Sensorless high-speed FOC reference design for drone ESC

The ESC module is a very important subsystem in non-military UAVs. Users need more efficient models to achieve longer flight times, better dynamic behavior and smoother and more stable performance. The design uses an electronic speed controller (ESC) commonly used in unmanned aerial vehicles (UAVs) or drones.

Speed ​​control is done sensorless and the motor was tested using FOC speed control up to 1.2kHz electrical frequency (12kRPM, 6 pole pair motor). Our drone ESC high-speed sensorless FOC reference design features a best-in-class FOC algorithm implementation that enables longer flight times, better dynamic performance, and higher integration resulting in smaller board size and BOM components less. Sensorless high-speed FOC control uses TI's FAST™ software observer, leveraging the InstaSPIN-Motion™ C2000™ LaunchPad and DRV8305 BoosterPack.

characteristic

• ● InstaSPIN-FOC™ sensorless FOC enables higher dynamic performance. Tested up to 12,000 RPM (using 3 Li-Polymer batteries)
• ● High dynamic performance: reaching 1 kRPM to 10 kRPM (electrical frequency 100Hz to 1kHz) speed in less than 0.2 s, enabling high-performance yaw and pitch actions
• ● Fast flipping ability suitable for completing flipping actions
• ● Longer flight times due to higher FOC efficiency on block switching
• ● Higher PWM switching frequency (tested up to 60kHz) can reduce current/torque ripple for low-inductance high-speed motors and avoid ultrasonic sensors
• ● Reduced time to market due to InstaSPIN-FOC’s automatic motor parameter recognition: automatically tuned sensorless FOC solution
• ● Motor temperature estimation based on winding resistance changes to protect the motor from damage during temporary overload conditions