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High-speed inductive resolver converter for electric motors

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Melexis has developed a new inductive sensing IC that is intrinsically immune to stray magnetic fields.

The MLX90510 is a high-speed resolver converter that minimises the load on the electronic control unit for maximum accuracy under extreme mechanical and electrical conditions.

With its superior electromagnetic performance, the MLX90510 is perfect for controlling electric motors and electronic servo brakes and power steering.

Melexis has introduced the first inductive sensor IC on the market.

The MLX90510 offers exceptional accuracy, with a deviation of less than +/- 0.36° up to 240,000 rpm.

It is designed for demanding high-speed sensing applications with high requirements for accuracy, immunity to electromagnetic interference and safety.

The device is intended for use in applications with an electric motor (electrically driven) and with electronic power brakes and power steering.

The MLX90510 offers differential analogue sine and cosine outputs and is based on a digital architecture. It incorporates Melexis' patented tracking ring technology.

This innovative architecture offers several advantages:

  • The system propagation delay is cut to 0 ns with a maximum of +/-120ns residual variation over the entire operating temperature range.
  • Input offset compensation and output angle zero position adjustment are performed within the IC, reducing the load on the controller.
  • The three-phase winding format simplifies linearity optimisation.
  • Decoupling between input and output enables unprecedented electromagnetic performance. It also ensures stable output amplitudes regardless of input signal strength related to air gap size.
  • The linearisation function, with up to 16 calibration points, handles the non-linearities of demanding sensor modes such as at the semi-axis side.

The MLX90510 works in combination with a set of PCB transformers whose scalable format can be easily adapted to the number of motor pole pairs.

By supporting multiple sensingmodes for on-axis (axle end) and off-axis (axle or transmission side) operation, the IC maximises flexibility in induction coil designs to meet the most demanding mechanical constraints.

With its overvoltage and reverse polarity protection (+/-24V on the power supply and +/-18V on the outputs), the MLX90510 offers excellent robustness in the presence of electrical issues.

In addition, the sensor is qualified according to the AEC-Q100 standard for operation over an extended temperature range of -40°C to +160°C.

Being fully compliant with ISO 26262 ASIL-C functional safety guidelines, the MLX90510 supports ASIL-D class system-level integration.

The MLX90510 is supplied in a TSSOP-16 RoHS package.

Comments

"An efficient electric powertrain requires synchronisation of the stator supply currents with the rotor position. This offers optimal control of efficiency and torque characteristics," says Lorenzo Lugani, Product Manager, Inductive Sensors at Melexis. "Thanks to the digital architecture and robust design, automotive engineers take full advantage of the MLX90510's immunity to electromagnetic interference with minimal load on the ECU side, resulting in lower module costs."

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