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Why are more and more BLDC motor controls using sensorless FOC?
The performance requirements for the thermal management system of new energy vehicles continue to upgrade - NVH assessment is becoming stricter, energy consumption indicators are tightening, BOM cost and reliability are under dual pressure, making BLDC control scheme iteration an industry must answer question. The fields of electric tools, industrial automation, and high-end consumer electronics are also driving the evolution of control methods from square wave drive to FOC, and then to sensorless FOC.
Sensorless FOC addresses which pain points of traditional solutions? What are the requirements for chips? This article breaks down from two levels: technical logic and implementation plan.
From Six Step Square Wave to Sensorless FOC, BLDC controlled Three Upgrades
The six step square wave driver is easy to implement and cost-effective, and has been widely used in scenarios such as fans and water pumps. However, due to the sudden change in current during the commutation process, it is easy to cause torque ripple and noise, and there is further room for optimization in low-speed stability, operating noise, and speed regulation accuracy.
FOC Through coordinate transformation, the stator current is decoupled into excitation and torque components for closed-loop control, enabling the motor to achieve smoother current and torque outputs. This has significant advantages in optimizing the smoothness, speed accuracy, and efficiency of operation.
On the basis of FOC, sensorless FOC further eliminates Hall position sensors. By collecting voltage and current and combining them with observer algorithms to estimate rotor position, reduces peripheral components, simplifies system design, and reduces cost and space pressure .
Five Hard Requirements of Sensorless FOC for Control Chips
Sensorless FOC significantly raises the bar for algorithmic complexity and real-time performance. The host controller must satisfy the following:
High-performance processing core — capable of running coordinate transformations, position estimation, and dual closed-loop control in real time.
High-precision PWM peripherals — complementary outputs with adjustable dead time, meeting the timing requirements of sinusoidal drive.
High-speed, high-precision ADC — satisfying the timing and accuracy requirements of single-shunt, dual-shunt, and three-shunt current sampling.
Integrated analog peripherals — on-chip op-amps, comparators, and gate drivers to minimize external components.
Comprehensive hardware protection — full-coverage protection against over-current, over-voltage, over-temperature, motor stall, and phase loss.
Highly integrated, real-time-capable dedicated motor-control SoCs are becoming the core platform for sensorless FOC solutions.
Jinxin Technology's Sensorless FOC Complete Solution
In response to the thermal management needs of new energy vehicles, Jinxin has launched a solution based on ADM32F036 The complete solution for the sensorless FOC of the series of automotive grade motor control SoC has passed AEC-Q100 certification. covers various BLDC applications such as electronic water pumps, electronic oil pumps, air conditioning compressors, cooling fans, blowers, valves, etc.
Provide multiple configurations for different scenarios:
ADM32F036Q ： 100MHz 32-bit fixed-point DSP core, integrated with CLA, ADC, operational amplifier, six channel NMOS pre drive and other resources, packaged in QFN56, certified by AEC-Q100;
ADM32F036A2Q is designed for 12V platforms and compatible with 24V/48V applications. It supports 5.5-40V input and integrates three-phase half bridge pre drive, LDO, and LIN/CAN-FD functions. It is suitable for motor control scenarios such as water pumps, oil pumps, fans, and blowers;
ADM32F036A3Q For 12V applications, integrates functions such as LDO, three-phase half bridge pre drive, VCP/VDS/GDF, and supports LIN/CAN-FD. It is suitable for automotive body actuators and small motor control scenarios;
ADM32F036B3Q is designed for 48V platforms and supports wide voltage inputs ranging from 10 to 80V. It integrates 12V DC-DC and three-phase half bridge pre drive ADC、 Operational amplifier and LIN/CAN-FD functions, suitable for 48V automotive motor control scenarios.
ADM32F036 The series provides a wide range of temperature and multiple power architecture options for automotive applications, and further simplifies system peripheral design by integrating LDO, pre drive, communication, and analog control resources.
Algorithm capability: self-developed seamless FOC algorithm library, ready to use out of the box
{Tag16 has a first-class self-developed non sensing FOC algorithm library in the industry, covering stable operation in the entire speed domain:
Multiple control modes compatible: square wave, sensing FOC, and non sensing FOC flexible switching; Single/dual/triple resistor sampling provides full coverage, and the single resistor scheme further reduces costs;
Accurate position observation: combines IPD, MARS observer, and HFI initial position detection to improve position estimation and operational stability during low-speed and start-up phases;
Intelligent parameter tuning: parameter self identification and PI self-tuning, reducing development barriers and shortening cycles;
Performance optimization : optimizes NVH performance through dead zone compensation, current harmonic suppression, and weak magnetic acceleration algorithms, and expands high-speed operation capabilities;
Full dimensional protection: Under voltage/over-voltage/over-current/phase loss/locked rotor/over temperature software and hardware dual protection.
For typical working conditions such as low temperature and high viscosity oil, Jinxin Technology has developed a low-temperature sensorless starting solution for oil pump applications, and has conducted practical verification around indicators such as low-temperature starting, full speed operation, and NVH.
Application solution: Complete coverage of multiple thermal management scenarios
Electronic water pump: DC 12V/24V/48V, 4000rpm, 40~1000W, LIN/PWM regulation, smooth start-up, high low-speed torque;
Electronic oil pump: -40 Start at low temperature of ℃ once, covering the fuel pump and transmission oil pump, suitable for high viscosity working conditions;
electronic fan/blower machine : 400W /600W/1200W three levels, LIN/PWM regulation, forward and reverse wind start, NVH noise reduction;
Air conditioning compressor : ADP32F036 +IPM scheme, DC 360V/540V high voltage, 3000-4000W, non inductive FOC+weak magnetic acceleration;
Electronic valves: low-power high integration solution, simplifying the periphery.
All solutions provide hardware reference designs and production grade algorithm source code, allowing customers to quickly complete product development.
With the increasing demand for low-noise, high-efficiency, and high reliability motor control in the automotive, industrial, and consumer electronics industries, sensorless FOC is expanding from some high-end applications to more motor control scenarios. Jinxin Technology will continue to deepen its cultivation of real-time control chips and motor control technology, providing higher performance and higher integration chips and application solutions for the automotive electronics, industrial control, and consumer electronics fields.
Get complete scheme information/apply for sample testing:
Contact email: sales @Advancechip.com
Company official website: www.advancechip.com
