Sensorless digital motor controller for high reliability applications

Today, "electric platform" based commercial and military aerospace, land vehicles and weapon systems are using adjustable speed PM motor systems to replace older fixed speed motors that have mechanical gearboxes. A high reliability motion control "platform" for sensorless vector controlled PM motors has been created to facilitate this change-over from geared motors, with additional benefits of removal of hall sensors, improved efficiency, high starting torque, and lower mechanical noise, as well as improved power factor. To speed development, a dedicated hardware motion control processor is used. This is an ASIC with embedded pre-configured sinusoidal FOC algorithm, ie. the chip is 100% dedicated to motor control function, reducing certification requirements (no software is required). Powerful commissioning tools allow the user to quickly create a high performance adjustable speed system capable of high inverter frequency and wide speed range. Applications include pumps, fans, and compressors for use in more challenging settings like aircraft, combat vehicles, weapon systems and ships. Features of a controller designed for low voltage PM 3 phase motors are discussed including new iMotion ASIC, gate drivers, MOSFETs, and feedback electronics which have been integrated into a very small package further reducing the overall controller cost. Test data is shared showing important performance characteristics.