Application

Description

Complete motor control solution featuring STM32 microcontrollers, STPOWER IGBTs/MOSFETs, and isolated gate drivers for industrial and automotive motor drive applications with up to 98% efficiency.

Core Advantages

High Efficiency Advanced FOC algorithm with optimized PWM patterns achieves up to 98% efficiency, reducing energy consumption and cooling requirements. ST's low-Rds(on) MOSFETs and fast-switching IGBTs minimize conduction and switching losses.
Robust Protection Comprehensive protection including overcurrent, overvoltage, undervoltage, overtemperature, short-circuit, and ground fault protection. Isolated gate drivers with DESAT protection ensure safe operation under fault conditions.
Fast Time to Market Complete reference design with production-ready software reduces development time by 6-12 months. STM32 ecosystem provides extensive libraries and tools for customization.
Scalable Architecture Modular design supports power range from 0.5kW to 250kW with common control platform. Easy to scale from low-power industrial drives to high-power EV traction applications.

Recommended Bill of Materials (BOM)

Item Part Number Description Quantity Datasheet
1 STM32F407VGT6 ARM Cortex-M4 MCU, 168MHz, 1MB Flash 1 📄 Download
2 STW48N60M2 600V N-Channel Power MOSFET, 48A 6 📄 Download
3 STGAP2SICS Isolated Gate Driver for SiC/MOSFET 2 📄 Download
4 L6491 High-Voltage High/Low Side Driver 1 📄 Download
5 LD39100S33R 3.3V Low-Noise LDO Regulator 1 📄 Download
6 Current Sense Resistors 0.01Ω 1% 3W Current Shunts 6 📄 Download

Applications

Industrial motor drives
HVAC compressors
EV traction motors
Servo drives
Pumps and fans

Technical Specifications

Input Voltage Range
110V - 690V AC ±10%
Output Power
0.5kW - 250kW
Switching Frequency
4kHz - 20kHz configurable
Efficiency at Full Load
≥ 97%
Power Factor
≥ 0.95
T H Di
< 5%
Protection Class
IP20 / IP54 / IP65 options
Operating Temperature
-25°C to +60°C
Control Method
FOC with sensorless vector control
Speed Range
1:100 (sensorless), 1:1000 (with encoder)
Torque Response
< 2ms
Position Accuracy
±0.01% (with encoder)

Customer Success Stories

Industrial Automation Manufacturer

Industrial Automation | Servo Motor Drive System

Challenge

A leading industrial automation company needed a high-performance servo drive solution with precise position control, fast torque response, and high efficiency for their next-generation CNC machines. The existing solution used discrete components with inconsistent performance and high energy consumption.

Solution

Implemented ST's motor control solution featuring STM32F407 MCU with FOC algorithm, STW48N60M2 MOSFETs for the inverter stage, and STGAP2SICS isolated gate drivers. The solution included sensorless vector control with encoder feedback option for high-precision applications.

Results

Achieved 97.5% efficiency at rated load, reducing energy consumption by 15% compared to previous design. Position accuracy improved to ±0.01% with <2ms torque response. The compact design reduced cabinet size by 30%. Product passed CE certification and entered production within 8 months.

EV Powertrain Developer

Automotive | Electric Vehicle Traction Inverter

Challenge

An EV startup required a compact, high-efficiency traction inverter for their electric delivery van. Key requirements included 98%+ efficiency, 100kW peak power, functional safety compliance (ISO 26262), and compact size for vehicle integration.

Solution

Designed custom traction inverter using ST's SiC MOSFETs (SCTW90N65G2V) for the power stage, STM32H7 high-performance MCU for control, and comprehensive safety architecture. Leveraged ST's automotive-qualified components and reference designs.

Results

Achieved 98.2% peak efficiency with SiC devices, exceeding target. Power density reached 25kW/L, enabling compact vehicle integration. Solution achieved ASIL-D functional safety rating. The inverter passed automotive qualification testing and is now in production for 10,000+ vehicles annually.

FAE Expert Insights

M

Michael Chen

Principal FAE - Motor Control

18 years

Professional Insights

Motor control is one of the most demanding applications for power electronics, requiring precise timing, robust protection, and high efficiency. Through my 18 years of experience supporting motor drive designs, I've found that the key to success lies in three areas: proper gate drive design, current sensing accuracy, and thermal management. ST's integrated solution addresses all three with isolated gate drivers providing reliable switching, high-precision current sensing enabling accurate FOC control, and comprehensive thermal design guidelines. The STM32 ecosystem is particularly valuable - the Motor Control Workbench tool can auto-generate FOC code, reducing software development from months to weeks. For high-power applications, I always recommend SiC MOSFETs over IGBTs when switching frequency exceeds 10kHz, as the efficiency gains justify the cost premium. The modular architecture of this solution allows customers to start with a lower power rating and scale up using the same control platform, protecting their software investment.

Key Takeaways

  • SiC MOSFETs enable 98%+ efficiency and should be used for high-frequency applications above 650V
  • Isolated gate drivers with DESAT protection are essential for reliable operation
  • STM32 Motor Control Workbench can auto-generate FOC code, reducing development time significantly
  • Proper thermal design is critical - calculate worst-case losses and verify junction temperatures
  • Modular architecture allows scaling from 0.5kW to 250kW with common control platform

Ready to Implement This Solution?

Contact our FAE team for design support and quotes

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Frequently Asked Questions

What motor types are supported by this solution?

The motor control solution supports various motor types including AC induction motors (IM), permanent magnet synchronous motors (PMSM), brushless DC motors (BLDC), and synchronous reluctance motors (SynRM). The FOC algorithm can be configured for different motor parameters including pole pairs, inductance, and back-EMF characteristics. Sensorless control is supported for most motor types using high-frequency injection or back-EMF estimation. For highest performance applications, encoder or resolver feedback can be added.

Contact our FAE team for motor parameter configuration and control algorithm optimization for your specific motor.

How do I implement sensorless control for my motor?

Sensorless control uses the STM32 to estimate rotor position from motor currents and voltages. The solution includes advanced observer algorithms that work across the speed range: High-frequency injection for zero and low-speed operation where back-EMF is insufficient

Back-EMF estimation for medium to high-speed operation

Smooth transition between methods. Key parameters include observer gains, injection frequency, and transition speed. The STM32 Motor Control Workbench provides tools to tune these parameters for your specific motor.

Use STM32 Motor Control Workbench to configure sensorless parameters. Start with auto-tuning and refine manually.

What safety features are included in the solution?

The motor control solution includes comprehensive safety features: Hardware protection including overcurrent detection with <1us response, DESAT protection for IGBTs, undervoltage lockout, and overtemperature shutdown

Software protection including overcurrent, overvoltage, undervoltage, overload, stall detection, and ground fault detection

Safe torque off (STO) function compliant with IEC 61800-5-2

Isolated gate drivers provide reinforced isolation between control and power

Diagnostic features include fault logging and predictive maintenance indicators.

All protection features are configurable. Contact us for safety certification support and SIL/PL rating documentation.

How do I scale the solution for different power ratings?

The solution uses a modular architecture allowing easy scaling: Control board with STM32 remains common across power ratings

Power stage scales by changing the number and rating of power devices

Gate drivers scale with power device requirements

Current sensing scales with shunt resistor value and amplifier gain

Cooling system scales with power dissipation requirements. The same software can be used across the power range with only parameter changes for current limits and protection thresholds.

Start with reference design closest to your target power and modify power stage components. Contact us for scaling guidelines.

What communication interfaces are supported?

The motor control solution supports multiple industrial communication protocols: Standard interfaces include RS485 (Modbus RTU), CAN (CANopen, DeviceNet), and EtherCAT for real-time control

The STM32 Ethernet MAC supports industrial Ethernet protocols

USB interface for configuration and diagnostics

Optional wireless connectivity for IoT applications. Protocol stacks are available through STM32Cube middleware. Custom protocols can be implemented using the available UART, SPI, and I2C interfaces.

Select communication interface based on your system architecture. EtherCAT recommended for multi-axis synchronized systems.

What is the typical development timeline for a custom motor drive?

Using ST's motor control solution significantly reduces development time: Hardware design and prototyping typically takes 4-6 weeks using reference design as starting point

Software development takes 6-8 weeks using STM32 Motor Control Workbench for FOC code generation

Testing and validation takes 4-6 weeks including thermal testing and protection verification

Certification (if required) takes 4-8 weeks depending on standards. Total time from concept to production is typically 4-6 months compared to 12-18 months for ground-up development.

Contact our FAE team for detailed project planning and timeline estimation for your specific requirements.