Power-efficient sensor-less brushless DC motor control design

April 01, 2021 // By Jean-Pierre Joosting
Power-efficient sensor-less brushless DC motor control design
Highly integrated motor control ICs and starter kit improve motor efficiency by 35 percent, and reduce board size by up to half.

Renesas Electronics Corporation has expanded its motor control portfolio with two system-in-package (SiP) ICs to simplify brushless DC (BLDC) motor control design for a wide range of cordless battery-powered applications such as power tools, drones, water pumps, vacuums, cleaning robots, fans, and other systems. Combining multiple functions into a SiP, the new RAJ306001 and RAJ306010 motor drive ICs deliver improved low-speed or high-speed rotation and high torque control compared with competitive devices while minimizing required board space and reducing cost. This results in a turnkey design for easy, efficient, and safe BLDC motor control.

The RAJ306001 and RAJ306010 are single-package motor control ICs that control three-phase BLDC motors used in a wide range of battery-powered devices. The ICs integrate an RL78/G1F microcontroller (MCU) and pre-driver into an 8x8mm QFN package, as well as a charge pump, linear regulators, current detection, programmable slew rate control and BEMF detect circuitry for sensor-less operation. The highly integrated SiP form factor allows customers to eliminate as many as 30 external components shrinking the solution area by up to 50 percent and with lower control system costs.

Designed with heat management in mind, the ICs feature self-aligned dead time (SADT) to prevent the shoot through and offer adjustable pre-driver output current capacity – up to 500mA – to drive large-capacity MOSFETs, which makes heat dissipation design easier. This allows the ICs to drive MOSFETs at the optimum switching timing – reducing FET switching margin times to approximately 1/10 the time compared with conventional systems and enabling highly efficient motor drive control with reduced heat generation.

The ICs support operating ranges from 6-30V (RAJ306001) and 6-42V (RAJ306010), while an SADT generator allows MOSFETs to run cooler while maintaining high efficiency. Sensor-less motor control enables stable operation from low-speed to high-speed rotation and could eliminate the Hall ICs. Integrated safety functions, including IEC 60730 safety standard support, can detect errors and halt the motor if an error occurs.

A new Renesas Solution Starter Kit (RSSK) is also available for developers working on a motor control solution using the RAJ306010 ICs. The new easy-to-use RSSK features a complete evaluation environment that includes a development board, motor, and reference firmware, offering easy motor control debugging and allows customers to immediately begin evaluating their motor control design, executing real-time analysis and tuning to accelerate development.


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