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X2Y Attenuators, LLC

DC Motor EMI Suppression


Presented at Ford Motor Company July 27, 2004
By Jim Muccioli

DC Motor EMI Suppression


1.

Why Do DC Motors Need EMI Suppression?

2.

Designing DC Motors for EMI

3.

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Filtering Elements
Building EMI suppression Filters

Filtering Examples

5.

Motor Housing Design


End Cap Design
Connector Design

Applying EMI Suppression to DC Motors

4.

System integration
Understanding EMI Noise Sources in DC Motors
Compliance with specs.

Radiated Emissions
Conducted Emissions
Transients

Summary/Questions

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System Integration

Integrating increased number of electronic


devices and electrical systems in a single
automobile fuels Electromagnetic
Compatibility (EMC) issues such as:

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Reliability
Anomalies
Functionality
Safety
Cost

Guaranteed EMC requires the suppression


of or immunity from electromagnetic noise
sources within a system (automobile).
This presentation examines DC motor
suppression for EMC

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Understanding EMI Noise Sources in DC Motors

Electrical Current Loop (antenna)

Power leads
Brushes
Commutator
Wire coil around armature stack

Brush/Commutator Contact Bounce (arc)


Power leads

Brushes

Armature

Polarized
magnets
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_+++ -_ + +

Commutator

Housing

Shaft
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Compliance with Specs.

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Ford Emissions Requirements


(From ES-XW7T-1A278-AC)

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DC Motor EMI Suppression


1.

Why Do DC Motors Need EMI Suppression?

2.

Designing DC Motors for EMI

3.

7/19/2004

Filtering Elements
Building EMI suppression Filters

Filtering Examples

5.

Motor Housing Design


End Cap Design
Connector Design
Metal Joint Design

Applying EMI Suppression to DC Motors

4.

System integration
Understanding EMI Noise Sources in DC Motors
Compliance with specs.

Radiated Emissions
Conducted Emissions
Transients

Summary/Questions

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Motor Housing Design

Housing should be metal or metalized to


provide shielding.
Slots should be eliminated or minimized to
keep from making them slot antenna.
Slots

Metalized motor housing

Plastic motor housing

Improved

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Motor Housing Design (Example)

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End Cap Design


End caps should be metal or metalized to
provide shielding.
Crimping tabs should not electrically connect
inside and outside surfaces.

Noise can couple outside the motor


case when using a plastic end cap.

A metal end cap works as a shield to


contain the noise within the motor case.

Improved
Crimping tabs

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Connector Design
Leads/connector pins should exit the housing
close together to reduce current loop.

Improved

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10

Exit points of Power Leads

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11

Metal Joint Design


Metal joints are typically only design with
mechanical strength.
Electrical conductivity and shielding should
also be considered.

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Joints should overlap and be interlocking.


Oils and paint should be removed.
Oxidization and galvanic action should be prevented at
the joints.

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12

DC Motor EMI Suppression


1.

Why Do DC Motors Need EMI Suppression?

2.

Designing DC Motors for EMI

3.

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Filtering Elements
Building EMI suppression Filters
Other Considerations for EMI Filtering Elements
Filtering Examples for Electronics Inside Motors

Filtering Examples

5.

Motor Housing Design


End Cap Design
Connector Design

Applying EMI Suppression to DC Motors

4.

System integration
Understanding EMI Noise Sources in DC Motors
Compliance with specs.

Radiated Emissions
Conducted Emissions
Transients

Summary/Questions
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13

Filtering Elements
Element

Disadvantage

Low cost, some transient suppression

Narrow filtering band, Limited to under


800MHz

Broad filtering band

Cost, Failure mode is a short

Easy Implementation, Filter more than 1


line, CM & DM configurations

Heat can cause saturation, Cost,


Moderate filtering performance

Effective below 300-500MHz

Heat can cause saturation, Quality


material and tolerance add cost

Filter 2 lines at once

Heat can cause saturation, Quality


material and tolerance add cost

MOV

Transient suppression

Cost, no filtering

X2Y

Broadband filtering (DC 6GHz), low


cost, Filter 2 lines, Good Tolerances,
transient suppression

Surface mount only, Location in the


circuit is critical

Capacitor

Feed Thru Capacitor

Ferrite Beads

Inductor

Common Mode Choke

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Advantage

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14

How to Spec. a Filter Element

Typical Electrical Testing provided by manufactures

Test Standards

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Capacitance distribution.
Capacitance balancing.
DC Voltage Breakdown testing.
Impulse/surge testing.
ESD testing.
Reliability testing.
Stress Test.
ISO 9001:2000
ISO 14001
OHSAS-18001
AEC-Q200

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Example Test Summaries Filter Element Testing

ESD Test Summary

Up to 6KV on Contact Discharge Test.


Up to 8KV on Air Discharge Test.

Reliability Test Summary

Upper Category Temperature +125C


Voltage 1.5 x Rated Line to Ground voltage
Number of Components
Test hours
Number of Failures

Note: These test summaries are courtesy of Syfer Technology Ltd.


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Other Considerations for EMI Filtering Elements


For broadband filtering consider:

X2Y

G1

Placement of a filter into a motor consider:

B
G2

Option

X2Y

G1

G2

Components parasitics
Trace/lead length parasitics widen path, avoid sharp 90 turns
Location, Location, Location prevent noise from coupling
around filter.
Failure mode (open/short)
Performance over temperature
Brush Dust filter may need a non-conductive coating to
protect from shorting.
Some filter technologies require housing to be grounded.

Improved
X2Y
G1
A

B
G2

Best

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17

Filtering Examples for Electronics Inside Motors

Hall Effect Sensor


Leads
Exiting
Housing

Leads
Exiting
Housing

A
VS

VS

Hall Sensor

Hall Sensor

GND

GND
G1
B

A
G2

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18

Building EMI Suppression Filters


(2) Caps + (2) Ferr. Beads + (1) 0.47 Hi-Cap Varistor

(5) element Filter

(4) element Filter

(2 ) C a p s + (2 ) In d u c to r s + (2 ) B e a d s + (1 ) H i-C a p V a r isto r

X2Y
(2) 0.22 uF, L-L
(1) 0.47 uF, L-G

Motor

(7) element Filter

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12 V

(1) element Filter

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Radiated Emission Filtering Performance


DC Motor Filter Performance Comparisons
60

50

dBuV

40

30

20

10

0
0

100

200

300

400

500

600

700

800

900

1000

Freq MHz

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No Filter on Motor

Four Component Filter

Seven Component Filter

Five Component Filter

KuTEM-Cell Ambient

One Component Filter

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DC Motor EMI Suppression


1.

Why Do DC Motors Need EMI Suppression?

2.

Designing DC Motors for EMI

3.

7/19/2004

Filtering Elements
Building EMI suppression Filters

Filtering Examples

5.

Motor Housing Design


End Cap Design
Connector Design

Applying EMI Suppression to DC Motors

4.

System integration
Understanding EMI Noise Sources in DC Motors
Compliance with specs.

Radiated Emissions
Conducted Emissions
Transients

Summary/Questions

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Radiated Emissions - ABS Motor

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Radiated Emissions - Air Compressor Motor

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Radiated Emissions - Blower Motors

Blower Motor #1

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30dB pre-amp was used.

Blower Motor #2

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Radiated Emissions - Lift Gate Motor

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30dB pre-amp was used.

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Radiated Emissions - Mirror Motor

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30dB pre-amp was used.

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Radiated Emissions - Radiator Fan Motor

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30dB pre-amp was used.

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Radiated Emissions - Seat Motors


Seat Motor #2

Seat Motor #3

Seat Motor #1

Note: 30dB pre-amp was used on Motor #1

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Radiated Emissions - Throttle Body Motor

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Radiated Emissions - Washer Pump Motors

Washer Pump Motor #1

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Washer Pump Motor #2

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Radiated Emissions - Window Lift Motor

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Radiated Emissions - Wiper Motor (3-brush, 2-speed)

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Conducted Emissions Radiator Fan Motor

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Conducted Emissions Fuel Pump Motor

cap & 2 inds

No Filter
X2Y
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Transient Testing 12v Brake Pedal Motor


12V Motor

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Transient Testing Seat Motor (UL Tested)

CCW-stalled-off to on

CCW-stalled-on to off

CW-stalled-on to off
CW-stalled-off to on

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36

Questions?
Please Contact:
X2Y Attenuators, LLC
37554 Hills Tech Dr.
Farmington Hills, MI 48331
248-489-0007
x2y@x2y.com

For more information on EMI filtering of DC motors go to www.x2y.com


and refer to Application Notes:

4001 - DC Motor Design with X2Y Technology


4002 - DC Motor Design with X2Y Example A
4003 - DC Motor Design with X2Y Example B
4004 - DC Motor Design with X2Y Example C

Suppression Techniques Using X2Y as a Broadband Filter, Symposium


Record Workshops and Tutorials, 2003 IEEE Symposium on
Electromagnetic Compatibility.
Using Image Planes on DC Motors to Filter High Frequency Noise. 2004
IEEE EMC Symposium, Santa Clara, CA. Aug 9-13, 2004.
www.jastech-emc.com

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