motor control workbook

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Motor Control

WORKBOOK

LInECArD

3Table of ConTenT

1. abstract 4

2. System level Problem 8 2.1 Motor Topologies and Drives 9

2.1.1 PMDC Permanent Magnet DC Motor 10

2.1.2 DC Motor Driver 12

2.1.3 Asynchronous Motor 12

2.1.4 Synchronous Motor 13

2.1.5 BLDC Brushless DC 14

2.1.6 SRM Switched Reluctance Motor 15

2.1.7 Bi-Polar Stepper Motor 15

2.1.8 AC Motor Driver 18

2.2 Motor Selection Criteria 19

2.3 Applications Summary and Overview 20

3. Solutions 21 3.1 Analog Devices 21

3.2 Freescale Semiconductor 23

3.3 International Rectifier 48

3.4 Infineon Technologies 70

3.5 Maxim 80

3.6 Microchip Technology 84

3.7 ON Semiconductor 98

3.8 Renesas Technology 100

3.9 STMicroelectronics 110

3.10 Texas Instruments 118

4. Glossary 144

54

The Engineers of Distribution.

www.silica.com 54


1. abstract

Going back in time over 30 or 40 years, brush

motors were the typical motor use. Most of the

control electronics were analog components, SCR

rectifiers for the power stage, control amplifiers

were often built with discrete components and

transistor amplifiers. Then, variable speed drives

were built with standard electronic system blocks

combined with computer drives. As an example

linear amplifiers were often used rather than

switching amplifiers. Typical applications were

in areas where drives could be afforded, such as

industrial servo drives, machine tools and computer

disk drives; there were also a number of very high

power drive systems.

Then there were a number of improvements

that brought about the different power switches.

Bipolar transistors became available for power

switching and motors started to be available beyond

the standard brush DC motor. Permanent magnet

synchronous motors and AC induction motors

became available and on the power electronics

side IGBTs, high performance micro processors

and integrated amplifiers; the result was more

sophisticated control.

Nowadays there is a whole selection of motors as

well as a lot more control technology such as DSPs

and micros, ASICs, etc. A lot of the mathematical

models that were developed to simulate AC

machines 40-50 years ago all of a sudden become

relevant: the field oriented control is based on

theory that was developed long before anyone knew

how to build a control around it. Consequently,

electrical drives are currently used in a variety of

applications, as it had been pointed out in the 2005

IMS report The WW Market for AC & DC Motor

Drives1):

Obviously, the biggest portion of the business (42%)

can be assigned to HVAC2), Pumps & Pumping

as well as the Food & Beverages Industries, so

traditional industrial applications.

On the other hand, with the increase of potential

application fields and a general increase of energy

consumption world wide, the efficiency of electric

appliances such as motors become more and

more an issue. In 2007 the International Energy

Agency (IEA) issued an Energy Efficient Electrical

End-Use Equipment3) report where the general

electricity consumption worldwide was outlined in

the following way:

1) http://www.aceee.org/conf/mt05/i4_offi.pdf2) HVAC - Heating, Ventilating and Air Conditioning3) http://www.iea.org/Textbase/work/2007/ia/Motors.pdf

3%

3%1 Cranes & Hoists2 Textiles3 Pulp and Paper4 Rubber & Plastics5 Metals & Mining6 Packaging7 Utilities8 Petro-chem9 Food & Beverage10 Pumps & Pumping11 Other12 HVAC

Estimated 2004 Motor Units/Industry

3%

3%

4%

7%

8%

9%

10%11%

18%

21%1 2 3

45

6

7

8

910

11

12

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Unit Value

Electricity production global (2006) PWh/a 18.6

Electricity production from fossil energy PWh/a (%) 12.4 (67%)

Electricity for industrial motors (not included household appliances, consumer electronics, office equipment, vehicles)

PWh/a (%) 7.4 (40%)

Capacity for electric motors (peak) TWe 1.6...2.3

Motor electricity, greenhouse gas emissions G t CO2/a 4.3

Motor system energy efficiency improvement potential (average within life cycle 10...20 years) minmax

20%30%

Electricity savings potential (industry and buildings)

Greenhouse gas emission reductions potential

Average electricity price (industrial end-users)

PWh/aminmaxG t CO2/aminmaxEuro/kWh

1.52.2

0.91.40.05

Electricity cost saveings potential (industry end-users) Billion Euro/aminmax

75110

As above breakdown points out, the energy

improvement potential in 2007 for electric drives

was being considered to be between 20...30%

(or in absolute values 1.5 2.2 PWh/a)4). One of the

reasons that forced the change up in mind in the

way to deal with available energy was probably the

significant increase of energy prices, especially

during the last couple of months.

Broken down into geographical regions, the

same report points out the following distribution

characteristic:

Population GDP Electricity

Mio % cumul Mio US $ % cumul TWh/a % cumul

1 China 1322 20.0% 2229 5.0% 2475 13.6% MEPS

2 India 1130 37.1% 785 6.8% 679 17.3%

3 United States of America 301 41.7% 12455 34.9% 4239 40.7% MEPS

4 Indonesia 235 45.3% 287 35.5% 123 41.3%

5 Brazil 190 48.1% 794 37.3% 405 43.6% MEPS

6 Pakistan 165 50.6% 111 37.5% 96 44.1%

7 Bangladesh 150 52.9% 60 37.7% 23 44.2%

8 Russia 141 55.0% 581 39.0% 952 49.5%

9 Japan 127 57.0% 4506 49.1% 1134 55.7%

10 Mexico 109 58.6% 768 50.9% 233 57.0% MEPS

11 Germany 82 59.9% 2782 57.1% 619 60.4%

12 Thailand 65 60.9% 176 57.5% 575 63.5%

13 France 64 61.8% 2193 62.5% 399 65.7%

14 United Kingdom 61 62.7% 2193 67.4% 399 67.9%

15 Italy 58 63.6% 1723 71.3% 301 69.6%

16 Korea, South 49 64.4% 788 73.1% 395 71.8% MEPS

17 South Africa 44 65.0% 240 73.6% 245 73.1%

18 Spain 40 65.6% 1124 76.1% 292 74.7%

19 Australia 20 66.0% 701 77.7% 243 76.0% MEPS

20 Canada 33 66.5% 1115 80.2% 594 79.3% MEPS

Total 4388 35610 14422

4) 1 PWh/a = 105 Wh/a

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Above table shows that countries like the US with

a population of 301 Million people (5% of the ww

population) but a total energy consumption of

4.239 PWh/a represent almost 23% of the total

energy consumption worldwide, while on the other

hand a country like China with 1300 Million citizens

(representing 21% of the total global population)

consumes a bit more then half the amount of the

energy the US are currently needing (13.3%). If

Chinas productivity was to be the same like the

US (annual energy consumption per population

18.67 PWh/a !!!) one can see that a 20 30% world

wide electrical efficiency improvement (hence 1.5

2.2 PWh/a in absolute values) are probably just an

initial step to the right direction with much bigger

problems to be expected in the future.

Although Chinas productivity may be far away from

above mentioned scenario a 20 30% world wide

efficiency improvement may sound pointless if we

take into consideration the consumption growth

rate of some countries over time. As an example

we can take an official report issued in 2002 by

U.S. Department of Energy5) where the expected

Midrange Savings where lined out to be 14.8%

(as compared to 20 30% setup in 2006); yet the

total power consumption for 2002 only represented

1.085 PWh/a, hence 31.39% of the consumption of

2007, meaning that the US national energy demand

almost tripled within a period of time of 5 years.

Measure Potential energy Savings GWh/Year Midrange Savings as Percent of

low** Midrange** High** Total Motor System GWh System-Specific GWh

Motor efficiency Upgrade*

Upgrade all integral AC motors to EPAct Levels*** 13,043 2.3%

Upgrade all integral AC motors to CEE Levels*** 6,756 1.2%

Improve Rewind Practices 4,778 0.8%

Total Motor efficiency Upgrade 24,577 4.3%

System level efficiency Measures

Correct motor oversizing 6,786 6,786 6,786 1.2%

Pump Systems: System Efficiency Improvements 8,975 13,698 19,106 2.4% 9.6%

Pump Systems: Speed Controls 6,421 14,982 19,263 2.6% 10.5%

Pump Systems: Total 15,396 28,681 38,369 5.0% 20.1%

Fan Systems: System Efficiency Improvements 1,378 2,755 3,897 0.5% 3.5%

Fan Systems: Speed Controls 787 1,575 2,362 0.3% 2.0%

Fan Systems: Total 2,165 4,330 6,259 0.8% 5.5%

Compressed Air Systems: System Eff. Improvements 8,559 13,248 16,343 2.3% 14.6%

Compressed Air Systems: Speed Controls 1,366 2,276 3,642 0.4% 2.5%

Compressed Air Systems: Total 9,924 15,524 19,985 2.7% 17.1%

Specialised Systems: Total 2,630 5,259 7,889 0.9% 2.0%

Total System Improvements 36,901 60,579 79,288 10.5%

Total Potential Savings 61,478 85,157 103,865 14.8%

* Potential savings for Motor Efficiency Upgrades calculated directly by applying engineering formulas to Inventory data.** High, Medium and Low savings estimates for system efficiency impriovements reflect the range of expert opinion on potential savings.*** Includes savings from upgrades of motors over 200 HP not covered EPAct standards.

5) http://www1.eere.energy.gov/industry/bestpractices/pdfs/mtrmkt.pdf

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Therefore, some of the market trends predicted

for the next couple of years become obvious by

now: the demand for higher Reliability as well as

Power Density are continuously increasing as a

result of price vs. demand shift, hence cost/unit as

well as cost/kW are steadily decreasing. A variety

of standards like the European CE or the National

Electric Code are addressing specific issues like

EMC filtering or thermal protection solutions.

Consequently, there is a great many of other costs

on top of the typical initial costs (purchase, parts,

etc.) which need to be taken into account when it

comes to the selection of a specific motor type.

As an example we can take a standard pumping

application, with the following cost breakdown6):

LCC = CIC + CIN + CE + CO + CM + CS + CENV + CD C = cost element

IC = initial cost, purchase price (pump, system,

pipes, auxiliaries)

IN = installation and comissioning

E = energy costs

O = operating cost (labor cost of normal

system supervision)

M = maintenance cost (parts, man-hours)

S = downtime, loss of production

ENV = environmental costs

D = Decommissioning

In above equation LCC stays for the total Life Cycle

Cost; on percentage level, the relationship between

all above mentioned parameters can be weighted

through the following high-level diagram:

Maintenance and Energy Costs ( electrical

efficiency) seem to be - besides performance

specific requirements - the driving factors with

respect to technology improvements and finally

when it comes to the selection of a motor.

The objective of this workbook will therefore be to

point out the main selection criteria for the most

usual motor types, point out the principles of

operation, provide an overview about the typical

applications where a given motor is traditionally

seen nowadays and finalize it with a set of selected

best fitting SILICA system solutions.

Axel Kleinitz, PhD

Poing, 20-Apr-09

Maintenancecosts

Initial costs

Energy costs

Other costs

6) http://www1.eere.energy.gov/industry/bestpractices/pdfs/variable_speed_pumping.pdf

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www.silica.com 98


2. System level Problem7)

In general terms, electric drives an motors

are appliances used to convert electrical into

mechanical (kinetic) energy. The power ranges

start at a couple of mW and can go up to a several

hundreds of MW per unit, meaning therefore a

variety of potential applications. However, although

the power ranges may significantly change from

motor to motor the principles of operation seem to

be always the same.

Within the context the typical block diagram of such

an energy conversion system (electric mechanic/

kinetic) could be drawn in the following way:

Although the complexity of above system block

may vary with the application, a motor drive system

will always require some sort of power conversion

stage (which will be depending upon the available

power source), combined with an open and in

case of more complex systems a closed loop

control unit.

Since neither the motor itself nor the energy

buffer system are intended to be a main matter of

discussion of the workbook, the focus will therefore

primarily be the Power Conversion stage and

up to a certain extent the Closed Loop Control

circuitry in the context of a given motor topology.

(Closed Loop)Control

Control Quantity&

Signals

Measurement Parameters

Energy Buffer

(Elect.)Power Source

Converter Motor ProcessingMachine

7) FAE Training Elektrische Maschinen, Labor fr Leistungselektronik, Maschinen und Antriebe, Dr.-Ing. Johannes Teigelktter

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2.1 Motor Topologies and Drives

Depending upon the principles of operations, following types of motors can be classified8):

Of course, each motor type can be combined with

another one mentioned in above table, significantly

blowing up this overview; however, the most

common once used nowadays would probably be

those highlighted in red. Out of those the most

commonly used DC motor is the mechanically

commutated permanent magnet PMDC9),

predominantly due to the relative low initial costs.

Yet, electrical efficiency as well as maintenance

costs seem to be relatively high as compared

to AC synchronous and asynchronous motors.

These two last once are rather cheap as far as the

The Complete Family of Electric Motors

AC

Asynchronous

Induction BLDC Sine Hysterisis Step Reluctance PMDC Wound Field

Shunt

Compound

SRM

SynchronousReluctance

PSMSingle Phase

CapacitorStart Cast Rotor

CapacitorRun

ShadedPole

InsertedRotor

WoundRotor

PolyPhase

Wound Field

Series

PermanentMagnet

Hybrid

VariableReluctance

Universal

Synchronous Commutator Homopolar

DC

initial costs are concerned, however with a much

better performance (efficiency) and almost no

maintenance costs. However, the complexity of the

electrical control is significantly higher then in case

of a DC motor.

In the following comparison some of the key

selection parameters for those red highlighted

motors have been put together providing an

overview of the most typical applications where

they can be seen today.

8) Motor, Drive and Control Basics, International Rectifier Corp. by Eric Persson & Michael Mankel9) PMDC - Permanent Magnet DC Motor

1110


www.silica.com 1110


2.1.1 PMDC Permanent Magnet DC Motor10)

The DC motor is a rotating electric

machine designed to operate from source of direct

voltage. The basic type is a permanent magnet DC

motor. The stator of a permanent magnet DC motor

is composed of two or more permanent magnet

pole pieces. The rotor is composed of windings

that are connected to a mechanical commutator.

The opposite polarities of the energized winding

and the stator magnet attract and the rotor will

rotate until it is aligned with the stator. Just as the

rotor reaches alignment, the brushes move across

the commutator contacts and energize the next

winding.

In order to understand the principles of operation,

we will start with a permanent magnet, mechanically

commutated DC motor and use the terminology

used in following block diagram11):

The main windings rotate (rotor) while the

magnetic field is fixed, usually through a

permanent magnet. DC voltages and currents

are provided though brushes. With N wires per

coil and multiple commutator bars, following

mathematical relationships are know to be valid:

T = 2NBrlI0 = KT I0 (1)

and

e = 2NBrl = Ke (2)

Communication of a Single-loop DC Machine

www.silica.com

10) http://www.freescale.com/webapp/sps/site/homepage.jsp?nodeId=02nQXG11) Motor, Drive and Control Basics, International Rectifier Corp. by Eric Persson & Michael Mankel

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with

KT: Torque Constant

T: Magnetic Torque

Ke: emf Constant

e: emf Induced Voltage (electromotive force)

B: Constant Magnetic Field, generated by the

permanent magnet

The relationship between Torque and rpm n leads

to following mathematical expression12):

n = n0 - M (3)

kM = c (4)

M = T - MR (5)

with

M: Torque

n0: Idle Speed

R: Total Resistance (rotor and brushes)

c: Engines Constant

: Magnetic Flux, constant in case B is constant

(permanent magnet!)

MR: Friction Losses

R

2 kM2

Two other types of DC motors are series wound

and shunt wound DC motors. These motors also

use a similar rotor with brushes and a commutator.

However, the stator uses windings instead of

permanent magnets. The basic principle is still

the same. A series wound DC motor has the stator

windings in series with the rotor. A shunt wound DC

motor has the stator windings in parallel with the

rotor winding. A series wound motor is also called

a universal motor. It is universal in the sense that

it will run equally well using either an AC or a DC

voltage source.

12) Handbuch Elektrische Antriebe, Hans-Dieter Stlting & Eberhard Kallenbach

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www.silica.com 1312


For obvious reasons, the H-bridge driver requires 4

switches, hence 2 less then the traditional 3-pahes

driver. The current flow and therefore the torque,

see equation (1) can be driven in either direction.

The control strategy can be designed for 4-quadrant

operation modes: 1 forward and 2 reverse motoring

as well as 3 forward and 4 reverse braking using

the emf induced voltage as a breaking effect.

These last two once may require shunt regulator for

braking (regeneration). With respect to modulation

there are a variety of strategies available, with PWM

as the most usual one.

2.1.3. asynchronous Motor14)

In an induction motor (asynchronous)

the stator (3 phase) windings are fixed while the

magnetic field rotates. AC voltages and currents

are provided to the stator while the AC currents

on rotor experience a slip at frequency; the

speed is always a little less than the synchronous

speed and speed drops with increasing load

(~5% max.).

The AC induction motor is a rotating electric

machine designed to operate from a three-phase

source of alternating voltage. The stator is a classic

three phase stator with the winding displaced by

120. The most common type of induction motor

has a squirrel cage rotor in which aluminum

2.1.2. DC Motor Driver

The traditional way to control the sense of rotation

would be by changing the polarity of the DC

commutator voltage; the speed itself through a

PWM duty cycle, using a classic H-bridge circuit.

With this approach 4 different operational modes

can be defined13):

H-bridge Motor Drive (be-directional)

www.silica.com

13) Motor, Drive and Control Basics, International Rectifier Corp. by Eric Persson & Michael Mankel14) http://www.freescale.com/webapp/sps/site/homepage.jsp?nodeId=02nQXG

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conductors or bars are shorted together at both

ends of the rotor by cast aluminum end rings. When

three currents flow through the three symmetrically

placed windings, a sinusoidally distributed air gap

flux generating the rotor current is produced. The

interaction of the sinusoidally distributed air gap

flux and induced rotor currents produces a torque

on the rotor. The mechanical angular velocity of the

rotor is lower then the angular velocity of the flux

wave by so called slip velocity.

The valid block diagram looks as follows15):

The slip, hence the difference between the rotor-

speed and the rotational-speed of the rotating-

field is been expressed through the following

relationship:

s = (6)

and

nS = (7)

representing the synchronous speed as a

relationship between 1, the stator current and p,

the number of pole-pairs. Therefore the relationship

between Torque, synchronous speed and rotor

speed is been expressed through the following

equation:

M = = (8)

with

P: Output Power

P: Rotor Loss

In adjustable speed applications, AC motors are

powered by inverters. The inverter converts DC

power to AC power at the required frequency and

amplitude. The inverter consists of three half-

bridge units where the upper and lower switches are

controlled complimentarily. As the power devices

turn-off time is longer than its turn-on time, some

dead-time must be inserted between the turn-off

of one transistor of the half-bridge and turn-on of

its complementary device. The output voltage is

mostly created by a pulse width modulation (PWM)

technique. The 3-phase voltage waves are shifted

120 to each other and thus a 3-phase motor can

be supplied.

2.1.4. Synchronous Motor16)

In a synchronous motor the speed

is synchronised to the stator voltage frequency;

speed is therefore directly proportional to stator

frequency. Since ns = n, s = 0.

Starconnection Deltaconnection

nS - nnS

P2n

P2nS

1p

15) Handbuch Elektrische Antriebe, Hans-Dieter Stlting & Eberhard Kallenbach16) http://www.freescale.com/webapp/sps/site/homepage.jsp?nodeId=02nQXG

1514


www.silica.com 1514


The PM Synchronous motor is a rotating electric

machine where the stator is a classic three phase

stator like that of an induction motor and the rotor

has surface-mounted permanent magnets. In this

respect, the PM Synchronous motor is equivalent

to an induction motor where the air gap magnetic

field is produced by a permanent magnet. The use

of a permanent magnet to generate a substantial

air gap magnetic flux makes it possible to design

highly efficient PM motors. A PM Synchronous

motor is driven by sine wave voltage coupled with

the given rotor position. The generated stator flux

together with the rotor flux, which is generated by

a rotor magnet, defines the torque, and thus, speed

of the motor. The sine wave voltage output have to

be applied to the 3-phase winding system in a way

that angle between the stator flux and the rotor flux

is kept close to 90 to get the maximum generated

torque. To meet this criterion, the motor requires

electronic control for proper operation.

The relationship between Torque and Rotor Speed

can be expressed through following term:

M - ML = J (9)

= p (10)

with

ML: Load torque

J: Total Moment of Inertia

: Mechanical Radial Frequency

For a common 3-phase PM Synchronous motor,

a standard 3-phase power stage is used. The

same power stage is used for AC induction and

BLDC motors. The power stage utilizes six power

transistors with independent switching. The power

transistors are switched in the complementary

mode. The sine wave output is generated using a

PWM technique.

2.1.5. blDC brushless DC17)

A brushless DC (BLDC)

motor is a rotating electric

machine where the stator is a classic three-phase

stator like that of an induction motor and the rotor

has surface-mounted permanent magnets. In this

respect, the BLDC motor is equivalent to a reversed

DC commutator motor, in which the magnet rotates

while the conductors remain stationary. In the DC

commutator motor, the current polarity is altered

by the commutator and brushes. On the contrary,

in the brushless DC motor, the polarity reversal

is performed by power transistors switching in

synchronization with the rotor position. Therefore,

BLDC motors often incorporate either internal or

external position sensors to sense the actual rotor

position or the position can be detected without

sensors.

The BLDC motor is driven by rectangular voltage

strokes coupled with the given rotor position. The

generated stator flux interacts with the rotor fluxes,

which is generated by a rotor magnet, defines the

torque and thus speed of the motor. The voltage

strokes must be properly applied to the two phases

of the three-phase winding system so that the angle

between the stator flux and the rotor flux is kept

1 p t

www.silica.com

17) http://www.freescale.com/webapp/sps/site/homepage.jsp?nodeId=02nQXG

1514


1514


close to 90 to get the maximum generated torque.

Due to this fact, the motor requires electronic

control for proper operation.

2.1.6. SRM Switched Reluctance Motor18)

A Switched Reluctance Motor is a rotating electric

machine where both stator and rotor have salient

poles. The stator winding is comprised of a set

of coils, each of which is wound on one pole. SR

motors differ in the number of phases wound on

the stator. Each of them has a certain number of

suitable combinations of stator and rotor poles.

The motor is excited by a sequence of current

pulses applied at each phase. The individual

phases are consequently excited, forcing the motor

to rotate. The current pulses need to be applied

to the respective phase at the exact rotor position

relative to the excited phase. The inductance profile

of SR motors is triangular shaped, with maximum

inductance when it is in an aligned position and

minimum inductance when unaligned. When the

voltage is applied to the stator phase, the motor

creates torque in the direction of increasing

inductance. When the phase is energized in its

minimum inductance position the rotor moves to

the forth coming position of maximal inductance.

The profile of the phase current together with

the magnetization characteristics defines the

generated torque and thus the speed of the motor.

The SR motor requires control electronic for its

operation. Several power stage topologies are

being implemented, according to the number of

motor phases and the desired control algorithm. A

power stage with two independent power switches

per motor phase is the most used topology. This

particular topology of SR power stage is fault

tolerant - in contrast to power stages of AC induction

motors - because it eliminates the possibility of

a rail-to-rail short circuit. The SR motor requires

position feedback for motor phase commutation. In

many cases, this requirement is addressed by using

position sensors, like encoders, Hall sensors, etc.

The result is that the implementation of mechanical

sensors increases costs and decreases system

reliability. Traditionally, developers of motion

control products have attempted to lower system

costs by reducing the number of sensors. A variety

of algorithms for sensorless control have been

developed, most of which involve evaluation of the

variation of magnetic circuit parameters that are

dependent on the rotor position.

2.1.7. bi-Polar Stepper Motor

In a bi-polar stepper motor, the stator poles change

polarity by varying current through each of the two

coils. The rotors magnetic poles, however, fixed

relative to the rotor itself. By definition, the bi-

polar stepper motor has one phase per stator pole

which requires advanced circuitry such as a driver

and H-bridge circuit to cause rotation and torque

by switching the poles by alternately changing the

current direction in each phase. The resolution of

a stepper motor is determined by arrangement of

the teeth.

18) http://www.freescale.com/webapp/sps/site/homepage.jsp?nodeId=02nQXG

1716


www.silica.com 1716


Step 1 Phase 1 energized with positive current

Phase 2 not energized

Step 2 Phase 1 is de-energized while

Phase 2 is energized with positive current

Rotor rotates 90 degrees to align with

north

Step 3 Phase 1 energized with negative current

Phase 2 not energized


north

Step 4 Phase 1 is de-energized while

Phase 2 is energized with negative current


north

n

S

Sn

Rotor

Stator Phase 1

Stator Phase 1

Stator Phase 2 Stator Phase 2

nS Sn

Stator Phase 1

Stator Phase 1


n SS n

Stator Phase 1

Stator Phase 1


n

S

Sn

Stator Phase 1

Stator Phase 1


www.silica.com

1716


1716


As a simplified example of how a stepper motor

operates, one can imagine a stepper motor with only

four teeth or two phases each controlling two poles

(Figure 1). When such a stepper motor is in full-step

mode, the rotor rotates 90-degrees by sequentially

changing the current in each phase. For example,

in Step 1 of Figure 1, Phase 1 is energised with a

positive current which causes the permanent

south pole of the roor to align with the north pole

of the phase 1 stator pole. If phase 1 is then de-

energised and a positive current is then applied

to phase 2, the position of the north pole changes

causing the rotor to align its south pole, therefore

rotating 90-degrees clockwise in this example

(Step 2 of Figure 1). In order to get the rotor to

continue in a clockwise motion, phase 1 is then

energised with a negative current which switches

the north and south poles from Step 1 causing the

rotor to align itself and turn 90-degrees clockwise

(Step 3, Figure 1). Phase 1 is then de-energised

and phase 2 is energised with a negative current,

once again rotating the rotor one quarter turn. The

cycle then starts over by de-energising phase 2 and

energising phase 1 with a positive current, which

puts the motor back to Step 1. This simple example

represents a stepper motor with 90-degree re-

solution, which for practical purposes is not typical.

The resolution of a stepper motor is determined

by the number of teeth and alignment and a

1.8-degree step provides motion with much less

vibration caused by the overshoot than our fictional

90-degree motor example above. However, the

vibration experienced in a stepper motor with only

1.8-degree incremental steps, or full-steps, can

be even further reduced by utilising stepper motor

drivers capable of micro-stepping.

Step 1 Both phases 1 and 2 energised with

positive current resulting in the rotor

aligning between full-steps

Very simply, micro-stepping is accomplished by

partially energising both phases allowing the rotor

to stop between steps as shown in Figure 2. By

energizing both phases using the same current

magnitude, the rotor is equally attracted to both

north poles which causes it to stop in-between the

two and resulting in a half-step, or as referred to in

most literature, a one-half microstep. By applying

currents to both phases in different ratios, advanced

stepper motor drivers can further reduce micro-

stepping increments to , 1/8, 1/16, 1/32 and even

1/64 microsteps. For the designer, this means that a

stepper motor specified to be capable of 1.8-degree

steps, or 200 steps per rotation, is now capable of

stepping in increments of 0.028-degrees or 12,800

steps per rotation. Not only does this allow finer

resolution in stepping, it also drastically reduces

vibration. Although the increased resolution

nS Sn

Stator Phase 1

Stator Phase 1


n

S

Rotor

1918


www.silica.com 1918


typically comes at a cost of 10% to 20% of torque,

the increase resolution has many applications

when the trade-offs are considered.

2.1.8 aC Motor Driver

Since AC motors require three AC phases to be

independently driven, the solution would be to

control both, synchronous and asynchronous

motors through a 3-Phase-Bridge-Driver like the

one represented in the following illustration19):

Depending upon the application, above 3-Phase-

Bridge can be realized with IGBTs like in above

example or with power MOSFETs. Performance

criteria mainly like power and heat dissipation

will determine which solution to go for. Yet, due

to the system, topology and circuitry architecture

peculiarities a further detailed discussion will be

performed in the context of specific solutions.

AC-DC

ACin

ACout

Motor

DC link DC-AC

www.silica.com

19) Motor Control Basics, International Rectifier Corp. by Aengus Murray

1918


1918


2.2. Motor Selection Criteria

When it comes to the selection of a specific motor

for a given application, the criteria based upon the

decision will have to be founded on, may significantly

complicate the decision process.

At a first stage the designer has to understand the

load requirements, meaning those parameters like

speed range, continuous and peak torque as well

as starting requirements, which will provide a first

decision base to deal with.

Besides that it is fundamental to understand those

performance requirements like efficiency, dynamic

performance, speed accuracy, torque and speed

ripple, acoustic noise, hence those parameters

that will have a direct impact on the applications

performance quality.

At a next step these needs will have to be put in line

with important Supply Considerations (AC or DC,

Voltage and current, connections, EMI/RFI) which

in many cases narrow down the applicability of a

potential candidate.

Once above criteria had been carefully taken into

consideration, the designer will have to determine

Mechanical and Environmental Issues like size

& weight, temperature, reliability, explosion

proof, integration of drive and control and safety

issues, hence those kind of parameters that may

significantly limit the usage of a selected solution

depending upon their importance in a given

application.

Finally, logistics and costs will be an issue that will

require a dedicated focus, especially if we remember

the analysis in the introduction. In specific those

criteria like annual usage and unit cost target will

have to be carefully considered. Within this context

the question about making or buying the complete

system (or part of it) will be depending on risk

factors like availability of suppliers, time to market,

development cost and technology risk.

Due to the complexity of this approach, the selection

of a specific motor for a given application may

become more sophisticated then initially expected;

taking into consideration all above mentioned

parameters, the overview presented on page 10

reflects a selection of those motor commonly used

for specific applications at the moment. Although

meant to be used as a guidance, it will still require

individual adaption to a given problem.

2120


www.silica.com 2120


2.3 applications Summary and overview electric Motor Topologies

Type

Func

tion

alP

rinc

iple

Mat

hem

atic

alR

elat

ions

hip

Cha

ract

eris

tics

Cos

t (C

IC)

Mot

or

Effi

cien

cy

Mot

orTe

chno

logy

Stag

e of

Dev

elop

men

t

Mai

nten

ance

Cos

ts (C

m)

Com

plex

ity

Elec

tron

icC

ircu

it

Volt

age

Ran

ges

Spee

d R

ange

s[r

pm]

Typi

cal

App

licat

ions

Pag

e

PM

DC

P

erm

anen

tM

agne

t DC

DC

C

omm

utat

orlo

wlo

whi

ghye

slo

w10

0 ...1

03 V

20.0

008,

96

ff

10, 1

6,

26, 8

4,

102,

118

12, 2

4,

67, 9

7,

109

16, 3

0,

66, 9

6,

106

13, 3

3,

66, 1

06

Han

d To

ols,

Was

hers

&D

ryer

s, S

tart

ers,

Wip

ers,

Pow

er W

indo

ws

Cas

t Mot

or

Squi

rrel

Cag

eR

otor

AC

Asy

nchr

onou

s

AC

Sync

hron

ous

low

good

high

nohi

gh22

0...4

40 V

20.0

00P

umps

, Fan

s, H

VAC

,W

hite

Goo

ds, H

eavy

Trac

tion

Mac

hine

ry

BLD

C

Bru

shle

ss D

Cm

oder

ate

very

goo

dm

iddl

eno

high

4...2

40 V

50.0

00

Was

hing

Mac

hine

s,El

ectr

ical

Pow

er

Stee

ring

, Ele

ctri

cal

vehi

cle

trac

tion

driv

e, R

efri

gera

tors

, AC

, PC

-Fan

, Cei

ling

Fan,

Blo

wer

s

PSM

P

erm

anen

tM

agne

tSy

nchr

onou

sM

otor

high

good

mid

dle

yes

high

110.

..240

V10

.000

Serv

o D

rive

s,El

ectr

onic

Pow

erSt

eeri

ng

SRM

S

wit

ched

Rel

ucta

nce

Mot

orlo

wve

ry g

ood

low

nom

oder

ate

Indu

stri

al: 1

10...

240

VA

utom

otiv

e: 1

2...2

4 V

100.

000

Fans

, App

lianc

es,

Emer

ing

Aut

omot

ive

App

licat

ions

M =

P

2n

2n SP

=

n =

n 0 -

R

M2

k M2

M -

ML =

J 1 pt

www.silica.com

2120


2120


3. Solutions

3.1 analog Devices

The aDM3251e in Motion Control applications

Introduction

For many years, communications in Motion Control

Systems has typically been implemented via an

RS-232 interface. The RS-232 bus standard has

proven itself to be a robust communication protocol,

particularly suited to noisy environments. Recent

enhancements in serial communication design

include the isolation of the RS-232 port from the

motion controller itself. The ADM3251E offers the

latest level of innovation, by combining both power

and data isolation in a single package.

A basic architecture of a motion control system is

depicted in Figure 1. To improve system reliability

within a noisy environment and protect against

voltage spikes and ground loops, isolation is

required between the RS-232 cable network and

the systems connected to it. Analog Devices Inc.

have developed the ADM3251E integrated isolated

RS-232 transceiver to solve these problems. Until

recently, transferring power across an isolation

barrier required either a separate dc-to-dc

converter, which is relatively large, expensive, and

has insufficient isolation, or a custom discrete

approach, which is not only bulky but also difficult

to design.

The ADM3251E combines iCoupler technology

with isoPower, which results in a complete

isolation solution within a single package. Not only

does the ADM3251E offer state of the art digital

signal isolation, having substantial advantage

over optocouplers in terms of power, size and

performance, but it also eliminates the need for

a separate isolated power supply. The ADM3251E

provides functional integration that can dramatically

reduce the complexity, size and total cost of an

isolated system.

RS-232 Port

Motion Controller

AMP/Drive

MOTOR MECHANICAL

FeedbackDevice

Figure 1. Block Diagram of a Typical Motion Control Application

2322


www.silica.com 2322


ADM3251E Features

The ADM3251E is a high speed, 2.5 kV fully isolated,

singlechannel RS-232 transceiver device that

operates from a single 5V power supply. Due to the

high ESD protection on the RIN and TOUT pins the

device is ideally suited for operation in electrically

harsh environments or where RS-232 cables are

frequently being plugged and unplugged.

Complete isolation of both signal and power is

achieved using iCoupler technology. iCoupler

technology is based on chipscale transformers

0738

8-00

1

DECODE

RECT REG

V

C40.1F16V

VOLTAGEDOUBLER

C1+ C1 V+ VISO C2+ C2

R

T

VOLTAGEINVERTER

VCC

ROUT

TIN

GND GNDISO

RIN*

TOUT

ADM3251E

OSC

ENCODE

ENCODE

DECODE

*5k PULL-DOWN RESISTOR ON THE RS-232 INPUT.

0.1F

C30.1F10V

C20.1F16V0.1F

C10.1F16V

Figure 3. ADM3251E Functional Block Diagram

rather than the LEDs and photodiodes used in

optocouplers. By fabricating the transformers

directly on chip using wafer level processing

iCoupler channels can be integrated with other

semiconductor functions as low cost. Transfer

of the digital signal is realised through the

transmission of short pulses approximately routed

to the primary side of a given transformer. These

pulses couple from one transformer coil to another

and are detected by the circuitry on the secondary

side of the transformer. The circuitry then recreates

the input digital signal.

Another novel feature of iCoupler technology is

that the transformer coils that are used to isolate

data signals may also be used as the transformers

in an isolated DC-DC converter, this extension of

iCoupler technology is termed isoPower. The result

is a total isolation solution.

For further information, please visit:

www.analog.com/ADM3251E

Figure 2.

2322


2322


3.2 freescale Semiconductor

freescale Solutions for Motor Control

Technologies

Comprehensive 8-, 16- and 32-bit systems with

advanced sensor and analog/mixed signal devices

Freescale offers complete solutions for every motor

control application. Our superior portfolio and

breadth of devices includes:

8-bit microcontrollers (MCUs)

16-bit digital signal controllers (DSCs)

32-bit embedded controllers

Acceleration and pressure sensors

Analog and mixed signal devices

Freescale delivers solutions that have wide ranging

banks of flash and RAM memories, configurable

timer options, pulse width modulators (PWMs),

and some even offer an enhanced Time Processing

Unit (eTPU). Freescale supports these devices with

motor control-related application notes, hardware/

software tools, drivers, algorithms and helpful

Web links including our motor control Web site at

www.freescale.com/motorcontrol.

Freescale Motor Control Solutions A full range of products, technology, services and tools

2524


www.silica.com 2524


Expertise Application Notes Analog and Sensors

Demos Development Tools

Software and Drivers

Online Training

Technical SupportWebsite

Reference Designs

MCUs, MPUs and DSCs

Freescale'sComplete MotorControl Solution

We are dedicated to providing comprehensive

system solutions that not only improve motor

efficiency but also minimise system updates,

development time and maintenance costs.

Freescale provides microcontrollers and develop-

ment tool solutions for all of your motor control

needs.

2524


2524


control for an incredible variety of applications.

The product roadmaps demonstrate that new

feature integration and software compatibility will

continue to drive future generations of embedded

motor control solutions. Freescale provides

microcontrollers and development tool solutions

for all of your motor control needs.

a Roadmap for Your future Design needs

Intelligent solutions driving new generations of

motor control applications

Freescale MCUs, MPUs and DSCs, when coupled

with analog/mixed-signal and power integrated

circuits, are designed to provide system solutions

for motor control, motion control and static load

32-bit MCU/MPU~3dP[0gXbETRcâ2^]ca^[~Câ`dT2^]ca^[~ETRcâ2^]ca^[P]S bT]bâ[TbbETRcâ2^]ca^[

16-bit DSC~ETRcâ2^]ca^[P]S bT]bâ[TbbETRcâ2^]ca^[

16-bit MCU~>_T]P]S2[^bT;^^_ E7IP]S"?W BT]bâ[Tbb028

2726


www.silica.com 2726


Recommended Devices

8-bit MCU: 908JK/JL, 908MR, 908QT/QY,

908QB, 908QC, 908GP, 908GR,

9S08AW, 9S08GB, 9S08GT, 9S08QG,

9S08QD

16-bit DSC: MC56F80x, MC56F80xx, MC56F83xx

32-bit MCU: MCF51AC, MCF521x, MCF523x,

MPC56x, MPC55xx

Analog/Mixed-Signal Power ICs

Power Supply: MC34702, MC34717, MC33730

Motor Driver: MC33932, MC34920, MC34921,

MC34923, MPC17533, MC33887,

MC33899, MC33926, MC33931,

MPC17529, MPC17531, MM908E626

Stepper Motors

General purpose stepper motor control

Advantages

Precise position control

Applications

Industrial machines

Health care scanners

Computers

Office equipment

Toys

MCU/DSC

PW

M

PWM1A

PWM2A

PWM1B

PWM2B

Coil A

Coil B

V+

V+

la lb

Application Notes

32-bit AN2353 The Essentials of the

Enhanced Time Processing

Unit

AN2848 Programming the eTPU

AN2869 Using the Stepper Motor (SM)

eTPU Function

2726


2726


Application Notes

32-bit AN2955 DC Motor with Speed and Current

Closed Loops, Driven by eTPU on

MCF523x AN2955SW

AN2958 Using the DC Motor Control eTPU

Function Set (Set 3)

AN3008 DC Motor with Speed and Current

Closed Loops, Driven by eTPU on

MPC5554 AN3008SW

brushed DC Motor

Dual feedback loop control

Advantages

Cost-effective control topology

High-precision speed, torque control and

position loop can be added

Recommended Devices

8-bit MCU: 908MR, 9S08GB, 9S08AC

16-bit DSC: MC56F80x, MC56F80xx,

MC56F83xx

16-bit MCU: S12XE


MPC56x, MPC55xx


Power Supply: MC34702, MC34717, MC33730,

MC34923

Motor Driver: MPC17510, MPC17529,

MPC17531, MPC17533, MC34920,

MC34921, MC33926, MC33887,

MC33899, MC33931, MC33932

Applications

Robots

Traction control

Servo systems

Automotive

Office equipment

Toys

Industrial machines

VCC

VCORE

VREG2

VREG1

Interface

HBDriver

CurrentSensing Encoder

DCMotor

Analog Power ASIC

SpeedCommand Speed

ControllerCurrent

Controller

PWM ADC QuadratureDecoder

MCU or DSC

2928


www.silica.com 2928


Applications

Robots

Traction control

Servo systems

Office equipment

Sewing machines

Fitness machines/treadmills

Toys

Industrial machines

brushless DC Motor (blDC)

Encoder

Advantages

Enables bi-directional operation with fast torque

response, low noise and high efficiency

High precision speed

Torque control

Position loop can be added

Power Stage Driver

+

+Motor

-Encoder

SpeedController

MCU/DSC

CurrentController

SpeedReference

Actual Speed

++

-

-

GPIO and Serial Interface PWMADC ADC Quadrature Decoder

Zero CrossingPeriod and

Position RecognitionCommuntation

Control

SpeedCalculation

PWM Duty Cycle

Phase Communication

1 or 3

Over Current

Recommended Devices

8-bit MCU: 908MR, 9S08AC, 9S08GB


16-bit MCU: S12XE


MPC56x, MPC55xx



Motor Driver: MPC17533, MC34923, MC33937,

MC33927

Application Notes

8-bit AN2356 Sensorless BLDC Motor Control on

MC68HC908MR32 Software Porting

to Customer Motor

AN2355 Sensorless BLDC Motor Control on

MC68HC908MR32 Software

AN1858 Sensorless Brushless DC Motor

Using the MC68HC908MR32

Embedded Motion Control

AN1853 Embedding Microcontrollers in

Domestic Refrigeration Appliances

AN2396 Servo Motor Control Application on

a Local Area Interconnect Network

(LIN)

2928


2928


DRM086 Sensorless BLDC Motor Control

Using MC9S08AW60

Development System 16-bit

AN1913 3-Phase BLDC Motor Control

with Sensorless Back-EMF ADC

Zero Crossing Detection Using

DSP56F80x


with Sensorless Back EMF

Zero Crossing Detection Using

DSP56F80x


with Quadrature Encoder Using

56F800/E

DRM078 3-Phase BLDC Drive Using Variable

DC Link Six-Step Inverter

DRM070 3-Phase BLDC Motor Sensorless

Control Using MC56F8013/23

32-bit MCU

AN2892 3-Phase BLDC Motor with Speed

Closed Loop, Driven by eTPU on

MCF523x AN2892SW

AN2948 Three 3-Phase BLDC Motors with

Speed Closed Loop, Driven by eTPU

on MCF523x AN2948SW

AN2954 BLDC Motor with Speed Closed

Loop and DC-Bus Break Controller,

Driven by eTPU on MCF523x

AN2954SW

AN2957 BLDC Motor with Quadrature

Encoder and Speed Closed Loop,

Driven by eTPU on MCF523x

AN2957SW

AN3005 BLDC Motor with Quadrature

Encoder and Speed Closed Loop,

Driven by eTPU on MPC5554

AN3005SW

AN3006 BLDC Motor with Hall Sensors and

Speed Closed Loop, Driven by eTPU

on MPC5554 AN3006SW

AN3007 BLDC Motor with Speed Closed

Loop and DC-Bus Break Controller,

Driven by eTPU on MPC5554

AN3007SW

Reference Designs

RDDSP56F8BLDCE 3-Phase BLDC Motor Control

with Encoder Using 56F80X

or 56F8300 Digital Signal

Controllers

3130


www.silica.com 3130


Applications

Large appliances

HVAC

Blowers, fans

Pumps

Lifts, cranes, elevators

Conveyors

Frequency inverters

Industrial controls

Treadmills

Industrial compressors

Universal inverters

aC Induction Motors (aCIM)

3-phase ACIM with V/Hz open-loop control

with PFC

Advantages

Enables bi-directional operation with fast torque

response

Simple cost-effective control topology

Controls both motor and PFC by single MCU

Targeted for modest applications accepting

low-precision speed control

High efficiency

Precise speed control

Enables indirect torque control

Tolerant of motor parameters fluctuation

Motor

Over Current

Power Stage Driver

PWM

3-PhaseSine PWMGeneration

MCU or DSC

DC-Bus VoltageCompensation

Slip Speed Calculation

V/HZ

VoltageBoost

SpeedReference

GPIO and Serial Interface ADC ADC

SineFrequency

Amplitude

1or3

3130


3130


Recommended Devices

8-bit MCU: 908MR, 9S08AC, 9S08GB


16-bit MCU: S12XE


MPC56x, MPC55xx



Motor Driver: MPC17533, MC34923, MC33937,

MC33927

Application Notes

8-bit AN2154 Cost-Effective, 3-Phase, AC Motor

Control System with Power Factor

Correction

Based on MC68HC908MR32

AN1857 3-Phase, AC Motor Control System

with Power Factor Correction


AN1664 Cost-Effective 3-Phase AC

Motor Control System Based on

MC68HC908MR32

AN1590 High-Voltage Medium Power Board

for 3-Phase Motors

AN2149 Compressor Induction Motor Stall

and Rotation Detection Using

Microcontrollers



16-bit AN1918 Indirect Power Factor Correction

for 3-Phase AC Motor Control with

V/Hz Speed

Open Loop Application

AN1930 3-Phase AC Induction Motor Vector

Control

AN1958 3-Phase AC Motor Control with V/

Hz Speed Closed Loop Using the

56F800/E

AN1942 DSP56F80x Resolver Driver and

Hardware Interface

DRM092 3-Phase AC Induction Vector

Control Drive with Single-Shunt

Current Sensing

AN3234 Washing Machine Three-Phase AC

Induction Motor Drive

3332


www.silica.com 3332


aC Induction Motors (aCIM)

3-phase ACIM with sensorless field oriented

control

Advantages

High-precision speed/torque control

Suitable for drives with high dynamic

requirements

Removal of speed sensor

Power Stage Driver

SVM/PWM

DC-Bus RippleCompensation

Over Current

ADCPWMADCADC

FluxController

Driver

GPIO and Serial Interface

SpeedReference

SpeedController

TorqueController

GPIOBreak Control

Multrs

Flux andSpeed

EstimatorSlip

FrequencyEstimatorDSC/MCU

2

3

ddt its

itm

ia

ib

isq

uts

ums

e-jq

ejq

y r

Te

wy

ws

wrqy

1or3

ua

ub

Applications

Large appliances

Industrial compressors

Water pumps

Construction machinery

Universal inverters

HVAC

Recommended Devices


32-bit MCU: MCF521x, MCF523x, MPC56x,

MPC55xx

Application Note

8-bit AN2154 Cost-Effective, 3-Phase, AC

Motor Control System with Power

Factor Correction Based on

MC68HC908MR32

AN1857 3-Phase, AC Motor Control System

with Power Factor Correction


3332


3332


AN1664 Cost-Effective 3-Phase AC

Motor Control System Based on

MC68HC908MR32

AN1590 High-Voltage Medium Power Board

for 3-Phase Motors



Microcontrollers



16-bit AN1918 Indirect Power Factor Correction

for 3-Phase AC Motor Control with

V/Hz Speed Open Loop Application

AN1930 3-Phase AC Induction Motor Vector

Control

AN1958 3-Phase AC Motor Control with V/

Hz Speed Closed Loop Using the

56F800/E


Hardware Interface

DRM092 3-Phase AC Induction Vector

Control Drive with Single-Shunt

Current Sensing

AN3234 Washing Machine Three-Phase AC

Induction Motor Drive

Reference Designs

RD56F801XACIM Design of an ACIM Vector

Control Drive Using the

56F801X

3534


www.silica.com 3534


Permanent Magnet Synchronous Motors (PMSM)

Sensored field oriented control

Advantages

Exceptionally low noise operation

Outstanding drive efficiency

Precise speed/torque control

U_DC bus

BreakControl

Line

AC AC

DC

PMSMLoad

QuadratureEncoder

Isa Isb Isc

Temperature

PWM

Quad TimerADCPWM

Sector

DC-Bus

TorqueCurrent

Controller

TorqueCurrent

Controller

Is_a Is_b Is_c

GPIO

U_dcb

PWM

Fault Protection

Faults

GPIO and Serial Interface

SpeedReference

ActualSpeed

MCU/DSC

DC-BusRipple

Compensation

Ua Ub

Usa

Usbq

ejq

isa

isb

Is_a_comp Is_b_comp Is_c_comp

TorqueCurrent

Controller

FluxCurrent

Controller

Us_q Us_d e-jq

wr

SpeedController

Is_d*

w

Dec

oupl

ing

(Bac

k-EM

F Fe

edfo

rwar

d)

Applications

Robotics

Elevators

Servo drivers

Traction systems

Industrial motion control

Automotive

Recommended Devices



MPC55xx

Application Notes

8-bit AN2357 Sine Voltage Powered 3-Phase

Permanent Magnet Motor with Hall

Sensor



Microcontrollers


3534


3534





(LIN)

DRM036 Sine Voltage Powered 3-Phase

Permanent Magnet Synchronous

Motor with Hall Sensors

16-bit AN1931 3-Phase PM Synchronous Motor

Vector Control


Hardware Interface

DRM102 PMSM Vector Control with Single-

Shunt Current-Sensing Using

MC56F8013/23

DRM099 Sensorless PMSM Vector Control

with a Sliding Mode Observer for

Compressors Using MC56F8013

Reference Designs

RD56F8300EMB Electro-Mechanical Braking

Using 56F8300 Digital Signal

Contollers

RD56F8300EPAS Electronic Power Assisted

Steering (EPAS) with 56F8300

Digital Signal Controllers

RD56F8300FRBBW FlexRay Brake-By-Wire

Using 56F8300 Digital Signal

Controllers

RDDSP56F8PMSDE 3-Phase PM Synchronous

Motor Control with Quadrature

Encoder Using 56F80X Digital

Signal Controllers

RDDSP56F8SMTVC 3-Phase PM Synchronous

Motor Torque Vector Control

Using 56F80X or 56F8300

Digital Signal Controllers

3736


www.silica.com 3736


Permanent Magnet Synchronous Motors (PMSM)

Sensorless sinusoidal field oriented control

with zero speed torque capability

Advantages

Low-noise operation

High drive efficiency

Suitable for drives with high dynamic

requirements

SpeedReference

TorqueControllerPI PI

estim

idq*

idq_estim_filt

BSF

estim

udqcomp

estim

ud_hfuhf(t)=Um*sin( hft)

dq

ABC

dq

ABC

dq

ABC

PI PITorque

Controller

BSF

estimPosition estimationSpeed estimation estim

IPMSMSensorlessAlgorithms

CurrentReconstruction

Algorithm

PWMGeneration

AC Mains

IPMSM

ADC

iABC

SoftwarePortion

HardwarePortion

3-ph Converter

High-precison speed/torque control

Removal of speed sensor

Applications

Appliances

HVAC

Compressors

Blowers

Industrial motion controls

Recommended Devices



MPC55xx

Analog/Mixed Signal Power ICs

Motor Driver: MC33927, MC33937

Application Notes

8-bit AN2357 Sine Voltage Powered 3-Phase

Permanent Magnet Motor with Hall

Sensor



Microcontrollers





(LIN)

DRM036 Sine Voltage Powered 3-Phase

Permanent Magnet Synchronous

Motor with Hall Sensors

16-bit AN1931 3-Phase PM Synchronous Motor

Vector Control


Hardware Interface

DRM102 PMSM Vector Control with Single-

Shunt Current-Sensing Using

MC56F8013/23

DRM099 Sensorless PMSM Vector Control

with a Sliding Mode Observer for

Compressors Using MC56F8013

3736


3736


Switch Reluctance Motor Drive

Sensorless

Advantages

Reliable electronics

High starting torque

Removal of position sensor

3-Phase SR Power Stage

SRM

PWMLoad

DC-Bus VoltagePhase CurrentTemperature

AC

DC

1or3

Commutation

Comparator

FaultProtectionPWM

GenerationCurrent

ControllerSpeed

ControllerSpeedRamp

Req.Speed

DesiredSpeed

SpeedError

DC-BusVoltage

ActualSpeed

MCU/DSC

SpeedCalculation

MUX

Commutation

CommutationAngle

ActualCurrent

DC-BusVoltage

CommutationAngle

CommutationAngle

Calculation

Estim.Flux

Refer.Flux

ReferenceFlux LinkageCalculation

Flux Linkageand

ResistanceEstimation

DesiredCurrent

CurrentError

DutyCycle

StartStop

Down

Up

Free MasterSCI

Applications

Industrial machines

Medical scanners

Computers, office equipment

Toys

Food processors

Vacuum cleaners

Machine tools

Large appliances

Recommended Devices


16-bit MCU: S12XE

Analog/Mixed Signal Power ICs

Motor Driver: MC33927, MC33937

Application Notes

16-bit AN1912 3-Phase Switched Reluctance (SR)

Motor Control with Hall Sensors

AN1932 3-Phase Switched Reluctance (SR)

Sensorless Motor Control

DRM100 Sensorless High-Speed SR Motor

Drive for Vacuum Cleaners Using

an MC56F8013

Reference Designs

RDDSP56F8SRDE 3-Phase Switched Reluctance

Motor Control with Encoder

Using 56F80X Digital Signal

Controllers

RDDSP56F8SRDHS 3-Phase Switched Reluctance

Motor Control with Hall

Sensor Reference Design for

56F80X or 56F8300 Digital

Signal Controllers

RDDSP56F8SRDS 3-Phase Switched Reluctance

Motor Sensorless Control

Reference Design Using

56F80X or 56F8300 Digital

Signal Controllers

3938


www.silica.com 3938


Power ICs for Motor Control Products

Analog/mixed-signal integrated circuits as part of

robust, highly integrated system solutions

Freescale offers the following analog evaluation

boards and modules:

Device P/N Evaluation Boards and Modules

MC33399 KIT33399DEVB

MC33661 KIT33661DEVB

MC33689 KIT33689DWBEVB

MC33742 KIT33742DWEVB

MC33800 KIT33800EKEVME

MC33810 KIE33810EKEVME


MC33887 KIT33887DWBEVB/KIT33887PNBEVB


MC33926 KIT33926PNBEVBE

MC33927 KIT33927EKEVBE

MC33972 KIT33972AEWEVBE

Power Supply

Management

Inter-ModuleCommunication

System Input

Conditioning

Feedback

Conditioning

Rotor Position(optional)

SPI or ParallelControl

Power Actuation

Motor

MechAssy

MCUDSP

ASSPController

Inter-ModuleCommunication

ProductsMC33390MC33399MC33661MC33790MC33897MC33990MC33910MC33911MC33912

ConditioningProducts

MC33287MC33811MC33884MC33972MC33975MC33993

Management Products

MC33689MC33742MC33889

MC33/34910MC33/34911MC33/34912

MC33989MC34701MC34702

MC34712MC34713MC34716MC34717MC34921MC33910MC33911MC33912

Power Products

MC33580MC33800MC33810MC33874MC33879MC33880MC33882MC33886MC33887MC33899MC33976MC33977MC33926MC33927MC33981

MC33982MC33984MC33991MC33996MC33999MC33920MC33923MC17510MC17511MC17529MC17533

MC908E624MC908E625MC908E626

Device P/N Evaluation Boards and Modules

MC33975 KIT33975AEWEVBE

MC33984 KIT33984PNAEVB


MC33996 KIT33996EKEVB

MC33999 KIT33999EKEVB



MC34712 KIT34712EPEVBE




MPC17C724 KIT17C724EPEVBE

Please visit www.freescale.com/analog for more

details.

3938


3938


8-bit Microcontroller Motor Control Products

Feature-rich portfolio that meets all of your 8-bit

needs

Freescales 8-bit portfolio includes several low-

end devices that provide cost-effective solutions

for motor control applications. From flash to ROM,

8-bit Product Summary

Device Flash RAMADC Timers

5V IO Analog Comparator Communications PackagesChannels Bits GPT ESCI SPI I2C ACMP

MC3PHAC 4 10 6 Output N/A Y UART 1, 13, 22

MC9S08AC 128 KB 2 KB 16 102 x 2-ch. x 16-bit/

6-ch. x 16-bit See GPT N Y UART, SPI, I2C 1, 2, 3, 4, 5

MC9S08DZ 128 KB 8 KB 24 122-ch. x 16-bit/ 8-ch. x 16-bit See GPT N Y 2 UART, CAN, SPI, I

2C 1, 4, 18, 19

MC9S08GB 60 KB 4 KB 8 10 3-ch. x 16-bit/ 5-ch. x 16-bit See GPT N UART, SPI, I2C 4, 5

MC9RS08KA 8 KB 0.25 KB 12 10 2 x 8-bit/2-ch. x 8-bit See GPT N Y 1 I2C 6, 7, 8, 9

MC908MR 32 KB 0.75 KB 10 104-ch. x 16-bit/ 2-ch. x 16-bit

6-ch. x 12-bit Y Y UART, SPI 5, 23

MC9S08QD 4 KB 0.25 KB 4 102-ch. x 16-bit/ 1-ch. x 16-bit See GPT N Y 16, 17

MC9S08QG 8 KB 0.5 KB 8 102-ch. x 16-bit/

1 x 8-bit See GPT N 1 UART, SPI, I2C 15, 6, 11, 20, 21

MC9S08SH 32 KB 1 KB 16 102 x 2-ch. x 16-bit/

1 x 8-bit See GPT N Y 1 UART, SPI, I2C

11, 12, 13, 14, 15, 16

** HDI = Hardware Deadtime Insertion

8 Bit Development Tool SummaryHCS08/RS08

Family Part NumbersStarter Kit Advanced Development

Demo Board Software Evaluation Board Kit Software

AC

MC9S08AC128/96 DEMOACKIT

CWX-HXX-SE*Compiles up

to 32k of object code

DEMOACKIT + DEMOACEX

Options starting at $395. More options

and information at www.freescale.com/

codewarrior

MC9S08AC60/48/32 DEMO9S08AC60E DEMO9S08AC60KIT

MC9S08AC16/8 DEMO9S08AC60E DEMO9S08AC16KIT

DZ MC9S08DZ128/ 96/60/32/16 DEMO9S08DZ60 EVB9S08DZ60

GB MC9S08GB60/32 M68DEMO908GB60E M68EVB908GB60E

KA

MC9RS08KA2/1DEMO9RS08KA2USBSPYDER08

EVB9S08DZ60MC9RS08KA8/4

DEMO9RS08KA8USBSPYDER08

MR MC908MR32/16/8 USBSPYDER08

QD MC9S08QD4/2DEMO9S08QD4USBSPYDER08

QG MC9S08QG8/4 DEMO9S08QG8

SHMC9S08SH8/4 DEMO9S08SH8

MC9S08SH32/16 DEMO9S08SH32

* Codewarrior Development Studio for HC(S)08 Special Edition is complimentary and is supplied with all Freescale development tools. Upgrade available to support expanded memory sizes with part number CWP-PRO-NL/FL.

Package InformationNumber Type Size (mm) Pitch (mm)

1 32 LQFP 7 x 7 0.82 44 LQFP 10 x 10 0.83 48 QFN 7 x 7 0.54 64 LQFP 10 x 10 0.55 64 QFP 14 x 14 0.86 16 LD PDIP 19 x 6.5 2.547 16 LD SOIC 10.3 x 7.5 1.278 20 PDIP 24.5 x 7.25 2.549 20 LD SOIC 12.8 x 7.5 1.27

10 80 LQFP 14 x 14 0.6511 16 TSSOP 5 x 4.4 0.6512 20 TSSOP 6.5 x 4.4 0.65

13 28 SOIC 18 x 7.5 1.2714 28 TSSOP 9.7 x 4.4 0.6515 24 QFN 4 x 4 0.5016 8 NB SOIC 5 x 4 1.2717 8 PDIP 10 x 6.35 2.5418 48 LQFP 7 x 7 0.5019 100 LQFP 14 x 14 0.5020 16 QFN 5 x 5 0.8021 8 DFN 4 x 4 0.8022 28 DIP 37 x 14 2.5423 56 SDIP 52 x 14 1.77

from 1 KB to 60 KB of memory and from tiny 8-pin

QFN to 64-pin quad flat packages, the HCS08 and

RS08 families are designed to meet all of your 8-bit

needs. They feature peripherals, such as 10-bit A/D

convertors and multi-channel timers, which make

them ideal candidates for low-end motor control

applications.

4140


www.silica.com 4140


16-bit MCU and Digital Signal Controller Motor

Control Products

Specialising in automotive and DSP processing

applications, the S12X and DSCs offer superior

functionality in a 16-bit package

16-bit digital signal controller (DSC) products The

56800 core-based family of DSCs combines the



5V IO Analog Comparator Communications PackagesChannels Bits GPT PIT PWM HDI** TPU

MC56F801x 16 KB 4 KB 2 x 4-ch. 12 4 x 16-bit See GPT 6-ch. x 15-bit Y Y UART, SPI, I2C 5

MC56F802x 32 KB 4 KB 2 x 8-ch. 12 2 x 4-ch. x 16-bit 3 x 16-bit6-ch. x 15-bit Y Y 2 UART, SPI, CAN, I

2C 6

MC56F803x 64 KB 8 KB 2 x 8-ch. 12 2 x 4-ch. x 16-bit 3 x 16-bit6-ch. x 15-bit Y Y 2 UART, SPI, CAN, I

2C 6

MC56F8123/8122 32 KB 8 KB 2 x 4-ch. 12 2 x 4-ch. x 16-bit 6-ch. x 15-bit Y Y UART, SPI 6

MC56F8135 64 KB 8 KB 4 x 4-ch. 12 2 x 4-ch. x 16-bit 6-ch. x 15-bit Y Y

UART, SPI, CAN, Quad Decoder 7

MC56F8147/8146/8145 128 KB 8 KB 4 x 4-ch. 12 2 x 4-ch. x 16-bit 6-ch. x 15-bit Y Y

UART, SPI, Quad Decoder 8





MC56F8323/8322 32 KB 8 KB 2 x 4-ch. 12 2 x 4-ch. x 16-bit 6-ch. x 15-bit Y Y

UART, SPI, CAN, Quad Decoder 6

MC56F8335 64 KB 8 KB 4 x 4-ch. 12 4 x 4-ch. x 16-bit 2 x 6-ch. x

15-bit Y Y UART, SPI, CAN, Quad Decoder 7

MC56F8347/8346/8345 128 KB 8 KB 4 x 4-ch. 12 4 x 4-ch. x 16-bit 2 x 6-ch. x

15-bit Y Y UART, SPI, CAN, Quad Decoder 8, 9





MC9S12XE 1024 KB 64 KB 2 x 16-ch. 12 8-ch. x 16-bit 8-ch. x 16-bit8/4-ch. x 8/16-bit Xgate Y UART, CAN, SPI, I

2C 1, 2, 3, 4

** HDI = Hardware Deadtime Insertion

DSC Development Tool Summary



56F8000

MC56F8011 DEMO56F8014-EE

CWX-568-SE*Compiles up

to 32k of object code



codewarrior

MC56F8013 DEMO56F8013-EEMC56F8014 DEMO56F8014-EE

MC56F802x/3x 56F8037EVM

56F8100

MC56F8123/8122

MC56F8367EVMEMC56F8135

MC56F8367EVMEMC56F8147/8146/8145MC56F8157/8156/8155MC56F8167/8166/8165

56F8300

MC56F8323/8322 MC56F8323EVMEMC56F8335

MC56F8367EVMEMC56F8347/8346/8345MC56F8357/8356/8355MC56F8367/8366/8365

S12X Development Tool Summary



XE

MC9S12XEP768/100

DEMO9S12XEP100

CWX-HXX-SE*Compiles

up to 32k of object code

EVB9S12XEP100



codewarrior

MC9S12XEQ512/384MC9S12XET256MC9S12XEG128

* CodeWarrior Development Studio for S12X Special Edition is complimentary and is supplied with all Freescale S12X development tools. Upgrade available to support expanded memory sizes with part number CWP-PRO-NL/FL.

Package InformationNumber Type Size (mm) Pitch (mm)

1 80 LQFP 14 x 14 0.652 112 LQFP 20 x 20 0.653 144 LQFP 20 x 20 0.54 208 MAPBGA 17 x 17 1.05 32 LQFP 7 x 7 0.86 64 LQFP 12 x 12 0.57 128 LQFP 20 x 14 0.58 160 LQFP 24 x 24 0.59 160 MAPBGA 15 x 15 1.0

* CodeWarrior Development Studio for 56800 Special Edition is complimentary and is supplied with all Freescale 56800 development tools. Upgrade available to support expanded memory sizes with part number CWP-PRO-NL/FL.

processing power of a DSP and the functionality of

a microcontroller, with a flexible set of peripherals

on a single chip. This creates an extremely cost-

effective motor control solution. MC9S12XE

family will deliver 32-bit performance with all the

advantages and efficiencies of a 16-bit MCU.

4140


4140


32-bit Microcontroller Motor Control Products

High performance for complex, real-time motor

control applications

These 32-bit embedded microcontrollers combine

higher performance with increased on-chip

functionality to address complex real-time control

applications that require more system throughput.

Both the ColdFire family and MPC500 and MPC5500

families built on Power Architecture technology

are capable of fulfilling the most demanding motor

control requirements in a wide range of operating

environments.



5V IO Analog Comparator Communications PackagesChannels Bits GPT PIT PWM HDI** TPU

MCF51AC 256 KB 32 KB 24 12 6 2 Y Y 2 I2C, SPI, CAN 1, 8

MCF521x 256 KB 32 KB 8 12 4-ch. x 32-bit 2 x 16-bit 8/4-ch. x 8/16-bit N UART, I2C, SPI, CAN 1, 2, 3, 4

MCF521xx 128 KB 16 KB 8 12 4-ch. x 32-bit 2 x16-bit 8/4-ch. x 8/16-bit N UART, I2C, SPI, CAN 1, 2, 3, 4

MCF5221x 128 KB 16 KB 8 12 4-ch. x 32-bit 2 x16-bit 8/4-ch. x 8/16-bit N UART, I2C, SPI, CAN,

USB 1, 2, 3, 4


USB 1, 2, 3, 4


Ethernet 8, 9, 10

MCF523x 64 KB 4-ch. x 32-bit 4 x 16-bit See TPU eTPU 32-ch. eTPU UART, CAN, I2C, SPI,

Ethernet 5, 6, 7

MCF5282 512 KB 64 KB 8 10 4-ch. x 16-bit 4 x 16-bit 1 x 16-bit N Y UART, CAN, I2C, SPI,

Ethernet, USB 7

MPC561/2 32 KB 32 10 6 x 16-bit 1 x 16-bit 6 x 16-bit TPU 2 x 16-ch. Y UART, CAN, SPI 11

MPC563/4 512 KB 32 KB 32 10 6 x 16-bit 1 x 16-bit 6 x 16-bit TPU 2 x 16-ch. Y UART, CAN, SPI 11

MPC565/6 1024 KB 36 KB 40 10 6 x 16-bit 1 x 16-bit 6 x 16-bit TPU 3 x 16-ch. Y UART, CAN, SPI 11

MPC5534 1024 KB 64 KB 2 x 40 12 24-ch. x 24-bit Part of GPT eMIOS/eTPU 32-ch. eTPU Y UART, CAN, SPI 12, 13

MPC5553 1536 KB 64 KB 2 x 40 12 24-ch. x 24-bit Part of GPT eMIOS/eTPU 32-ch. eTPU Y UART, CAN, SPI 12, 13, 14

MPC5554 2048 KB 64 KB 2 x 40 12 24-ch. x 24-bit Part of GPT eMIOS/eTPU2 x 32-ch.

eTPU Y UART, CAN, SPI,

Ethernet 12, 13, 14

MPC5565 2048 KB 80 KB 2 x 40 12 24-ch. x 24-bit Part of GPT eMIOS/eTPU 32-ch. eTPU Y UART, CAN, SPI 13

MPC5566 3072 KB 128 KB 2 x 40 12 24-ch. x 24-bit Part of GPT eMIOS/eTPU2 x 32-ch.

eTPU Y UART, CAN, SPI,

Ethernet 14 * listed are for the superset device in each family. Memory sizes, peripherals and communication options vary by device. Please see appropriate data sheet for further information. ** HDI = Hardware Deadtime Insertion

ColdFire Development Tool Summary



MCF51ACxxx MCF51AC256/128 DEMOACKIT CWX-HXX-SE* DEMOACKIT/DEMOACEX



codewarrior

MCF521xMCF5213/2/1 M5211DEMO

CWX-MCF-SE*

M5213EVBEMCF5216/4 M5282LITEKIT M5282EVBE

MCF521xx MCF52110/52100 M52210DEMO M52211EVB

MCF522xxMCF52211/52210 M52210DEMO M52211EVB

MCF52223/1 M52223EVBMCF5223x MCF52

motor control workbook

Documents

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