Download BLDC_868_v52

Brushless DC
Motor Control
with
Drives & Control
June 2003
A. Jansen
1
C868
and
CAPCOM6
Agenda
 Basics of a BLDC Motor
 Topology
 BLDC Motor with Hall Sensors
 BLDC Motor with Hardware
BEMF-Detection
 BLDC Motor Sensor less Control
 Switching Pattern for Driving a
BLDC
 How to use the CAPCOM6E for a
BLDC
 Introduction CAPCOM6E for
BLDC purpose
 CAPCOM6E & ADC
Drives & Control
June 2003
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2
Electrical Motor Types
Electric
Motor types
AC
Asynchronous
DC
Synchronous
Induction
PMSM
Drives & Control
June 2003
A. Jansen
3
Synchronous
Switched Rel.
Stepper
BLDC
Basics
Drives & Control
June 2003
A. Jansen
4
Basics of a BLDC Motor
+
U
V
 DC Motor with 3 Brushes
W
 3-Phase Brush-less DC Motor
According to the theory of DC machine, the motor rotational speed can be written as
follows:
N = ( Ud -  I  R ) / (Ke  )
While,
Drives & Control
June 2003
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5
“N” stands for the motor rotational speed
“Ud” stands for the DC voltage applied to the motor windings
“R” is the pure resistance of the winding while “I” stands for the winding current
“Ke” is the magnet coefficient while “” stands for the motor magnetic flux
From the above formula, there are two methods to change the speed of DC motor: One is to change the DC
voltage of the motor windings (Ud), the other one is to change the magnetic flux of the motor (). As the BLDC
motor has permanent magnet rotor, only the first method can be used in practical application. The principal of
generating variable DC voltage is to use PWM for chopping: change the duty cycle of the PWM voltage,
proportionally change the DC voltage.
How an Inverter Turns a BLDC (1)
1
1
A
C+
C’
B’
N
0
S
B-
C
B
A’
Drives & Control
June 2003
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6
How an Inverter Turns a BLDC (2)
1
1
A
C+
C’
B’
N
0
S
B-
C
B
A’
Drives & Control
June 2003
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How an Inverter Turns a BLDC (3)
1>>0
1
A
C+
C’
B’
N
S
0
B-
C
B
A’
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June 2003
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How an Inverter Turns a BLDC (4)
0
1
A
C+
C’
S
N
0
B’
AC
B
A’
Drives & Control
June 2003
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How an Inverter Turns a BLDC (5)
1>>0
0
A
B+
B’
S
C’
N
0
A-
C
B
A’
Drives & Control
June 2003
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How an Inverter Turns a BLDC (6)
1>>0
0
A
B+
B’
C’
S
0
N
A-
C
B
A’
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June 2003
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BLDC with Hall Sensors – Switching Pattern
 Typical Switching Pattern for a BLDC
 Hall Sequence depends on motor construction
 Output pattern levels depends on inverter topology
Drives & Control
June 2003
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BLDC with
Hall Sensors
Drives & Control
June 2003
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BLDC with Hall Sensors -- Topology
 Typical Circuit Block Diagram
 Hall Sensors detect the position
 Over current protection and control via ADC
V+
C868
HV Driver
+
-
Drives & Control
June 2003
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Motor
Hall Sensor
CTRAP
CCPOS2
CCPOS1
CCPOS0
CC60
COUT60
CC61
COUT61
CC62
COUT62
Block Diagram CAPCOM6E for BLDC Usage
capture
channel 0
T12
T13
trap
control
compare
channel 1
channel 2
compare
channel 3
compare
multi-channel control
noise
filter
2
2
2
3
1
port control
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June 2003
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CTRAP
CCPOS2
CCPOS1
CCPOS0
CC62
COUT62
CC61
COUT61
CC60
COUT60
capture/compare input / output control
Usage of CAPCOM6E to Control a BLDC (1)
 BEMF-Detection/Hall
Signals
HW-noise filter on
CCPOSx inputs
(BEMF-signals)
CC60
act. speed
CC61
phase delay
CC62
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ch2 compare
for timeout
Capture
Event
Resets T12
CCPOS0
1
1
1
0
0
CCPOS1
0
0
1
1
1
CCPOS2
1
0
0
0
1
CC6x
June 2003
ch1 compare
for phase delay
timeout
Hardware Noise
Suppression
Drives & Control
ch0 gets captured
value for act. speed
COUT6y
0
1
1
Usage of CAPCOM6E to Control a BLDC (2)
 BEMF-Detection/Hall
Signals
HW-noise filter on
CCPOSx inputs
(BEMF-signals)
automatic reset of
T12 with interrupt
actual speed by
capture ch0
CC60
act. speed
CC61
phase delay
CC62
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ch1 compare
for phase delay
timeout
Hardware Noise
Suppression
ch2 compare
for timeout
Capture
Event
Resets T12
CCPOS0
1
1
1
0
0
CCPOS1
0
0
1
1
1
CCPOS2
1
0
0
0
1
CC6x
Drives & Control
ch0 gets captured
value for act. speed
COUT6y
0
1
1
Usage of CAPCOM6E to Control a BLDC (3)
 BEMF-Detection/Hall
Signals
HW-noise filter on
CCPOSx inputs
(BEMF-signals)
automatic reset of
T12 with interrupt
actual speed by
capture ch0
phase delay
function on ch1
CC60
act. speed
CC61
phase delay
CC62
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ch1 compare
for phase delay
timeout
Hardware Noise
Suppression
ch2 compare
for timeout
Capture
Event
Resets T12
CCPOS0
1
1
1
0
0
CCPOS1
0
0
1
1
1
CCPOS2
1
0
0
0
1
CC6x
Drives & Control
ch0 gets captured
value for act. speed
COUT6y
0
1
1
Usage of CAPCOM6E to Control a BLDC (4)
 BEMF-Detection/Hall
Signals
HW-noise filter on
CCPOSx inputs
(BEMF-signals)
automatic reset of
T12 with interrupt
actual speed by
capture ch0
phase delay
function on ch1
time out function
on ch2
CC60
act. speed
CC61
phase delay
CC62
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ch1 compare
for phase delay
timeout
Hardware Noise
Suppression
ch2 compare
for timeout
Capture
Event
Resets T12
CCPOS0
1
1
1
0
0
CCPOS1
0
0
1
1
1
CCPOS2
1
0
0
0
1
CC6x
Drives & Control
ch0 gets captured
value for act. speed
COUT6y
0
1
1
Usage of CAPCOM6E – Hall Sensor Mode (1)
 CCPOSx Inputs
 for Hallsensor Interface
H2
1
1
0
H1
1
0
0
H0
0
0
0
start
Dead Time Counter
after edge detection
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 MCMOUTSH / MCMOUTSL
 SW programmable state
machine
Hall n+1
n+2
Hall n
n+1
?
?
Usage of CAPCOM6E – Hall Sensor Mode (2)
 CCPOSx Inputs
 edge detection triggers
Dead Time Counter
H2
1
1
0
H1
1
0
0
H0
0
0
0
 MCMOUTSH / MCMOUTSL
compare
valid level
after
DTC count down
Drives & Control
June 2003
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 compare CCPOSx level
with programmed value
Hall n+1
n+2
Hall n
n+1
?
?
noise
Correct
expected
Hall Event
Usage of CAPCOM6E – Hall Sensor Mode (2)
 CCPOSx Inputs
Drives & Control
June 2003
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 MCMOUTSH / MCMOUTSL
 switch to next state on
valid edge by hardware
H2
1
1
0
H1
1
0
0
H0
0
0
0
Hall n+1
n+2
Hall n+1
n+2
?
!
noise
Correct
expected
Hall Event
set
CHE-flag
Usage of CAPCOM6E – Hall Sensor Mode (3)
 CCPOSx Inputs
 MCMOUTSH / MCMOUTSL
 wait on edge
 prepare next state by
software
prepare next state
H2
1
1
0
H1
1
0
0
H0
0
0
0
Hall n+2
n+3
Hall n+1
n+2
?
?
wait on
edge
Drives & Control
June 2003
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Usage of CAPCOM6E –
Modulation Control (some Choices)
1
T12.COUT0
1
MODT13out
1
1
T12.COUT0
1
MODT13out
MCMOUTH.1
1
MCMOUTH.1
1
CTRAP#
0
CTRAP#
1
T12.COUT0
1
T12.COUT0
MODT13out
A-
A-
1
MCMOUTH.1
0
MCMOUTH.1
1
CTRAP#
1
CTRAP#
T12.COUT0
MODT13out
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June 2003
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MODT13out
1
MCMOUTH.1
1
CTRAP#
A-
A-
A-
Usage of CAPCOM6E –
Generate the PWM Pattern for BLDC
H2
H1
1
0>0>0>1>1>0>0
T12.COUT2
H0
MODT13out
C-
MCMOUTH.5
1
CTRAP#
1
T12.CC2
1
1>1>0>0>0>0>1
1
1
MODT13out
CTRAP#
T12.COUT1
MODT13out
1>0>0>0>0>1>1
CTRAP#
1
T12.CC1
1
MODT13out
1
1
CTRAP#
T12.COUT0
CTRAP#
June 2003
1
T12.CC0
A. Jansen
1
MODT13out
25
0>0>0>0>1>1>0
1
A-
MCMOUTH.1
1
Drives & Control
B+
MCMOUTH.2
MODT13out
0>1>1>0>0>0>0
B-
MCMOUTH.3
1
0>0>1>1>0>0>0
C+
MCMOUTH.4
MCMOUTH.0
CTRAP#
A+
Usage of CAPCOM6E –
Generate the PWM Pattern for BLDC
H2
H1
1
0>0>0>1>1>0>0
1
T12.COUT2
H0
MODT13out
C-
MCMOUTH.5
CTRAP#
1
T12.CC2
1
MODT13out
1>1>0>0>0>0>1
1
CTRAP#
1
T12.COUT1
MODT13out
1>0>0>0>0>1>1
1
CTRAP#
T12.CC1
1
MODT13out
CTRAP#
1
T12.COUT0
MODT13out
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1
CTRAP#
T12.CC0
1
MODT13out
1
A-
MCMOUTH.1
1
0>0>0>0>1>1>0
B+
MCMOUTH.2
1
0>1>1>0>0>0>0
B-
MCMOUTH.3
1
0>0>1>1>0>0>0
C+
MCMOUTH.4
MCMOUTH.0
CTRAP#
A+
Usage of CAPCOM6E –
Generate the PWM Pattern for BLDC
H2
H1
1
0>0>0>1>1>0>0
1
T12.COUT2
H0
MODT13out
C-
MCMOUTH.5
CTRAP#
1
T12.CC2
1
MODT13out
1>1>0>0>0>0>1
MCMOUTH.4
1
CTRAP#
1
T12.COUT1
MODT13out
1>0>0>0>0>1>1
CTRAP#
1
T12.CC1
1
MODT13out
CTRAP#
1
T12.COUT0
MODT13out
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CTRAP#
1
T12.CC0
1
MODT13out
1
A-
MCMOUTH.1
1
0>0>0>0>1>1>0
B+
MCMOUTH.2
1
0>1>1>0>0>0>0
B-
MCMOUTH.3
1
0>0>1>1>0>0>0
C+
MCMOUTH.0
CTRAP#
A+
Usage of CAPCOM6E –
Generate the PWM Pattern for BLDC
H2
H1
1
0>0>0>1>1>0>0
T12.COUT2
H0
MODT13out
C-
MCMOUTH.5
1
CTRAP#
1
T12.CC2
1
1>1>0>0>0>0>1
1
1
MODT13out
CTRAP#
T12.COUT1
MODT13out
1>0>0>0>0>1>1
CTRAP#
1
T12.CC1
1
MODT13out
1
1
CTRAP#
T12.COUT0
CTRAP#
June 2003
1
T12.CC0
A. Jansen
1
MODT13out
28
0>0>0>0>1>1>0
1
A-
MCMOUTH.1
1
Drives & Control
B+
MCMOUTH.2
MODT13out
0>1>1>0>0>0>0
B-
MCMOUTH.3
1
0>0>1>1>0>0>0
C+
MCMOUTH.4
MCMOUTH.0
CTRAP#
A+
Usage of CAPCOM6E –
Generate the PWM Pattern for BLDC
H2
H1
1
0>0>0>1>1>0>0
1
T12.COUT2
H0
MODT13out
C-
MCMOUTH.5
CTRAP#
1
T12.CC2
1
MODT13out
1>1>0>0>0>0>1
MCMOUTH.4
1
CTRAP#
1
T12.COUT1
MODT13out
1>0>0>0>0>1>1
CTRAP#
1
T12.CC1
1
MODT13out
CTRAP#
1
T12.COUT0
MODT13out
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CTRAP#
1
T12.CC0
1
MODT13out
1
A-
MCMOUTH.1
1
0>0>0>0>1>1>0
B+
MCMOUTH.2
1
0>1>1>0>0>0>0
B-
MCMOUTH.3
1
0>0>1>1>0>0>0
C+
MCMOUTH.0
CTRAP#
A+
Usage of CAPCOM6E –
Generate the PWM Pattern for BLDC
H2
H1
1
0>0>0>1>1>0>0
1
1
1>1>0>0>0>0>1
1
T12.COUT2
H0
MODT13out
C-
MCMOUTH.5
CTRAP#
T12.CC2
MODT13out
C+
MCMOUTH.4
1
CTRAP#
1
T12.COUT1
MODT13out
1>0>0>0>0>1>1
1
MCMOUTH.3
CTRAP#
1
T12.CC1
1
MODT13out
0>0>1>1>0>0>0
CTRAP#
1
T12.COUT0
MODT13out
Drives & Control
June 2003
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CTRAP#
1
T12.CC0
1
MODT13out
1
A-
MCMOUTH.1
1
0>0>0>0>1>1>0
B+
MCMOUTH.2
1
0>1>1>0>0>0>0
B-
MCMOUTH.0
CTRAP#
A+
Usage of CAPCOM6E –
Modulation and Synchronization
Correct
Hall Event
T13pm
write by software
6
T12pm
Reset
T12om
MCMPS
MCMOUTSL
Flag
T12c1cm
SW-Trigger
no action
T12zm
T13zm
MCMP
direct
6
Drives & Control
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to modulation
selection
MCMOUTL
Usage of CAPCOM6E –
Modulation and Synchronization
Correct
Hall Event
T13pm
write by software
6
T12pm
Reset
T12om
MCMPS
MCMOUTSL
Flag
T12c1cm
SW-Trigger
no action
T12zm
T13zm
MCMP
direct
6
Drives & Control
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to modulation
selection
MCMOUTL
Usage of CAPCOM6E –
Modulation and Synchronization
Correct
Hall Event
T13pm
write by software
6
T12pm
Reset
T12om
MCMPS
MCMOUTSL
Flag
T12c1cm
SW-Trigger
no action
T12zm
T13zm
MCMP
direct
6
Drives & Control
June 2003
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to modulation
selection
MCMOUTL
Usage of CAPCOM6E –
Modulation and Synchronization
Correct
Hall Event
T13pm
write by software
6
T12pm
Reset
T12om
MCMPS
MCMOUTSL
Flag
T12c1cm
SW-Trigger
no action
T12zm
T13zm
MCMP
direct
6
Drives & Control
June 2003
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to modulation
selection
MCMOUTL
Usage of CAPCOM6E to Control a BLDC (5)
1
MCMOUTSL
A
MCMOUTSH
C+
0
1
0
0
1
1
0
1
0
0
0
0
C’
0
B’
N
0
1
1
0
MCMOUTL
0
0
1
1
0
1
0
MCMOUTH
0
S
0
B-
C
B
A’
Drives & Control
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Usage of CAPCOM6E to Control a BLDC (6)
1>>0
MCMOUTSL
A
MCMOUTSH
C+
0
1
0
0
1
0
1
0
0
0
0
C’
0
1
1
0
MCMOUTL
0
0
1
0
0
0
0
MCMOUTH
0
B’
N
S
0
0
1
BC
B
A’
Drives & Control
June 2003
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Usage of CAPCOM6E to Control a BLDC (7)
0
MCMOUTSL
A
MCMOUTSH
C+
0
1
0
0
1
0
0
0
0
0
0
C’
1
1
0
0
MCMOUTL
1
0
1
0
0
0
0
MCMOUTH
0
B’
S
N
0
0
1
AC
B
A’
Drives & Control
June 2003
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Usage of CAPCOM6E to Control a BLDC (8)
0
MCMOUTSL
A
MCMOUTSH
B+
1
1
0
0
0
0
0
0
0
0
C’
1
B’
S
0
1>>0
0
1
0
0
MCMOUTL
1
0
0
0
0
0
0
MCMOUTH
1
N
0
A-
C
B
A’
Drives & Control
June 2003
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BLDC
Sensor less
Drives & Control
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BLDC in Theory – Back Electro Magnetic Force
 Theory

UP = (R x i) + (L x di/dt) + eP
where
"UP"
"R"
"i"
"L"
"di/dt"
"eP"
stands for phase voltage
stands for winding resistance
stands for actual phase current
stands for phase inductance
stands for changment of phase current over time
stands for electromagnetic voltage caused by magnet
while
i = 0 and di/dt = 0:
UP = eP
by measuring UP
a position detection
is possible
Drives & Control
June 2003
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via
30°
ia
120°
vib
ib
BLDC in Reality (1) – BEMF vs. Current
 Real BEMF Voltage and Current:
 shape depends on magnets, motor speed, voltage
ia
via
Drives & Control
June 2003
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BLDC in Reality (2a) – BEMF vs. Current
 Zoom In:
 BEMF is only visible at active switching
Phase
Current
BEMF
Voltage
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June 2003
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BLDC in Reality (2b) – BEMF vs. Current
V+
 Current Commutation in a Coil
 Freewheeling diode conducts
Motor
Current
Flow
Phase
Current
GND
V+
BEMF
Voltage
Motor
Current Flow
Freewheeling
Diode
Drives & Control
June 2003
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GND
BLDC in Reality (3) – All Important Signals
BEMF
Voltage
Drives & Control
June 2003
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Phase
Current
BLDC Sensor less with Hardware BEMF-Detection
 Typical Circuit Block Diagram
 Comparators and RC-Filter detect the BEMF zero crossing
for position detection
V+
C868
HV Driver
+
-
Drives & Control
June 2003
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45
Motor
RC
Filter
CTRAP
CCPOS2
CCPOS1
CCPOS0
CC60
COUT60
CC61
COUT61
CC62
COUT62
+
+
+
virtual
Star
BLDC Sensor less Using ADC
 Typical Circuit Block Diagram
Use simple resistor divider and ADC for position detection
V+
C868
HV Driver
CC60
COUT60
CC61
COUT61
CC62
COUT62
CTRAP
AN2
AN1
AN0
+
-
Drives & Control
June 2003
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Motor
BEMF
Detection
CAPCOM6E & ADC
 Synchronize ADC on T13




T13 period match can trigger the ADC
equidistant sampling of analog signals
exact timing guaranteed by hardware
no timing jitter due to software delays
f(n+2)
f(n-1)
f(n)
analog
signal
f(n+1)
T13
start sampling
by hardware
Drives & Control
June 2003
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ADC
conversion
channel 0
CAPCOM6E & ADC
 Synchronize T13 on T12
 T13 performs delay for
stable measurement
 T13 period match
triggers ADC
 Useful for Current
Measurement
 E.g. induction machine
Compare value
T12
synchronize
T13 on T12cm
T13
CC6x
Phase
Current x
Drives & Control
June 2003
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48
Start ADC when
signal is stable after a
programmable delay
CAPCOM6E & ADC
 T13PM triggers ADC
 Delay between T13PM
and high voltage
switching event due to
driving circuit
 Useful for Voltage or
Current Measurement
 E.g. BEMF detection
 Sample shortly before
power device is
switched off (BEMF is
noise free)
T13
Modulation for
Block-Commutation
CC6x
IGBT’s gate signal
IGBT
drain
volt.
Delay due to
IGBT driving circuit
BEMF
signal
Voltage signal at
currentless phase
for position detection
Drives & Control
June 2003
A. Jansen
49
Start ADC sampling
CAPCOM6E & ADC
 T13PM triggers ADC
 Delay between T13PM
and high voltage
switching event due to
driving circuit
 Useful for Voltage or
Current Measurement
 E.g. Current in DC link
path
 Sample shortly before
power device is switched
off (current is noise free)
Drives & Control
T13
Modulation for
Block-Commutation
CC6x
IGBT’s gate signal
IGBT
drain
volt.
Delay due to
IGBT driving circuit
DC Link
Current
June 2003
A. Jansen
50
Start ADC sampling
BLDC Sensor less Using ADC
 T13 used for
Modulation
ADC trigger
CompareValue
T12_ch1
T12
 T12 used for
 Phase delay
 Software (for 60°
sector)
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June 2003
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51
 With every T13PM
the BEMF voltage is
sampled and
compared to a BEMFwave table
 When crossing a limit
the software
generates a CHEevent (1)
 Speed reference is
captured and phase
delay for T12ch1 is
calculated
 At T12ch1 the pattern
for the next sector is
switched (2)
1
2
T13
BEMF
Voltage
Phase
C
Analog
CompareValue
Current
Phase C
Current
Phase A
Measure
BEMF-Voltage
(Phase C)
Measure
DC-Link Current
(Phase A)
Measure
Voltage
(Phase
B)
BLDC Sensor less with Current Control
 T13 used for
Modulation
ADC trigger
CompareValue
T12_ch1
T12
 T12 used for
 Phase delay
 Software (for 60°
sector)
 With every T13PM the
ADC alternatively
samples
 BEMF voltage
 Phase current
 The current set value
can be controlled by
adjusting the PWM
duty cycle
Drives & Control
June 2003
A. Jansen
52
2
1
T13
BEMF
Voltage
Phase
C
Analog
CompareValue
Current
Phase C
Control
Current Value
Current
Phase A
Measure
DC-Link
Current
(Phase C)
Measure
DC-Link
Current
(Phase A)
Measure
BEMF
Voltage
(Phase C)
Measure
DC-Link Current
(Phase A)
Measure
BEMF
Voltage
(Phase
B)
BLDC Sensor less Scope Shots
Port pin toggles when
BEMF is below limit
Phase
Current
Drives & Control
June 2003
A. Jansen
53
BEMF
Voltage
High Voltage 3-Phase Brushless DC / Induction Motor
Reference Design and Development Kit
 Application: Line powered Industrial Drives
 Power: 750 W
 Current: max. 5 A
 AC Input Voltage: 110 to 264 VAC
 Features:
Drives & Control
June 2003
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54
 8-bit MCU: C868 with on-chip 8 kB SRAM, with 8bit ADC and powerful PWM module
 CoolSet: TDA61831G instead of a transformer for
12V supply
 6 rugged IGBT DuoPacks
 EEPROM: 8 kB to store program + stand alone
boot option
 Optically Isolated Serial Interface to PC for SW
development + boot from PC option
 Protection: shut down protection for over current
and over temperature
 Extension for alternative MCU like XC164 or
TC1775
 SW environment: Keil Compiler + Debugger or
Mini Debugger (free software)
 Board can be used for current/torque or speed
control
 Supports Hall-Effect sensors or sensor-less
control
Low Voltage 3-Phase Brushless DC / Induction Motor
Reference Design and Development Kit
 Application: Industrial & Automotive Drives
 Power: 1.2 kW
 Current: max. 50 A
 Voltage: 12 - 24 V DC
 Features:
 8-bit MCU: C868 with on-chip 8 kB SRAM, with 8bit ADC and powerful PWM module
 3-Phase Bridge Driver: TLE6280G
 6 OptiMOS MOSFETs
 EEPROM: 8 kB to store program + stand alone
boot option
 RS232: Interface to PC for SW development +
boot from PC option
 Protection: shut down protection for over current
and over temperature
 Extension for alternative MCU like XC164
 SW environment: Keil Compiler + Debugger or
Mini Debugger (free software)
 Board can be used for current/torque or speed
control
 Supports Hall-Effect sensors or sensor-less
control
Drives & Control
June 2003
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55