xEV Inverter Solution With An Inductive Position Sensor Application Model and Software PDF

XEV INVERTER SOLUTION
WITH
INDUCTIVE POSITION
SENSOR(IPS2550)
AUGUST 3RD 2022

GUANYUAN CHEN
STAFF APPLICATION ENGINEER
AUTOMOTIVE ANALOG PRODUCT MARKETING DIVISION
RENESAS ELECTRONICS CORPORATION
© 2022 Renesas Electronics Corporation. All rights reserved.

AGENDA
▪ Market trend change
▪ Renesas platform solutions for xEV system
▪ inductive position sensor IPS2550
▪ xEV traction inverter solution with inductive position sensor IPS2550
▪ IPS2550:xEV inverter solution evaluation environment
▪ Comparison of IPS and resolver evaluation results
▪ Summary
© 2022 Renesas Electronics Corporation. All rights reserved. Page 3

MARKET TREND CHANGE
➢ The market is clearly shifting toward BEV due to technology evolution trends and environmental policies
➢ A possible transitory step to FHEV prior to BEV seems likely in China but could also occur in EU/US markets
2025 2025
2025 2021 2021
2021
8806 9689
2163
4607 3370 5300 K unit
K unit K unit K unit
K unit K unit
Incl.
Shanghai VW, etc.
Changes in Carbon Neutral Policies of National Governments 2025

With the change of government, the policy has shifted to environmental measures. 2021
Returning to the Paris Agreement, promoting the shift to xEVs.
Announced Sustainable and Smart Mobility Strategy to increase the number of
zero-emission passenger vehicles such as EVs to 30 million by 30 years. 2073 4735
K unit K unit
Announced plan to convert more than 50% of its new vehicle sales to NEVs (BEVs,
PHEVs) and the rest to FHEVs by 2035.
Announced goal of reducing greenhouse gas emissions to virtually zero by 2050 at
2020 G20 summit,and declared to further raise its 2030 reduction target in 2021.
Source : Strategy Analytics: Automotive Electronics System Demand, updated Jan 2021, OEM nationality base BEV: Battery Electric Vehicle
© 2022 Renesas Electronics Corporation. All rights reserved. Page 4 PHEV: Plug-in Hybrid Vehicle
FHEV: Full Hybrid Vehicle
RENESAS PLATFORM SOLUTIONS FOR xEV SYSTEMS
Broad Product Portfolio serves wide range of automotive applications
“Digital + Analog + Power + Software” - Fully Integrated Application Based Optimized Solutions
Inverter On-Board Charger BMS*1
Gate IGBT / Diode Turnkey
driver Gate IGBT
Position MCU driver MOS solution
sensor MCU
BLE BMIC*3 MOSFET
PMIC*2
Turnkey PMIC*2
Contactor
solution Driver
DC/DC
Controller Gate IGBT PMIC*2
driver MOS Diode
MCU
IPD*4
PMIC*2
*1: BMS: Battery Management System *2: PMIC: Power Management IC *3: BMIC: Battery Management IC *4: IPD: Intelligent Power Device

FUNCTIONS OF XEV INVERTER SEMICONDUCTORS
The main functions of each inverter semiconductor are as follows
Calculates the control value for the motor based on the Generates IGBT/MOS gate drive
command value from the host ECU and sensor feedback, then signals from MCU output signals
outputs the control signals for the power devices
Gate driver IGBT / MOS
Position MCU
sensor Click to add text
Monitors motor position to ensure

PMIC
the correct current flow to the motor
Single chip power supply IC that supplies Applies AC current to the motor
power to all circuit blocks

IPS2550:INDUCTIVE POSITION SENSOR
Tx1 - Tx2 (3-5MHz)
⚫ Ideal for control applications of electric motors
(especially BLDC motors)
➢ Sine cosine (differential analog) output SIN - SINN
Rx1 - Rx3
Rx2 - Rx4 COS - COSN
0 90 180 270 360
⚫ Rotational Speed: up to 600,000 (el) rpm High accuracy

≤ 0.1% full scale (ideal coil)
⚫ Automotive AECQ100 Grade-0 Designed & Qualified

Functional safety: supports ASIL C @ single IC
⚫ Temperature range: -40℃ to 160℃ ambient

XEV INVERTER SOLUTION WITH INDUCTIVE POSITION SENSOR(IPS)
Block diagram

IPS2550 CAN REDUCE COST
Excitation
circuit
Resolver Motor

IPS2550: XEV INVERTER SOLUTION EVALUATION ENVIRONMENT
In a high-voltage inverter environment, di/dt fluctuation and dv/dt fluctuation are high, so sufficient noise immunity is required.
As an operation verification of IPS2550, a motor drive ability was test with Renesas xEV Dyno.
The input of the MCU verifies both RDC and ADC interfaces.
RDC: resolver digital converter
ADC: analog digital converter Conditions
・MCU I/F：RDC、ADC
・dv/dt: ~400V, di/dt: ~500Arms
・Maximum power: 100kW
xEV motor(100kW) with ・Max rotation: 9500rpm
IPS2550 ・Max torque: 260N・m
Enlarged

COMPARISON OF IPS AND RESOLVER EVALUATION RESULTS
-MAX TORQUE
▪ Vbus voltage：400V, rotation speed: 2800rpm,torque: 260N・m
Resolver IPS2550
Same
Vbus torque
Power meter U,V, Rotation
data W-3 speed
Inverter
phase
efficiency
curre
nt
Same
Motor 3-phase
current waveform
Under the conditions of applied voltage = 400V and torque = 260N ・ m (dv/dt = 400V, di/dt = 350Arms),
there is no change in the three-phase current and rotation speed. (No difference from resolver)

-MAX CURRENT
▪ Vbus voltage：400V, rotation speed: 3500rpm,Max three-phase current: 500Arms
IPS2550
Resolver
Same
Vbus torque
Power meter
U,V, Rotation
data W-3 speed
phase Inverter
efficiency
curre
nt
Same
Motor 3-phase
current waveform
Under the conditions of applied voltage = 400V and three-phase current = 500Arms (dv/dt = 400V, di/dt =
500Arms), there is no change in the three-phase current and rotation speed. (No difference from the resolver.)

-MAX ROTATION
▪ Vbus voltage：400V, Max rotation speed: 9500rpm, torque: 82N・m (square wave control: One pulse condition)
Resolver IPS2550
Same
Power meter Vbus torque
U,V,
data W-3
Rotation
speed
phase Inverter
efficiency
curre
nt
Same
Motor 3-phase
current waveform
Under the conditions of applied voltage = 400V and rotation speed = 9500rpm (dv/dt = 400V, di/dt = 165Arms),
there is no change in the three-phase current and rotation speed. (No difference from the resolver.)

VIDEO OF CONTROLLING A MOTOR WITH IPS2550 ON A RENESAS
MOTOR BENCH
https://www.renesas.com/us/en/video/xev-inverter-solution-inductive-position-
sensor-ips2550

COIL PATTERN DESIGN SUPPORT
We support the design of coil patterns that match your motor.
From concept to coil design and PCB layout design support .
◼ System analysis ,feasibility

◼ Coil design and optimization
◼ PCB layout
360°

BENEFIT: R&D PERIOD AND COST REDUCTION
Coil pattern Reference sample A sample

Silicon B-sample
simulation board software Test & Tuning
Competitor A Customer
Competitor B Customer
Customer
Renesas solution contribute to save the R&D period of approx. 6 months and its R&D cost

SUMMARY
Solution value proposition
◼ IPS2550 contributes to high accuracy angle ≤ 0.1% full scale (with ideal coil), high-speed rotation up to
600,000rpm(electric angle), small size, light weight and thin size.
◼ Lower Bill-of-Material: > 30％*1 less expensive than resolvers. Contributes to the reduction of BOM components *1 Based on Renesas research
◼ Verified noise immunity in high voltage inverter environments (400V, 100kW, 500Arms)
Renesas value proposition

◼ Easy to design and optimize your own IPS Tx/Rx coil pattern.
◼ Sample software can be provided for quick evaluation.
Renesas can be proposed as a traction motor system in combination with a traction inverter solution and
functional safety support.
https://www.renesas.com/application/automotive/electrified-drivetrain-xev/xev-inverter-solution-inductive-position-sensor-ips#overview

PLEASE VISIT RENESAS.COM
Renesas.com
PRODUCTS SECURE PORTAL My Renesas
▪ Products pages for detail information; Datasheet, Application note etc. ▪ Access to secure content
− Automotive RH850 Power ICs − Registration and Log-IN at Renesas.com
APPLICATIONS
▪ Select Renesas products from Automotive Applications DESIGN & SUPPORT
▪ Winning Combinations ▪ Quality & Packaging
− Renesas' complementary automotive product portfolios of ▪ FAQ, Contact form

Analog + Power + Embedded Processing work together to ▪ User Forum site | RenesasRulz RenesasRulz
deliver comprehensive solutions. Automotive Analog
− Please visit and post in Rulz Automotive Analog
− Winning Combinations for Automotive Product page

XEV INVERTER APPLICATION
MODEL AND SOFTWARE
AUGUST 3RD 2022

CHENGZHE LI
SR STAFF SOFTWARE ENGINEER
AUTOMOTIVE ANALOG PRODUCT MARKETING DIVISION
RENESAS ELECTRONICS CORPORATION

AGENDA
▪ TARGET MARKET AND APPLICATIONS
▪ WHAT IS XEV
▪ WHAT KIND OF MOTORS ARE USED IN XEV
▪ WHAT IS INVERTER
▪ WHAT IS INVERTER SOFTWARE
▪ WHAT ARE ISSUES IN SOFTWARE DEVELOPMENT
▪ WHAT ARE SOLUTIONS IN SOFTWARE DEVELOPMENT
▪ KEY FEATURES AND BENEFITS
▪ WEBPAGE CONTENT

TARGET MARKET AND APPLICATIONS
▪TARGET MARKET
−xEV
▪APPLICATION
−SOFTWARE DEVELOPMENT OF INVERTER

WHAT IS XEV
COMMON ELEMENTS OF ELECTRIC VEHICLE
INVERTER
BATTERY
MOTOR

WHAT IS XEV
COMBINATION OF COMMON ELEMENTS AND ADDITIONAL ELEMENTS
COMMON ADDITIONAL NAME ABBREVIATION
ELEMENT ELEMENT
MOTOR CHARGING BATTERY ELECTRIC BEV
BATTERY VEHICLE
INVERTER CHARGING PLUG IN HYBRID ELECTRIC PHEV
ENGINE VEHICLE
ENGINE HYBRID ELECTRIC HEV
VEHICLE
FUEL CELL FUEL CELL ELECTRIC FCEV
HYDROGEN VEHICLE
TANK
xEV is a general term for BEV, PHEV, HEV, and FCEV.

WHAT KIND OF MOTORS ARE USED IN XEV
TARGET MOTORS OF THIS
EXAMPLE OF MOTORS USED IN XEV SOLUTION
Electric power
e-4WD Traction
steering
Generation
High power
alternator
Electronic stability Electronic throttle

control control
In-wheel
Air conditioner
compressor
Electrical oil pump

WHAT IS INVERTER
INSIDE MOTOR AND OPERATION PRINCIPLE
INSIDE MOTOR OPERATION PRINCIPLE
ROTOR STARTOR ①Rotor is a permanent magnet.
MOTOR ②Stator is a coil.
③When an electric current flows

through the coil, a magnetic field is
generated.
④A coil that allows current to flow,

and by changing the strength
and direction of the current,
a magnetic field that rotates
around the rotor is generated.
STARTOR

WHAT IS INVERTER
CURRENT FLOWING THROUGH XEV MOTOR (STATOR)
U PHASE V PHASE W PHASE
CURRENT CURRENT CURRENT
U PHASE
V PHASE W PHASE

WHAT IS INVERTER
EXAMPLE OF BATTERY
BATTERY PACK BATTERY CELL
A battery pack of several hundred V consists of

hundreds of hundreds of battery cells of several V.

WHAT IS INVERTER
SIMPLE BLOCK DIAGRAM OF XEV BATTERY
Battery Pack Voltage
If it can be assumed that the voltage change

The battery pack consists of a series- due to the change in the remaining battery
parallel connection of battery cells. level is small, the voltage can be regarded as
almost constant.

WHAT IS INVERTER
Inverter is a power electronic device that changes direct current to alternating current
and controls the motor.
INVERTER
Battery Pack Current
DC AC

WHAT IS INVERTER
INSIDE INVERTER
Software is executed
in Micro Controller
Unit

WHAT IS INVERTER SOFTWARE
SOFTWARE STRUCTURE (Red frame is the software provided by this solution)
APPLICATION CREATED BY CUSTOMER OR RAM MONITOR
(NOT INCLUDED IN THIS SOLUTION)
SAMPLE SOFTWARE
APPLICATION SOFTWARE
(IMPLEMENTATION OF MOTOR CONTROL THEORY)
DRIVER SOFTWARE
(HARDWARE CONTROL)
MCAL
(NOT INCLUDED IN THIS SOLUTION)

WHAT ARE ISSUES IN SOFTWARE DEVELOPMENT
APPLICATION CREATED BY CUSTOMER OR ROM MONITOR
SAMPLE SOFTWARE
①Rework after evaluation using actual machine because it is ②Effort to develop application software from complex
difficult to study input / output in a desk study mathematical formulas
③ Effort to combine application software with driver

software
DRIVER SOFTWARE
④Effort to develop a driver dedicated to motor control that is not supported by MCAL
MCAL ⑤Effort to configure driver software for the board

①Rework after evaluation using actual machine because it is difficult to study input / output in a desk
study
Example of a simple diagram a motor control system Example of Input / output
Motor control includes feedback as described above. It takes a lot of effort to calculate the above input /
output with a spreadsheet tool etc.

①Rework after evaluation using actual machine because it is difficult to study input / output in a desk
study
DESIGN CODING EVALUATION
REWORK RESULT CHECK

②Effort to develop application software from complex mathematical formulas
Conversion example of integral formula
Formula (continuous time) Formula (discrete time) Difference equation
1 Software
𝐺 𝑠 =
𝐴𝑠
Waveform Waveform
(Continuous time) (Discrete time)
Conversion example of Reverse Clarke conversion

2 β 3
V
𝐼𝑈 = 𝐼𝛼
3 2 Reverse Clarke for
1 1 1 120
𝐼𝑉 = − 𝐼𝛼 + 𝐼𝛽 − 2 phase current to 3
6 2 2 α phase current
U
1 1 Conversion
𝐼𝑊 = − 𝐼𝛼 − 𝐼𝛽
6 2 3
W −
2

③Effort to combine application software with driver software
Relationship between model and micro controller unit (MCU) Application software
Model Call of driver software to control ADC

MCU and RDC for input
Voltage output
Pulse width
modulation
(PWM) Application software generated from
application model
Current input Angle input

Analog digital Resolver digital
conversion (ADC) conversion (RDC)
Call of driver software to control
PWM for output

APPLICATION CREATED BY CUSTOMER OR ROM MONITOR
SAMPLE SOFTWARE
(IMPLEMENTATION OF MOTOR CONTROL THEORY)
DRIVER SOFTWARE
Voltage output Other …
Angle input
Pulse width modulation (PWM) Automatic cutoff of voltage
Resolver digital conversion (RDC) output in case of fault
3-phase, dead time
MCAL

⑤Effort to configure driver software for the board
Configuration example
Inverter solution reference kit
① ②
The microcomputer mounted on the Therefore, it is necessary to set which pin
board has many pins. The input / is input and which pin is output by software
output assigned to this pin can be based on the circuit diagram of the
selected by software. reference kit.

WHAT ARE SOLUTIONS IN SOFTWARE DEVELOPMENT
②Efforts to develop application software from complex mathematical

①Rework after evaluation using actual machine because it is formulas
difficult to study input / output in a desk study ③ Effort to combine application software with driver software
=>Providing a model that can be simulated on a PC =>Providing automatic generation of software from models and
support for embedding software in development environments
⑤Efforts to configure driver software for the board
=>Providing driver software that has been configured and confirmed to work in the reference kit
Reduce effort to learn how to use models and software by providing Application note
Winning Combo to provide the above solution

is xEV Inverter Application Model and Software
Providing a model that can be simulated on a PC

Providing automatic generation of software from models and support for embedding software
in development environments
Application model Application software
Software automatic
generation from model

Providing software that has been configured and confirmed to work in the reference kit
Configuration file Evaluation environment
Configuration operation
check
Feedback of operation check

results

Reduce effort to learn how to use models and software by providing Application note
Application note Example contents included in Application note

Motor control block
How to use model How to use software diagram

KEY FEATURES AND BENEFITS

KEY FEATURES AND BENEFITS
Effect of reducing software development effort
Development item Effect of reducing development effort

Development of Application model
Embedding automatically generated application software
in the software development environment Roughly reducing 6 months
Driver configuration and operation check for reference kit

Acquisition of how to use the development environment

WEBPAGE CONTENT
WEB PAGE COLLATERAL

www.renesas.com

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XEV INVERTER SOLUTION

AUGUST 3RD 2022

© 2022 Renesas Electronics Corporation. All rights reserved.

▪ Renesas platform solutions for xEV system

▪ inductive position sensor IPS2550

▪ xEV traction inverter solution with inductive position sensor IPS2550

▪ IPS2550:xEV inverter solution evaluation environment

▪ Comparison of IPS and resolver evaluation results

© 2022 Renesas Electronics Corporation. All rights reserved. Page 3

Changes in Carbon Neutral Policies of National Governments 2025

© 2022 Renesas Electronics Corporation. All rights reserved. Page 5

Monitors motor position to ensure

© 2022 Renesas Electronics Corporation. All rights reserved. Page 6

Rx2 - Rx4 COS - COSN

0 90 180 270 360

⚫ Rotational Speed: up to 600,000 (el) rpm High accuracy

⚫ Automotive AECQ100 Grade-0 Designed & Qualified

⚫ Temperature range: -40℃ to 160℃ ambient

© 2022 Renesas Electronics Corporation. All rights reserved. Page 7

© 2022 Renesas Electronics Corporation. All rights reserved. Page 8

© 2022 Renesas Electronics Corporation. All rights reserved. Page 9

© 2022 Renesas Electronics Corporation. All rights reserved. Page 10

© 2022 Renesas Electronics Corporation. All rights reserved. Page 11

© 2022 Renesas Electronics Corporation. All rights reserved. Page 12

© 2022 Renesas Electronics Corporation. All rights reserved. Page 13

© 2022 Renesas Electronics Corporation. All rights reserved. Page 14

◼ System analysis ,feasibility

© 2022 Renesas Electronics Corporation. All rights reserved. Page 15

Coil pattern Reference sample A sample

© 2022 Renesas Electronics Corporation. All rights reserved. Page 16

Renesas value proposition

© 2022 Renesas Electronics Corporation. All rights reserved. Page 17

− Automotive RH850 Power ICs − Registration and Log-IN at Renesas.com

− Renesas' complementary automotive product portfolios of ▪ FAQ, Contact form

© 2022 Renesas Electronics Corporation. All rights reserved. Page 18

AUGUST 3RD 2022

© 2022 Renesas Electronics Corporation. All rights reserved.

▪ WHAT KIND OF MOTORS ARE USED IN XEV

▪ WHAT IS INVERTER SOFTWARE

▪ WHAT ARE ISSUES IN SOFTWARE DEVELOPMENT

▪ WHAT ARE SOLUTIONS IN SOFTWARE DEVELOPMENT

▪ KEY FEATURES AND BENEFITS

© 2022 Renesas Electronics Corporation. All rights reserved. Page 20

© 2022 Renesas Electronics Corporation. All rights reserved. Page 21

© 2022 Renesas Electronics Corporation. All rights reserved. Page 22

xEV is a general term for BEV, PHEV, HEV, and FCEV.

Electronic stability Electronic throttle

© 2022 Renesas Electronics Corporation. All rights reserved. Page 24

ROTOR STARTOR ①Rotor is a permanent magnet.

MOTOR ②Stator is a coil.

③When an electric current flows

④A coil that allows current to flow,

© 2022 Renesas Electronics Corporation. All rights reserved. Page 25

© 2022 Renesas Electronics Corporation. All rights reserved. Page 26

A battery pack of several hundred V consists of

© 2022 Renesas Electronics Corporation. All rights reserved. Page 27

Battery Pack Voltage

If it can be assumed that the voltage change

© 2022 Renesas Electronics Corporation. All rights reserved. Page 28

Battery Pack Current

© 2022 Renesas Electronics Corporation. All rights reserved. Page 29

© 2022 Renesas Electronics Corporation. All rights reserved. Page 30

© 2022 Renesas Electronics Corporation. All rights reserved. Page 31