How to implement scalable real-time control resources and sustainable platform development in power conversion applications

[Guide]In the real-time power conversion field where higher performance and efficiency are constantly required, it is important for designers to devote themselves to the research of scalable and sustainable industrial and automotive power conversion solutions. In turn, this demand puts forward higher requirements for real-time control systems in servo drives, power transmission, grid infrastructure, and on-board charging applications, including millions of instructions per second (MIPS), pulse width modulators (PWM ) And analog-to-digital converter (ADC).

How to implement scalable real-time control resources and sustainable platform development in power conversion applications

In the real-time power conversion field where higher performance and efficiency are constantly required, it is important for designers to devote themselves to the research of scalable and sustainable industrial and automotive power conversion solutions. In turn, this demand puts forward higher requirements for real-time control systems in servo drives, power transmission, grid infrastructure, and on-board charging applications, including millions of instructions per second (MIPS), pulse width modulators (PWM ) And analog-to-digital converter (ADC). At the same time, this also requires developers to build and maintain their product lines in a simple and low-risk way. Performance scalability and product series compatibility provide developers with a cost-effective way to expand real-time control resources and maintain a long-term power conversion solution platform.

Extend real-time control resources through distributed architecture

The rise of renewable energy has pushed the power level of applications such as photovoltaic inverters to a higher direction. With the increase of power levels, the demand for real-time control resources such as MIPS, PWM and ADC that play an important role in the power conversion process is also increasing. Usually, a central controller can meet the above requirements, which will control multiple power stages in the photovoltaic inverter system. But what if the controller’s resources are not enough to meet higher power levels and more power levels? Distributed architecture is the solution that designers have been looking for.

The concept of the distributed architecture is as follows: by connecting multiple real-time control MCUs, the system expands the number of resources and peripherals.This implementation scheme enables designers to achieve the required performance and efficiency of their products without affecting the following points

●The cost of multi-chip solutions

●The complexity and interface speed of connecting multiple devices across the isolation layer

●Insufficient peripherals of host/master device with external memory interface

TI’s C2000™ series of real-time control MCUs achieves reliable power conversion while meeting the above three points through a distributed architecture implementation solution:

●TI’s new version of C2000™ real-time control MCU product series, TMS320F28002x series, realizes low cost through distributed architecture and supports designers to reduce BOM cost. In order to further reduce system cost, other features of the C2000™ real-time control MCU product series (such as accelerators, configurable logic blocks, analog comparators and peripherals) can be integrated at the system level.

●Fast Serial Interface (FSI) can help achieve reliable, robust and high-speed inter-chip communication or inter-board communication at a rate of up to 200MBPS. Other interfaces such as CAN or SCI have low rates and do not provide delay compensation, so they are not suitable for connecting multiple MCUs across the isolation layer. Compared with FSI, FSI has more advantages. Due to the inherent delay compensation capability and rate of FSI, it can provide an efficient and robust interface option for connecting multiple MCUs to achieve resource expansion. Figure 1 shows how to use FSI to connect multiple real-time control MCUs to achieve MIPS, PWM and ADC expansion in photovoltaic inverters and other applications.

●The host interface controller (HIC) used in F28002x can use the MCU as a network bridge, and finally make the main processor indirectly use the FSI and other peripherals in the controller. Therefore, regardless of whether the main processor provides FSI or not, F28002x enables designers to achieve scalability through a distributed architecture.

How to implement scalable real-time control resources and sustainable platform development in power conversion applications

Figure 1: Use FSI to connect multiple controllers to expand resources

Simplify migration and platform development with product family compatibility

In addition to resource scalability, designers are also facing the challenge of building and maintaining product platforms. In order to effectively deal with this challenge, designers need to build high-, mid-, low-end product lines in an efficient and low-risk method.

The C2000™ real-time control MCU product series has peripherals and code compatibility in each device series, reducing the workload of developers to operate multiple products. Therefore, the migration process can be simplified and various products based on similar MCU technologies can be constructed to realize sustainable platform solutions. Figure 2 shows the third-generation high-, middle- and low-end C2000™ real-time control MCU’s pin-to-pin, peripheral, and code-compatible device series.

How to implement scalable real-time control resources and sustainable platform development in power conversion applications

Figure 2: Peripheral and code compatibility of the entire C2000™ product family

With the continuous development of the automotive and industrial power conversion markets, designers continue to seek innovations to help meet two key design challenges, namely how to easily expand real-time control resources, and how to build and maintain platform solutions for a long time. Connecting multiple C2000™ real-time control MCUs through FSI to realize MIPS, PWM and ADC expansion in applications such as photovoltaic inverters and distributed multi-axis servo drives is an efficient, low-risk and cost-effective solution for expanding real-time control resources plan. At the same time, the code and peripheral compatibility of each device in the C2000™ product series can enable long-term, high-efficiency and low-risk platform development. The F28002x device family not only provides a way to cost-effectively expand real-time control resources through a distributed architecture, but also adds new members to the existing compatible C2000™ series to support designers in building long-term and sustainable solutions.

Other resources

View data sheets, technical reference manuals and samples in the F28002x product folder.

●Please check our latest reference design:

●TIDM-02006, realize real-time control of distributed multi-axis servo drives through FSI, F2838x and F28004x/F28002x.

●TIDM-1001: A two-phase interleaved LLC resonant converter reference design that uses F28002x and is suitable for automotive OBC/DC/DC PSU and server PSU applications.

●Download the following development kits:

●MotorControl software development kit suitable for C2000™ MCU.

●DigitalPower software development kit suitable for C2000™ MCU.

(Source: Texas Instruments)

The Links:   LM64P701 LQ065T9DZ03