Magna LIEFERANTEN-INNOVATIONSTAG 2015 Tech-Session DAEC™ - Dynamic Angle Error Compensation

1. HERZLICH WILLKOMMEN ZUM
LIEFERANTEN-INNOVATIONSTAG 2015
TOGETHER WE MOVE
18. November 2015

2. TECH-SESSION:
VERNETZUNG & ASSISTENZ
14:30 – 16:00 Uhr
TOGETHER WE MOVE
• ff

3. DAEC TM – Dynamic Angle
Error Compensation| Heinz
OYRER, ams AG
15:00 – 15:25 Uhr
TOGETHER WE MOVE
• ff

4. 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

5. Confidential © ams AG 2015
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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

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• 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

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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

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Opportunities for efficiency
• Addressing the efficiency of electric motors is
an important topic that needs to be tackled.
Source: CleanTechnica, abb.com/energyefficiency

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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

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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

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• 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 & emissions
Advanced Magnetic Position Sensors in Electronic Power Steering Applications
Source: Center for Climate and Energy Solutions

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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.

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Business drivers - ISO26262 Compliance
The 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.

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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

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• 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?

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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 IC
Enables Efficient Motor Commutation

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• 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

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• 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

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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

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DAEC™ Video

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Angle Accuracy: Ideal Slope

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Angle Accuracy: INL Error

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Angle Accuracy: Noise Error / Jitter Effect

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Angle Accuracy: System Propagation Delay

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DAE – Dynamic Angle Error
Speed 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]

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Integrated Dynamic Angle Error Compensation
Dynamic Angle Error
MagneticPositionSensorSystem
• 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.

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Integrated Dynamic Angle Error Compensation
Dynamic Angle Error
External HW + SW compensation needed
MagneticPositionSensorSystem
• 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™.

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Integrated Dynamic Angle Error Compensation
Dynamic Angle Error
Hardware Compensation integrated!
No Software needed!
External HW + SW compensation needed
MagneticPositionSensorSystem

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Integrated Dynamic Angle Error Compensation
Hardware Compensation integrated!
No Software needed!
MagneticPositionSensorSystem
• 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

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• 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 Works
Enables low latency and fast refresh rates
Elimination of Angle Measurement Lag and Fast Refresh Rates (1.9μs) at High RPMs

31. Confidential © ams AG 2015
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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

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• Electrical power
steering (EPS)
• Dual Clutch
Transmission (DCT)
• Pumps
• Starters
Steering Transmission Miscellaneous Automotive Parts
Typical markets/applications - automotive
• Alternators
• Brake Actuators

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Application example
BLDC Motor for EPS

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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

35. Confidential © ams AG 2015
Thank you for your Attention
Please visit our website at www.ams.com

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