Power Integrations has upgraded its hardware-software bundle for brushless DC motors (BLDC) with BridgeSwitch-2, a new high-voltage integrated half-bridge (IHB) motor-driver IC family targeting applications up to 1 HP (746 W). The motor drivers, featuring high- and low-side drivers and advanced FREDFETs with integrated lossless current sensing, deliver inverter efficiency of up to 99 percent.
(Source: Power Integrations)
BridgeSwitch-2 is supported by the company’s MotorXpert software suite, which includes single-phase trapezoidal control and three-phase sensor-less field oriented control (FOC) modules for faster development. The GUI-based tool, terminal emulator and MISRA C-compliant code library of MotorXpert simplifies the design process, the company said, allowing the motor architecture to be optimized in real-time without repeated firmware updates.
The hardware-software combo cuts inverter sleep-mode consumption to less than 10 mW. By reducing the power consumption, more power is available under regulated standby power limits to be allocated for loads such as network access and monitoring, the company said.
The IHB architecture eliminates hot spots, reduces component count by 50% and saves PCB area by 30% over discrete designs by eliminating shunt resistors and associated signal conditioning circuits, Power Integrations said. In addition, a smaller EMI filter may be used thanks to an accurate turn-on/off gate drive and a soft-body diode that results in a typical EMI profile 10 dB lower than existing drivers.
BridgeSwitch-2 ICs handle a power range of 30 to 746 W (1 HP), making them suited for a range of applications including heat exchanger fans, refrigerator compressors, fluid and circulation pumps, gas boiler combustion fans, washing machine drums and kitchen blenders and mixers.
Other features include built-in DC overvoltage protection and current limits that protect the inverter and the system without relying on system software; a choice of error-flag or fault bus reporting that supports a range of system requirements; and precise motor control with the built-in real-time reporting of phase current (IPH) information.
The high accuracy of the built-in IPH information and comprehensive reporting via the fault bus enables emerging use cases like failure prediction, according to the company.
The BridgeSwitch-2 ICs handle operational exceptions in hardware, which permits the use of IEC 60730 Class A safety software, reducing certification time by months and enabling designers to meet new EU ERP regulations. In addition, the motor drivers are microprocessor agnostics, making them easier to adopt in existing systems. Thanks to the built-in low- and high-side over-current protection, they meet IEC 60335-1 Class A requirements.
Pricing for BridgeSwitch-2 ICs starts at $0.48 in quantities of 10,000. A 150-W reference design and design report (RDK-974) are available. They are available direct from Power Integrations or via its authorized distributors: DigiKey, Newark, Mouser and RS Components.
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