Electromagnetic Compatibility Of Direct Current Motors In .

Electromagnetic Compatibility ofDirect Current Motors in anAutomobile EnvironmentJames Muccioli, X2Y Attenuators, LLCTerry North, DiamlerChryslerKeith Frazier, Ford Motor CompanyDale Sanders, X2Y Attenuators, LLC

Why is there a need for this paper?Motor suppression has become a major issue forBig three¾ The number of electronic applications in automobilesis increasing Applications have broader and higher operatingfrequencies¾ The number of motor applications in automobiles isincreasing A typical automobile has a range of 50 – 80 DC motors¾ Cost – typical motor suppression cost 1-3 per motor¾ If current electronic and motor applications continue,suppression requirements will increase.205AE-218

What is the purpose of this paper?The purpose of this paper is 3-fold¾“Handbook” of Big Three DC motor EMCrequirements¾Frame Motor EMC in terms of an industry wideissue¾Address design considerations of DC motorsthat effect EMC305AE-218

Myth – EMC isn’t cost-effective¾EMC improves performance & reliability,which lowers warranty cost.¾Module level EMC reduces system levelintegration issues, thus time-to-market andcost.¾JD Power customer satisfaction numberswhich effect sales.¾Allows for system engineering which reducestime-to-market405AE-218

System Engineering for DC MotorsOEMVehicle RequirementsLink betweenRequirements andValidationVehicle Test &ValidationEx: Automobile1st TierSystem RequirementsLinkSystem Test &ValidationEx: HVAC unit2nd TierModule RequirementsLinkModule Test &ValidationEx: Blower MotorBuild Process505AE-218

When should EMC suppression be addressed?EMC suppression should be addressed at thebeginning of a design¾ More cost-effective design options available¾ Cost can be driving consideration for designOtt, Henry. “Noise Reduction Techniques in Electronic Systems,” 2nd edition, John Wiley & Sons, Inc., New York, 1998, page 6.605AE-218

What are the OEM requirements?DaimlerChrysler (DCX) – https://adxi.autoweb.net¾ DC-10614 “EMC Performance Requirements --- Components”¾ DS-100 “Vehicle Design Requirements for EMC Compliance”¾ DC-10615 “Electrical System Performance Requirements for Electricaland Electronic Components”Ford Motor Company – www.fordemc.com¾ ES-XW7T-1A278-AC “Component and Subsystem ElectromagneticCompatibility Worldwide Requirements and Test Procedures” 10 October2003.General Motors (GM) – http://global.ihs.com/¾ GMW3103 “General Specification for Electrical/Electronic Componentsand Subsystems; Electromagnetic Compatibility; Global EMCComponent/Subsystem Validation Acceptance Process”¾ GMW3097 “General Specification for Electrical/Electronic Componentsand Subsystems, Electromagnetic Compatibility (EMC)”705AE-218

Types of Motor ClassificationDC Motors are defined by type ofcommutation and duration it is used.¾Commutation Brush commutated (BC) or sparked generated Electronically commutated (EC) or non-sparkedgenerated.¾Duration Long-duration Short-duration (operator controlled)805AE-218

What are the Required EMC Tests?There are 3 main test performed on DCmotors. Specific limit levels and requiredtests depend on motor classification.¾Conducted Emissions (CE)¾Radiated Emissions (RE)¾Conducted Transients (CT)905AE-218

DaimlerChrysler (DCX)Frequency Spectrum¾ Conducted Emissions (CE) EC 150 kHz – 110 MHz BC 150 kHz – 200 MHz¾ Radiated Emissions (RE) EC 76 MHz – 1 GHz BC none¾ Conducted Transients (CT) 12V & 42V motors 80V 24V 80/-150V1005AE-218

General Motors (GM)Frequency Spectrum¾ Conducted Emissions (CE) EC 150 kHz – 1.71 MHz BC 150 kHz – 1.71 MHz SD same as EC & BC¾ Radiated Emissions (RE) EC 150 kHz – 1.583 GHz BC 150 kHz – 439 MHz SD 150 kHz – 242.4 MHz EC & BC 100/-150V SD same as EC & BCEC or BCCISPR 25 CEGM - SD¾ Conducted Transients (CT)CISPR 25 RE(voltage & current)Note: conducted emissions and conducted transients spectrum/requirements depend on whether the motor is EC or BC and are notaffected by the classification of "Short Duration". The classification of "Short Duration" is platform specific. Only radiated emission'sspectrum/requirements are affected by the classification of "Short Duration" and requirements are dependant on market.MHz110.1110100100010,00005AE-218

Ford Motor CompanyFrequency Spectrum¾ Conducted Emissions (CE) EC 150 kHz – 108 MHz BC 150 kHz – 200 MHz¾ Radiated Emissions (RE) EC 150 kHz – 2.5 GHz BC 150kHz – 2.5 GHz¾ Conducted Transients (CT) EC & BC 100/-150V1205AE-218

Design Considerations for Motor EMC¾Lead length between power leads and filter¾Ground connection to filter¾Housing/end-cap material and holes¾Location of filter¾Joints1305AE-218

Lead Length between Power Leads and Filter15Pwr Leads #2Pwr Leads #1dBuV1050-50100200300400500600700800900Frequency (MHz)1405AE-2181000

Ground Connection to Filter45AmbientX2Y 1812 330nF [gnd 2 screws]X2Y 1812 330nF [gnd 2 screws and uency (MHz)1505AE-2181000

Housing/end-cap material and holes¾¾Housing/end cap should be metal or metalizedto provide shielding.Slots should be eliminated or minimized tokeep from making them “slot antenna”.SlotsPlastic motor housing/end cap16Metalized motorhousing/endcap05AE-218

Housing/end-cap material and holes40Ambient35X2Y 0.44uF (Holes)X2Y 0.44 uF(No uency Mhz1705AE-2181000

Location of FilterFilter should be located at the exit point ofthe power leads to prevent noise fromcoupling around the filter.Exit point of Power Leads1805AE-218

Filtered Connectors¾¾¾¾Easy to implementReduce design timeDoesn’t require internal modificationsCost-effectiveFilter*Pictures courtesy of ITT Industries (Cannon)1905AE-218

Filtered Connectors (continued)CISPR 25 ConductedLevels in dB(µV)0.15MHz 0.53MHz 5.9MHz 30MHz 68MHztototototoClass 0.3MHz 2.0MHz 6.2MHz 54MHz 056050404024Broadband Conducted emissions as per table 6 of CISPR 25This part passes at level 5 from 0.53MHz up to 108MHz*Data courtesy of ITT Industries (Cannon)2005AE-218

Filtered Connectors (continued)CISPR 25 RadiatedLevels in dB(µV)0.15MHz 0.53MHz 5.9MHz 30MHz 68MHz 142MHz 380MHz 820MHztotototototototoClass 0.3MHz 2.0MHz 6.2MHz 54MHz 108MHz 175MHz 512MHz 42431374534629291818253154338232312121925Broadband Radiated emmisions as per Table 10 of CISPR 25Worst case values taken from both horizontal and vertical measurements*Data courtesy of ITT Industries (Cannon)2105AE-218

Joints¾ Metal joints are typically only design with mechanicalstrength.¾ Electrical conductivity and shielding should also beconsidered. Joints should overlap and be interlocking. Oils and paint should be removed. Oxidization and galvanic action should be prevented at the joints.2205AE-218

Summary/QuestionsCost-Effective Motor suppression¾ Requires knowledge of specs for all tier suppliers¾ Must be address early in design cycle at all levels to meetcost targets¾ System Engineering approach¾ Thank you Terry North, DCXKeith Frazier, Ford Motor CompanyDon Seyerle & Mark Steffka, GMDale Sanders, X2Y Attenuators, LLCDoug Walz, Johnson ElectricIan Grey, ITT Industries (Cannon)2305AE-218

Electromagnetic Compatibility of Direct Current Motors in an Automobile Environment James Muccioli, X2Y Attenuators, LLC . ¾Allows for system engineering which reduces time-to-market 05AE-218. 5 System Engineering for DC Motors 05AE-218 OEM Vehicle Requirements Link between Requirements and Validation Link