Stellaris® Brushed DC Motor Control RDK User`s Manual
Contents
1. WET E TA 8 ile Servo ype gt sss Weitere Vedere N SER m speed control input 7 Limit switch inputs Coast Brake select P Quadrature encoder input QEI Wire retention hooks Analog potentiometer input November 1 2008 5 Reference Design Kit RDK Overview 6 November 1 2008 CHAPTER 2 Using the Reference Design Kit This chapter provides information about the RDK BDC kit contents and on using the RDK Reference Design Kit Contents The RDK BDC contains everything needed to evaluate 12 V brushed DC motor control The RDK BDC includes MDL BDC motor control module Suitable for motors up to 12 V 40 A Uses aStellaris LM3S2616 microcontroller Mabuchi RS 555PH 5255 Brushed DC Motor 5000 RPM 12V 3A Universal input wall power supply 12V1 25A Plug adaptors for US UK EU and AUST BDC CAN console Convenient tool for controlling key MDL BDC functions Integrated graphics display and navigation switches Firmware update feature Based EK LM3S2965 Evaluation2. ff CAS 2 el EES EE sey SERVO E ANA air Coast Brake Jumpers hold the limit default brake switch inputs closed Fault Detection Software and hardware in the MDL BDC continually monitors for various fault conditions Fault Conditions A slow flashing Red LED indicates a fault condition The MDL BDC will detect and shutdown the motor if any of the following conditions are detected m Power supply under voltage Over temperature 16 November 1 2008 Stellaris amp Brushed DC Motor Control User s Manual Over current m Limit switch activated in the current direction of motion The LED will indicate a fault state during the fault condition and for 3 seconds after the fault is cleared except for the limit switch fault which is cleared instantaneously Loss of CAN or Servo style Speed Link A slow flashing Yellow LED indicates that the MDL BDC is not receiving a valid control signal The control link error is cleared immediately when a CAN or PWM signal is restored November 1 2008 17 Using the Reference Design Kit 18 November 1 2008 CHAPTER 3 BDC Can Console The BDC CAN console included in the RDK BDC provides a convenient way to evaluate some of the capabilities of the CAN interface Overview The BDC CAN console is based on Luminary Micro s LM3S2965 Evaluation Board The board ships with the console application
3. n 21 DEVICE ISU susu gua M y 21 Firmware 22 22 22 Chapter 4 Firmware Updates and Debugging l u u u u 23 General 23 Firmware Update Using CAN uuu edt bak n dd dac d dada 23 How to Load Firmware from a PC to the CAN Console sse 23 Firmware Update Using BDC CAN Console 25 Firmware M eRIIDPE 26 Chapter 5 Hardware Description u u u annnm nnn uu uu u u 29 Hardware Descriptio u ERE umasa 29 SY i uu ints PEE 29 Key Hardware 29 11 1 08 1 Schematic DescriptiOh ecce e eite Entre eee ote e reel I lela gta 30 Microcontroller CAN and I O Interfaces Page 1 l nennen nnne 30 Output Stage and Power Supplies Page 2 n 31 6 Tro bleshooting u UL P m 33 Appendix A Schematics u A Q a
4. 35 Appendix B Board Drawing 1212 U U u uuu uu uu uuu u uu 39 Appendix C Bill of Materials 1 U U U u u u uuu uu uu uuu 41 Appendix D Contact Information uu uu u u erae E ae QS SI u i upi yas 45 2 11 1 08 Stellaris amp Brushed DC Motor Control User s Manual List of Figures Figure 1 1 Figure 1 2 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 3 1 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 5 1 Figure 5 2 Figure 5 3 Figure B 1 11 1 08 Brushed DC Motor Control Module n an 3 MDL BDC Module Key Features top view 5 MDL BDC s Servo PWM Input Stage a 11 Basic wiring with a Servo style speed command for open loop motor control 13 Wiring diagram showing CAN based control for closed loop motor control 14 MDL BDC Mechanical Drawing sess enne nnne nns innen nnn sinn 15 MDL BDC Default Jumper 16 CAN Ben mec 19 Diagram showing the two step firmware update 23 Luminary Micro Flash Programmer Configuration essen 24 Transfer in
5. 25 Locating the JTAG SWD 26 Firmware debugging using 5 s 27 MDE BDG Circuit BOard 5 cies tette erit Leider 29 MDL BDC JTAG SWD 30 Network Connector Pin Assignments 0 eene 31 Component Placement Plot sse eene nennen nnne nri trennt en rennes nns 39 11 1 08 Stellaris Brushed DC Motor Control User s Manual List of Tables Table 2 1 Mabuchi RS 555PH 3255 Motor Specifications sse 9 Table 2 2 Control Method Comparison a nn 9 Table 2 3 Recommended Values for External Resistor a 11 Table 2 4 MDL BDC Factory Default Configuration r 12 Table 2 5 Normal Operating Conditions seen nennen nennen nennen 15 Table 3 1 RDK BDC Available Cables uu a asas apasqa nnns 20 Table 6 1 COMMON Problems ULU ni kk dui eek da eid eee a aed ek dua ee kd e 33 Table C 1 RDK BDC Bill of 41 11 1 08 1 11 1 08 CHAPTER 1 Stellaris Brushed DC Motor Control Reference Design Kit RDK Overview The RDK BDC is a Luminary Micro reference design for the MDL BDC a Controller Area Network
6. ICKSWCLK 52 pcortcK SWCLK PDO IDXO 6 QE INDEX 33V JPI B PCI TMS SWDIO PDI 02 1 PC TDI PD2 ADCS PRAKEN BRAKE EN pest PC3 TDO SWO PD3 ADC4 485 PSU vBoorB t Brake default PCA PhAO D3 PC5 C0o 2 HDR IX3 PC6 PhBO PEO ADC3 VBOOTA Brake Coast Jumper PCT CI Clo PELADC2 5 NSE PEJADCI ISENSE 1 1 PEXADCO VSENSE At OSCO PEA FAULTO Gsorosc gt OSCI XOSCO NC be 0 NV XOSCI ne 8 POT ANA 16 00MHz T E 33V R8 WAKE L3 4 m 12 10K Position Pot m 10K HIB VDD33 35 D4 VDD3 C5 cs RST VDD33 9 oo ooa 0 1UF 0 1UF 0 01UF 5 GND VBAT GND A GND B GND 2 QE INDEX i GND LDO GND GND 5025 55 cii 2 HDR IX5 GND VDD25 5s 0 0109 0 1UF Encoder GND VDD25 E GNDA VDD25 al 1 LM3S2616 333 GSOTOSC Factory Test R12 10K J6 i 33V History 33V TPI M LIMIT2 m u Jumper Installed default Date Description Q2 RXD SPDIN D6 Debug RI3 1 HDR 1X2 1 July 08 First production design 10K TXD D Limit Switch 2 Reverse d 1 4 TMS SWDIO CE 1 08 Improve Isense circuit Change AIN pin out TMS SWDIO O MS SWDI S S 2 5Sept 08 Change R42 to 150 ohms oN WEEK oF TCK SWCLK R14 D 20 Oct 08 Add to op amp circuit TDI 10K GSOTOSC B MICRO RESETn IP7 TDI LIMITI
7. C16 X5R 0805 Yuden C17 C18 C22 C23 3 C15 ESMG250ELL332MN2 Capacitor 3300uF UCC Digikey 565 1066 ND 0S 25V Electro 20x20mm 4 C3 C4 C0805C100J5GACTU Capacitor 10pF 50V Kemet Mouser 80 C0805C100J5G 596 Ceramic NPO COG 0805 5 C5 C6 C9 C0805C103J5RACTU Capacitor 0 01uF Kemet Mouser 80 0805 103 5 C10 C19 50V 596 0805 X7R C20 C21 C24 6 D1 WP59SRSGW CC LED Bi Color Red Kingbright Digikey 754 1235 ND WP59EGW Grn 5mm Com Mouser Cathode 7 D2 D3 GSOTOSC Diode Dual ESD Vishay Digikey 751 1415 2 ND D4 D5 D6 SMO5T1GOS Protection Device 754 1232 ND SOT 23 8 D7 D8 CD1005 S0180 Diode 80V high Bourns Mouser 652 CD1005 S0180 speed 1005 size 9 1 2 90512 003LF 04911 Connector 11 FCI Digikey 609 1064 ND Mod J ack 6 4 Vert 4ucon 4ucon 04911 Flange BIk 10 3 PPTCO31LFBN RC Connector Female Sullins Digikey S7001 ND 00526 00526 1x3 socket 0 1 4ucon 4ucon 8 5mm gold flash 11 4 JP1 00798 Header 1x3 0 1 4ucon 4ucon 00798 6mm contact 3mm tail gold November 1 2008 41 Table C 1 RDK BDC Bill of Materials Continued 12 J5 1 00806 Header 1x5 0 1 4ucon 4ucon 00806 6mm contact 3mm tail gold 13 J6 8 1 15948 Header 2x2 0 1 4ucon 4ucon 988 6mm contact 3mm tail gold 14 7 0 M50 3500542 Connector 2x5 Harwin Mouser 855 M50 3500542 Header 1 27mm pitch OMIT 15 J9 1 35362 0210 Connector 2 Pin Molex Arrow 35362 0250 Sherlock 2mm vert header 16 JP1b J6b 3 151 80
8. Kit CAN cable Connects the console to the MDL BDC CAN terminator Plug in 120 O terminator USB cable Provides power and communication to the BDC CAN console Adapter cable for ARM JTAG SWD fine pitch header Luminary Part ADA2 Ribbon cable for ARM JTAG SWD 20 position cable for using the BDC CAN console as a debug interface Reference design kit CD Complete documentation including Quickstart and user s guides Luminary Micro Flash Programmer utility for firmware updates Complete source code schematics and PCB Gerber files The source code can be modified and compiled using tools from Keil IAR CodeRed CodeSourcery and GCC November 1 2008 Using the Reference Design Kit Important Information WARNING In addition to safety risks other factors that may damage the control hardware the motor and its load include improper configuration wiring or software Minimize the risk of damage by following these guidelines Always wear eye protection and use care when operating the motor Read this guide before connecting motors other than the motor included in the RDK DC motors may not be directly interchangeable and RDK parameter changes may be necessary before the new motor will operate correctly Damage to the control board and motor can result from improper configuration wiring or software Developing with the RDK The recommended steps for using the RDK are m Follow the Quickst
9. The MDL BDC should be mounted so that the vents in the top and sides of the module are not restricted any way A clearance of 1 2 inch should be maintained around the module to aid cooling Status LED Table 2 5 lists all LED status and fault codes Fault information is prioritized so only the highest priority fault will be indicated Table 2 5 Normal Operating Conditions Normal Operating Conditions Solid Yellow Neutral speed set to 0 Fast Flashing Green Forward Fast Flashing Red Reverse November 1 2008 15 Using the Reference Design Kit Table 2 5 Normal Operating Conditions Continued Solid Green Full speed forward Solid Red Full speed reverse Fault Conditions Slow Flashing Yellow Loss of CAN or servo link Slow Flashing Red Fault Calibration or CAN Conditions Flashing Red and Green Calibration mode active Flashing Red and Yellow Calibration mode failure Flashing Green and Yellow Calibration mode success Slow Flashing Green CAN ID assignment mode Fast Flashing Yellow Current CAN ID count flashes to determine ID Flashing Yellow CAN ID invalid that is Set to 0 awaiting valid ID assignment Jumper Settings Figure 2 5 shows the factory default jumper settings Figure 2 5 MDL BDC Default Jumper Settings
10. Wiring diagram showing CAN based control for closed loop motor control lt Power In I C Suppy GND lt n 4 Supply lt d I CAN cable to from other devices NET Motor Out Hail Weg Motor el N X E 4 m H Coast L Brake External coast brake control optional GND 3V Reference 10kQ Potentiometer 0 3V signal position sensor opt GND 14 Motor User switch E sets CAN ID XX _ CAN cable to from other devices Normallyclosed limit switches Reverse Limit Forward Limit GND Encoder opt November 1 2008 Stellaris amp Brushed DC Motor Control User s Manual Mechanical Drawing Figure 2 4 shows the MDL BDC s physical dimensions The module has two 0 175 4 5 mm diameter mounting holes as indicated Figure 2 4 MDL BDC Mechanical Drawing 3 500 1 987 e 2 000 3 843 Important
11. contains a CAN boot loader The main firmware image should be loaded at 0x0800 Firmware Update Using CAN The MDL BDC firmware can be updated over CAN using the BDC CAN console board included in the reference design kit The capability to update the MDL BDC firmware may also be added to any CAN Host controllers by implementing the necessary CAN protocol The BDC CAN console comes with a firmware image already loaded and ready for transfer to the MDL BDC Of course updating the firmware is a redundant process unless the firmware in the console is newer than the firmware in the module How to Load Firmware from a PC to the BDC CAN Console The MDL BDC firmware is stored in the top of flash memory in the CAN console This image can be replaced with new software using the resident serial flash loader and the LM Flash software from Luminary Micro Figure 4 1 Diagram showing the two step firmware update process PC running LM Flash Utility MDL BDC Firmware Image MDL BDC Firmware Image Transfer over CAN 1 Transfer over USB Virtual COM Port November 1 2008 23 Firmware Updates and Debugging The console stores the MDL BDC firmware image length at 0x20000 and the actual image starting at 0x20004 Step One Install USB Drivers for the Console The USB driver installation is covered in the RDK BDC Quickstart Guide See that document for full details Once the USB drivers are installed the cons
12. lt 1 Installed default 4 e jumper Installed defau Drawing Tile Jaguar Brushed DC Motor Control OQ FANN HDR 1X2 Page Title TP9 Limit Switch 1 Forward ade Title MCU Network and Interface 4 Size B Document Number RDK BDC Date 10 20 2008 nest don 1 2 3 5 6 2 HY Ris 97 12V WA 47 4 CD0805 S0180 Q2 omen FDP8874 FDP8874 FDP8874 d ER DEF DB R16 R17 R18 100 7 100 7 100 GATE BH 12V POWER IN 7 5 R19 V 2 PQILASO3MSPQ ee PQILA333MSPQ 300K 4 vin vour 5 4 vin VBOOTB 16 Motor 5109 4 R22 CI5 ON amp 4 NR ON NR 10K ci6 Loa cis i 9 z m V FS 3300UF VSENSE TUE Z SU 5 on TUE White 01 a 0 01UF a 0 01UF CTRLB gt 2 0 01UF 3 GATE BL R27 10K 4 12v 9 1 Red 12V D8 lt FANN Black 27 AMEMTAZE CD0805 S0180
13. module includes fan cooling Flexible configuration options Easy to customize full source code and design files available Factory source code compiles to less than 16 KB Specification Overview Key specifications of the MDL BDC include Quiet control of brushed DC motors 15kHz PWM frequency Two options for Speed control Industry standard R C servo type PWM interface Controller Area Network CAN interface CAN communication Multicast shared serial bus for connecting systems in electromagnetically noisy environments 1 Mbits s bit rate CAN protocol version 2 0 A B Full configurability of module options Real time monitoring of current voltage speed and other parameters Status LED indicates Run Direction and Fault conditions Motor brake coast selector Limit switch inputs for forward and reverse directions Quadrature encoder input Index input 5 V supply output to encoder Analog input Accepts 10kQ potentiometer or 0 3 V input Screw terminals for all power wiring Headers 0 1 inch pitch for all control signals For detailed specifications including electrical parameters see the MDL BDC data sheet November 1 2008 Stellaris amp Brushed DC Motor Control User s Manual Figure 1 2 MDL BDC Module Key Features top view Internal cooling fan NN Power terminals Motor terminals
14. ready to run For more information on the capabilities of this board see the LM3S2965 Evaluation Board User s Manual Note that the LM3S2110 CAN Device board is not included in the Reference Design Kit Figure 3 1 The application provides a simple user interface for the brushed DC motor controller board running on the EK LM3S2965 board and communicating over CAN In addition to running the November 1 2008 BDC CAN Console mA mmm gH ep 4 Ped i Reference Design Kit 1 us Sco Foult 9 9 CCP4 1 352965 EVAL BOARDS 6 Soxo ADC1 9 ADC3 Saot CANORX 550 SSIoRX scu PHA ni T V USB GNO 59 55 9 19 040 6 2 056320 CANIRX P 907 cz o PH O nii 28 s 5 S z 22 4 LECT SSHTX 55 9500 605532 7 19 amp BDC Can Console motor the motor status can be viewed the CAN network enumerated and the motor controller s firmware can be updated Using the Console Cables Set Up 20 The CD included in the RDK BDC contains a Quickstart guide that covers basic operation of the MDL BDC and console See this document for step by step instructions for connecting and using the RD
15. simple errors in wiring software or use can affect normal operation This chapter provides guidance on resolving common problems Table 6 1 Common Problems No LED activity LED always off Power source is out of specification Use a volt meter to confirm that 12 V is present between the Red Black terminals and the polarity is correct Incorrect firmware possibly containing bugs or intended for another target Load new firmware into the console and re program the MDL BDC It is possible in this case that the module can not be updated via the CAN interface and therefore must be updated using JTAG SWD No firmware loaded Only the boot loader is resident in memory Load firmware into the console and re program the MDL BDC LED indicates under voltage fault when running The power supply is unable to maintain voltage under load Recharge battery or change to a power supply with a higher ampere rating The LED blinks erratically when motor is running Motor fails to run The power supply is unable to maintain voltage under load and is dropping below 6V which is resetting the MDL BDC electronics Limit switches are open Recharge battery or change to a power supply with a higher ampere rating Install jumper shunts to hold limit switch inputs closed Motor operates in one direction only Limit switch is open Check limit switch operation or insert the appropriate jumpe
16. spinning in the opposite direction There are three parameters that can be adjusted on this panel the ID voltage and ramp rate The up and down buttons are used to select the parameter to be modified and the left and right buttons are used to adjust the parameter s value The following parameters can be adjusted ID which selects the motor controller to which commands are sent If the ID is changed while the motor is running the motor will be stopped m Voltage which specifies the output voltage sent from the motor controller to the motor A positive voltage will result in voltage being applied to the white output terminal and ground being applied to the green output terminal while a negative voltage will apply voltage to the green output terminal and ground to the white output terminal If the select button is pressed changes to the output voltage will not be sent to the motor controller immediately allowing the ramp to be used The text color of the voltage changes from white to black to indicate that a deferred update is active Pressing select again will send the final output voltage to the motor controller creating a step function m Ramp which specifies the rate of change of the output voltage When set to the output voltage will change immediately When set to a value the output voltage is slowly changed from the current to the target value at the specified rate This can be used to avoid browning out the pow
17. 00 05734 Jumper Shunt Kobiconn Mouser 151 8000 05734 J8b 0 1 gold 4ucon 4ucon 17 Q1 Q2 12 FDP8874 Mosfet N Channel V Fairchild Arrow FDP8874 Q3 Q4 30V 114A TO 220 Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12 18 Q13 1 FDV301N Mosfet N Channel Fairchild Arrow FDV301NTR ND SOT 23 19 R1 R16 13 Resistor 100 ohms Panasonic Digikey P100ATR ND R17 R18 596 0805 R24 R25 R26 R29 R30 R31 R36 R37 R38 20 R15 R28 2 Resistor 4 7 Ohms Panasonic Digikey P4 7ATR ND 5 0603 21 R2 R5 3 Resistor 150 ohms Panasonic Digikey P150ATR ND R42 5 0805 22 R6 R7 4 Resistor 1 0K 1 Panasonic Digikey P1 00KCTR ND R23 R34 0805 42 November 1 2008 Stellaris amp Brushed DC Motor Control User s Manual Table C 1 RDK BDC Bill of Materials Continued 23 R3 R4 R8 16 Resistor 10 0K 196 Panasonic Digikey P10 0KCTR ND R9 R10 0805 R11 R12 R13 R14 R20 R21 R22 R27 R33 R39 R41 24 R35 1 Resistor 0 0005 Stackpole Digikey CSNL20 00051 RT Ohms 2W 1 2512 R ND 25 R19 R32 3 Resistor 390K 1 Vishay Digikey 541 390KCRTR ND R40 0805 26 R43 1 Resistor 470K 1 Panasonic Digikey P470KCTR ND 0805 27 SW1 1 B3S 1000P Switch Momentary Omron Arrow SW415 ND Tact 160gmf 6mm Future 28 T1 1 7701 2 Terminal Screw Keystone Bisco 7701 2 Vertical 15A Red Screw 29 T2 1 7701 3 Terminal Screw Keystone Bisco 7701 3 Vertical 15A Black Screw 30 T4 1 7701 4 Terminal Screw Keystone Bisco 7701
18. 0608 01 plastic 3 pieces F3 4 90380A110 Screw 4 x 0 500 McMaster McMaster 90380A110 plastite for fan F4 4 90380A108 Screw 4 x 0 375 McMaster McMaster 90380A108 plastite for enclo sure 44 November 1 2008 APPENDIX D Contact Information Company Information Luminary Micro Inc designs markets and sells ARM Cortex M3 based microcontrollers MCUs Austin Texas based Luminary Micro is the lead partner for the Cortex M3 processor delivering the world s first silicon implementation of the Cortex M3 processor Luminary Micro s introduction of the Stellaris family of products provides 32 bit performance for the same price as current 8 and 16 bit microcontroller designs With entry level pricing at 1 00 for an ARM technology based MCU Luminary Micro s Stellaris product line allows for standardization that eliminates future architectural upgrades or software tool changes Luminary Micro Inc 108 Wild Basin Suite 350 Austin TX 78746 Main 1 512 279 8800 Fax 1 512 279 8879 http Awww luminarymicro com Support Information For support on Luminary Micro products contact support luminarymicro com 1 512 279 8800 ext 3 November 1 2008 45 46 November 1 2008
19. 2008 Stellaris amp Brushed DC Motor Control User s Manual The BDC CAN console automatically jumps to the Firmware Update panel when the transfer is initiated Progress bars appear on the console display and the LM Flash Programmer window Figure 4 3 Transfer in Progress Luminary Micro Flash Programmer m e xl Configuration Program Flash Utilities Other Utiities Heb Select bin file C StellarisWare boards ydk bdc gs bdc gec qs bdc bin Browse Options Erase Method Erase Entire Flash Faster Erase Neces ry Pages slower verify After Pragram Reset After Program Program Address Offset ox o Program LUMINARYMICRO When programming completes the MDL BDC firmware is resident in the console s Flash memory If an MDL BDC with the currently selected CAN ID is connected the console immediately starts a firmware update over CAN The update over CAN may also be initiated manually This procedure is covered in more detail in the following section called Firmware Update Using BDC CAN Console Firmware Update Using BDC CAN Console The following steps show how to transfer the firmware image from the console into the MDL BDC During this operation the USB cable is required only as a power source to the console Step One Establish CAN connection Connect the console to the MDL BDC using the CAN cable Follow the Set Up on page 20 for step by step instru
20. 4 Vertical 15A White Screw 31 T3 1 7701 6 Terminal Screw Keystone Bisco 7701 6 Vertical 15A Green Screw 32 U1 1 LM3S2616 IC Microcontroller Luminary Luminary LM3S2616 Stellaris Cortex M3 64 TQFP 33 U2 1 SN65HVD1050D IC CAN Transceiver TI Arrow 296 19416 5 ND SO 8 Digikey 34 U3 1 H11L1SR2VM IC Optocoupler Fairchild Arrow H11L1SR2VM H11L1SR2M Schmitt Trigger H11L1SR2M SMD 8 35 U4 1 PQ1LA503MSPQ IC Voltage regula Sharp Mouser 852 tor 5 0V 500mA PQ1LA503MSPQ SOT89 5 November 1 2008 43 Table C 1 RDK BDC Bill of Materials Continued 36 U5 1 PQ1LA333MSPQ IC Voltage regula Sharp Mouser 852 tor 3 3V 500mA PQ1LA333MSPQ SOT89 5 37 U6 U7 2 FAN5109BMX IC Half Bridge Gate Fairchild Arrow FAN5109BMX Driver SO 8 38 U8 1 4174155 NL IC Op amp Rail to Fairchild Arrow 4174155 Rail SOT 23 39 1 1 5032 Crystal 16 00 2 NDK Digikey 644 1037 2 ND 16 000000MHZ 5 0x3 2mm SMT 40 Z 1 8902 LED standoff plastic Keystone Mouser 534 8902 0 16 for LED D1 41 Z 1 BD BDC B2 PCB FR 406 2 layer Advanced Advanced BD BDC B2 3 375 x3 500 2 oz finished 116 Final Assembly Item Ref Qty Part Number Description Mfg Supplier Stock No F1 1 412 FH Fan 12VDC EBM EBM Direct 412 FH KDE1204PFV2 11 MS 40x40x10mm 7CFM Sunon Digikey 259 1351 ND A GN w 2 lead w Molex Sherlock connector F2 1 LM 0608 01 Enclosure ABS Cypress Cypress LM
21. CAN based DC motor control The MDL BDC motor control module provides variable speed control for 12 V brushed DC motors at up to 40 A continuous current Features include high performance CAN networking as well as a rich set of control options and sensor interfaces including analog and quadrature encoder interfaces High frequency PWM enables the DC motor to run smoothly and quietly over a wide speed range MDL BDC uses highly optimized software and a powerful 32 bit Stellaris LM3S2616 microcontroller to implement open loop speed control as well as closed loop control of speed position or motor current The Reference Design Kit RDK BDC contains an MDL BDC motor control module as well as additional hardware and software for evaluating CAN communication After evaluating the RDK BDC users may choose to either customize parts of the hardware and software design or use the MDL BDC without modification See the MDL BDC board data sheet available for download from www luminarymicro com for complete technical specifications Figure 1 1 Brushed DC Motor Control Module November 1 2008 3 Reference Design Kit RDK Overview Feature Summary The MDL BDC control board provides the following features Controls brushed 12 V DC motors up to 40 A continuous Controller Area Network CAN interface at 1 Mbit s Industry standard servo pulse width modulation PWM speed input interface Limit switch encoder and analog inputs Fully enclosed
22. E 12V Fan FAN ON gt 5 LON gt 3 ecu FDV30IN 1 S R31 0 GATE AH 4 Cooling Fan Control Motor e Green R43 FAN4174IP5X AOK CIRLAD m 4 2 FDP8874 ES ai E R35 PWMA gt R38 DO 0 0005 OHM T GATE AL L R39 10K 4 R41 Current Sense Amplifier 10K UT MICRO Drawing Tile Jaguar Brushed DC Motor Control lite Power Supplies and Output Stage Size B Document Number RDK BDC Date 10 20 2008 es sea 7 APPENDIX B Board Drawing This appendix contains details on component locations including m Component placement plot for top Figure B 1 Figure B 1 Component Placement Plot BLK RED os 7 m NET 2 D8 03132 R33 R39 1 U2 D m alma COAST BRAKE ANALOG A A November 1 2008 01 R19 R22 R27 Us 07 R2 RI R9 RIO 05 RH ENCODER CONTROL R20 C21R23 JTAG SWD RISRB R2 CH mm 5 716 RM LIMIT 2 39 40 November 1 2008 APPENDIX C Bill of Materials BOM Table C 1 provides the BOM for the RDK BDC Table C 1 RDK BDC Bill of Materials 1 C1 C2 C7 C0805C104M5RACTU Capacitor 0 1uF Kemet Mouser 80 C0805C104M5R C8 C11 50V 20 0805 X7R C25 2 C12 C13 TMK212BJ105KG T Capacitor 1 0uF 25V Taiyo Digikey 587 1291 1 ND C14
23. ERE aa puedes 10 Calibrating the PWM Input nennen enne nennen nennt innen 10 Calibration PIOGedLlfe nte e Dna ee us dag dud AR d d nt e d ug Ln a 10 Electrical Interface iier de etw aded ue RR ade 10 CO Mim MiG AUG i u u uuu u u u tetro E Te E 11 Default Parameters 12 WINN 12 Mechanical Drawing u n 15 Status LED uuu uuu u ARAA NEE 15 Jumper Settings a n ii cr ee u ee ver div udo 16 Fault E 16 5 asa 16 Loss of CAN or Servo style Speed Link enne nnne tenens enne nnn sinn 17 Chapter 3 Can Console U U u u u uu u J J 19 nocicnt ein cu nase mae Ue NR M MIN atau INSEL S DES cee 19 Using the Console T 20 P U cs 20 IH c A 20 iu
24. K BDC Table 3 1 shows several cables that are used in conjunction with the BDC CAN console and that are included in the RDK Table 3 1 RDK BDC Available Cables CAN cable Connects the console to the MDL BDC CAN terminator Plug in 120 O terminator USB cable Provides power and communication to BDC CAN console ADA2 JTAG adapter Adapts 10 pin JTAG SWD header to 20 pin JTAG ribbon cable 20 position cable for using the BDC console as a debug interface a These cables are only required for software debugging When controlling more than one MDL BDC modular cables 6P 4C or 6P 6C should be used to link the modules Suitable cables include the Digikey H2642R 07 ND cable Power for the console comes from a USB cable The CAN cable also included in the RDK has a RJ 11 6P 4C connector at one end and a 10 pin socket at the other end Connect cables as follows 1 Connect the CAN cable between the console CAN connector P1 and either NET connector on the MDL BDC 2 Use RJ11 RJ14 modular cables to daisy chain CAN communications to any other MDL BDC devices The cables should be 6 position with either 4 or 6 contacts installed Suitable cables have plugs crimped on opposite sides of the cable and are referred to as reverse or straight cables because pin 1 connects to pin 1 3 Thelast MDL BDC in the chain should have a CAN terminator inserted in its NET connector The BDC CAN console has an integrated terminati
25. LUMINARYMICRO Stellaris Brushed DC Motor Control Reference Design Kit USER S MANUAL RDK BDC 00 Copyright 2008 Luminary Micro Inc Legal Disclaimers and Trademark Information INFORMATION IN THIS DOCUMENT IS PROVIDED IN CONNECTION WITH LUMINARY MICRO PRODUCTS NO LICENSE EXPRESS OR IMPLIED BY ESTOPPEL OR OTHERWISE TO ANY INTELLECTUAL PROPERTY RIGHTS IS GRANTED BY THIS DOCUMENT EXCEPT AS PROVIDED IN LUMINARY MICRO S TERMS AND CONDITIONS OF SALE FOR SUCH PRODUCTS LUMINARY MICRO ASSUMES NO LIABILITY WHATSOEVER AND LUMINARY MICRO DISCLAIMS ANY EXPRESS OR IMPLIED WARRANTY RELATING TO SALE AND OR USE OF LUMINARY MICRO S PRODUCTS INCLUDING LIABILITY OR WARRANTIES RELATING TO FITNESS FOR A PARTICULAR PURPOSE MERCHANTABILITY OR INFRINGEMENT OF ANY PATENT COPYRIGHT OR OTHER INTELLECTUAL PROPERTY RIGHT LUMINARY MICRO S PRODUCTS ARE NOT INTENDED FOR USE IN MEDICAL LIFE SAVING OR LIFE SUSTAINING APPLICATIONS Luminary Micro may make changes to specifications and product descriptions at any time without notice Contact your local Luminary Micro sales office or your distributor to obtain the latest specifications before placing your product order Designers must not rely on the absence or characteristics of any features or instructions marked reserved or undefined Luminary Micro reserves these for future definition and shall have no responsibility whatsoever for conflicts or incompatibilities arising from future changes to th
26. art Guide included on the kit CD The Quickstart guide will help you get the RS 555 motor up and running using the BDC CAN console in just minutes It also contains important safety information that should be read before using the RDK Use the BDC CAN console to evaluate and optimize target motor operation Once the module is installed in the end application use the BDC CAN console to configure and monitor motor operation Using CAN the console gives real time access to a range of operating parameters m Customize and integrate the software and or hardware to suit an end application This user s manual and the RDK BDC Firmware Development Package User s Guide are two important references for completing hardware and software modifications New software can be programmed in the MDL BDC using either the console over CAN or using JTAG SWD debug interface The BDC console includes a JTAG SWD debug interface feature Power Supply Selection The MDL BDC is designed primarily for use with 12 V sealed lead acid batteries although other power sources may be used as long as the voltage range is not exceeded There are two important considerations when selecting a power supply The first is finding a supply that can supply the starting current of the motor Even unloaded motors may have a starting current that can momentarily exceed 60 A Many switching power supplies will shut down very quickly when starting a brushed DC motor The power supply doe
27. ctions Move to Step 2 once the console screen shows a valid CAN connection to the MDL BDC Step Two Navigation to the Firmware Update Panel Press the Up navigation switch to highlight the panel Title bar The default mode is Voltage Control Mode Press the select switch to bring up the list of panels Navigate to the Firmware Update title and press select again to move to that panel This panel allows the firmware on the MDL BDC to be updated over the CAN network A firmware image for the motor controller is first stored in the flash of the console board and then used to update the motor controller November 1 2008 25 Firmware Updates and Debugging The ID of the motor controller to be updated can be selected on this panel By using the console resident firmware image multiple motor controllers can be updated one at a time using this panel without the need to download from a PC each time When not updating the firmware version of the currently selected motor controller is displayed If there is no motor controller on the CAN network with the current ID the firmware version displays as By pressing the Select button when the Start button is highlighted the motor controller firmware update starts When the firmware is being transferred either from the PC using the UART or to the motor controller using the CAN network the ID firmware version and Start buttons will all be grayed out A progress bar will appear bel
28. dcast messages system level November 1 2008 11 Using the Reference Design Kit commands motor control commands configuration commands and motor control status information The interface also provides a method to extend the network protocol to other devices by defining a CAN device encoding that takes into account device type and manufacturer See the RDK BDC Software User s Guide for complete details The RDK BDC includes a CAN board with an example application that demonstrates CAN control Default Parameters The MDL BDC parameters have the following default values Parameters can be modified using CAN commands or by modifying the software source code Parameters modified using CAN commands are volatile and must be reloaded if the power is cycled Table 2 4 lists the factory default configuration of the MDL BDC Table 2 4 MDL BDC Factory Default Configuration Accelerate rate Instantaneous change Deceleration rate Instantaneous change Motor control mode Open loop speed control using voltage For additional information on parameters see the RDK BDC Firmware Development Package User s Guide Wiring 12 The MDL BDC is controlled using either a servo type PWM source or CAN commands Figure 2 2 on page 13 shows a typical simple wiring arrangement with power motor PWM control and optional limit switch connections Control wires should be looped through the wire retention hooks to prevent the connectors shakin
29. em Copyright O 2008 Luminary Micro Inc All rights reserved Stellaris Luminary Micro and the Luminary Micro logo are registered trademarks of Luminary Micro Inc or its subsidiaries in the United States and other countries ARM and Thumb are registered trademarks and Cortex is a trademark of ARM Limited Other names and brands may be claimed as the property of others Luminary Micro Inc 108 Wild Basin Suite 350 4 Austin TX 78746 Main 1 512 279 8800 Fax 1 512 279 8879 http www luminarymicro com orte Intelligent Processors by oc a a ARM LUMINARY MICRO 2 November 1 2008 Stellaris amp Brushed DC Motor Control User s Manual Table of Contents Chapter 1 Stellaris Brushed DC Motor Control Reference Design Kit Overview 3 Feature S MMANY Q usu 4 SPecification OVelVI W u EDAM 4 Chapter 2 Using the Reference Design Kit U u u u uu uu u u u J 7 Reference Design Kit Contents 1 a rennes enne nns 7 Important Monnan essin tt e rte utu e v tcn Eu MR eu rt de RE Eu itt PR ERR RET aces 8 Developing with the uu k 22222 8 Power Supply Selection inet Festes E ua RR 8 Notor uuu TOTIUSQUE 9 Operating eric n 9 Servo Style PWM Input uuu uyu S
30. er supply or to avoid over torquing the motor on startup for example preventing a loss of traction when a wheel is being driven The bottom portion of the panel provides the current motor controller status Three fault conditions are indicated m Over Current fault C m Over Temperature fault T m Under Voltage fault V Device List This panel lists the motor controllers that reside on the CAN network All 63 possible device IDs are listed with those that are not present shown in dark gray and those that are present in bright white By moving the cursor to a particular ID and pressing the select button a device ID assignment will be performed The motor controller s will wait for five seconds after an assignment request for its button to be pressed indicating that it should accept the device ID November 1 2008 21 BDC Can Console assignment So for example if there are three motor controllers on a network the following sequence can be used to give them each unique IDs 1 Move the cursor to number 1 and press select The LED on all three motor controllers will blink green to indicate that assignment mode is active 2 Press the button on one of the motor controllers It will blink its LED yellow one time to indicate that its ID is one Move the cursor to number 2 and press select Press the button on the second motor controller It will blink its LED yellow two times to indicate that its ID is two Move the cursor to
31. g loose during operation November 1 2008 Stellaris amp Brushed DC Motor Control User s Manual Figure 2 2 Basic wiring with a Servo style speed command for open loop motor control gt Z Power In x Motor Out AA AA Supply a E o Z ZA Z Motor A 2 Supply 2 Motor E n 72 Z ji 2 ry T YYW Z lt a LE SS Fo ES H H A PA B T N E Digital Speed Signal Normally closed ormally closed PWM Forward Direction Reverse Direction Limit Switch es Limit Switch es November 1 2008 13 Using the Reference Design Kit Figure 2 3 shows an advanced wiring configuration using the CAN interface Wiring for position sensing using both a position potentiometer and a quadrature encoder is detailed Although two sensor types are shown the MDL BDC software supports control and monitoring of only one sensor at a time Figure 2 3
32. half of an H bridge is only an issue when changing from forward direction to reverse direction Because the high side MOSFETs are N Channel types a positive Vgs is required to switch them on The gate drivers use a simple boot strapping technique to ensure that the high side Vgs remains above the Vgs on threshold Whenever the low side MOSFETS are on the associated boot strap capacitor C24 or C23 charges to 12 V through the resistor diode network Later when the high side MOSFETS turn on the boot strap capacitor maintains power to the high side driver with respect to the Motor terminal One issue with the boot strap capacitor method is that the capacitor voltage will decay to an unacceptable level unless a low side MOSFET is periodically switched on This state only occurs when the motor is running full forward or full reverse The MDL BDC software intermittently switches to the low side MOSFETS for a short duration to replenish the bootstrap capacitor The short duration has no impact on motor speed Power Supply Two cascaded voltage regulators create 5 V and 3 3 V power supply rails from the 12 V input 5 V is used only for the CAN transceiver and quadrature encoder functions The cascaded arrangement also provides a way to spread the thermal dissipation of the linear regulators with the 5 V taking most of the burden 3 3 V is used by the MCU and peripheral circuitry Current Sensing The current sensing circuit consists of a lo
33. n J4 1 to drop 300 mV from the 3 3 V rail when the potentiometer is connected Output Stage and Power Supplies Page 2 Page 2 of the schematics details the power supplies gate drivers output transistors sensing and fan control circuits Motor Output Stage The motor output stage consists of an H bridge with High Low side gate drivers Each leg of the H bridge has three paralleled MOSFETs The MOSFETs are connected in parallel to reduce Rds on to about 1 8 mQ and to provide additional surface area for fan cooling The fan blows directly on the TO 220 MOSFETS which are arranged radially around the DC bus capacitor A plastic ring encompasses the MOSFE Ts which provide mechanical support and ensures that the tabs do not touch The gate drivers provide up to 2 Amps of peak current to rapidly switch the gates of the MOSFETs when directed by the microcontroller s PWM module The gate drivers are designed for high voltage operation but work equally well in this 12 V application In a variation from their typical use the PWM signal is applied to the Enable ODn input to modulate either the high or low side MOSFE Ts A general purpose output signal from the microcontroller controls the gate driver s PWM input which selects whether it is the high or low side that is being controlled by the November 1 2008 31 Hardware Description microcontroller s PWM signal In this configuration dead time the delay between switching states on one
34. number 3 and press select Press the button on the third motor controller It will blink its LED yellow three times to indicate that its ID is three Once complete this panel will then show that there are devices at IDs 1 2 and 3 Firmware Update This panel allows the firmware on the MDL BDC to be updated over the CAN network A firmware image for the motor controller is first stored in the flash of the console board and then used to update the motor controller See the Firmware Updates and Debugging on page 23 of this document for full details on this process Help This panel displays a condensed version of this application help text Use the up and down buttons to scroll through the text About This panel simply displays the startup splash screen 22 November 1 2008 CHAPTER 4 Firmware Updates and Debugging The MDL BDC supports two methods for updating the firmware resident in the LM3S2616 microcontroller The primary method uses the CAN interface and a Flash resident boot loader for firmware transfer During firmware development direct access and debug capability is preferable The MDL BDC included in the RDK has a JTAG SWD connector installed for this purpose General Information Firmware revisions released by Luminary Micro are referenced using four digit numbers that increase with new releases but are not necessarily contiguous that is numbers may be skipped The flash memory region between 0x0000 and 0x07FF
35. ocontroller The LM3S2616 contains a peripheral set that is optimized for networked control of motors including 6 high speed ADC channels a motor control PWM block a quadrature encoder input as well as a CAN module The microcontrollers PWM module can generate two complementary PWM signal pairs that are fed to the power stage The LM3S2616 has an internal LDO voltage regulator that supplies 2 5 V power for internal use This rail requires only three capacitors for decoupling and is not connected to any other circuits Clocking for the LM3S2616 is facilitated by a 16 MHz crystal Although the LM3S2616 can operate at up to 50 MHz in order to minimize power consumption the PLL is not enabled in this design The 32 bit Cortex M3 core has ample processing power to support all features including 1 Mbits s CAN with a clock speed of 16 MHz Debugging The microcontroller supports JTAG and SWD debugging as well as SWO trace capabilities To minimize board area the MDL BDC uses a 0 050 pitch header footprint which matches ARM s fine pitch definition Figure 5 2 The connections are located on the bottom of the module under the serial number label The module included in the reference design kit has a header installed however the standard MDL BDC available as a separate item does not have the header installed Some in circuit debuggers provide a matching connector Other ARM debuggers can be used with the adapter board included in the RDK Figu
36. ole appears as a Virtual Com port on your PC Step Two Install LM Flash Programmer Luminary Micro Flash Programmer is a Windows GUI or command line application for programming Stellaris microcontrollers using a variety of interfaces Install and run the Luminary Micro Flash Programmer on a Windows PC Step Three Configure LM Flash Programmer for Serial Transfer Select the Configuration tab and from the Quick Set drop down select Manual Configuration see Figure 4 2 Then select Serial UART Interface in the Interface drop down menu Next select the COM Port assigned by Windows to the console board This can be identified using the Windows Device Manager Finally verify that the baud rate is 115200 and then click the checkbox to Disable Auto Baud Support Figure 4 2 Luminary Micro Flash Programmer Configuration Luminary Micro Flash Programmer 4 iol x Configuration Program Flash Utilities Other Utilities Quick Set Manual Configuration see below v r Interface COMPort 24 Device Manager serial UART Interface Baud Rate 115200 LUMINARYMICRO Program Complete 16208 Bytes Programmed Step Four Program the Console with the MDL BDC firmware Select the Program tab see Figure 4 3 Then Browse to select the new binary file to download The Program Address Offset is ignored by the console Click on the Program button to start the transfer 24 November 1
37. on resistor so it must be used as an end point 4 Connect the USB cable between the BDC CAN console and the USB port of a PC The console application software will then start see Figure 3 1 on page 19 5 If USB drivers were not previously installed then follow the procedure in the Quickstart guide before proceeding USB drivers are necessary for using the console board as a firmware update and or debugging tool November 1 2008 Stellaris amp Brushed DC Motor Control User s Manual Operation The direction buttons left right up and down on the left side of the BDC CAN console are used to navigate through the user interface The select button on the right side of the console is used to select items The user interface is divided into several panels the top line of the display always contains the name of the current panel By moving the cursor to the top line and pressing select a menu appears which allows a different panel to be displayed by pressing select again The panels in the user interface will be individually discussed below At startup the Voltage Control Mode panel is displayed first Voltage Control Mode The Voltage Control mode panel allows the motor to be controlled by directly selecting the output voltage The speed of the motor is directly proportional to the voltage applied and applying a negative voltage in other words electronically reversing the power and ground connections will result in the motor
38. ow those buttons to indicate what is happening and the how far it is through the process The MDL BDC automatically restarts when the firmware update is complete Firmware JTAG SWD The MDL BDC included in the RDK BDC has a 2x10 header installed for firmware programming and debugging using JTAG SWD JTAG is a four wire interface SWD is a high performance two wire interface with similar capabilities Figure 4 4 Locating the JTAG SWD Connector 26 JTAG SWD Connector Pin 1 is atthis end N AIEO N When using the JTAG SWD cable pay special attention to the location of pin 1 on the connector When inserted correctly the cable will run back across the bottom of the case covering the Luminary Micro logo See the Chapter 5 Hardware Description for additional information on the JTAG SWD connector The BDC CAN console board is based on the Luminary Micro EK LM3S2965 Evaluation board November 1 2008 Stellaris amp Brushed DC Motor Control User s Manual The console board can be used as a low cost In circuit Debug Interface ICDI for both programming and debugging The ICDI circuit is compatible with the Luminary Micro Flash Programmer as well as leading development tools for ARM Cortex M3 Evaluation versions for several tools are available from www luminarymicro com Figure 4 5 Firmware debugging using JTAG SWD 10 pin to 20 pin Ribbon cable Adapter Cable PC running LM Flash Utility or third
39. party Development tools November 1 2008 27 Firmware Updates and Debugging 28 November 1 2008 CHAPTER 5 Hardware Description Hardware Description The MDL BDC motor control module uses a highly integrated Stellaris LM3S2616 microcontroller to handle PWM synthesis analog sensing and the CAN interface Only a few additional ICs are necessary to complete the design The entire circuit is built on a simple two layer printed circuit board All design files are provided on the RDK CD System Description A unique aspect of the MDL BDC design is the integrated CAN interface and low cost fan cooled MOSFET array that handles high current in a small form factor The motor control consists of an H bridge arrangement which is driven by fixed frequency PWM signals Key Hardware Components Figure 5 1 shows the MDL BDC circuit board with the enclosure and cooling fan removed Figure 5 1 MDL BDC Circuit Board DC Bus capacitor MOSFETS Current sense circuit JTAG SWD IEEE EN connector other side Voltage regulators Microcontroller User switch PWM input 16MHz crystal optocoupler Gate driver CAN connector CAN transceiver Status LED November 1 2008 29 Hardware Description Schematic Description Microcontroller CAN and I O Interfaces Page 1 Page 1 of the schematics details the microcontroller CAN interface and sensor interfaces Microcontroller At the core of the MDL BDC is a Stellaris LM3S2616 micr
40. r shunt November 1 2008 Luminary Micro Confidential For Use Under NDA Only 33 Troubleshooting 34 Luminary Micro Confidential For Use Under NDA Only November 1 2008 APPENDIX A Schematics This sections contains the schematic diagrams for the Intelligent Display Module m RDK BDC MCU Network and Interface on page 36 m RDK BDC Power Supplies and Input Stage on page 37 November 1 2008 35 1 2 3 4 5 6 PIN6 i PINS Status LED 5 CAN I2C Port Calibrate ID RI Tie 1 1 cann 82 CANHISCE BINT SWI 100 CANRX XD CANIS IO CANL SDA i SWITCH 1 6 SW B3S1000 LED RED R2 58 ns 3 5 n 150 Red vec PING GND VREF i PINS H Pin 2 Port NGSHVDIOS0D 2 IN 0 1UF L3 PINI Lee Ul k PAO UORX PBO PWM2 ae PWMB gt gt J PBI PWM3 gt 33V m LED GRN 47 CANH SCL RS PB2 DCOSCL 57 CANI SDA 1 5 NE 5 2 150 GANT PA4 CANORx PB4 CO R6 lt PAS CANOTx PBS CI TIM FANON gt LOK lt PWMA PAG PWMO PB6 C0 RXD SPDIN FEMALE 1X3 CTRLA PB7 NMI PWM Speed Input
41. re 5 2 MDL BDC JTAG SWD Connector 12 3 3V 9 TMS SWDIO GND 9 TCK SWCLK GND 6 TDO 9 4 TDI GND SRSTn 9 10 Figure 5 2 shows the pin assignments for the JTAG SWD connector as viewed from the bottom connector side of the circuit board CAN Communication A key feature of the LM3S2616 microcontroller is its CAN module that enables highly reliable communications at up to 1 Mbits s The MDL BDC control board adds a standard CAN transceiver U2 additional ESD protection D2 and connectors The pin assignments for the RJ11 RJ14 30 November 1 2008 Stellaris amp Brushed DC Motor Control User s Manual 6P 4C connectors are defined in CAN in Automation CiA DS102 Figure 5 3 shows the network connector pin assignments Figure 5 3 Network Connector Pin Assignments CANL CANH V GND CAN Socket Viewed from Top Tab down The V signal Pin 2 is not used in the MDL BDC however it is passed through to support other devices that either provide or use power from this terminal The typical application for V is in providing a small amount of power to optocouplers for isolating CAN signals Other Interfaces Several other interfaces are provided on 0 1 pin headers The connections to the microcontroller are ESD protected and in most cases have 10 kQ pull up resistors The analog input has a 0 to span In order to use a 10 potentiometer a 1 padding resistor is provided o
42. re that sets new values for full forward full reverse and points in between Calibration is typically only required in applications where the PWM source has uncertainties due to analog radio links or other variables Direct digital sources are unlikely to require calibration Calibration Procedure To calibrate the servo style PWM input for a specific range Hold down the user switch for five seconds see Figure 1 2 on page 5 Set the controller to send a full forward signal Set the controller to send a full reverse signal Set the controller to send a neutral signal 5 Release the user switch The MDL BDC samples these signals and centers the speed range and neutral position between these limits If the MDL BDC does not detect suitable servo signals during calibration then the calibration fails This condition is indicated by flashing the LED Red and Yellow Electrical Interface The servo PWM input is electrically isolated from other circuits using an optocoupler The MDL BDC board data sheet contains electrical specifications including common mode voltage limits for the input stage 10 November 1 2008 Stellaris amp Brushed DC Motor Control User s Manual Figure 2 1 MDL BDC s Servo PWM Input Stage U3 FEMALE 1X3 PWM Speed Input HIILIM The on board resistor R5 has been selected to allow a signal of only a few volts to drive the optocoupler At 3 3 V or more it is advisable to add additional series resi
43. s not need to maintain regulation during start but it must ensure that the supply voltage remains above the under voltage limit The second consideration is how the power supply handles back EMF and regeneration currents During rapid deceleration of loads with high inertia the motor acts as a generator This current is rectified by the MDL BDC back into the bus capacitor As the capacitor charges the voltage at the supply terminals may increase It is important that the power supply can handle this momentary condition without entering a fault condition The power supply must also present sufficiently low impedance so that the MDL BDC s voltage rating is not exceeded A sealed lead acid battery easily meets these requirements NOTE The MDL BDC does not have reverse polarity input protection 8 November 1 2008 Stellaris amp Brushed DC Motor Control User s Manual Motor Selection The MDL BDC operates 12 V brushed DC motors Typical motors include model BI802 001A from CIM and model RS 555PH 3255 from Mabuchi see Table 2 1 for motor specifications Some very small DC motors or motors in lightly loaded applications may have a limited useful speed range when controlled with PWM based voltage controls The MDL BDC can also drive resistive loads with some de rating to allow for increased ripple current inside the module See the MDL BDC board data sheet for full specifications Table 2 1 Mabuchi RS 555PH 3255 Motor Specifications At ma
44. stance to limit the current into the LED The PWM input stage is essentially a current driven device so the threshold for a logic high level input is defined in milliamps Some recommended values for an external resistor are listed in Table 2 3 Table 2 3 Recommended Values for External Resistor 2 5 V 0 Q none 3 0 V 00 1500 5 0 V 560 Q 12V 2 2 Communication Controller Area Network CAN provides a powerful interface for controlling one or more MDL BDC modules The MDL BDC has two RJ11 RJ14 sockets for daisy chaining modules using standard cables Each end of the CAN network should be terminated with a 1200 resistor The BDC CAN console has a built in terminator Each MDL BDC module on the CAN bus is accessed using an assigned ID number The ID defaults to 1 but can be changed by sending a CAN assign ID command to the bus Pressing the USER switch on the MDL BDC informs that particular module to accept the previously specified code The CAN protocol used by the MDL BDC includes the following capabilities Firmware update over CAN Read supply voltage motor voltage temperature and current Set motor voltage or target position Set control mode to speed or position Configure parameters Enable features such as closed loop speed and position control The CAN protocol provides a number of commands and divides them into groups based on the type of command The commands are grouped according to broa
45. w side shunt resistor R35 and a non inverting voltage amplifier Due to the high current in the bridge the shunt resistor is just 500 uQ Op amp U8 amplifies the signal across R35 by a factor of 40 Because the sense resistor is in the low side of the H bridge the current through it is only positive when the low side MOSFETS are on The software takes this into consideration when sampling the current waveform Resistor R43 biases the op amp input by 10 mV to allow for negative input offset voltage The software automatically zeroes out this small offset before the motor is started R42 and C25 form a low pass filter to isolate the op amp s power supply from the other devices on the 3 3 V power supply rail Voltage Sensing A simple divider resistor network R20 21 and R23 scales the 12 V rail down to the range of the ADC 0 3 V Two additional dividers allow the bootstrap supplies to be monitored in software This is an optional feature Fan Control 32 The cooling fan is self contained and uses a small brushless DC motor The MDL BDC supports On Off software control of the fan using Q13 The fan operates when the motor is running or when the temperature exceeds a certain threshold The LM3S2616 microcontroller has an internal temperature sensor A simple software table correlates the microcontroller temperature to overall system temperature November 1 2008 CHAPTER Troubleshooting 6 Although the MDL BDC is simple to use
46. ximum efficiency Speed 3953 RPM Current 1 244 A Power 7 139 w Torque 17 25 mMm At maximum power Speed 2325 RPM Current 3 627 A Power 14 w Torque 57 5 mMm General characteristics No load speed 4650 RPM No load current 0 223 A Operating Modes The MDL BDC can be controlled using either the servo style PWM Input or the CAN interface Table 2 1 compares the capabilities of each control method Table 2 2 Control Method Comparison Servo Style PWM input CAN Interface Speed Control Yes Yes Analog Position Control No Yes Encoder Position Control No Yes November 1 2008 9 Using the Reference Design Kit Table 2 2 Control Method Comparison Continued Servo Style PWM input CAN Interface Configurable Parameters No Yes Voltage Current Measurement No Yes Limit Switches Yes Yes Coast Brake Feature Yes Yes Firmware Update No Yes The MDL BDC supports the simultaneous use of CAN for monitoring and the servo style input for speed Servo Style PWM Input The MDL BDC incorporates support for speed and direction control using the standard servo style interface found on many radio control receivers and robot controllers See the MDL BDC data sheet for specifications on the default timing of this signal Calibrating the PWM Input To accommodate variation in the timing of the supplied signal the MDL BDC has a calibrate featu
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