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TIDA-00142: 24 VDC / 250 Amps BLDC Controller

Kamran
Intellectual 270 points

Part Number: TIDA-00142
Other Parts Discussed in Thread: DRV8343-Q1

Hello,

I need to design a motor controller for a 24 VDC / 250 Amp BLDC.for electric-powered hydraulic steering-assist pump.

There are different techniques:

 1- with Hall-Effect sensors

 2- Sensor-less BEMF zero-crossing detection

 3- Sensor-less INSTA-SPIN

Which technique should I select?

Thanks!

  • 0
    Intellectual 270 points

    Kamran said:

    Part Number:

    Hello,

    I need to design a motor controller for a 24 VDC / 250 Amp BLDC.for electric-powered hydraulic steering-assist pump.

    There are different techniques:

     1- with Hall-Effect sensors

     2- Sensor-less BEMF zero-crossing detection

     3- Sensor-less INSTA-SPIN

    Which technique should I select?

    Thanks!

  • 0 in reply to Kamran
    TI__Guru 66550 points

    Kamran,

    Please tell us:

    1. Do you need automotive qualified parts?
    2. Will you be using an existing MCU or adding an MCU based on our recommendation?
    3. Are there any other design considerations you know of?

    Usually the customer has an idea of which technique they would like to implement, they each have their own strengths and weaknesses.

    Regards,

    -Adam

  • 0 in reply to Adam Sidelsky
    Intellectual 270 points

    Hi Adam,

    1. Yes parts need to be automotive qualified

    2. I have no selected MCU. I can use one based on your recommendation

    3. At this stage, I really do not have more details. All I know is that the motor is 24V / 250 Amps

    I am not sure which technique will be more easy and safe to switch the MOSFETs at this current magnitude. I am not sure if it is practically easy to design this high power controller. It would be great to get some guidance from you if you guys have done similar high power controller (around 6 kW).

    Thanks!

    Kamran

  • 0 in reply to Kamran
    TI__Intellectual 2595 points

    Hi Kamran,

    Ultimately the choice of commutation method will come down to a tradeoff of performance, cost, and complexity. Your choice of motor will also have an impact as well (trapezoidal vs sinusoidal motor windings).

    In general, a commutation technique based on sensors (like hall sensors) is much easier to implement than sensorless, but they require some additional cost in the motor to add the sensors. Additionally, sensorless systems usually require the motor to start moving before it can accurately detect rotor position, or some form of initial position detection. For a pump, this is likely not a big issue since the motor will likely be continuously spinning in one direction during operation.

    If you're unsure what technique to use, or unfamiliar with motor commutation in general, I would probably recommend using the hall sensor technique. Especially when dealing with high power systems, having definite information on the position of the rotor from the hall sensor will make it much easier to ensure you're driving the motor correctly.

    Also, I see you mentioned the DRV3205 in your post title. Does this system require a functional safety device, or just automotive qualified? If it only requires an automotive device, I would recommend you take a look at the DRV8343-Q1. It is a new device designed for 24V automotive systems, and in my opinion is an easier device to work with for non-functional-safety applications.

    Thanks,

    Garrett