Brushless DC motor hardware and software combination reduces inverter sleep mode consumption

     Power Integrations has introduced a new high-voltage integrated half-bridge (IHB) motor driver IC family, the BridgesWITCH2, which enhances its BLDC hardware package, targeting applications up to 1HP (746W). The new ic features high - and low-side drivers as well as advanced FREDFETs with integrated lossless current sensing, providing inverter efficiency of up to 99%. The IHB architecture eliminates hot spots, improves design flexibility and reliability, reduces the number of components, and saves PCB area. BridgeSwitch-2 is powered by the company's MotorXpert software suite, which includes a single-phase trapezoid control and a three-phase sensorless FOC module that accelerates inverter development.

     The ic handles operational anomalies in hardware and allows the use of IEC 60730 Class A security software, reducing certification time by months. The static brushless DC inverter can enter the sleep mode, reducing the power consumption of the drive to less than 10mW; This allows more standby power limits to be allocated to loads such as network access and monitoring.

     Cristian ionescu-katrina, Product Marketing Manager at Power Integrations, said: "The low standby power consumption of motor drives based on bridgeswitch-2 enables designers to meet new and emerging EU ERP regulations. The BridgeSwitch-2 ic is also much more efficient than the IGBT-based ipm over the entire load range." He continued, "From startup to performance optimization, MotorXpert's GUI-based tools, terminal emulators, and MISRA C-compliant code base greatly simplify the design process, allowing motor architectures to be optimized in real time without the need for repeated firmware updates. The BridgeSwitch-2 is microprocessor-independent, which makes it easy to apply to existing systems, which is important for engineers to update designs to meet stricter standby regulations."

     These ics range in power from 30 to 746W (1HP) and cover a wide range of applications, including heat exchanger fans, refrigerator compressors, fluid and circulation pumps, gas boiler combustion fans, washing machine drums, and kitchen mixers. By eliminating shunt resistors and associated signal conditioning circuitry, the IHB architecture reduces the number of components by 50% and the PCB space by 30% compared to the current design. It also eliminates the shunt loss and improves the efficiency. Accurate motor control is achieved through built-in real-time phase current (IPH) information reporting. Precise on/off gate drivers and software diodes enable typical EMI curves to be 10dB lower than existing drivers, so smaller EMI filters can be selected.

     The ic features built-in DC overvoltage protection and current limiting to protect inverters and systems without relying on system software. The choice of error flags or integrated fault bus reports supports a range of system requirements. With the high accuracy of built-in IPH information and comprehensive reporting through the fault bus, emerging use cases such as fault prediction are now possible. The motor drivers feature built-in hardware-based low and high side overcurrent protection to meet IEC 60335-1 Class A requirements. The BridgeSwitch-2 can also operate without an auxiliary power supply, further reducing the PCB area and the number of components.