mcrp03: brushless dc motor control reference platform...

APPLICATION NOTE

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R8C/11 MCRP03: Brushless DC Motor Control Reference Platform using Hall sensors

Introduction

This application note shows how to use the R8C/11's output compare function of Timer C. It shows a sample application of how to implement sensored driving of a BLDC motor that makes use of three hall-sensors positioned at 120 electrical degrees. This example applies to MCUs in the R8C/11 – R8C/13 Group and is based on the Renesas R8C/Tiny Motor Control Reference Platform MCRP03.

R8C/11 MCRP03: Brushless DC Motor Control Reference Platform

using Hall sensors

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Contents

MCRP03: BRUSHLESS DC MOTOR CONTROL REFERENCE PLATFORM USING HALL SENSORS. 1

INTRODUCTION .......................................................................................................................................... 1

CONTENTS .................................................................................................................................................. 2

HARDWARE SPECIFICATIONS:................................................................................................................ 3

CONTROL METHODS................................................................................................................................. 4

SYSTEM CONFIGURATION / CONTROL BLOCK DIAGRAM: ................................................................. 5

SOFTWARE SPECIFICATIONS:................................................................................................................. 6

LIST AND BRIEF DESCRIPTION OF THE SOFTWARE MODULES IN “VOLTAGE MODE”.................. 8

PWM IN “VOLTAGE MODE”: ................................................................................................................... 10

LIST AND BRIEF DESCRIPTION OF THE SOFTWARE MODULES IN “CURRENT MODE”................ 11

PWM IN “CURRENT MODE”: ................................................................................................................... 13

1. HOW TO OUTPUT WAVEFORMS FOR 120-DEGREE COMMUTATION ........................................... 14

1A. SPEED CONTROL IN “VOLTAGE MODE” ....................................................................................... 14

1B. MOTOR CURRENT CONTROL IN “VOLTAGE MODE”.................................................................... 14

2A. SPEED CONTROL IN “CURRENT MODE” ....................................................................................... 14

2B. MOTOR CURRENT CONTROL IN “CURRENT MODE” ................................................................... 14

DETERMINING THE OUTPUT PATTERN (VOLTAGE AND CURRENT MODE) .................................... 15

MCRP 03 BASIC DESCRIPTION. ............................................................................................................. 33

USER INTERFACE BOARD BASIC DESCRIPTION................................................................................ 33

USER INTERFACE BOARD BASIC DESCRIPTION................................................................................ 34

R8C CPU BOARD...................................................................................................................................... 35

HALL SENSORS CONNECTION. ............................................................................................................. 35

HALL SENSORS CONNECTION. ............................................................................................................. 36

HALL SENSORS/SENSORLESS TUNING PROCEDURE....................................................................... 37

OSCILLOSCOPE EVALUATION TESTS. ................................................................................................. 39

MEASUREMENT EXAMPLES................................................................................................................... 40

PHASE CURRENT SHUNT IN CASE OF VOLTAGE MODE............................................................................ 40

PHASE CURRENT SHUNT IN CURRENT MODE. ........................................................................................ 41

PROTECTION SHUNT RESISTOR CURRENT READING............................................................................... 42

WEBSITE AND SUPPORT ........................................................................................................................ 43


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Hardware Specifications: Motor: Surface-mounted permanent magnet synchronous motor (SPMSM)

- Model: MB057GA240 or MB057GA140 (EXMEK) - Number of poles: 4 (2 pairs)

Power Stage Board (DIP-IPM): - Model: PS21564/PS21563 - Rating: 600 V, 15 A / 600V, 5A - Connection: Three-phase inverter

CPU Board: - Microcontroller: R8C/11 – R8C/13

Power supply: - Model: AP70 - Input voltage: 85 to 265 V AC - Output voltage: 15 to 24 Vdc - Output power: 70 W

Fig. 1: Hardware Configuration

BLDC Motor

Power Stage

Board

Interface

Board

CPU

Board

Sensor/Sensor-less

Board

24 Volt DC

Power Supply BEMF – Detection Lines

HALL Sensors User Interface Board

Serial Interface (RS232)


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Control methods. There have been used two methods to drive the motor; the first named “voltage mode” and the second named “current mode”. In the first one, the high side of the IGBTs are driven with PWM commands and the speed is proportional to the duty cycle. The current limitation is performed via software by reading the dc current (see fig.1a and fig.5) and reducing the PWM duty to an appropriate value. In the second one, the PWM is used to set a reference current (see fig.1a); all the IGBTs are driven ON with dc commands and refreshed every 62.5μs software interrupt, but when the current reaches the reference value settled via PWM, the output of the amplifier goes low and an interrupt is generated. The high side IGBTs are driven OFF until the next 62.5μs software interrupt is generated.

V

dc current Op amp

Comparator

Reference current (pwm)

to P1_2 pin (interrupt pin)

Fig.1a

to P07/AN0 pin (analog to digital converter pin)


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System configuration / control block diagram: The block diagram of fig.2 shows the system operation. The speed set is entered via RS232 from the User Interface Board, then it is compared with the actual speed (calculated by counting the hall sensors edges) to feed the PI block. Output of speed PI is clamped by the “motor current limitation block” and the result is fed into the “output pattern settling block”, which turn on the IGBTs of the IPM to switch the current in the phases, according to the actual rotor position (calculated from the hall sensors configuration). Fig.2

+ -

PI speed control

Motor current limitation Output

pattern settling

DIP-IPM

SPMSM

Dc motor current

Hall sensors detection and speed calculation

actual speed

Speed reference input from RS232 User Interface


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Software Specifications: Control method 120-degree commutation using trapezoidal waves

Rotor position detection Detected by hall-sensors detection

Carrier frequency 16 kHz

Forward rotation: 500 rpm to 2100 rpm Range of rotation speed control Reverse rotation: –500 rpm to –2100 rpm

Error detection The Fo signal (forced shut-down signal) of the IPM is input to the P04 pin of the MCU. Thus, if the Fo signal goes low, the three-phase output is forcibly stopped and the three-phase output pins are placed in the high-impedance state.


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Outline in VOLTAGE MODE: The RS232 connection with the User Interface Board is used to receive the rotation-speed command. At power-up the microcontroller starts to receive command from User Interface Board. If a set speed is received the microcontroller outputs the pattern accordingly to the state of hall-sensors signal. The PWM duty cycle is calculated from the actual speed of rotation and the rotation speed reference, using a PI algorithm; PWM is used only with the high side IGBTs. The PWM duty cycle is clamped to limit the motor current to its rated value. Switching of the output pattern is made every edge of the hall-sensors signal (6 times every electrical time period). The actual rotation speed is calculated by counting the edges of the hall-sensors signal. Outline in CURRENT MODE: The RS232 connection with the User Interface Board is used to receive the rotation-speed command. At power-up the microcontroller starts to receive command from User Interface Board. If a set speed is received the microcontroller outputs the pattern accordingly to the state of hall-sensors signal. The reference current is calculated from the actual speed of rotation and the rotation speed reference, using a PI algorithm; a reference current PWM signal is generated. Every time the motor current exceeds the reference value, a interrupt is generated and the high side IGBTs are driven OFF until the next 62.5μs software interrupt is generated (see fig. 1a). Switching of the output pattern is made every edge of the hall-sensors signal (6 times every electrical time period). The actual rotation speed is calculated by counting the edges of the hall-sensors signal.


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List and brief description of the software modules in “VOLTAGE MODE” HWSETUP: this module performs all the I/O port settings and the SFR settings. INITCOM: this module performs the serial communication setup (UART, 9600baud, N81, internal clock). SET_TIMER_C: this module perform the timer C setup in order to generate a periodic interrupt every (1250*50)ns=62.5μs. Every interrupt, “Cmp1_int” is executed. START_TIMER_C: this module performs the timer C start. Ges_Com: this module perform serial communication management slave routine: the slave is waiting for a command (reception mode); when a serial command is received, the slave interprets it and eventually sends a reply. Ges_gen: this module performs:

- motor current filtering and load register for sending value via serial communication - speed calculation for visualization and load register for sending value via serial

communication - enabling first ON management when the motor stops - first on management: all low IGBT's ON for 1ms to charge the bootstrap

Ges_vb: this module performs the bus DC voltage management (reading, filtering and scaling) and load register for sending value via serial communication. Ges_ntc: this module performs the NTC management (temperature calculation using linear interpolation) and load register for sending value via serial communication. Ram_vel: this module performs acceleration and deceleration ramps; step increment is DELTAINC, and step decrement is DELTADEC. SpeedReg: this module performs speed calculation and PI speed regulation; the output of this module is the reference current. Cmp1_int: this module performs the main interrupt function every 62.5μs:

- ad conversion management: motor current, bus voltage and temperature sensor voltage

- motor current limitation - serial communication polling - main loop synchronization

sens_hall: this module performs the detection of the hall sensors configurations init_hall: this module performs the initial position calculation by using the hall sensors configurations


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Int3_int: interrupt related to hall A rotor position sensor Int1_int: interrupt related to hall B rotor position sensor Int0_int: interrupt related to hall C rotor position sensor The fig. 3 shows the flow chart of the operations performed by the software. Fig. 3

- HWSETUP: hardware setup

- INITCOM: serial comm. setup

- SET_TIMER_C: timer C setup

- START_TIMER_C: start timer C

Reset

Main:

GesCom: serial communication handling

ges_gen: general routines

ges_vb: Vbus calculation

ges_ntc: temperature calculation

ram_vel: acceleration and decelaration ramps

SpeedReg: speed calculation and PI speed regulation

- ad conversion management

- serial communication polling

- motor current limiting

Cmp1_int:

int3_int, int0_int, int1_int:

- hall sensors related interrupt

62.5μs


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PWM in “VOLTAGE MODE”: The PWM output is implemented by using the MCU's output compare mode of Timer C. In output compare mode, TM1 is used to control the carrier wave period and TM0 to control the PWM output. Settings of Timer C Output Compare Mode In this software, output compare mode of Timer C is configured as follows (see timerC related register settings in “hwsetup.c” source code). Item Description

Mode Output compare mode (The input capture mode is not used.)

P30 to P32 pin functions P30 (Up): The pin function is switched between port I/O andCMP output. P31 (Vp): The pin function is switched between port I/O andCMP output. P32 (Wp): The pin function is switched between port I/O andCMP output.

Interrupt Compare 1 interrupt (A compare 1 interrupt is generated oncompare-match of the TC register and TM1 register.)

Timer-counter source clock

Timer C: f1 (20 MHz)

Timer C reload selection The TC register is set to 0000h on a match of compare 1.

Compare 0 and 1 output mode selection

The CMP output is driven high on a match of compare 0. The CMP output is driven low on a match of compare 1.


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List and brief description of the software modules in “CURRENT MODE” HWSETUP: this module performs all the I/O port settings and the SFR settings. INITCOM: this module performs the serial communication setup (UART, 9600baud, N81, internal clock). SET_TIMER_C: this module perform the timer C setup in order to generate a periodic interrupt every (1250*50)ns=62.5μs. Every interrupt, “Cmp1_int” is executed. START_TIMER_C: this module performs the timer C start. Ges_Com: this module perform serial comunication management slave routine: the slave is waiting for a command (reception mode); when a serial comman is received, the slave interprets it and eventually sends a reply. Ges_gen: this module performs:

- motor current filtering and load register for sending value via serial communication - speed calculation for visualization and load register for sending value via serial

communication - enabling first ON management when the motor stops - first on management: all low IGBT's ON for 1ms to charge the bootstrap

Ges_vb: this module performs the bus DC voltage management (reading, filtering and scaling) and load register for sending value via serial communication. Ges_ntc: this module performs the NTC management (temperature calculation using linear interpolation) and load register for sending value via serial communication. Ram_vel: this module performs acceleration and deceleration ramps; step increment is DELTAINC, and step decrement is DELTADEC. SpeedReg: this module performs speed calculation and PI speed regulation; the output of this module is the reference current. Cmp1_int: this module performs the main interrupt function every 62.5μs:

- ad conversion management: motor current, bus voltage and temperature sensor voltage

- if the motor current don’t exceeds the reference current (i.e. the output of comparator is high (see fig.1a)), the IGBTs of the correct pattern are driven ON.

- load PWM duty register with the reference current calculated in “SpeedReg”, and output it to P1_0 pin. This signal is filtered and inputted to the pin + of comparator (see fig.1a)

- serial communication polling - main loop synchronization

sens_hall: this module performs the detection of the hall sensors configurations


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init_hall: this module performs the initial position calculation by using the hall sensors configurations Int3_int: interrupt related to hall A rotor position sensor Int1_int: interrupt related to hall B rotor position sensor Int0_int: interrupt related to hall C rotor position sensor ki3_int: interrupt related to the negative edge of comparator (see fig.1a); the high side IGBTs are driven OFF The fig. 3 shows the flow chart of the operations performed by the software.

- HWSETUP: hardware setup

- INITCOM: serial comm. setup

- SET_TIMER_C: timer C setup

- START_TIMER_C: start timer C

Reset

Main:

GesCom: serial communication handling

ges_gen: general routines

ges_vb: Vbus calculation

ges_ntc: temperature calculation

ram_vel: acceleration and decelaration ramps

SpeedReg: speed calculation and PI speed regulation

- ad conversion management

-serial communication polling

- IGBTs of the correct pattern are driven ON

- load pwm duty register with the reference current

Cmp1_int:

int3_int, int0_int, int1_int:

- hall sensors related interrupt

62.5μs

ki3_int:

- negative edge of comparator related interrupt (see fig.1a); all igbt,s are driven OFF

Fig. 4


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PWM in “CURRENT MODE”: The PWM output is implemented by using the MCU's output compare mode of Timer C. In output compare mode, TM1 is used to control the carrier wave period and TM0 to control the PWM output. Settings of Timer C Output Compare Mode In this software, output compare mode of Timer C is configured as follows (see timerC related register settings in “hwsetup.c” source code). Item Description

Mode Output compare mode (The input capture mode is not used.)

P10 pin functions P10 : The pin function is always CMP output.

Interrupt Compare 1 interrupt (A compare 1 interrupt is generated oncompare-match of the TC register and TM1 register.)

Timer-counter source clock

Timer C: f1 (20 MHz)

Timer C reload selection The TC register is set to 0000h on a match of compare 1.

Compare 0 and 1 output mode selection

The CMP output is driven high on a match of compare 0. The CMP output is driven low on a match of compare 1.


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1. How to Output Waveforms for 120-Degree Commutation Described below is an example of waveform output for 120-degree commutation that is implemented through the use of the Timer C function.

1a. Speed Control in “VOLTAGE MODE” In 120-degree commutation using trapezoidal waves, the speed of rotation is basically proportional to the voltage. To be specific, the active period of the output waveform is controlled by rewriting the TM0 setting each time the rotation speed command is changed, using a PI algorithm. Only the high side IGBTs are PWM controlled; the low side IGBTs are driven with dc commands. Only two IGBTs are ON at the same time: one high and one low according to the Output Pattern determined from the position obtained through the detection of hall-sensors signals. In this way only two phases are ON at the same time.

1b. Motor Current Control in “VOLTAGE MODE” The motor current is detected through one DC shunt and converted by the ad converter module. If the current exceeds the set value, then the duty cycle is reduced.

2a. Speed Control in “CURRENT MODE” In this case, the PWM is used to set a reference current calculated by a PI algorithm; all the IGBTs are driven ON with dc commands and refreshed every 62.5μs software interrupt, but when the current reaches the reference value settled via PWM, the output of the comparator goes low and an interrupt is generated (see fig.1a). The high side IGBTs are driven OFF until the next 62.5μs software interrupt. In this way the motor current (and then the voltage) will be the right value needed to get the reference speed. Only two IGBTs are ON at the same time: one high and one low according to the Output Pattern determined from the position obtained through the detection of hall-sensors signals. In this way only two phases are ON at the same time.

2b. Motor Current Control in “CURRENT MODE” The motor current is always under control like a hardware control. As soon as the current exceeds the set value, the IGBTs are driven OFF by the “ki3_int” interrupt routine. The system dynamics is very good.


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Determining the Output Pattern (VOLTAGE and CURRENT MODE) The output pattern (0 to 5) is determined from the position obtained through the detection of hall-sensors signals. The situation shown in fig. 6 and table 1 is related to ccw rotation. For ccw rotation the sequence of the patterns is from pattern5 to pattern0 and the current flows in accordance with the black arrows; for cw rotation (see fig. 6a and table 2), the sequence of the patterns is from pattern0 to pattern5 and the current flows in accordance with the black arrows. Note that in case of ccw direction, the edges of hall-sensors signals are to be inverted (for example, the positive edge of hall A sensor in cw direction, will be negative in ccw direction).

Q1

Q4 Vdc

Q3

Q6

Q5

Q2

Phase coils

W V U

I

Fig.5: IGBTs configuration

dc current


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iV

iW

iU

Q5: pwm

Q3: pwm Q1: pwm

Q4: dc Q2: dc Q6: dc

Q5: pwm

W V U V V V V V W U W U W U W U W U

Software processing: int3_int, interrupt related to hall A signal

Software processing: int1_int, interrupt related to hall C signal

Software processing: int0_int, interrupt related to hall B signal

Pattern 0 Pattern 1 Pattern 2 Pattern 3 Pattern 4 Pattern 5

Ccw direction Motor current flows in cw direction:

Hall A signal

Hall B signal

Hall C signal

Fig.6: motor current flows and configuration of IGBTs in ccw direction; read the diagram from right to left.

0˚ 30˚ 60˚ 90˚ 120˚ 150˚ 180˚ 210˚ 240˚ 270˚ 300˚ 330˚ 360˚


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iV

iW

iU

Q2:dc Q6: dc Q4: dc

Q1: pwm Q5: pwm Q3: pwm

Q2: dc

W V U V V V V V W U W U W U W U W U

Software processing: int3_int, interrupt related to hall A signal

Software processing: int1_int, interrupt related to hall C signal

Software processing: int0_int, interrupt related to hall B signal

Pattern 0 Pattern 1 Pattern 2 Pattern 3 Pattern 4 Pattern 5

Cw direction Motor current flows in cw direction:

Hall A signal

Hall B signal

Hall C signal

Fig.6a: motor current flows and configuration of IGBTs in cw direction; read the diagram from left to right.

0˚ 30˚ 60˚ 90˚ 120˚ 150˚ 180˚ 210˚ 240˚ 270˚ 300˚ 330˚ 360˚


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Period of pattern (ccw direction)

Output pattern Comments

Pattern5 From positive edge of hall C signal to negative edge of hall A signal

Q5(high):PWM, Q4(low):dc Q1,Q2,Q3,Q6=OFF

Current flows from W to U

Pattern4 From negative edge of hall A signal to positive edge of hall C signal


Current flows from V to U

Pattern3 From positive edge of hall A signal to negative edge of hall B signal


Current flows from V to W

Pattern2 From negative edge of hall C signal to positive edge of hall A signal


Current flows from U to W

Pattern1 From positive edge of hall B signal to negative edge of hall C signal


Current flows from U to V

Pattern0 From negative edge of hall A signal to positive edge of hall B signal


Current flows from W to V

Tab. 1: pattern outputs in ccw direction (see fig.6)


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Period of pattern (cw direction) Output pattern Comments

Pattern0 From positive edge of hall A signal to negative edge of hall C signal


Current flows from V to W

Pattern1 From negative edge of hall C signal to positive edge of hall B signal


Current flows from V to U

Pattern2 From positive edge of hall B signal to negative edge of hall A signal


Current flows from W to U

Pattern3 From negative edge of hall A signal to positive edge of hall C signal


Current flows from W to V

Pattern4 From positive edge of hall C signal to negative edge of hall B signal


Current flows from U to V

Pattern5 From negative edge of hall B signal to positive edge of hall A signal


Current flows from U to W

Tab. 2: pattern outputs in cw direction (see fig. 6a)


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The figures 7, 8, 8a, 9, 10, 11, 12 and 13 shows the flow charts of the module involved in the motor control.

SpeedReg

Speed reference=0

y

n

Integral speed loop register=0;

mv int=0;

Actual speed calculation:

counts the edges of hall sensors signal every 1ms

Sum of the last 5 speed calculated and then multliplied by 256

IIR filtering (16 step filtering); the result is “speed_fil”

v_err=|speed_rif-speed_fil|;

Integral speed loop: mv_int=mv_int+k_i_v*v_err

Proportional speed loop: reg_aux=k_p_v*v_err

proportional + integral, scalingand clamping; the result is “i_rif”

return

Fig. 7: voltage and current mode


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Cmp1_int

Ad conversion result management.

Motor current limitation:

if the current motor exceed the set value, then the pwm duty, “i_rif”, is decreased.

The result is “i_rif_out”.

Load the pwm duty register:

tm0=i_rif_out;

serial communication polling

main loop synchronization

Start the next ad conversion

return

Fig.8: voltage mode


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Cmp1_int

Ad conversion result management.

Load the pwm duty register:

tm0=i_rif_out; enabling pwm output to P1_0 pin.

serial communication polling

main loop synchronization

Start the next ad conversion

return

Fig.8a: current mode

Output of comparator is low (p1_3=low)?

All high IGBTs driven OFF

n

y

Igbt configuration ON (according to the actual pattern)


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Init_hall

all igbt's off

motor enabled

Hall sensors level detection

0 - 60deg position

cw ccw

Turn on LOW_W and HIGH_V IGBTs

Turn on LOW_V and HIGH_W IGBTs

break

all igbt's off

Turn on LOW_Uand HIGH_V IGBTs

Turn on LOW_V and HIGH_U IGBTs

60 - 120deg position

cw ccw

y

y

y

break break

break break



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cw ccw

Turn on LOW_U and HIGH_W IGBTs

Turn on LOW_W and HIGH_U IGBTs

Turn on LOW_V and HIGH_W IGBTs

Turn on LOW_W and HIGH_V IGBTs


cw ccw

break break

y

y

break break


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cw ccw

Turn on LOW_V and HIGH_U IGBTs

Turn on LOW_U and HIGH_V IGBTs

Turn on LOW_W and HIGH_U IGBTs

Turn on LOW_U and HIGH_W IGBTs


cw ccw

break break

return

y

y

break break


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0 - 60deg position

cw ccw

Turn on LOW_W and HIGH_V IGBTs, and count edges increment

Turn on LOW_V and HIGH_W IGBTs, and count edges increment


cw ccw

break break

y

y

int3_int



- Off arms

- hall sensors level detection

break break



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cw ccw


cw ccw

break break

return

y

y

Turn on LOW_W and HIGH_U IGBTs, and count edges increment

Turn on LOW_U and HIGH_W IGBTs, and count edges increment



break break


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cw ccw




cw ccw

break break

y

y

int0_int



- Off arms


break break

Fig.11: voltage and current mode


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cw ccw


cw ccw

break break

return

y

y

Turn on LOW_U and HIGH_V IGBTs, and count edges increment

Turn on LOW_V and HIGH_U IGBTs, and count edges increment



break break


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cw ccw




cw ccw

break break

y

y

int1_int



- Off arms


break break



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cw ccw

0 - 60deg position

cw ccw

break break

return

y

y





rising edge selected

ySet rising edge

Set falling edge

break break


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ki3_int

- Off all high IGBTs arms

Fig. 13: current mode

return


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MCRP 03 Basic description.

High voltage power supply (up to 220Vac)

External PFC connection

Motor connection

Low voltage power supply (24 Vdc)

RS232

RS232

Hall sensors connection

Encoder connection

Tacho connection

E7/E8 interface

TM interface

User interface connection

DC Vbus

I/O connection

E7/E8 interface

DC Brushlessmotor

User interface board

Power board Direct interface board R8C based microcontroller board


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User interface board basic description.

Stop key: pressing this key the motor stops.

Reverse speed key: pressing this key the motor starts to rotate in the opposite direction.

Display key: pressing this key the LCD shows alternatively the actual motor current, the actual bus dc voltage, the actual temperature (the sensor is placed on the power board).

Encoder 2: this is used to change the speed of the motor.

Stop key

Display key

Reverse speed

Encoder 1: Speed

gnd

gnd

gnd

gnd

Communication selection:

- this setting for

wired communication

Reset key

Encoder 2

Potentiometer 2 Potentiometer 1

analog input: 0÷10Vdc

analog input: 0÷10Vdc

analog output: 0÷3.3Vdc

analog output: 0÷3.3Vdc


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R8C CPU Board.

Communication selection:

- this setting for wired communication

- the other setting for infrared communication

Feedback solution selection:- this setting for 3 hall-sensor solution - the other setting for sensorless solution (under development)

Reset key

Gnd

Rx

Tx PC


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HALL Sensors connection.

Black-white: U

Yellow-white: V

Red-white: W

White: Hall-

Red: Hall sensors 5Vcc supply

Blu: Hall-WGreen: Hall-Black: Hall sensors GND

1.1.1.2 J3

1.1.1.1 J1


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HALL Sensors/Sensorless tuning procedure.

Fig. 2tp

This picture shows how to place the oscilloscope probes to get exact connection of the motor and hall sensors cables into the demo-board.

The fig.3tp shows the relationship between the back-EMF of one phase and its hall sensor signal, by rotating the motor in cw direction (see fig.2tp). It is mandatory to couple one phase of the motor with its hall sensor and connect them in the exact sequence in the connector J35 and J12 (see fig.1: U motor phase with U hall sensor, V motor phase with V hall sensor and W motor phase with W hall sensor).

Furthermore the sequence of the motor phases (and then the sequence of the hall sensors) must be as in fig.4tp.

Three resistor (approx.

10K) star connected.

U-0 back-emf

voltage

Cw direction


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Fig. 3tp.

Fig. 4tp: sequence of motor phases rotating the motor in cw direction.

- Relationship between hall-sensor signal and motor voltage (back-emf), rotating in cw direction (see fig.2)

- Yellow trace: hall sensor signal

Blue-light trace: back-emf

- This figure refers to U-0 voltage vs Hall-U sensor, or V-0 voltage vs Hall-V sensor, or W-0 voltage vs Hall-W sensor.

30 electrical deg delay

- Relationship between all the three phase motor voltage (back-efm), rotating in cw direction (see fig.2 )

- Yellow trace: back-emf of U motor phase

- Blue-light trace: back-emf of V motor phase

- Pink trace: back-emf of W motor phase

.


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Oscilloscope evaluation tests.

It is possible to download 2 different kind of software onto the CPU board:

1) Voltage mode.

2) Current mode.

Voltage mode is used when no load is applied to the motor shaft.

This mode allows the motor to be relatively silent even if no load is applied, it’s not a real application control method but it is nice to see in standard demonstration environments.

Current more has to be used in order to properly manage the motor in a real application when a standard load is applied.

It is not usable when no load is applied because, in this case, the motor current is so low that the current level read by the shunt is so low that is lower than the inverter noise so that the motor noise is quite annoying.

Here some possible waveform reading using a normal oscilloscope.

NOTE: This kind of measurements must not be made by not authorized and expert personnel in case high voltage is applied.

In case standard 24V DC power supply unit is applied the following measurement can be made without any particular care using a standard oscilloscope.

Pls. only remember that, in case of phase current reading only one shunt voltage can be read at the same time because all the shunt voltage grounds do not match.

Wrong ground connection could damage both the oscilloscope and/or the MCRP hardware. The most important measurement points are the 2 phase shunt. The phase shunts are the 2, parallel, black, big resistors close to the motor phases connector.

Another interesting measurement point is the protection shunt; it is the other resistor, similar to the previous 2, where you can read the motor global current.


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Measurement examples. Phase current shunt in case of voltage mode.


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Phase current shunt in current mode.


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Protection shunt resistor current reading.


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REG05B0049-0100/Rev.1.00 March 2009 of 44

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