Inteligent Power Module (IPM) Board for Brushless Motors

Intelligent Power Module (IPM) board has been designed using FSBS5CH60 IC from Fairchild, which provides a fully-featured, high-performance inverter output stage for AC Induction, BLDC, and PMSM motors. These modules integrate optimized gate drive of the built-in IGBTs to minimize EMI and losses, while also providing multiple on-module protection features including under-voltage lockouts, over-current shutdown, and fault reporting. The built-in, high-speed HVIC requires only a single supply voltage and translates the incoming logic-level gate inputs to the high-voltage, high-current drive signals required to properly drive the module’s internal IGBTs. Separate negative IGBT terminals are connected to shunt resistor to provide the current feedback to the micro-controller. This IPM module helps to develop lots of power applications and also can be used as H-Bridge for brushed DC motor. The module is manly helps to drive Hall sensor based or encoder based motors, it doesn’t support FOC algorithm, FOC based IPM board is under development and will be publish soon. This board designed to evaluate Fairchild Semiconductor’s FSBS5CH60. The motion SPM is installed as the motor power module on the board to drive a three-phase AC Induction Motor (ACIM), Brushless DC (BLDC) motor, Brushless AC (BLAC) motor, or Permanent-Magnet Synchronous Motor (PMSM). The board has bulk capacitors and microcontroller (MCU) interface circuitry. As this board is designed for a wide variety of motor types, not all included circuitry is required for all types of motors. Some motor types may require some additional circuitry be added, depending on the control algorithms being implemented. The board is designed to connect DC power sources feeding current to the motor. The three-phase motor output terminals (U-M1, V-M2, W-M3) from the screw terminal should be connected to the motor windings. Three bootstrap power supply circuits are designed into the board, one per phase. A bootstrap capacitor, charge resistor for charging the capacitor, and the blocking diode for high-voltage isolation make up each bootstrap supply. The microcontroller (MCU) or motion-controller development board connects to this IPM board via the provided 16 Pin header connector. Six low-pass filters are used between the signal input connector and the gate input signal pins of the IC. Short-circuit current protection is provided by a single shunt resistor, op amp, and low-pass filter. Additional resistor divider circuitry is included to monitor bus voltage, inverter phase current, and module temperature. This board is made for low voltage motor up to 90V DC load up to 5Amps, however it can be used for higher voltage motor up to 400V DC by changing bulk capacitor, refer note for more details. Two 4mm holes provided to mount heat-sink on top of the IC. Board also has 28-40 Pin PIC Micro-Controller and DSpic shield which helps easy interface with many PIC micro-controllers and Motor DSpics. 16 PIN header connector can be hookup to any port pin of PIC/DSpic development board using female to female wire harness.”

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