Texas Instruments-Stellaris-LM3S2616-Development
Contents
1. 282 I H MOR TG n 1 z INA282 z White 4 ona c31 EEN VC080530A650DP ap Oh Tee Brew I 1 tr 1 e 0 1UF U8 Gi m g C42 4 J c33 21 vpp VBB R26 R27 e g l j ERREG a e e OMIT x GA Cooling Fan Control 20 5V 1 Am 1 arr GHA 19 SA 3 E Red ALO 21 ato GLA lt FANN G Black 33v de w a en MOLEX 35362 pp 84 em GHB FANON 1 Elo SB LON gt FDV30IN RA BLO 1 BLO GLB Ga V a Si 10K a GD_FAULTn Cp m 1 RESET cP2 C sd e m ee GND 3 RDEAD Q GND Ne co AGND GND 4 Motor DIKS e MOTOR El 14 j Q Gren TEXAS INSTRUMENTS A4940 z2 x Drawing Title D VC080530A650DP Black Jaguar Brushed DC Motor Control Page Title Power Supplies and Output Stage Size Document Number B Date 9 10 2010 Sheet_ 2 GEES 1 2 3 4 5 6 26 January 5 2011 Board Drawing This appendix shows the component placement plot for top Figure B 1 Figure B 1 Component Placement Plot JAGUAR DC MOTOR CAN RS232 Ty SPEED January 5 2011 27 28 January 5 2011 Bill of Materials BOM Table C 1 provides the BOM for the RDK BDC24 Table C 1 RDK BDC24 Bill of Materials BOM January 5 2011 Texas Instruments Part Number RDK BDC24 BD BDC24 Final Assembly BOM PCB Assembly Enclosure Bill Of Materials Created 11 11 2010 Item Ref Qty D2. FC 67997 104HLF 18 Up 1 Connector RJ 11 Mod J ack 6 6 Vert FC 90512 001LF Flange Blk 4UCON 04912 19 8 1 Connector RJ 11 Mod J ack 6 4 Vert FC 90512 003LF Flange Blk 4UCON 04911 20 j9 1 Header 1x2 Surelock 2mm Thole Molex 35362 0250 Vertical shrouded 21 L1 1 nductor 47uH SMD 7mmx7mm 0 9A TDK SLF7045T 470MR90 H 0 180hm 22 PCB1 1 PCB RDK DD Black ag Rev C Advanced RDK BDC24 Rev C 23 Q1 Q2 Q4 Q5 8 MOSFET N CH TO 220 40V 60V 80A Fairchild FDPO50ANO6A0 Q6 Q7 Q8 Q9 Fairchild FDP038AN06A0 24 Q3 1 MOSFET N CH SOT 23 25V 220mA Fairchild FDV301N 25 R1 1 Resistor 100 OHM 1 8W 5 0805 Panasonic ERJ 6GEYJ 101V Thick 26 R13 1 Resistor 390K Ohm 1 8W 1 0805 Vishay CRCW0805390KFKEA Thick 27 R14 R17 2 Resistor 82K OHM 1 8W 5 0805 Panasonic ERJ 6GEY 823V m ER hl 29 Table C 1 RDK BDC24 Bill of Materials BOM continued 30 Texas Instruments Part Number BD BDC24 Final Assembly BOM PCB Assembly Enclosure Bill Of Materials Created RDK BDC24 11 11 2010 28 R16 es or 11K Ohm 1 8W 1 0805 RJ 6ENF1102V 29 IR19 fre or 1 87K Ohm 1 8W 1 0805 CO805FR 071K87L 30 R2 R4 2 Resis or 150 OHM 1 8W 5 0805 Panasonic ERJ 6GEYJ 151V Thick 31 R20 1 Resistor 162K Ohm 1 8W 1 0805 Rohm MCR10EZPF1623 hick 32 R21 R22 R26 Resistor 27 OHM 1 8W 5 0805 Thick Panasonic E
3. Peripherals Consumer Electronics Energy and Lighting Industrial Medical Security Space Avionics and Defense Transportation and Automotive Video and Imaging Wireless TI E2E Community Home Page www ti com communications www ti com computers www ti com consumer apps www ti com energy www ti com industrial www ti com medical www ti com security www ti com space avionics defense www ti com automotive www ti com video www ti com wireless apps Mailing Address Texas Instruments Post Office Box 655303 Dallas Texas 75265 Copyright 2011 Texas Instruments Incorporated
4. Pre production release Designer Drawing Title Oct 7 09 Adjust Isense and SMPS circuit values DAY JAG KAK Black Jaguar Brushed DC Motor Control sept9 10 Added INA282 current sense circuit as a futu Drawn by Page Title build option INA282 parts are omitted DAY JAG KAK MCU Network and Interface Approved Size Document Number B x Date 9 10 2010 Sheet I of gt 1 2 3 4 5 6 cis d 12 24V POWER IN ka LI k us SLU SLF7045T 470MR90 H PN ue FIAN VM TPS54040 gt i TPS73633DBV A a BAL BOOT pu He Um ortz e VIN COMP R RIE 11 0K Z Zum Z nr a E 4 __VSENSE gt 1800uF ston to E 5 Set e a a RIS av LOUF LOUF R17 SSIR amp Q VSNS 10UF 10K C28 50V 50V 82K RT CLK 6 PwRGD 2 16v ars 0 01UF c29 0 01UF o 0 01UF 1 ENE 5V T 281 av 5V SHUNT R VBAT 1K ohm 100 MHz Lo 0 1UF 3 R23 IE 154 Ken ISENSE_193 4 U7 B INAI93AID 3 3V VM VM 3 3V SHUNT FB2 AAA L ceso IK ohm 100 MHz QI o seh CU OMIT OMIT m 1 He L St z 8 i J R21 R2 CLUE d E pe OMIT Motor ISENSE
5. ade et el 13 Motor Selectiibnaasdansta Fra ER EIET 14 Chapter 3 Firmware Updates and Debugging rrrssvrnnnvvnnnnvnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnen 15 General MOKMALION EE 15 Firmware Update Using RS232 CAN sssssssssessssisssisssirssirnsstnssttunttntttn tuttu nuttu natnn ttt Ea SE En SSE EA SEES SnEnn nunn Ennn nnen n nnt 15 Firmware Update and Debugging Using JTAG SWD nsrernsnrnnnnnvnnnenvrvnnnrrnnnnnnnnrnnrrernnnnnnrrrrenennnnererrenennnnenennneenn 15 Chapter 4 Hardware DescriptiOn ssrrnnnvnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnner 17 System Heel pllort gereest deeg e ie le 17 Key Hardware Components ieri uroen an anne arena EISE E AE AT EEA EAA TEE ARIANE ATEA EE AEEA EAEE 17 Shemale DESCHIPLIONE e eusan a a A A E A TAE T A A ES 17 Microcontroller CAN and I O Interfaces Schematic page 71 17 Output Stage and Power Supplies Schematic page 21 19 Texas Instruments Featured Parts nnrrnnvnnnnrnnnnvnnnnnnnnnvnnnnnnnnvnnnnnnnnnenennnnnnnennnnnnnsenennnnnnneennnennnennnnnnnneennnnnnnnen 22 Appendix A Schematics u issues facccecetic Seege gees deer e 23 Appendix B Board Drawing 2uisskemesteielekegsttbdemeesde tenderte ee EES 27 Appendix C Bill of Materials BOM rrnnnrnnnnvrnnnnnnvnnnnvennnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnennnnnnnnnnen 29 January 5 2011 3 January 5 2011 Stellar
6. the RDK are E Follow the README First document included on the kit CD The README First document will help you get the RS 555 motor up and running using the BDC COMM Windows application in just minutes It also contains important safety information that you should read before using the RDK m Use the BDC COMM to evaluate and optimize target motor operation Once the module is installed in the end application use the BDC COMM to configure and monitor motor operation Using RS232 the BDC COMM gives real time access to a range of operating parameters The MDL BDC24 Getting Started Guide covers module setup and use in customer applications m Customize and integrate the software and or hardware to suit an end application This user s manual and the RDK BDC24 Firmware Development Package User s Guide are two important references for completing hardware and software modifications New software can be programmed in the MDL BDC24 using either BDC COMM or using a JTAG SWD debug interface Power Supply Selection The MDL BDC24 is designed primarily for use with 12 V or 24 V sealed lead acid batteries Other power sources may be used as long as the MDL BDC24 s voltage range is not exceeded under any condition There are two important considerations when selecting a power supply The first is specifying 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 Some
7. 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 gate driver has an internal sense circuit the inserts small low side pulses whenever the bootstrap voltage decays The short duration has no measurable impact on motor speed The boot strap monitor capability is the reason that the gate driver controls dead time rather than the LM3S2616 microcontroller Switching Scheme To reduce power dissipation in the H bridge the MDL BDC24 uses synchronous rectification Synchronous rectification uses the complementary MOSFET rather than a diode to provide a low resistance current path during the PWM off period Figure 4 4 shows the current paths through a complete PWM_ON Dead time PWM_OFF cycle The motor is modelled primarily as an inductor During the PWM_ON period Q1 on the high side and Q2 on the low side provide a path that increases current in the motor The 2us DEAD TIME period starts with Q1 turning OFF Current continues to flow through the load with the path being completed by the Q2 intrinsic diode and Q4 The voltage drop across Q2 is equal to a forward biased diode Next the synchronous rectification period PWM_OFF occurs when Q2 is ON The voltage drop across Q2 is now greatly reduced The load current decays during this period 20 January 5 2011 Stellaris Brushed DC Motor Control User s Manual Figure 4 4 Synchr
8. 2 Vertical Unshrouded 56 R24 1 Resistor 1K Ohm 1 8W 1 0805 Panasonic ERJ 6ENF1001V hick i i n men January 5 2011 Stellaris Brushed DC Motor Control User s Manual Table C 1 RDK BDC24 Bill of Materials BOM continued Texas Instruments Part Number RDK BDC24 BD BDC24 Final Assembly BOM PCB Assembly Enclosure Bill Of Materials Created 11 11 2010 Final Assembly Bill Of Materials Item 58 JP1b J5b J7b Jumper 0 100 Gold Black Closed SPCO2SYAN 59 60 61 Fan Assembly 40x40x10mm 5V 5 3CFM 2 Lead w Molex Sherlock connector KDEO504PFV2 EEE Enclosure ABS plastic 3 pieces LM 608 01 Label with Model Serial Firmware info BJ AG LABELS 62 63 January 5 2011 4 Screw 4 x 0 375 plastite for McMaster 90380A108 enclosure Screw 4 x 0 625 Pan Head Sheet McMaster 90077A112 Metal Phillips Slotted for fan 31 32 January 5 2011 IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries Tl reserve the right to make corrections modifications enhancements improvements and other changes to its products and services at any time and to discontinue any product or service without notice Customers should obtain the latest relevant information before placing orders and should verify that such information is current and complete All products are sold subject to Tl s terms and conditions of sale supplied at the time of order acknowledgment TI warrants
9. KB Flash SN65HVD1050 High Speed EMC CAN High electromagnetic immunity EMI Optimized CAN communications Very low electromagnetic emissions EME Transceiver Bus fault protection of 27 V to 40 V Dominant time out function Power up down glitch free bus inputs and outputs TRS3221E Single Channel RS232 Operates up to 250 kbits sec RS 232 communications Low standby current 1 uA Typ Compatible Line External Capacitors 4 x 0 1 UF Driver Receiver RS 232 bus pin ESD protection exceeds 15 kV using human body model HBM TPS54040 0 5 A Step Down 5V Power Supply 3 5 V to 42 V input voltage range SWIFT 200 mQ high side MOSFET Converter with High efficiency at light loads with a pulse skipping Eco Mode Eco Mode 100 kHz to 2 5 MHz switching frequency TPS73633 Cap Free NMOS 3 3V Power Stable with no output capacitor or any value or type of 400 mA Supply capacitor Bae Input voltage range of 1 7 V to 5 5 V eguiator wi Itra low dr voltage 75 mV Reverse Current re ee Protection Low reverse leakage current Low noise 30 iVRMS typ 10 Hz to 100 kHz 0 5 initial accuracy INA193 Voltage Output Motor current Wide common mode voltage 16 V to 80 V High Side measurement Low error 3 0 over temp max Measurement Wide bandwidth up to 500 kHz Current Shunt Monitor Low quiescent current 900 vvuA max Complete current sense solution 22 January 5 2011 Schematics This section contains the schematic diagrams for the RDK BDC24 m MCU
10. Network and Interface on page 24 m Power Supplies and Output Stage on page 25 January 5 2011 23 1 2 3 4 5 6 Status LED Ze Ul Calibrate ID LED GRN RI Al Green U3 43 3V CH y L Ts a e K WORE PAO UORX PBO PWM2 BHI Swit 5 Perle DOE PAL UOTX PBI PWM3 BLO ie ones SW B3S1000 LED RED R4 A2 LED GRN 1 0K PAZ PWM4 PB2 I2COSCL Red cS SPDIN SPDIN 4 3 FEMALE 1X3 150 S Zeags PA3 PWMS PB3 I2COSDA 3 E SE N CANTX PA4 CANORX PB4 CO GD_RESETn peedinpi DI PAS CANOTx PBS CI FAN ON gt AHI PA6 PWMO PB6 CO Ce TEN AGN Sb 433V ALO PAT PWMI PB7 NMI Sr Coast Debus F TCK SWCLK Elei POUND al QE_INDEX H Brake default 33V R 10K WDIO PCI TMS SWDIO poi LS BOARD ID arte PC2 TDI PD2 ADCS Lt BRAKE EN DE 1 2 TMS SWDIO DO Did pcarporswo PD3 ADCA ae TSENSE 282 A D 1 Brake Coast Jumper zee TCK SWCLK QE DJ reen R24 eer 5 6 TDO GD_FAULT r PC5 C00 1 0K E C40 oe _ i QEB I 6 2 p H TED RED g PCO PhBO PEO ADC3 ISENSE 193 OMIT SET PCTICI Clo PEI ADC2 BOTANA L LANE PE2 ADCI SENSE R6
11. RJ 6GEY 270V R27 R29 R30 33 R23 1 Resistor 0 001 OHM 4W 1 2725 SMD Stackpole S2725FT1L00 Electronics 34 R3 R6 R18 3 Resistor 1K Ohm 1 8W 1 0805 Panasonic 6ENF1001V Thick 35 R34 1 Resistor 47K OHM 1 8W 5 0805 Rohm MCR10EZP 473 hick 36 R5 R7 R8 R9 Resistor LOK Ohm 1 8W 1 0805 Panasonic ERJ 6ENF1002V R10 R11 R12 Thick 37 SW1 1 itch B3S 1000P 38 T1 1 8191 2 non captive 39 T2 1 Terminal Screw Vertical 15A Black 8191 3 40 T3 1 Terminal Screw Vertical 15A White 8191 4 Screw non captive 41 T4 1 Terminal Screw Vertical 15A Green 8191 6 Fairchild H11L1SR2M Fairchild H11L1SR2VM 43 U2 1 CAN Transceiver 8 SOIC SN65HVD1050D 44 U3 HE LM352616 IQR50 A0 LM352616 IQR50 A0 TRS3221ECPWR nstruments MAX3221ECPW 46 U5 Regulator SWIFT Step Down 0 5A 42V MSOP10 nstruments 47 U6 1 Regulator Linear 3 3V SOT23 5 DBV Texas nstruments 48 U7 1 Current Shunt Monitor INA193 20V V Texas 49 U8 1 Full Bridge MOSFET Driver Allegro 24 Allegro eTSSOP NX5032GA 16 000000MHZ ABM3 16 000MHZ B2 T 51 Z1 Z2 2 TvS Varistor 30V 30A Transguard AVX VC080530A650DP PCB Do Not Populate List Shown for information only 52 C30 Capacitor 0 1uF 50V 20 0603 X7R C0603C104M5RACTU 53 C41 C42 C43 4 Capacitor 0 1uF 50V 20 0805 X7R C0805C104M5RACTU C44 54 FB2 1 Ferrite Bead 400mA 1K Ohm 100Mhz Murata BLM18AG102SN1D 55 2 1 Header 2x5 0 050 1 27mm TH Harwin M50 350054
12. Stellaris RDK BDC24 Brushed DC Motor Control Module User s Manual di TEXAS INSTRUMENTS RDK BDC24 UM 03 Copyright 2010 2011 Texas Instruments Copyright Copyright 2010 2011 Texas Instruments Inc All rights reserved Stellaris and StellarisWare are registered trademarks of Texas Instruments 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 Texas Instruments 108 Wild Basin Suite 350 Austin TX 78746 I TEXAS http www ti com stellaris I NSTRUMENTS n EE E SR ortex e Si or Si r a SR Intelligent Processors by ARM ARM 2 January 5 2011 Stellaris Brushed DC Motor Control User s Manual Table of Contents Chapter 1 Stellaris Brushed DC Motor Control Reference Design Kit RDK Overview 005 9 Feature Summary ata age erre eels foe ete vend aina 10 Specification Overview 3 c0iti cake aa end eset coin ieee idl peed nee ede 10 Reference Design Kit Contents ssssseeessesssessssessitssstrsstrnsttunetnnattnnttnnat tunnt nnns Aast tAnSSE ESSEE ESSE Ensenat E nsen nenn nenene 11 Chapter 2 Using the Reference Design Kit rrnnnvnnnnnnvnnnnnvnnnnnvnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnner 13 duet ago n E te BEE 13 Developing with the RDM 2 stusser berede ae kranser eee ent hanke 13 Power Supply Selection 0 cisssiveh Eege at eee
13. al 120Q terminator but it accelerates the bus return to the recessive state which is important in high data rate high node count applications RS232 Communication The MDL BDC24 supports a full set of network control and configuration functions over a standard RS232C serial interface The command protocol is essentially the same as the protocol used on the CAN interface thereby allowing the MDL BDC24 to automatically bridge all commands between the RS232 and CAN interfaces A TRS3221E RS232 transceiver was selected to translate the CMOS logic levels from the LM3S2616 s UARTO to RS232 levels Its internal charge pump generates positive and negative voltages from the 5 V supply pin Integrated ESD protection means that no external protection device is necessary Other Interfaces Interfaces for an encoder or tachometer limit switches and brake control 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 brake and user switch inputs use the LM3S2616 microcontroller s internal pull up resistor The analog input has a 0 to 3 V span In order to use a 10 kQ potentiometer a 1 kQ padding resistor is provided on J4 1 to drop 300 mV from the 3 3 V rail when the potentiometer is connected Output Stage and Power Supplies Schematic page 2 Page 2 of the schematics details the power supplies gate drivers output transistors sensing and fan c
14. all associated warranties conditions limitations and notices Reproduction of this information with alteration is an unfair and deceptive business practice TI is not responsible or liable for such altered documentation Information of third parties may be subject to additional restrictions Resale of TI products or services with statements different from or beyond the parameters stated by TI for that product or service voids all express and any implied warranties for the associated TI product or service and is an unfair and deceptive business practice TI is not responsible or liable for any such statements TI products are not authorized for use in safety critical applications such as life support where a failure of the TI product would reasonably be expected to cause severe personal injury or death unless officers of the parties have executed an agreement specifically governing such use Buyers represent that they have all necessary expertise in the safety and regulatory ramifications of their applications and acknowledge and agree that they are solely responsible for all legal regulatory and safety related requirements concerning their products and any use of TI products in such safety critical applications notwithstanding any applications related information or support that may be provided by TI Further Buyers must fully indemnify TI and its representatives against any damages arising out of the use of TI products in such safety critical ap
15. aveform When operating smaller motors or lightly loaded large motors the INA193 may be operating with a Vsense less than 20 mV This region has reduced current sense amplifier accuracy See the INA193 data sheet for full details on Low Vsense Case 1 and Case 3 The PCB design has an option to populate an INA282 current sense amplifier This was done to evaluate a future build option The INA282 and supporting components are omitted from the assembly January 5 2011 21 Hardware Description Voltage Sensing A simple divider resistor network 16 and R18 scales the Vpus rail down to the range of the ADC 0 3 V The full scale ADC measurement ADC 1023 corresponds to a bus voltage of 36 V Fan Control The cooling fan is self contained and uses a small 5 V brushless DC motor The MDL BDC24 supports On Off software control of the fan using Q3 The fan operates when the motor is running or when the temperature exceeds a certain threshold The LM3S2616 microcontroller has an internal temperature sensor and a simple software table correlates the microcontroller temperature to the overall system temperature Texas Instruments Featured Parts The MDL BDC24 features a range of semiconductors from Texas Instruments as shown in Table 4 1 Table 4 1 Detailed List of Texas Instruments Featured Parts LM3S2616 Stellaris System control ARM Cortex M3 core Microcontroller Motion control capabilities 64
16. board data sheet for full specifications Table 2 1 Mabuchi RS 555PH 3255 Motor Specifications Parameter Value Units At maximum 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 WwW Torque 57 5 mMm General characteristics No load speed 4650 RPM No load current 0 223 A 14 January 5 2011 Firmware Updates and Debugging The MDL BDC24 supports two methods for updating the firmware resident in the LM3S2616 microcontroller The primary method commonly used for field updates uses the CAN or RS232 interface and a Flash resident boot loader for firmware transfer During actual firmware development direct access and debug capability is preferable The MDL BDC24 included in the RDK has a JTAG SWD connector installed for this purpose General Information StellarisWare firmware revisions 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 contains a CAN RS232 boot loader The main firmware image should be loaded at 0x0800 Firmware Update Using RS232 CAN The MDL BDC24 firmware can be updated over RS232 or CAN using the BDC COMM utility and the cables included in the reference design kit See the MDL BDC24 Getting Started Guide for step
17. by step instructions Firmware Update and Debugging Using JTAG SWD The MDL BDC24 included in the RDK has a 2 x 5 fine pitch 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 3 1 on page 15 shows how to locate the JTAG SWD connector Figure 3 1 Locating the JTAG SWD Connector JTAG SWD Connector FE Ad January 5 2011 15 Firmware Updates and Debugging When using the JTAG SWD cable pay special attention to the location of pin 1 on the connector When inserted correctly the cable runs back across the bottom of the case covering the rectangular inset See Chapter 4 Hardware Description for additional information on the JTAG SWD connector Any Stellaris evaluation boards can be used as a low cost In circuit Debug Interface ICDI for both programming and debugging The ICDI circuit is compatible with LM Flash Programmer as well as leading development tools for ARM Cortex M3 Evaluation versions for several tools are available from www ti com stellaris Figure 3 2 Firmware Debugging Using JTAG SWD 16 Ribbon cable ADA2 10 pin to 20 pin PC running LMFlash Adapter Cable Programmer or other Develop ment tool Any Stell aris Evaluation Board No software required January 5 2011 CHAPTER 4 Hardware Description The MDL BDC24 motor control module use
18. erview Plug adaptors for US UK EU and AUST m DB9S to 6P6C adapter Connects the MDL BDC24 to a PC RS232 port m 6P 6C modular cable 7 ft Use for RS232 or CAN connection m CAN terminator Plug in 120 Q terminator m Adapter cable for ARM JTAG SWD fine pitch header Texas Instruments Part ADA2 m Reference design kit CD Complete documentation including Quickstart and user s guides LM 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 GCC and Code Composer Studio 12 January 5 2011 Using the Reference Design Kit This chapter provides information about using the RDK BDC24 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 m Damage to the control board and motor can result from improper configuration wiring or software Developing with the RDK The recommended steps for using
19. escription Mfg Part Number 1 C1 C6 C7 C10 15 Capacitor 0 1uF 50V 20 0805 X7R Kemet C0805C104M5RACTU C12 C13 C14 C15 C16 C17 C18 C31 C32 C39 C40 2 C11 C19 C20 6 Capacitor 1 0uF 25V 10 X5R 0805 Taiyo Yuden TMK212BJ 105KG T C34 C36 C37 3 C2 C3 C25 3 Capacitor 10pF 50V 5 0805 COG Kemet C0805C100 5GACTU 4 C21 1 Capacitor 1800uF 35V 20 Panasonic EEU FC1V182S 18mmx20mm 5 C22 C23 2 Capacitor 2 2uF 50V 10 X7R 1210 Kemet C1210C225K5RACTU 6 C24 C33 2 Capacitor 10uF 16V 10 X7R 1210 Murata GRM32DR71C106KAO1L 7 Cp 1 Capacitor 0 1uF 50V 20 0603 X7R Kemet C0603C104M5RACTU 8 C4 C5 C8 C9 8 Capacitor 0 01uF 50V 5 0805 X7R Kemet C0805C103 5RACTU C26 C27 C28 C29 9 D1 1 LED Green Red 5mm T hole dual Kingbright Corp WP59SRSGW CC 10 D1b 1 SPACER PCB LED T1 3 4 109Mil Keystone 8902 11 D2 D3 D4 D5 5 Diode 2 Line 5V ESD Suppressor SOT Vishay GSOTO5C GS08 D6 23 ON SMOST1G Semiconductor 12 D7 1 Diode Schottky 60V 1A Vishay SS16 E3 61T 13 FB1 1 Ferrite Bead 400mA 1K Ohme100Mhz Murata BLM18AG102SN1D 14 VI 1 Header 1x3 0 100 T Hole Vertical 4UCON 00523 Female Sullins PPTCO31LFBN RC 15 1J3 JP1 2 Header 1x3 0 100 T Hole Vertical 4UCON 00798 Unshrouded 0 230 Mate FC 68001 103HLF 16 UA 1 Header 1x5 0 100 T Hole Vertical 4UCON 00806 Unshrouded 0 230 Mate FC 68000 105HLF 17 J5 J7 1 Header 2x2 0 100 T Hole Vertical 4UCON 00998 Combined Unshrouded 0 230 Mate
20. is Brushed DC Motor Control User s Manual List of Figures Figure 1 1 Figure 1 2 Figure 3 1 Figure 3 2 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure B 1 MDL BDC24 Brushed DC Motor Control Module 9 MDL BDC24 Module Key Features top view 11 Locating the JTAG SWD Connechor nnna 15 Firmware Debugging Using JTAG SWD a ssssssesssesssnsssnessnessessteesstnssstnsstnnsttnnetnnennnnennnntnnnnnnnnnnn nt 16 MDL BDC24 Circuit Board 17 MDL BDC24 JTAG SWD Conmechor utn tntnu natnn tttnansrnnnsnn nnn nnen nnna 18 Network Connector Pin Aesignments 19 Synchronous Rectification necne aa eraai ia ia aaan a iaa ED EK NE iR 21 Component Placement Plot 27 January 5 2011 5 January 5 2011 Stellaris Brushed DC Motor Control User s Manual List of Tables Table 2 1 Mabuchi RS 555PH 3255 Motor Specifications c cccccccececeeeeeeeeeeeeeeeeeeaaeeeseaeeeseaeeesecaeeeseeeeeaas 14 Table 4 1 Detailed List of Texas Instruments Featured Partei 22 Table C 1 RDK BDC24 Bill of Materials BOM cceccceeeeeeeeeneeeceeeeeeaeeeceeeeeeeaaeeeeeeeeesaaeeeeeaeeeseaeenaeeeee 29 January 5 2011 January 5 2011 Stellaris Brushed DC Motor Control Reference Design Kit RDK Overview The RDK BDC24 is a Stellaris reference design for speed control of 12 V and 24 V brushed DC motors at up to 40 A continuous current Features include high performance CAN and RS232 networking as well as a rich set of con
21. onous Rectification VM During PWM_OFF assuming a 40 A load Q2 losses are approximately 40W without synchronous rectification This drops to just 4W if synchronous rectification is used Rds on 2 5 mQ Synchronous rectification significantly improves drive stage efficiency particularly at lower duty cycles 50 and less when the PWM_OFF time is longer that the PWM_ON time Power Supply The MDL BDC24 uses a TPS54040 based switching power supply for optimal efficiency over a wide operating range Resistor R20 sets the switching frequency at around 700kHz which allows the use of a small inductor and output capacitor The 5 V rail is used for the cooling fan CAN and RS232 transceivers current sense amplifier and quadrature encoder functions A low drop out voltage linear regulator TPS73633 generates the 3 3 V rail which is used by the MCU and peripheral circuitry Current Sensing The current sensing circuit consists of a high side shunt resistor R23 and a specialized current sense amplifier INA193 Due to the high current capabilities of the bridge the shunt resistor is just 1 mQ The INA193 amplifier has a fixed gain of 20 V V which results in a signal into the ADC of 20 mV A for a full scale reading of 150 A Because the sense resistor is in the high side of the H bridge the current through it is only positive when the high side MOSFETs are on The MDL BDC24 software takes this into consideration when sampling the current w
22. ontrol circuits January 5 2011 19 Hardware Description 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 two paralleled MOSFETs The MOSFETs are connected in parallel to reduce total Rds on to about 2 5 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 MOSFETs providing mechanical support and ensuring that the tabs do not touch The gate driver provides high peak currents to rapidly switch the gates of the MOSFETs when directed by the microcontrollers PWM module An internal charge pump allows the drivers to maintain MOSFET gate voltage even under low voltage conditions Resistor R34 sets the gate drive dead time to approximately 2us Because the high side MOSFETs are N Channel types a positive Vgs is required to switch them on The gate driver uses 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 C34 or C36 charges from the internal charge pump regulator 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 restriction with the boot strap capacitor method is that the capacitor voltage will decay
23. or Other ARM debuggers can be used with the adapter board included in the RDK Figure 4 2 MDL BDC24 JTAG SWD Connector 1 2 3 3V e TMS SWDIO GND e TCK SWCLK GND e TDO TDI GND SRSTn 10 Figure 4 2 shows the pin assignments for the JTAG SWD connector as viewed from the bottom connector side of the circuit board CAN Communication 18 A key feature of the LM3S2616 microcontroller is its CAN module that enables highly reliable communications at up to 1 Mbits s The MDL BDC24 control board uses a Texas Instruments SN65HVD1050D CAN transceiver U2 additional ESD protection D6 and connectors The pin assignments for the 6P6C 6P4C connectors are defined in CAN in Automation CiA DS102 Figure 4 3 shows the network connector pin assignments January 5 2011 Stellaris Brushed DC Motor Control User s Manual Figure 4 3 Network Connector Pin Assignments CANH CANL CANH CANL V GND 6P6C RS232 CAN Socket Viewed 6P4C CAN Socket Viewed from Top Tab down from Top Tab down The V signal Pin 2 is not used in the MDL BDC24 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 For 1 Mbps CAN communication over distances up to 20 feet the network should be terminated at each end with a 100Q resistor This value is slightly lower the norm
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26. r 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 Complementary PWMs are important for synchronous rectification see Output Stage and Power Supplies Schematic page 2 on page 19 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 and RS232 with a clock speed of 16 MHz Debugging The microcontroller supports JTAG and SWD debugging as well as SWO trace capabilities To minimize the board area the MDL BDC24 uses a 0 050 pitch header footprint which matches ARM s fine pitch definition Figure 4 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 BDC24 available as a separate item does not have the header installed Some in circuit debuggers provide a matching connect
27. s a highly integrated Stellaris LM3S2616 microcontroller to handle PWM synthesis analog sensing and the CAN RS232 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 BDC24 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 4 1 shows the MDL BDC24 circuit board with the enclosure and cooling fan removed Figure 4 1 MDL BDC24 Circuit Board DC bus capacitor Current sense circuit MOSFET H bridge JTAG SWD connector Switching power other side supply Stellaris amp LM3S 2616 a Microcontroller User switch a5 RS232 transceiver Servo PWM input optocoupler 16 MHz crystal Gate driver 6P6C CAN RS232 connector Status LED CAN transceiver Schematic Description Microcontroller CAN and I O Interfaces Schematic page 1 Page 1 of the schematics shows the microcontroller CAN port RS232 port and sensor interfaces in detail January 5 2011 17 Hardware Description Microcontroller At the core of the MDL BDC24 is a Stellaris LM3S2616 microcontroller The LM3S2616 contains a peripheral set that is optimized fo
28. switching power supplies will shut down very January 5 2011 13 Using the Reference Design Kit quickly when starting a brushed DC motor The power supply does 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 BDC24 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 BDC24 s voltage rating is not exceeded A sealed lead acid battery easily meets these requirements NOTE The MDL BDC24 does not have reverse polarity input protection Motor Selection The MDL BDC24 operates 12 V to 24 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 BDC24 can also drive resistive loads with some de rating to allow for increased ripple current inside the module See the MDL BDC24
29. trol options and sensor interfaces such as analog and quadrature encoder interfaces High frequency PWM enables the DC motor to run smoothly and quietly over a wide speed range The MDL BDC24 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 BDC24 contains an MDL BDC24 motor control module as well as additional hardware and software for evaluating RS232 communication After evaluating the RDK BDC24 users may choose to either customize parts of the hardware and software design or use the MDL BDC24 without modification See the MDL BDC24 board data sheet available for download from http www ti com stellaris for complete technical specifications In addition the MDL BDC24 Getting Started Guide GSG MDL BDC24 provides a step by step guide to wiring and using the module Figure 1 1 MDL BDC24 Brushed DC Motor Control Module January 5 2011 9 Stellaris Brushed DC Motor Control Reference Design Kit RDK Overview Feature Summary The MDL BDC24 control board provides the following features Controls brushed 12 V and 24 V DC motors up to 40 A continuous Controller Area Network CAN interface at 1 Mbit s Industry standard servo PWM speed input interface RS232 to CAN bridge Limit switch encoder and analog inputs Fully enclosed module includes cooling fan Fle
30. up go Ban 3 PE3 ADCO koennen VSENSE 10K D er OSCH PE4 FAULTO 1 2 OSCI POT ANA 2 p p XOSCO NC s S 4 XOSCI NC ZS BDO 16 00MHz Zeen B r 10K Position Pot Factory Test GN m i Lo c3 ei WAKE vppa 3 D3 10PF 10PF Bes So YDD 1 1P2 SPDIN RESET 0 VDD33 C4 C5 CR C7 93 RST VDD33 not ong 0 1UF 0 1UF TMS SWDIO PP JD TOK SWCLK DE ae ar J TPS TDO es AAR EST GSOTOSC V TP6 om GND y e TP7 FANN GND o FANN GND 5 l TP8 GND LDO D4 Sa GND 1 HDR 1X5 GND VDD25 CH C10 C11 l I N Encoder GND VDD25 om orl vm GND vpp2s 38 2 GNDA vpp2s z Sc GSOTOSC RS232 Transceiver LM3S2616 GH u4 10K J5 UOTX 1 13 TXD LIMIT2 DIN DOUT PING Jumper Installed default UORX 9 rour Rin 13 RXD PINS ER S ae CAN RS232 Port al gt I a 43 FORCEOFF INVALID gt INS eae Limit Switch 2 Reverse FORCEON ai ces r 4 Cl e y CANOT CAN Transceiver PIN 1 2 3 Ci U2 RJII 6P VERT ores V 10K GSOTOSC D 7 5 C13 0 1UF CANTX LIMITI 1 cu Fr V ve 6 CANRX Se ee p y 2 Jumper Installed default oe 5V 0 1UF 0 1UF_14 15 I 5V HDR 1X2 GND vec 1 156 RS ENE CAN Port Limit Switch 1 Forward TRSF3221E 5 TR GND VREF aE AK Ne C17 a GSOTOSC RI1 1 6P VERT Date Description g Sept 9 09 Internal Prototype Et p TI AEC Austin Sept 11 09 Pre production See Round up for change list S I EXAS INSTRUMENTS Se Sept 14 09 Change to use conventional Isense resistors Austin TX 78746 Sept 21 09
31. ures top view Maintain 0 5 clearance For power wiring use around all vents 12AWG Wire with 6 ring Motor output is not protected f against shortcircuits or spade terminals From Power i i Distribution D k ped a u Module EI yy Motor In J TEXAS o Motor NSTRUMEN VG Mounting holes M 3 50 centers User Switch Maintain 0 5 clearance e 3 Og amp around all vents CAN Port 6P6C CAN RS232 Port ge Status LED e Limit switch inputs SERVO PWM Use hooks to prevent wires shaking loose Encoder Input Analog input 0 3V Motor coast brake jumper Reference Design Kit Contents The RDK BDC24 contains everything needed to evaluate brushed DC motor control The RDK BDC24 includes ms MDL BDC24 motor control module Suitable for motors up to 24 V 40 A Uses a Stellaris LM3S2616 microcontroller m Mabuchi RS 555PH 3255 Brushed DC Motor 5000 RPM 12 V JA m Universal input wall power supply 12V1 25A January 5 2011 11 Stellaris Brushed DC Motor Control Reference Design Kit RDK Ov
32. xible configuration options with simple source file modification Easy to customize full source code and design files available Specification Overview Key specifications of the MDL BDC24 include m Quiet control of brushed DC motors 15 kHz PWM frequency m Three options for Speed control Industry standard R C servo type PWM interface Controller Area Network CAN interface RS232 serial interface m CAN communication Multicast shared serial bus for connecting systems in electromagnetically noisy environments 1M bits 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 Firmware update m RS232 serial communication Bridges RS232 port to a CAN network Directly interfaces to a PC serial port or National Instruments cRIO Status LED indicates Run Direction and Fault conditions Motor brake coast selector Limit switch inputs for forward and reverse directions Quadrature encoder input QE Index input 5 V supply output to encoder 10 January 5 2011 Stellaris Brushed DC Motor Control User s Manual m Analog input Accepts 10 kQ potentiometer or 0 3 V input m Screw terminals for all power wiring m Headers 0 1 inch pitch for all control signals For detailed specifications including electrical parameters see the MDL BDC24 data sheet Figure 1 2 MDL BDC24 Module Key Feat
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