BLDC馬達為對象,提出新型BLDC馬達控制晶片的電路架構,發展類比數位混和IC設計技術,建立一個以電腦輔助馬達控制IC設計的發展環境,設計BLDC馬達無感測控制IC,發展泛用型的可程式混合式馬達控制IC。本階段將整合所設計的BLDC馬達無感測控制IC與DSP控制,發展適應參數自調控制方法,同時將發展應用於馬達驅動的高效率高功率密度電源轉換技術,研製適用於小功率馬達的DC/DC與DC/AC電源模組,整合功率轉換電路設計與類比IC設計技術,研製小功率的馬達功率驅動模組。本階段將整合所設計的微小馬達測試平台、BLDC馬達無感測控制IC、與可組合式數位伺服控制IC,進行實驗測試與性能評估,並以此做為控制IC改良與智慧型積體化馬達設計的基礎。

第三年:智慧型無刷直流馬達控制IC之研製
本階段將發展嵌入式DSP即時多工馬達控制器與網路介面軟體,結合VLSI數位與類比設計技術,發展智慧型馬達控制模組。針對智慧型馬達進行以電腦輔助設計為基礎的系統化設計方法之研究,同時發展以電腦輔助為基礎的積體化馬達功率驅動電源模組的、散熱分析、與電磁干擾分析方法。本階將發展完成具有網路介面並應用於IA控制馬達的網路通訊IC,並將之整合完成一個具有網路介面的智慧型馬達控制IC。

本計畫研製的智慧型積體馬達與發展的關鍵技術,將可應用於合作廠商發展下一代高性能的光碟機與超高容量資訊儲存系統。本計畫所發展之積體馬達整合設計技術,具有廣泛的應用價值,是Motor Control System in a Chip具體的實現。本計畫之執行,相信對我國自動控制、數位與類比IC整合設計、馬達控制、電力電子等產業的技術發展與人才培育,均會有具體之貢獻。

英文摘要


Keywords: brushless dc motor, integrated electromechanical motor, intelligent motor, sensorless control, auto-tuning adaptive control, motor control IC, real-time communication, computer-aided design.  

This three-year industry-academic integrated research project aims on the development of key technologies in the design and manufacturing of integrated electromechanical (IEM) motor, which can be applied to a wide range of applications, such as internet appliance, industry automation, and more electric vehicles. In general, small motors are defined as motors with rated power lower than 3W. This project is focused, however not limited, on the development and integration of key technologies for the design of small IEM motors. The developed technologies can be used in a wide range of applications. The control and IC design for the high-speed brushless dc motors used in DVD-ROM is one major application. System integration is often overlooked in the design of motor control IC. This project will develop a rapid System-On-Chip (SOC) integration technology for motor control IC design. The proposed approaches are based on efficient reuse of Intellectual Property (IP), architectural abstraction, design parameterization, and HW/SW co-design. This three-year project targets on the development of key technologies in the design of an integrated intelligent motor, such as BLDC motor control IC design, sensorless auto-tuning control technique, mixed-mode BLDC motor control IC sesign, DSP embedded BLDC motor control technique, and real-time network motor control technique. A more detailed description of the research abstract for each year is as follows: 

The First year: Development of Sensorless Control Techniques for BLDC Motors
In the first stage of this project, we try to develop new sensorless control scheme for small BLDC motor under high-speed operating condition. Mixed-mode control structure, an integration of analog and digital circuit realization technique, will be developed for the sensorless control of BLDC motors. Field-weakening control technique of BLDC motor for high-speed (> 10,000 rpm) sensorless control will be developed. Integer arithmetic realization issues of the sensorless control scheme will be studied. Experimental verification of the proposed hybrid sensorless control scheme will be carried out on a single-chip DSP (TMS320F240) controller with design analog circuit. DSP embedded controller for BLDC motor control will be implemented. In the development of motor control IC design methodology, we will also study on the implementation for the shared common techniques and develop a set of generic IP cores based on these techniques. Configurable motor control IC design technique will be developed. A computer-controlled platform will be constructed for the testing and performance measurement of the BLDC motor and drives. The proposed sensorless control scheme will be evaluated and be used as the control structure in design of the BLDC motor control IC in the following research.

The Second Year: Development of BLDCM Hybrid Sensorless Control IC
In the second stage of this project, we will propose new hardware control architecture for the design and implementation of a hybrid motor control IC. Analog and digital IC design techniques will be integrated in the design of the sensorless BLDC motor control IC. We will construct a motor control IC design environment to integrate various engineering disciplines in approaching the Motor Control SOC. The design DSP controller will combine with the hybrid motor control IC to realize the auto-tuning control algorithms. Another important issue during the second stage is the research on the feasibility in application of high power density power IC in realized an integrated electromechanical motor. We will integrate the design sensorless BLDC motor control IC, configurable control IC, power IC, and the BLDC motor in a constructed testing platform for performance measurement and evaluation.

The 3rd year: Design and Implementation of an Intelligent BLDC Motor Control IC
In the final stage of this project, we will focus on the development and integration of computer-aided design techniques in design of the IEM BLDC motors. Special efforts will put on the development of real-time communication techniques for distributed motor and motion control systems. A DSP embedded motor control chip will be developed to achieve intelligent control of the BLDC motors. The integrated computer aided design methodologies will be studied. We will try to construct an environment to integrate the design of motor, power IC, analog IC, digital IC, DSP embedded software control, and real-time communication for motor and motion. An intelligent IEM BLDC motor with real-time network communication interface will be constructed to verify the proposed design strategy. Based on the constructed design environment, further future research on the development of intelligent IEM motors can be carried out.

In the development of motor control IC, this project intends to achieve following goals: (1) to synthesize and verify the motor IC that can meet flexible real-time constraints, (2) to port the motor control scheme correctly into the selected architecture, and (3) develop methodology which can efficiently and economically complete the SOC integration, simulation, and verification.

The very central idea of this project is to combine the up-to-date microelectronics, power electronics, and motor control technologies in approaching the design and implementation of small intelligent IEM motors. Research and development on such a topic with multiple engineering disciplines by using microelectronics technology is vital important. The execution of this project should be beneficial to the technology development and manpower training in automatic control, motor control, mixed-mode IC design, and power electronics.


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