Over Current Protection Alternatives

Motor Current Control With INA240

MHRS-Current Sensing Team
Dan Harmon, Automotive & Communications Marketing
Sept-2016

TI Information – Selective Disclosure 1

Agenda
• 5 mins – Current & Power Measurement Introduction

• 20 mins – Over Current Protection: Circuits & Techniques

» Discrete vs. Integrated
» Dedicated / Analog Output / Multiple ALERTs
» Power Monitors

• 25 mins – Motor Current Control With INA240

» Introduction to Motor Current Sensing
» INA240 Performance Competitive Study

TI Information – Selective Disclosure 2

Current & Power Measurement use cases
Solutions customers seek

Current and power

Real-time overcurrent Current measurement for
monitoring for system
protection (OCP) closed loop circuits
optimization

TI Information – Selective Disclosure

TI’s wide range of Current Sensing solutions

INAXXX
AMCXXX DRV401
ISO12X DRV421
0.1%
MEASUREMENT

Closed-loop Fluxgate sensors

ACCURACY

Current Sensing
shunt solutions 2x DRV425
1%

Discrete OpAmp
shunt solutions
Open-loop DRV425
10 %

OpAmps

100A 1000A
TI Information – Selective Disclosure
PRIMARY CURRENT 4
Overcurrent Protection Alternatives

The strengths and challenges of the various overcurrent protection

alternatives

TI Information – Selective Disclosure 5

Why is overcurrent protection important?
• Overcurrent protection is the most basic form of current monitoring
• Historically, OCP has been managed by measuring the system’s temperature.
– Temperature typically is a lagging indicator.
– The increase in system temperature normally is a result of increased current flow.
– Measuring the current allows the system integrator to manage the thermals in their
systems more efficiently and anticipate problems instead of reacting to potential
issues.
• System thermal management has become more critical as two trends work
against each other in modern electronic systems: driving higher performance
in smaller form factors.

TI Information – Selective Disclosure 6

Fuses for overcurrent protection
• Using a fuse is the most common overcurrent implementation, “after the fact”.
• The sole purpose is to open in the event of an extended over-current condition
– Very simple
– Effective in protecting the system from gross, over-current events
• Challenges to overcome:
– Offers protection for a single event
• The fuse is destroyed by the over-current event while protecting the remainder of the system
• For the system to become functional again, the fuse must be replaced
– This could involve rework at the board level to remove and replace the blown fuse
– Typically requires that the current significantly exceed (4 times or more) the rating of the fuse in
order for a quick open to occur
• Difficult to predict the precise over-current level at which the fuse will open; requires more margin to be
built into the protection scheme.
– Does not provide information on the system’s actual operating conditions.
• It is better to protect “before the fact”, what are the alternatives?
– The next serval slides will try to picture the very condensed history of the evolution of current
protection with active circuits.
TI Information – Selective Disclosure 7
Classic Op-amp & Comparator Implementation
• Strengths:
– Possibly the lowest cost to implement
– Fastest response time with high-speed
amp and fast comparator
– Offers both overcurrent detection and
current monitoring
– Second source alternatives
• Challenges:
OP – ACCURACY & SPEED cost money!
RI AMP CBypa ss
• Temperature drift
RF
Op Amp +
Shunt
2512

RI
RPULL -UP
Comparator – Typically Low-side only
CBypa ss • High-side limited to op-amp supply rail
RF
OCP
RDIV RDIV
COMPARAT OR
– Board Space / Component Count

TI Information – Selective Disclosure 8

Current Sense Amplifier & Comparator Implementation
• Strengths:
– More accurate current measurement than
typical op-amp implementation
• Smaller shunt enabled by lower VOFFSET
lowers power consumption
– Fast response time with fast comparator
– Offers both overcurrent detection and
current monitoring
– Comparator second source alternatives
CBypa ss RPULL -UP CSM + • Challenges:
Shunt

CSM
– For comparator function:
2512

SC70

Comparator • ACCURACY costs money!

RDIV

CBypa ss

COMPARAT OR OCP – Temperature drift on comparator

RDIV • SPEED costs money!
– Board Space / Component Count

TI Information – Selective Disclosure 9

Overcurrent Alert Only Implementation
- INA300 Current-Sense Comparator

• Strengths:
– Simplest implementation with only a single external
threshold setting resistor required and no additional
design considerations
– High-side or low-side capable
– 70% smaller footprint versus op-amp and
comparator implementation
– Miniaturization of Over–Current Detection enables
rethinking system level management via subsystem
monitoring
• Utilization & efficiency: Only use those portions
of the system that are needed & are enabled
• Localized Fault Identification
• Offload event detection: Operates independently
and only wakes system controller when needed
Shunt

INA300
2512

CBypa ss

INA300 • Challenges:
RPULL -UP
– ALERT only – no actual current information supplied
to system
RLI MIT

TI Information – Selective Disclosure 10

Overcurrent Alert w/ Analog Output Implementation
- INA301 high-speed, precision current sense amplifier with integrated comparator
2.7V to 5.5V
Power Supply
0V to 36V • Strengths:
– Offers both overcurrent detection and
VS

INPUT
RPULL-UP
IN+
+ VOUT

IN-
current monitoring
+ ALERT – High-side or low-side capable

OUTPUT
Load

– Simple implementation with only a single

LIMIT
GND

external component required

– Fast response time
• INA301 @ 1µs (0.6us Typ)
• Challenges:
– Design needs to comprehend current
range, over-current limit, and following
stage input range.

Total Propagation Delay

TI Information – Selective Disclosure 11
Multi-Level Overcurrent Alert w/ Analog Output
Implementation
RLIMIT1
Device Supply
2.7V to 5.5V • Strengths:
– Offers both overcurrent detection and
LIMIT1 VS
current monitoring

INPUT
RPULL-UP
Power Supply
0V to 36V + ALERT1
– Dual ALERTS - enables system
RESET1
IN+
Gain = 20,
50, 100
+
implementation flexibility such as WARNING
VOUT

IN-
and SHUTDOWN
– High-side or low-side capable

OUTPUT
RESET2
+
ALERT2
LOAD

LIMIT2 GND
DELAY
CDELAY – Simple implementation with only a single
RLIMIT2 external component required per comparator
– Fast response time
• INA302 @ 1µs
• INA302
– High/Low-Side, Bi-Directional, Zero- • Challenges:
Drift Current Sense Amplifier with – Design needs to comprehend current range,
Multi-Alert High-Speed Comparators over-current limit, and following stage input
range
– In development, sample in 3Q2016
TI Information – Selective Disclosure 12
 Windowed Multi-Level Overcurrent Alert w/ Analog
Output Implementation
RLIMIT1
Device Supply
2.7V to 5.5V • Strengths:
LIMIT1 VS
– Offers both overcurrent detection and
Power Supply
RPULL-UP
current monitoring
0V to 36V

INPUT
+
– Window ALERTS enables bi-drectional
ALERT1

Gain = 20,

IN+
+
50, 100
VOUT
current measurement or both OVER and
IN- UNDER current detection
RESET

– Simple implementation with only a single

OUTPUT
+ ALERT2
LOAD
DELAY
REF LIMIT2 GND CDELAY
external component required per comparator
Reference
Voltage
RLIMIT2
– Fast response time
• INA303 @ 1µs
• INA303 • Challenges:
– High/Low-Side, Bi-Directional, Zero-Drift
Current Sense Amplifier with High-Speed – Design needs to comprehend current range,
Window Comparator over-current limit, and following stage input
– In development, sample in 3Q2016 range

TI Information – Selective Disclosure 13

Over-Current Detection Topologies – A summary
INA300: Overcurrent Alert Only INA301: Overcurrent Alert w/ Analog Output
Power Supply +2.7 V to 5.5 V 2.7V to 5.5V
(0 V to 36 V) Power Supply
0V to 36V

INPUT

INPUT
VS RPull-up
VS
10 kΩ RPULL-UP
IN+
+ IN+
+ VOUT
CMP IN-
IN-
-
+ ALERT
LIMIT Load

OUTPUT

OUTPUT
GND LIMIT
Load
GND

INA302: Multi-Level Overcurrent Alert w/ Analog Output INA303: Windowed Multi-Level Overcurrent Alert w/ Analog Output
2.7V to 5.5V 2.7V to 5.5V
Supply

VS VS
RPULL-UP
INPUT

INPUT
Power Supply Power Supply ALERT1
ALERT1
0V to 36V CMP 0V to 36V CMP
RLIMIT 1
LIMIT1 RLIMIT LIMIT1

IN+ IN+
+ VOUT + VOUT

IN- CDELAY IN-

ALERT2
Load CMP
Load
ALERT2 LIMIT2
OUTPUT

OUTPUT
CMP

LIMIT2 RLIMIT GND DELAY RLIMIT 2

CDELAY
GND

TI Information – Selective Disclosure 14

Production New Roadmap

Over-current Protection Roadmap
Production or Past PPR Planned for 2017
• INA300 QFN/MSOP - Now • INA302-Q1/INA303-Q1
• INA301 MSOP – Now
• INA301-Q1 – Now • INA380/INA2380/INA4380
– INAx180 + comparator/ch – 1,2,4 ch
• INA300-Q1- MSOP – 8/16
• INA380/INA2380/INA4380-Q1
• INA302 – sample 9/16
• INA303 – sample 9/16 • INA311/INA312/INA313
– INA240 + INA302/3 Comparator – 3
SKUs
• INA311/INA312/INA313-Q1

TI Information – Selective Disclosure 15

Digital Power Monitor Implementation
• Strengths:
– Offers both overcurrent detection and
current monitoring
• Additionally, offers bus voltage and
power monitoring
– Flexible, Programmable ALERT settings:
• Over/Under Current
• Over/Under Bus Voltage
• INA226 • Over Power
• INA231 – Low-side or High-side Capable
– Programmable conversion time
• INA219
• Challenges:
• INA220 – Response time can be slower due to
digitization
TI Information – Selective Disclosure 16
Over-current Protection via Power Monitor
Roadmap
Production or Past PPR Planned for 2017
• INA219 MSOP - Now • INA226 WCSP
• INA220 MSOP - Now • INA230 MSOP
• INA220-Q1 MSOP - Now • INA230-Q1 MSOP
• INA226 MSOP - Now • 1.8v INA3221
• INA226-Q1 MSOP - Now • INAxxx – HV INA226
• INA230 QFN - Now
• INA231 WCSP – Now
• LMP92064 xxx - Now
• INA3221 QFN - Now
TI Information – Selective Disclosure 17
 OCP TI Design - Automotive Precision eFuse TI Design #: TIDA-00795
Features/Benefits

Current limit: up to 30A (scalable to >100A) Accuracy <3%

Response time: max 15µs (configurable) Reverse polarity protection

Configurable delay time to accommodate inrush current for 10µs,

Power off resettable fuse
50µs &100µs based on application

Target Applications
• Automotive • Body Control • High-side smart Battery Reverse Polarity Current Sense
Protection & Battery
eFuse Box Module switch / LOAD Switch / LOAD

Tools & Resources INA300 INA300

Transient Transient
• TIDA-00795 Suppression Suppression

• Design Guide
LM9036
• Design Files: Schematics, BOM,
Gerbers, and more
• Devices: Ground
‒ INA300-Q1
TI Information – Selective Disclosure ‒ LM9036
18
Motor Control / Solenoid / Induction loads
Current Monitoring
Why, where, and the strengths and challenges of each of the options.

TI Information – Selective Disclosure 19

Motor Current Sensing - Discrete vs. Integrated:
- Why do I need separate Current sensor(s) anyway?
• Many motor drivers, such as DRV series
have built-in current sensors.
• Trade off between cost and performance:
– Driver integrated current sensor
• Limited performance
• No additional cost, great if adequate for
the job!
– Discrete Current Sensor
• Can be optimized considering topology,
performance and cost
• TI offers a broad portfolio of dedicated
Current Sensors, including Current Shunt
Monitors (CSM) to address whichever
sensing topology you choose!

TI Information – Selective Disclosure 20

DC Motor Driver Topologies(with variations)
• Half bridge
– Brushed DC motor;
– Three modes: Run, Coasting and Breaking
• H bridge
– Brushed DC motor
– Four modes: Run, Reverse, Coasting and Breaking
• 3 Phase
– BLDC motor – electrically commutated.
– Four modes: Run, Reverse, Coasting and Breaking

TI Information – Selective Disclosure 21

Half bridge & H-Bridge Motor Control Current Monitoring Options

• Current information is used in:

– Current is directly related(proportional) to torque
– Speed/Torque control
– Safety - guard against short circuit, stalled motor and
used to monitor the general health of the motor
• Current sensing techniques in motor control
– Noninvasive
• Current transformer: 𝐼𝐼1= 𝑁
𝑁
2
2 1
• Hall sensor
– Resistor based current sensing
• High side
• Low side
• In-line
TI Information – Selective Disclosure 22
Resistor based motor current sensing techniques – pros and cons
• Low side • High side • In-line
– Advantages – Advantages – Advantages
• Low common mode voltage • Stable Common mode voltage • True motor phase current
• Low voltage Amp possible • Fault detection – Disadvantages
– Disadvantages – Disadvantages • PWM common mode voltage
• Ground variation • Stable but high Vcm • Sensing amp must have good
• Unable to detect fault • Driver current does not DC and AC CMRR
• Driver current does not necessarily equal to motor phase
necessarily equal to motor phase current
current

TI Information – Selective Disclosure 23

3Phase Motor Control Current Monitoring Options
• Three choices
– Low side (DC link or separate driver leg
High-side measurement )
– High side(including DC link, or separate
driver leg measurement )
– In line
• Why do we measure current in motor
control?
– Torque and speed control (two-loop)
In-Line
– Safety
Low-side
– Could be used for rotor position sensing
in sensorless BLDC, replacing Hall
sensors or BEMF sensing
TI Information – Selective Disclosure 24
High-side & Low-side Motor Current Monitoring Vsupply

+
-

• High-side (DC link or bridge)

– Stable Vcm  M

– High voltage I_sense Amp 

+
-
– Driver current does not always equal to phase current  +
-
+
-
+
-

Vsupply

• Low-side (DC link or bridge)

-

– Low Vcm 
M

– Low voltage I_sense Amp 

– Driver current does not always equal to phase current 

+
-
– Ground variation  +
-
+
-
+
-

TI Information – Selective Disclosure 25

Conventional High-side or Low-side sensing: –
What Does TI have to offer?
• TI’s broad CSM portfolio for sure can offer you one device for either High or Low
side current sensing:
• http://www.ti.com/lsds/ti/amplifiers-linear/current-sense-amplifiers-overview.page

TI Information – Selective Disclosure 26

In-line 3phase Motor Current Monitoring
• True phase current at all times, NO guess work  Vsupply

• PWM Common Mode voltage seen by I_sense

+
-

Amp 
• High voltage combined with high dV/dT poses M

steep challenge to I-sense Amp 

+
-
• Availability of suitable Current Sensors limits the + + +

adoption of this topology. - - -

Signal’s Frequency Contents:

• The differential signal (useful information) is relatively narrow-band, and small;
• The CM PWM signal (not useful) is wide-band and BIG.
An ideal inline sensor:
• Amplifies only differential signal; “blind” to Common Mode signal.

TI Information – Selective Disclosure 27

Why Is Inline Current Measurement Challenging?
– The tale of a competitor… it is not a trivial task!
This is how the phase current should
look like

This is how this competitor looks like

Competitor Paper: http://www.edn.com/design/analog/4369564/Monitor-PWM-load-current-with-a-high-side-current-sense-amplifier

TI Information – Selective Disclosure 28
How Does INA240 Solve the Problem?
Novel Architecture:
– Chopper amplifier achieves exceptionally
accurate Gain; zero Vos; zero Drift over
temperature.
– In-package E-trim achieves superior resistor
matching, resulting in excellent DC CMRR of
better than 120dB.
– Minimizing coupling - Chopper amplifier
without conventional feedforward path for
improved AC CMRR performance, better
than 90dB @50KHz
– Fully differential signal path further
suppresses CM signal
Small signal bandwidth 150KHz@G100
– Exceptional settling, capable of PMW of
100KHz.
– Most motor drivers work in 20-40KHz range.

TI Information – Selective Disclosure 29

INA240
Features/Benefits
• Fast-transient common-mode voltage input filtering Allows for in-line motor and solenoid/actuator current
• High AC CMRR: 90 dB @ 50 kHz sensing
High Accuracy, High-speed performance Enables precise current measurement under harsh motor
• VOS = 100 µV & VOS Drift = 0.3 µV/°C environments
• Gain Error = 0.25% & Gain Error Drift = 10 ppm/°C
• 100 kHz Bandwidth (Gain = 100)
Wide common-mode input voltage range: -4 V to 80 V Allows for motor supply voltages as high 48 V and inductive
kick-back

Tools & Resources Target Applications

• Motor control • Telecomm Equipment
• INA240EVM • Solenoid / Valve Control • Pressure Regulator
• User’s Guide • Power Delivery Systems
• TINA-SPICE Model
• INA240 Datasheet

TI Information – Selective Disclosure

 Performance With Fast Edge, CM Step Input –
How does INA240 compare with competition?
• Common Mode input voltage
• INA240 can survive 100V/10nS
• Some competitors claim ABS MAX of 65V
• In our test a step of 50V/10nS often blows the
competitor parts up
• That is why we settled on 40V/10nS step for this
study
• INA240 and other competitor devices are tested
• The inputs of the DUT are shorted together
• The same CM input voltage is fed to one device at a
time.
• An ideal inline sensor:
• Should reject CM input completely.
• The sensor output should show no disturbances at all.

TI Information – Selective Disclosure 31

Common Mode Step Rejection Performance Comparison
- Common Mode Input of 40V; rise time 10nS.

AD8207 LT1999

MAX9918
AD8418

INA240

TI Information – Selective Disclosure 32

Performance As Inline Sensor –
How does INA240 perform?

• Three (3) INA240, each in one of the 3 phases

• INA240EVM is perfect for this task with its versatility
• sense resistor footprint provided;
• configurable output reference for bi-directional output;
• configurable input source and filtering.
• The INA240’s are inserted between the motor and
controller

TI Information – Selective Disclosure 33

Test Results – INA240 as inline sensor

FULL SPEED

LOW SPEED
(BEMF ∝ Motor Speed)

LOW SPEED
(Zoom in)

TI Information – Selective Disclosure

Performance As Inline Sensor –
How does INA240 compare with competition?

• PWM 40V/100nS
• Differential voltage developed
across R_sense due to current flow
• The total input voltage is composed
of a small differential voltage and a
PWM CM voltage
• The same input voltage is fed to
INA240 and other competitor parts
• A good inline sensor should:
• Have excellent AC CMRR - small
over shoot at transitions
• Settles quickly after step transition
• Other subtle criteria such as DC
CMRR, accuracy that are not easy
to tell visually
TI Information – Selective Disclosure 35
Test Results –inline sensor comparative study: Left Column top to bottom: AD8207 AD8417(G=60) AD8418 MAX9918; Right Column top to bottom:
LT1999 INA282(G=50) INA240. Scale 1V/Div for all.

AD8207 LT1999: large spikes

AD8207: strange settling behavior

MAX9918: this is really bad!

• Compared with AD8207, INA240 wins by:

 Settling faster
 Higher Abs Max CM voltage 100V
INA240 (AD8207 claimes 65V)
 Survivability at high dV/dT – 100V/10nS
(AD8207 often blows up with 50V/10nS
CM step)

TI Information – Selective Disclosure

Summary

INA240 offers best in class performance for motor inline current

sensing:
• Exceptional accuracy
• -4V to 80V specified CM operation
• Unparalleled High dV/dT survivability
• Superior DC and AC common mode rejection
• Fast settling

TI Information – Selective Disclosure 37