Motor Control Daughter Board Revision 3.0 User`s Manual
Contents
1. 902 317 S38GOV OYO SWALSAS M31VNHSI uo 9051937 3s iu au AS 902 2022 3170 8 08 lt AS 31 0 80 4 3WYN A8 295 ON 2d 0 611190 3WVN 3113 o 902 1007 1 808 LDOTNI 905 onze 50 0217 3022 902173042 py 900 soci 8 118 902 2 3021327 axle _ 9021 389001 12 in 2 9021 HONK WA MOT WA N3 79 8 Na 9051404001 jau ns XNIT180HS eter 26058 OXL 4 MBLOS ZEZXVW NYO 086301 2018 9021 ML 942 1009 1 9021 100781 8021 44 00 9021 3020 Lo IBONS OWS NATAS ant saat 902 9021 eu 902134 001 9021 037 902148 NYO GNWS snI E 181 9021 9 soroa 2 4 5 NNI LECHS y 7 GWS snzF 35 LHO B Nid 6 9021 30 WNIT LHOHS vat WHOLOS3NNOO Ipdp uojjnqusnd 2612 88 14 67 support ishnatek com Ishnatek Confidential MCDB User s Manual 9407 133HS 11092412 390148 1104 LAASOW SH3AIHO LAASOW FHL 22 01 01162. 411150 1 Full Step Mode 200 Steps Rev 0 Half Step Mode 400 Steps Rev Ishnatek Confidential 55 support ishnatek com MCDB User s Manual 1 STEPPER_RNG CTR_REG_5 0 1 Stepper Motor Range Select Stepper Motor 1 Maximum speed 1440 RPM 0 Maximum speed 720 RPM Note For rpm calculation refer to sec in user guide MST SC OR PWM CTR_REG_5 0 1 Microstepping is TZ SINE Form Stepper Motor 5 0 0 Brushed or Brushless Motor 1 Microstepping in Trapezoidal form 0 Microstepping in sine form For Brushed or Brushless Motor this control is used to Turn PWM ON or OFF 1 PWM ON 0 PWM OFF CTR_REG_3 ADDRESS 2 0 011 Read Write Bits Name Description 3 2 NO MSTP OR BL CTR_REG_5 0 1 Number of Steps in Microstepping MD 1 0 Stepper Motor Mode 00 8 Steps 01 16 Steps 10 32 Steps 1 Reserved REG 5 0 0 Mode of Operation of BLDC Motor Brushed or 00 Complementary drive Brushless 01 PWM control to high side BLDC amp drivers REG 4 1 20 10 PWM control to low side BLDC Brushless drivers 11 control to high side as well as low side BLDC drivers 1 0 FREQ SEL 1 For brushed and brushless motor these two bits are used to 0 select the PWM Frequency 00 39 kHz 01 2 78 kHz 102156 kHz 11 312 kHz Ishnatek Confidential 56 supportQ ishnatek com
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4. motor Motor Connections 3 2 5 2 BLDC Motor Connections Phase A Color Code Phase A MOT_A To Back Panel Phase B Blue MOT_B To Back Panel Phase C Green MOT_C To Back Panel Phase D Black MOT_D To Back Panel CABLE E 3 wires Motor Connections MOT A To Back Panel Phase Blue MOT B To Back Panel Phase Green MOT C To Back Panel Note Only one motor can be connected to the back panel For sensorless operation it is not necessary to remove the Hall connections Ishnatek Confidential 221125 support ishnatek com MCDB User s Manual 3 3 Precaution After making connections as per instructions and wiring diagram given take the following steps for turning ON or OFF the connections to the kit These steps should be followed strictly to protect the boards WARNING In order to protect the I O s of the Fusion Part a proper Power up and Power Down sequence has to be followed This will ensure that there is no back power from the daughter board to fusion board and hence protect the I O s Kit Power Up Sequence Step 1 Power up Fusion Board Step 2 Power up Motor Control Kit Kit Power Down Sequence Step 1 Power Down Motor Control Kit Step 2 Power Down Fusion Board Ishnatek Confidential 12 support ishnatek com MCDB User s Manual 4 Operational Se
5. 5 5 Switches Switches Function Notes SW12 Daughter board power supply 12V Ref Voltage 12V 2A ON OFF Connect to Dual Supply 12V 2A Tap if provided slide switch RUN Press RUN to start the motor Push to ON tactile switch STOP Press STOP to stop the motor Push to ON tactile switch STEP Press STEP to single step the stepper motor Push to ON tactile Note The step size is chosen based on the position of switch the HF toggle switch RPM Press to increase speed of motor Push to ON tactile switch RPM Press RPM to decrease speed of motor Push to ON tactile switch SW_M_B ST_BD ON ON Microstepping ON Toggle tactile Stepper OFF Microstepping OFF switch ST_BD OFF ON Brushed motor Brushed Brushless OFF Brushless motor DIR Motor rotation direction Toggle tactile ON Clockwise switch OFF Counterclockwise A_D Motor Control Type Toggle tactile ON Analog POT switch OFF Digital RPM and RPM switches ST_BD Motor Type Toggle tactile Stepper switch OFF Brushed or Brushless HF_FL ST_BD ON ON Full Step 1 8 degrees Toggle tactile Stepper OFF Half Step 0 9 degrees switch amp SW_M_B OFF ST_BD OFF ON drive using on Brushed Brushless board comparator amp OFF BEMF drive using SW M B OFF Fusion s onboard ADC BLDC motor SW10 10 9 ST BD OFF PWM FR SEL I1 0 10 Way dip switch Brushed 00 39 KHz Brushless 01 78 KHz 10 156 KHz 1
6. 103 por pa f LJLJ LILI 629 en 949 g 2 90 0 2 80046190 NN 622 Ident Top 73 support ishnatek com Ishnatek Confidential MCDB User s Manual 20688662 5891530 HOOTON 23 mm LLLI 610 un LA to m Ll Li Lj LJ LJ Cu C 283 652 C30 SOAONL2 004611190 rTTT LIU 888 2 0 gi r mam LJ r1 L pm B cee f 8 LJ ETSI ri BOL 522 Ident Bottom support ishnatek com 74 Ishnatek Confidential MCDB User s Manual 9 4 Appendix D Connection Pictures Miscellenous CABLE C and CABLE D to FUSION Ishnatek Confidential 75 support ishnatek com 10 Contact Details Ishnatek Systems and Services Pvt Ltd Suite 3 B Devgiri P No 117 1B Kothrud Industrial Area Pune 411029 Maharashtra INDIA Tel 91 20 25435376 Fax 491 20 25411579 Website www ishnatek com Support support ishnatek com Ishnatek Confidential 76 MCDB User s Manual support ishnatek com
7. 4 ADDRESS 2 0 100 Read Write 3 2 Description BL_TAC 1 0 CTR_REG_5 0 2 0 Brushed or Brushless amp REG 4 1 20 Brushless MCDB User s Manual Description Brushless Motor Acceleration Time in BEMF Mode 00 208ms 01 2312ms 10 2 520ms 11 23 74sec Note For Acceleration time calculations refer to Section in User Guide 1 MST OR BD BL CTR REG 5 0 2 1 Stepper motor 1 MicroStepping on 0 MicroStepping off 5 0 2 0 Brushed or Brushless 1 Brushed Motor 0 Brushless Motor 0 Reserved Reserved REG 5 ADDRESS 2 0 101 Read Write Bits 3 HALL OR Description This control is used for brushless motor REG 5 0 20 amp 4 1 0 only Feedback using hall sensor 0 Feedback using back EMF 2 COMP OR ADC crossing implemented This control is used for brushless motor REG 5 0 20 amp 4 1 0 only It will use comparator to sense the back BEMF zero 0 It will use ADC to sense the back BEMF Zero crossing Because of pin limitation this ADC feature is not 1 0 A OR D STEPPER OR BDB L Ishnatek Confidential 0 Digital control Stepper Motor 57 This control is used to select analog speed control or digital speed control for all the motors 1 Ana
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9. Communication Control Properties 5 x File values Load Defaults Save defaults Save For Session Only Set Recommended values Comm Port Enable Fake Handshaking In Buffer Size 104 Input Len Input 0 Null Discard Tue tt Out Buffer Size i4 Parity Replace 00000 RTS Enable Fase Settings 9600n81 STheshod Recommended Values 2 or 1 True 2 comRTS 1024 0 D Text Mode True 512 or 1024 1 True 9600 n 8 1 1 Load Defaults Load Default values into the Actual Values column Save As Defaults Save the Actual Values to Registry so next time these settings would be restored Save for Session Only The changes in the Values will not be updated to the registry so this mode will temporarily change the settings the default values in the registry would not be changed Set Recommended Values Load recommended values into actual values column Ishnatek Confidential support ishnatek com MCDB User s Manual Startup Options Using Startup Options option in COMM menu you can load default settings or recommended settings The default options are the one that have been stored in the registry Motor Control Application Software File Bemf_Settings Microsteppi BRUSHED BLDC CONTROLS Click on Open Port option from COMM Menu bar
10. s Manual 5 2 2 Motor Control Kit Picture Figure 5 2 2 Motor Control Kit Ishnatek Confidential 16 support ishnatek com MCDB User s Manual 5 3 Status LED s LED Function LD1 RxD Indicator RED Indicates serial reception in progress Reserved LD2 TxD Indicator YELLOW Indicates serial transmission in progress Reserved LD3 Fault_OT Indicator RED ON Over temperature fault condition detected OFF Over temperature condition not detected LD4 Fault_OC Indicator RED ON Over current condition detected OFF Over current not detected The threshold for over current will determined by the shunt resistor and the flags generated out of the Analog Current Monitor in Smartgen 1105 DIR Indicator ON Motor will move in clockwise direction When JP10 is closed OFF Motor will move in counterclockwise direction LD6 5V int Indicator GREEN 5V signal on Daughter Board Active JP4 SV_int 1 2 gt 5 _ 5V from Fusion board 2 3 gt SV_REF 5V through on board regulator LD7 ST_BD Indicator RED ON Stepper motor selected When JP12 is closed OFF BLDC motor selected LD8 HF_FL Indicator RED In case of Stepper motor Or ON Full step mode Comp or ADC Indicator OFF Half step mode When JP13 is closed In case of BLDC motor ON BEMF drive using on board comparator OFF BEMF drive using Fusion ADC LD9 A_D Indicator RED ON Analog Control o
11. 6 2 8 BEMF Sensing Circuit Most of the 3 phase motors only have 3 signals to the motor which are the winding connections A Neutral point to the junction of these three windings is not available A virtual Neutral point will have to be created in order to have a relative voltage level The difference between the virtual neutral and the voltage of the floating terminal is used to detect BEMF This is achieved using resistor network as shown in schematics This virtual neutral point is connected to the negative input of the comparator module DC DC Figure 6 2 7 1 Floating winding compared to Virtual Neutral To sense BEMF properly a lot of attenuation and filtering is necessary The motor winding voltages are scaled down to below 5 in the range of the comparator LM339 input voltage ranges The PWM frequency is filtered from the BEMF signal by additional High pass filters in the circuit as shown The filtered signals are fed to the positive terminals of the comparator module Figure 4 2 7 2 below shows the zero crossing detection circuit for the BEMF signal Ishnatek Confidential 43 support ishnatek com MCDB User s Manual V3p3_FN BMFC_A V3p3_FN BMFC_B To Fusion Board gt Used for Commutation MOT_B V3p3_FN BMFC_C Figure 6 2 7 2 Floating winding BEMF compared to Virtual Neutral The comparator outputs are then fed to the Fusion Board for auto commutat
12. Close Connects VM CS from the daughter Sensing board Open Disconnects _ from the daughter board JP21 LOW signal for Close Connects LOW from the Current Sensing daughter board Open Disconnects LOW from the daughter board JP22 Selects data reception from 1 2 CP2103 USB to Serial Chip Ishnatek Confidential 19 support ishnatek com MCDB User s Manual 232 2103 2 3 232 5232 Interface Chip JP23 Selects data transmission 1 2 CP2103 USB to Serial Chip from MAX232 or CP2103 2 3 232 RS232 Interface Chip JP24 Configure the IO s of Close default Configure the IO s of CP2103 CP2103 to 3 3V Open Configure the IO s of CP2103 to 1 8V JP25 SW from the Close Connects Key SW M B from the Daughter Board daughter board Open Disconnects Key SW M from the daughter board Use external keypad to control SW M B signal command to Fusion JP26 Disconnects Motor ground Close Connects motor power supply ground to JP27 from board ground the reference board s ground JP28 Open Disconnects motor power supply ground from the reference board s ground 3 Jumpers are provided for stronger ground SIP 1 RESERVED Reserved for internal use keep Open SIP 2 Ishnatek Confidential 20 support ishnatek com MCDB User s Manual
13. Decrement Speed FREQ SEL H 1 0 Output PWM Frequency Select J14 J15 00 39 KHz 01 48 KHz 10 105 KHz 11 312 KHz A OR DH Output Analog or Digital Control of RPM J2 1 Analog through Potentiometer on AVO 0 Digital through PLUS_H and MINUS_H keys if hardware R_nW_LCD Output Read Write signal for LCD Panel 5 RS_LCD Output LCD control signal DI EN LCD Output Enable LCD Signal D3 DATA LCD 3 0 Output 4 Bit LCD data bus E2 E3 F5 F6 CHK TEMP Output Test signal 11 BAUD_RATE_SEL 2 0 Input Baud Clock setting for serial communication H13 H15 CHK_CURRENT Output Test signal B11 rpm_value 7 0 Output 8 bit PWM setting displayed on Fusion MB A14 LED s B14 A13 B13 D11 13 12 Ishnatek Confidential 2612 support ishnatek com MCDB User s Manual 9 2 APPENDIX B Motor connections Legend for back panel connections The four motor connections on the daughter board are brought out to the back panel as MOT_A MOT_B MOT_C and MOD_D respectively The color coding for these 4 connections are as follows From Daughter Back Panel of the Board Phase A Orange To Back Panel Phase B Yellow To Back Panel Phase Green _ To Back Panel Phase D MOT_D To Back Panel NOTE Only One Motor can be connected to the daughter board via this back panel
14. In this mode also the motor has to go through the acceleration phase 6 3 Brushed Drive A DC Brushed Motor can be connected between the two Motor phases MOT_A and on the back panel of the kit Please ensure that the voltage rating of the motor 18 higher than the Motor Power Supply 12V 5A provided on the kit Polarity of the motor is not important The direction of the rotor movement can be altered using the DIR switch or the Clockwise Counterclockwise button on the GUI At this time only one DC motor is supported Ishnatek Confidential 46 support ishnatek com MCDB User s Manual 7 Software Control The application also contains PC master software which supports communication between the Fusion Device and PC via an RS232 serial interface This tool allows access to pre assigned memory locations to control the motor parameters The programmer can run the application using the GUI environment using a USB to Serial Bridge available The picture below shows the opening screen of the MOTOR CONTROL APPLICATION Software Graphical User Interface Settings MicroStepping Settings COMM MOTOR CONTROL APPLICATION BLDC BRUSHED Port Open TxD RxD STEPPER CONTROLS BRUSHED BLDC CONTROLS STEP TYPE rBLDCDRIVE FULL 1 8 Degrees HALL HALF 0 9 Degrees Complime
15. Inductance per phase Holding torque 4 35 10 ohm 4 90 mH 70 Detent torque Rotor inertio 12 0 12 kg 10 mNm Mass Dimensions unit mm 30 44 0 5 35 Depth 3 5Min AWG26 UL1007 17 820 1 27 Depth 5 1Min REVISIONS DATE ADD COMMENT BLACK COVER 20031222 55 2005 8 24 CHANGE BEARING from 619 5 22 to 625 27 Change Endcaps from 15 75 0 13 to 17 8 0 1 comment 1 BLACK ENDCAPS 2 Use 62577 bearing 59 005 180 AS 14HY ODL 0010 Ishnatek Confidential 65 24 06 8 29 support ishnatek com Stepper Motor Wiring Diagram MCDB User s Manual Original wire leads on Motor the motor Connections Phase A Red MOT_A To Back Panel Phase Blue MOT_B To Back Panel Phase Green MOT_C To Back Panel Phase D Black MOT_D To Back Panel Note Only one motor can be connected to the back panel Ishnatek Confidential 66 support ishnatek com MCDB User s Manual tics 3 APPENDIX C Board Schema 9 9301 133 5 2 zi 2 in 5 1 2 4 a xiNaOHd Iz z e 42038 1VNINH3I M3HOS LI 21028 531719405 YIMOd SHOLOSNNOO 104100 ya PeuUsT mv 29
16. Purple MSTP 0 7 H14 Gray Acceleration time 1 6 H16 Acceleration time 0 5 G11 Black Stepper_range 4 G14 Ishnatek Confidential 9 support ishnatek com MCDB User s Manual 3 2 3 Baud Rate Selection The baud rate wires may be left unconnected they have internal pull ups and have been programmed to 9600 baud rate If you want to change the baud rate for serial communication then you can connect these as per the data sheet that follows Keep same baud rate setting for hardware as well as software Wire From Wire To Color Code Fusion Pin Baud Rate Select Cable Baudclock reg 2 As per baud rate Orange H11 selection table below Baudclock reg 1 GND or VDD Yellow H13 Baudclock reg 0 15 3 2 4 Baud Rate selection table Baudclock reg 2 Baudclock reg 1 Baudclock reg 0 BAUDRATE White 0 0 0 1220 0 0 1 2440 0 1 0 4880 0 1 1 9600 1 0 0 19200 1 0 1 Reserved 1 1 0 Reserved 1 1 1 Reserved For more macro view you may look at additional pictures available in Appendix D Ishnatek Confidential 10 support ishnatek com 3 2 5 Motor Connections MCDB User s Manual You can either connect a Stepper Motor 4 Wire or a BLDC Motor 3 Phases to the back panel provided on the kit as below to the back 3 2 5 1 Stepper Motor Connections CABLE F 4 Wires Original wire leads
17. Refer to the motor connection legend that follows the motor specifications Ishnatek Confidential 62 support ishnatek com MCDB User s Manual BLDC Motor 45 Flat motor 0745 mm brushless 30 Watt A with Hall sensors B sensorless 254 155 3 O E 2 M M 1 2 Stock program Order Number Standard program Special program on request with Hall sensors 200142 sensorless Motor Data pe He 1 Assigned power rating 30 30 2 Nominal voltage Volt 12 0 12 0 3 No load speed rpm 4400 4400 4 Stall torque mNm 260 220 5 Speed torque gradient rpm mNm 17 5 20 5 6 No load current mA 150 150 7 Terminal resistance phase to phase Ohm 1 20 1 40 8 Max permissible speed rpm 10000 10000 9 Max continuous current at 5000 rpm A 2 30 2 30 10 Max continuous torque at 5000 rpm mNm 53 8 53 8 11 Max efficiency 77 6 76 0 12 Torque constant 25 5 25 5 13 Speed constant rpm V 374 374 14 Mechanical t me constant ms 17 0 20 0 15 Rotor inertia gcm 92 5 92 5 16 Terminal inductance phase to phase mH 0 410 0 410 17 Thermal resistance housing ambient K W 4 0 4 0 18 Thermal resistance winding housing K W 6 0 6 0 19 Thermal time constant windings 5 11 6 11 6 20 Thermal time constant stator 8 42 2 42 2 Specifications Operating Range Comments Details on page 149 Axial preload 3 gt 5 Curve of constant
18. SUME NSG HOOTON SWALSAS X31VNHSI sozi anl 99 2 2353 27 9021 301 OFF 1417 N3dsns ugsn axu laNvilanz y lt ssm ox 890 0X1 5 sen dxi oma aas lt SIQ NvMs Tn473147MS MOD MOME m INIT NI zxoz SANW MS gt x snid ms gt dal M gt NIT 7 orar gt so WA gt F vi avra gt mi ucro wires gt S 3 1 2 155 5 5 WR 02 SARIN MS ao Wn 251714 sie Ni 8 16 83157745 Ni VOR ae TV 2015 MS Ni Na 8 gt 5 NH Nao gt 2 5 71 support ishnatek com Ishnatek Confidential MCDB User s Manual 9309 133 8 tt 3159 02 ON een v9dd OL QuvO8 YALHONVI HOLOS3NNOO VHIX3 91 3190 A8 3NVN AG Qdv Ag Qd lt 31 0 A8 3WVN A8 A8 NSG HOOTON Ag 9 ON 2 08611190 3WNVN 31 3 WO2 X98389UUST MMM S 3N00Vv SWALSAS 9331VNHSI 9Nidd31SONOIM XNI11HOHS 1 138 LHOI VHIS NId AWM THOLIMS d
19. 52089 0410 Becommontad Pin for design with Hall sensors AECS 35 3 page 262 11 pole pitch 1 0 mm top contact style DEC 50 5 264 DECV 50 5 265 Internal pull up 7 13 on pin 1 EPOS 24 1 271 e iri i EPOS 24 5 271 For wiring diagram for Hall sensors see p 26 Notes i7 April 2005 edition subject to change maxon EC motor 187 Ishnatek Confidential 63 support ishnatek com BLDC Motor Wiring Diagram MCDB User s Manual Color Code Motor Connections Phase Red A To Back Panel Phase B Blue To Back Panel Phase Green MOT To Back Panel Hall Brown Connect to 5 Pin Right TT Angle connector as per the Orange _ Board Legend J2 HALL Hall Yellow This connector is pre Ground Black connected Red Note Only one motor can be connected to the back panel For sensorless operation it is not necessary to remove the Hall connections Ishnatek Confidential 64 support ishnatek com MCDB User s Manual Stepper Motor Hybrid Stepping Motor Type 14HY5401 www General specifications F HYBRID STEPPING MOTOR Electrical specifications Wiring Diagram Step angle 1 8 55 Rated voltage Rated current 3225 V 075 5 9929 Number of phase 2 Insulation resistance 100Mohm Min 500V DC Insulation class Class B Resistance per phase
20. Kit Provided 4 Pin Straight Connector To Fusion Starter Kit Provided Baud Rate Select Cable to Fusion Starter Kit Provided BLDC Motor Maxon EC 45 Flat Provided Appendix B for Details Stepper Motor Hybrid Stepping Motor 14HY5401 Provided Appendix B for Details Motor and Reference Power Supply Dual Output Provided 12 5A Motor Power Supply 12 2A Reference Power Supply 00000 0 Software Requirements o USB Cable Provided o Motor Control Software and USB Drivers Provided o Operating System Windows XP or Higher Required Fusion STP Files Provided There are 2 versions of STP files available depending on the feature set as described below mcdb rev3 adc drive stp This version does not support temperature and current sense features o mcdb rev3 ts cs stp This version does not support BEMF drive using Fusion ADC Apart from the above differences both version supports all the other features as described in the introduction Ishnatek Confidential 6 support ishnatek com MCDB User s Manual 3 Connection steps and Precaution 3 1 Connection steps Please follow the steps carefully in order to avoid damage to Fusion Board Make sure the power to Fusion Kit and the Motor Control Kit are OFF 3 1 1 Important Pre Connection Checks Make sure the AC input voltage switch on Kit is set to 110V If not open the back lid of the kit and change it to 110V Don t Plug the Power Supply cord i
21. Method BEMF Zero Crossing Detection x Zero Crossing Detection Options Acceleration Settings C FAST MED High C Fusion ADC C MED Low C SLOW CONFIRM of Sensored operation there is no need to run the motor in open loop Ishnatek Confidential 53 support ishnatek com MCDB User s Manual Zero Crossing Detection Options e Comparator On Board Use the comparators LM339 provided on board to do the zero crossing detection to drive the BLDC in sensorless mode Fusion ADC Use the scaled version of the winding voltages to generate threshold flags from Fusion ADC Also the BEMF is a function of RPM The motor needs to be run open loop until a good enough BEMF is generated for automated commutation Acceleration Settings e FAST is for very high speed motor 30000 to 40000rpm In this case the motor accelerates to higher rpm quickly so power consumption is minimal e MEDIUM HIGH and MEDIUM LOW for Mid Range Motors 11000 30000rpm e LOW setting is for low speed motors 2300rpm The acceleration time is long in LOW setting hence the consumption of current is also very high during the acceleration period Choose the appropriate acceleration time for the motor you plan to drive In the current setup for Maxon EC45 Flat use MEDIUM HIGH or MEDIUM LOW setting PWM FREQUENCY Four different PWM frequencies are provided which are used to generate
22. Pin 2of JP68 Wire From Board Pin Names Color Code Fusion Pin Daughter Board CABLE C Pinl of J6 T RTN Orange R12 Pin 2of JP62 Pin 2 of J6 T SIG Red T12 Pin 2of JP68 Note that the temperature sensing method used is quite susceptible to Noise For higher accuracy it is necessary to use high resolution temperature sensors which are not susceptible to noise To filter out the noise connect a capacitor of value 10nF between Pins R12 and 12 of fusion board Ishnatek Confidential 8 support Q ishnatek com MCDB User s Manual 3 2 Connection Details 3 2 1 Connect the 40 Pin Connector should match on the Fusion Side and the Board side This cable does not have polarization and it could go in either way hence it is very important that the marking should be matched perfectly else this would cause damage to the board A Silver colored dot indicates Pin 1 on the connector Make sure these match perfectly before turning on the Board Warning You could blow up the board if this is not done right Black Pin 40 and Dark Brown is Pin 1 3 2 2 extra 8 wire connector CABLE D should be connected to Fusion board as per table below Wire from Wire to Color Signal Dip FUSION switch pin 10 way FUSION Brown MST_SC_OR_PWM 3 K16 DIP on board Yellow PWM freq sel 1 10 J14 daughter Green PWM freq sel 0 9 J15 card Blue NO MSTP OR BL 1 8 12
23. Port Open indicator on the screen turns green from red this indicates that the communication port is successfully opened and ready for communication Click on Close Port to close any open ports It is recommended that you close the port before exiting the program Ishnatek Confidential 50 support ishnatek com MCDB User s Manual MOTOR TYPE Choose the MOTOR out of the three options STEPPER BLDC BRUSHED The options available for the respective motor would be activated for modifications COMMON CONTROLS The controls in this window except 5 are common for both bldc and stepper Before we start motor we have to initialize motor parameters This step is very important settings you choose on the screen to run motor get refreshed when you click on Initialize Motor Parameters otherwise motor will run on your previous settings When you click on option in COMM menu you can change the settings such as the baud rate handshaking enable etc these setting are stored in registry in HKEY CURRENT USER software gt VB and program settings motor control application gt properties DIRECTION controls the direction of rotation of motor Motor speed control can be ANALOG i e through potentiometer connected to pin M6 or DIGITAL RPM UP RPM DN START and STOP controls to start and stop the motor respectively RPM UP RPM DN for increasi
24. Supply 2 Pins WHITE and BLACK for 6 wire stepper motor 4 Pins PH B PH C PH D Motor Phases 1 WHITE 2 BLACK 3 4 VM GND 5 6 7 PH D 8 PH B 9 PH J2 Hall 5 Pin Connector for Hall sensor feedback from Motor VCC 2 GND 3 4 5 13 USB connector for serial interface JA 40 Pin Bus Connector from Daughter Board to Fusion Motherboard May need to make a cut in the header to accommodate this cable on Fusion side J5 12 Pin Straight Connector SW10 3 2 SW10 4 3 SWIO 5 4 SW10 6 5 5 10 7 6 SW10 8 7 5 10 9 8 SWIO 10 9 D Scaled BEMF D 10 MOT C Scaled BEMF C 11 MOT B Scaled BEMF B 12 MOT A Scaled BEMF A J6 Ishnatek Confidential 4 Pin Straight Connector 524 Other Control Status Feedback Signals to Fusion 1 RTN support ishnatek com MCDB User s Manual temperature sense return 2 510 temperature sense signal 3 5 current sense out 4 VM_LOW_OUT voltage sense out RS232 Serial Interface Connector Optional if USB Connector not provided Only RxD TxD and GND used Ishnatek Confidential 24 support ishnatek com MCDB User s Manual 6 Detailed Design Description 6 1 Stepper Motor Stepper Motor would require four push pull drivers to commutate The stepper motor requires a fixed seque
25. s Manual The control vectors required for microstepped motors are more complex but the basic idea remains the same Higher level control system is designed that will generate appropriate control trajectories moving the motor one step half step or microstep 6 1 1 Stepper Drive 6 1 1 1 Full Step Mode In this case the motor commutates 1 8 mechanical degrees The motor would require 200 such full steps for one mechanical revolution of the rotor The control trajectory for stepping though one full electrical cycle using full stepping is as follows Sequence 1 1 0 1 0 2 1 0 0 1 Clockwise 3 0 1 0 1 4 0 1 1 0 Table 6 1 1 1 Full Step Stepper Motor Sequence 6 1 1 2 Half Step Mode In this case the motor commutates 0 9 mechanical degrees every step The motor would require 400 such half steps for one mechanical revolution The control trajectory for stepping though one full electrical cycle using half stepping is as follows 1 1 0 1 0 2 1 0 0 0 Clockwise 5 0 1 0 1 6 0 1 0 0 7 0 1 1 0 8 0 0 1 0 Table 6 1 1 2 Full Step Stepper Motor Sequence Ishnatek Confidential 26 support ishnatek com MCDB User s Manual 6 1 1 3 Micro Step Mode Micro stepping can be done in trapezoidal form or sine form with 8 16 or 32 steps Micro steps mean fraction of full step 1 8 1 16 or 1 32 The step rate has to be increased by a corresponding fac
26. signal You can run motor on different PWM frequencies Ishnatek Confidential 54 support ishnatek com 8 Fusion Software Control Register Communication Data Format MCDB User s Manual ADDRESS 2 0 3 Bit Address to address 8 register locations of 4 bit data bank DATA 3 0 4 bit Data to be written to or Read from the addressed location WR 1 Write to Specified Register 0 Read from Specified Register CTR REG 0 ADDRESS 2 0 000 Read Write Bits Description 3 RUN Start the Motor 2 STOP Stop the Motor 1 PLUS Increase the Speed RPM of Motor Digital Control 0 MINUS Decrease the Speed RPM of Motor Digital Control CTR REG 1 ADDRESS 2 0 001 Read Write ES Description STEP Step the Stepper Motor REG 2 2 will decide Full Step or Half Step Full Step 1 8 Degree Step 200 Steps per Rev Half Step 0 9 Degree Step 400 Steps per Rev 2 1 Reserved Reserved for Future Use 0 SYS Software System Reset REG 2 ADDRESS 2 0 010 Read Write Bits Description 3 CW OR CCW Stepper BLDC or Brushed Motor 1 Rotation Direction Motor will rotate in Clockwise Direction 0 Motor will rotate in Counterclockwise Direction 2 FULL OR HALF REG 5 0 1 This control bit is used to select the Stepper Motor Full step or Half step mode when Microstepping is off
27. 1 312 KHz Ishnatek Confidential 21 supportQ ishnatek com MCDB User s Manual 8 7 ST BD ON NO MICROSTEP 1 0 Stepper 00 8 Steps amp 01 16 Steps SW M B 10 32 Steps ON 11 Reserved ST BD OFF BLDC MODE 1 0 Brushed 00 Complementary PWM Brushless amp 01 High Side PWM SW_M_B 10 Low Side PWM OFF 11 Both Sides PWM BLDC 6 5 ST_BD OFF ACCEL_TIME 1 0 Brushed 00 206 milliseconds Brushless amp 01 312 milliseconds SW_M_B 10 520 milliseconds OFF 11 3 74 Seconds BLDC 4 ST BD ON RANGE SEL STEPPER Stepper amp ON High RPM Range SW M B OFF Low RPM Range OFF 3 ST_BD ON MICROSTEP_TZ_SINE Stepper amp ON Microstep in SW_M_B Trapezoidal form ON OFF Microstep in sine form ST_BD OFF PWM_ON_OFF Brushed PWM Brushless OFF PWM OFF 2 ST BD OFF HALL OR BEMF Brushed Brushless amp ON HALL Sensor SW M OFF BEMF Control OFF BLDC 1 HW SW ON Hardware Control OFF Software Control Ishnatek Confidential 22 support ishnatek com 5 6 Connectors Connector 151 amp JS2 Power Description 12V Power Connector Round PTH type 3 pin barrel connector MCDB User s Manual Notes 12V 2A power supply for reference board Stepper BLDC Brushed Motor Connections 9 Pin Phoenix Terminal Connector 3 Pins VM VM_GND VM for Motor Power
28. 48 022 01 01 48 02 0170 4 44 Li Nyos T MMM SS38HGO0VY SWALSAS M331VNHSI 3021 440001 902138 4001 90214802021 02 ON THS ON NYC vais 31VG 3 8VN AS gt Aga NSG ROS 22 ON 2d 08611190 3WVN 3113 sozi 372 9021460 279 902 44 00 575 21 902 49400 9021 ocu 9021 34 01 ery A 8 3n01 4 902138 001 05 2 ote 902 9021 3066 rcu 9105 9021 143 9021 36x00 40 9021 306 24 20 90213490001 05 9021 34 001 9021 Zee 80217 30ce giu 975 022 01 0 18 41 022 0 118 6481 HOM WA SITNA MOTNA 0228 0108 648 3021 342001 9021 oro AES 4001 152 483021 9021 zee stu 9021 ccs ACO 9 12 9021 YIN 9080 9021 34 001 1342 9021 3066 628 9021 38001 FED 9021 3066 129 91085 01 28 9021 394001 902 3006 028 as 9021399001 902 218 68 ishnatek com Ishnatek Confidential 940 133HS bb 37 28 018 43187 5 HOWL exe bd Bach Mose
29. 5 1 Output Phase A Low Side Signal J3 PHASEB_H Output PhaseB High Side Signal J1 PHASEB_L Output PhaseB Low Side Signal K1 PHASEC_H Output PhaseC High Side Signal K6 PHASEC_L Output PhaseB Low Side Signal L2 PHASED_H Output PhaseD High Side Signal L4 PHASED_L Output PhaseB Low Side Signal M3 FULL_HALF_OR_CAD_H Output For stepper motor J4 Step Size when microstepping off 1 Full Step 200 steps per revolution 1 8 degrees per step 0 Half Step 400 steps per revolution 0 9 degrees per step For BLDC motor 1 BEMF drive using on board comparator 0 BEMF drive using ADC HALL A Input Hall Sensor A from Motor G6 HALL B Input Hall Sensor B from Motor Gl HALL_C Input Hall Sensor from Motor H2 H 1 0 Output Acceleration Control H16 00 206 milliseconds 11 01 312 milliseconds 10 520 milliseconds 11 3 74 Seconds FAULT_OC Output Over Current Fault Detection M5 SD Output Shutdown Can be caused by FAULT_OC 15 or FAULT_OT HALL OR BEMF H Output Sensor Mode 1 Hall Sensor Operation OFF Operation STEP_H Output Step Motor in Half or Full Step depending G4 on FULL_HALF_STEP_H HW_SW Output Hardware or Software Control N3 ON Hardware OFF Software PLUS_H Output Increment Speed G3 Ishnatek Confidential 60 support ishnatek com MCDB User s Manual MINUS_H Output
30. Control Register Map 22 9 Appendix 59 9 1 APPENDIX A AFS600 FG256 Pin List 59 9 2 APPENDIX B Motor Specifications amp Connections 62 9 3 APPENDIX C Board Schematics 67 10 Contact Details Support 76 Ishnatek Confidential 3 support ishnatek com MCDB User s Manual 0 0 Before Starting 0 1 Safety Warnings 0 1 1 General In operation the Motor Control Kit has un insulated wires moving or rotating parts as well as hot surfaces In case of improper use wrong installation or mal operation there is danger of serious personal injury and damage to property All operations installation and maintenance are to be carried out by skilled technical personnel national accident prevention rules must be observed When the Motor Control board is supplied with voltages greater than 24 V AC DC all of the board and components must be considered and any contact with the board must be avoided The operator should stay away from the board as well risk of projection of material in case of components destruction especially when powering the board with high voltages The rotating parts of motors are also a source of danger Never try to stop the motor by holding the rotating shaft by hand The Motor Control Kit contains electrostatic sensitive components which may be damaged through improper use 0 1 2 Intended Use The ISH ACT MCK Starter Kit is made of components designed for demonstration purposes and must not be included
31. MCDB User s Manual a ashnatek Motor Control Daughter Board Revision 3 0 User s Manual Revision History 09 08 2006 1 0 Revision 1 0 Shivachandra Javalagi Preliminary Document Ishnatek Systems 30 12 2006 2 0 Revision 3 0 Shivachandra Javalagi Final Document Ishnatek Systems Ishnatek Confidential 1 supportQ ishnatek com MCDB User s Manual Ishnatek Confidential 2 support ishnatek com MCDB User s Manual CONTENTS Before Starting Introduction Contents and System Requirements Connection steps and Precaution 3 1 Connection steps 3 2 Connection Details 3 3 Precaution 4 Operational Settings 5 Detailed Board Description and Usage 5 1 Block Diagram 5 2 Board s picture 5 3 Status LED s 5 4 Jumpers 5 5 Switches 5 6 Connectors 6 Detailed Design Description 6 1 Stepper Motor 6 1 1 Stepper Drive 6 1 2 Stepper control state machine 6 1 3 Stepper speed calculation 6 2 BLDC Drive 6 2 1 Sensored Drive HALL 6 2 2 Sensorless Drive BEMF 6 2 3 PWM Frequency Speed control 6 2 4 Speed Control 6 2 5 Fault Protection 6 2 6 Commutation 6 2 7 PWM Modes 6 2 7 1 PWM to High Side 6 2 7 2 PWM to Low Side 6 2 7 3 PWM to Both Sides 6 2 7 4 Complementary PWM 6 2 8 BEMF Sensing Circuit 6 2 9 BLDC Control State Machine 6 3 Brushed Drive 65658601 92022 JS eS fes Den fen Ie e ri Re 7 Software 47 8 Fusion Software
32. able At slower frequencies in forced commutation mode the current consumption is very high Hence the motor is brought to auto commute mode by accelerating quickly to the rpm where is above the threshold The acceleration times are variable through the switches provided on board for experimenting with this phenomenon Ishnatek Confidential 33 support ishnatek com MCDB User s Manual Acceleration Settings The IP supports four different acceleration time settings e Fast 206 milliseconds e Medium low 312 milliseconds e Medium high 520 milliseconds e Slow 3 74 seconds 624Hz 312Hz 206mS 156Hz C Tat Tct 31205 5205 37405 a 78Hz 39Hz Tp TIME Figure 6 2 2 Acceleration timings The forced commutation frequency for startup operations depend very much on the motor type and loading Most of the times this will be adjusted only experimentally Ishnatek Confidential 34 support ishnatek com MCDB User s Manual 6 2 3 PWM Frequency The PWM frequency can be variable for running different motor types Typically the PWM frequency must be much higher approx 10X than the electrical frequency of the motor and below the threshold frequency of the switching mosfets lt 100 KHz PWM Frequency PWM_GEN_FREQUENCY 256 There are 4 different opti
33. ar to the motor supplied with the kit and this behavior may not be seen with another motor configuration which has different inductance and resistance value for the windings 4 5 Temperature and Current Sensing If supported by the STP file These sensing results are not to be treated as accurate This feature is just provided for sampling the current and temperature values at the switching instant The sensors are not highly accurate and the tolerance of these sensors is very loose so the displayed results may vary For LCD display on Fusion Press and hold switch 1 Current display Press and hold switch 2 Temperature display Ishnatek Confidential 13 support ishnatek com MCDB User s Manual 5 Board Description and Usage 5 1 Block Diagram PC Motor GUI Control Fusion Daughter Starter Kit Serial or Board USB Interface Figure 5 1 1 BLDC Stepper Motor Controller Serial Interface RS 232 DRIVE1_P N STA STP Bosnie A DRIVE1_N For DRIVE2 P N rection CWICCW inim DRIVE2 Commutation UP 2 DRIVE3_P N DN DRIVE3_N DRIVE4 P N DRIVE4 N BEMF Hall Comparator Figure 5 1 2 Fusion Motor Controller IP Ishnatek Confidential 14 support ishnatek com MCDB User s Manual 5 2 Pictures 5 2 1 Motor Control Daughter Board Rul 8 Figure 5 2 1 Motor Control Daughter Board Ishnatek Confidential 15 support ishnatek com MCDB User
34. assigned power rating Max ball bearing loads 14000 axial dynamic 2 8N 45099 30 Watt r Continuous operation radial 7 5 mm from flange 5 5N In observation of above listed thermal resistances Force for press fits static 50N 10000 lines 17 and 18 the maximum permissible winding static shaft supported 1000 N 8000 temperature will be reached during continuous oper Ambient temperature range 40 100 ation at 25 ambient e Max permissible winding temperature 125 0009 Thermal limit Weight of motor 883 4000 Short term operation Version with and without Hall sensors 2000 The motor may be briefly overloaded recurring 16 pole permanent magnet 3 phased coil stator with 4 pole shoes each 10 20 30 40 50 60 M mNm Values listed in the table are nominal OS 15 25 25 32 FEE Motor with high resistance winding Connection with Hall sensors sensorless 1200142 Motor with low resistance winding Pin 1 4 5 18 VDC Motor winding 1 05 10 15 20 25 30 Pin2 Hall sensor 3 Motor winding 2 Pin3 Hall sensor 1 Motor winding Overview 17 21 4 Hall 2 neutral point Pin 5 GND Spur Gearhead Pin 6 Motor winding 3 045 eH Pin 7 Motor winding 2 peius m Ex Pin 8 Motor winding 1 Bu page Adapter Order number Order number see p 275 220300 220310 Connector Article number Article number AMP 1 487951 1 487951 4 MOLEX 52207 1190 52207 0490 MOLEX 52089 1110
35. cally there are three hall effect sensors provided inside the motor The three sensors comprise of six states namely 001 010 011 100 101 and 110 Six steps are required to perform one complete electrical cycle The electrical to mechanical ratio is based on the pole pairs inside the motor Each state corresponds to the actual rotor position inside the motor This determines the required direction of voltage vector based on the direction in which the rotor needs to be moved A vector table is generated for the sensor state and the next commutation sequence The Hall sensors require an external power supply Ishnatek Confidential 31 support ishnatek com MCDB User s Manual 1 Electrical Cycle gt 0 60 120 180 24 300 360 540 720 i i Hall A 1 4 i 4000001000001 D T 201 m Anigh Bua Baigh Cun Anigh Bun Chigh low Cisy Cow Cus Figure 6 2 1 1 Commutation using Hall sensors VM HIGH Commutation Sequencer Figure 6 2 1 2 Mosfet bridge circuit for commutation Ishnatek Confidential 32 support ishnatek com MCDB User s Manual 6 2 2 Sensorless Drive BEMF Sensing In case of a BLDC motor each stator winding
36. cy NO OF STEPS 2 4881 Hz DIV BY N 1 For e g DIV BY N 6 NO OF STEPS 32 The PWM Frequency would be 11 158 KHz The PWM Generator Frequency is 11 158 KHz X 256 i e 2 85 MHz Ishnatek Confidential 28 supportQ ishnatek com MCDB User s Manual 6 1 1 3 2 Trapezoidal Microstepping Method In this mode the Stepper commutation sequence is applied as shown below One Sequence A HIGH LOW 11 B HIGH pii S c mcn MU TR C LOW 3 1 1 Tl 4 DHIGH NNN m 00 D_LOW A being Energized while D is being De Energized in Trapezoidal Fashion 4 8 16 Steps Figure 6 1 1 3 2 Trapezoidal Microstepping Method Ishnatek Confidential 29 support ishnatek com MCDB User s Manual 6 1 2 STEPPER motor control state machine Apply stepper sequences based on Full Half Step mode setting Apply next stepper sequence based on Full Half Step mode setting Figure 6 1 2 Stepper motor control state machine 6 1 3 Stepper motor speed calculation FULL STEP If range select switch is ON Speed in rpm 9764 div_by_N 1 200 60 If range select switch is OFF Speed in rpm 4882 div_by_N 1 200 60 HALF STEP If range select switch is ON Speed in rpm 9764 div_by_N 1 400 60 If range select switch is OFF Speed in rpm 4882 div_by_N 1 400 60 Ishnatek Confidential 30 support ishnatek com MCDB User s Manual 6 2 BLDC Dri
37. e mode The raw motor windings contain too much spikes and noise which might exceed rated voltages of the Fusion Chip Provision for giving this raw signal directly to Fusion is available on the board Care has to be taken and ensured that the signals are within voltage and current limits in order to safe guard the Fusion I O s A provision for snubber circuit is made on board to suppress these spikes There is a mode where Fusion s ADC is being used to detect zero crossing based on measurements Ishnatek Confidential 44 support ishnatek com MCDB User s Manual 6 2 9 BLDC Control State Machine Start Bring Motor to Known State for Fixed Time Alignment Phase RST Accelerate Motor Sensorless in steps till enough xN BEMF is generated Sensored 72 Commutation R Stop Stop Figure 6 2 8 BLDC control state machine Ishnatek Confidential 45 support ishnatek com MCDB User s Manual 6 2 10 BEMF Sensing using Fusion ADC The motor voltages are scaled down by a factor of 10 to below 1 2V levels If the motor supply is 12V filtered and then applied to the Analog I O s of Fusion The threshold flags are generated for every signal which toggles the output based on the value of the scaled motor voltages These outputs are in the range of 0 to 3 3V These threshold outputs are then applied to the daughter board to run the motor in Sensorless mode using Fusion ADC
38. er The PWM frequencies can be made variable based on motor specifications Ishnatek Confidential 38 support Q ishnatek com MCDB User s Manual 6 2 7 1 PWM to High Side In this case the PWM signal is applied only to the high side of the Mosfet Pair While the low side is driven 100 of the commutation period AB AC BC BA CA CB AB AC 4 5 1 2 Ahigh E Alow Bhigh Blow RH D Chigh Clow Figure 6 2 7 1 PWM to high side Phase PhaseA_H PhaseA_L PhaseB_H PhaseB_L PhaseC_H PhaseC_L Phase Table 6 2 7 1 Phase sequence when PWM to high side Ishnatek Confidential 39 support ishnatek com MCDB User s Manual 6 2 7 2 PWM to Low Side In this mode the PWM signal is applied only to the low side of the Mosfet Pair While the high side is driven 100 of the commutation period AB AC BC BA CA CB AB AC 1 2 3 4 5 6 1 2 EM NN Ahigh a a U U Bhigh EE Blow Chigh Lm EM INN o NER EM Figure 6 2 7 2 PWM to low side Phase PhaseA L PhaseB PhaseB_L PhaseC PhaseC_L _ o of o mes 9 mec 9 FC Phases 0 PWM L9 T Table 6 2 7 2 Phase sequence when PWM to low side Ishnatek Confidential 40 support ishnatek com MCDB User s Manual 6 2 7 3 PWM to Both Sides In this mode the PWM s
39. er Board Board Open Disconnects Key A_D from the Daughter Board When Open user can use external keypad to control A_D signal command to Fusion JP12 ST BD from the Close Connects Key 5 BD from the Daughter Board daughter board Open Disconnects Key ST BD from the daughter board When Open user can use external keypad to control ST BD signal command to Fusion JP13 from the Close Connects Key FL from the Daughter Board daughter board Open Disconnects Key HF_FL from the daughter board Use external keypad to control HF FL signal command to Motherboard JP14 Snubber Circuit for These signals are used to drive BLDC motor MOT_A direct feedback using Fusion s onboard ADC Signal Fusion s ADC generates threshold flags which JP15 Snubber Circuit for MOT_B are then used to commutate the motor direct feedback Signal JP16 Snubber Circuit for MOT_C These are scaled down voltages through a direct feedback Signal resistor divider network JP17 Snubber Circuit for Connect MOT_A to M9 MOT_B to N7 MOT_D direct feedback MOT C to if IP supports this mode Signal JP18 TSIG Signal for Close Connects TSIG from the daughter Temperature Sensing board Open Disconnects TSIG from the daughter board JP19 TRTN Signal for Close Connects TRTN from the daughter Temperature Sensing board Open Disconnects TRTN from the daughter board JP20 VM CS signal for Current
40. f RPM When JP11 is closed OFF Digital Control of RPM During Analog Control Switches RPM and RPM will have no effect on the RPM The RPM is controlled using the potentiometer on pin AVO of Fusion LD10 5V_FN Indicator RED 5V from the Fusion board is chosen and active LD11 12V REF Indicator RED 12V Supply on the daughter board is active 1012 SW M B Indicator RED In case of Stepper motor When JP25 is closed ON Microstepping ON OFF Microstepping OFF In case of Brushed or Brushless motor ON Brushed motor OFF Brushless motor 1013 USB 5V Indicator RED USB cable is plugged in Ishnatek Confidential 17 support ishnatek com MCDB User s Manual 5 4 Jumpers Short Links Jumper Function Notes JP1 Link for low side polarity of 1 2 gt GND connects to VM_Low motor power supply 2 3 gt VM connects to VM_Low JP2 LED for Serial Reception Close Connects LED for serial reception Open Disconnects LED for serial reception LED for Serial Close Connects LED for serial transmission Transmission Open Disconnects LED for serial transmission JP4 Jumper to select 5V power 1 2 gt Use 5V from Fusion Board to be used on Daughter 2 3 gt Use 5V from Daughter Board IC7805 Board regulator 5 RUN from the Daughter Close Connects Key RUN from the daughter Board board Open Disconnects Key RUN from the daughter board When Open user can u
41. for phase M9 AV3 Input Scaled down voltage for phase N7 AV4 Input Scaled down voltage for phase N9 NO_MSTP_OR_BL_MD_H Output For Stepper Motor in micro step mode H12 1 0 No of Micro step 14 00 8steps 01 16steps 10 32steps 11 Reserved For BLDC motor PWM Mode 00 Complementary PWM 01 Low Side PWM 10 High Side PWM 11 Both Sides PWM STOP_H Output Motor Stop F4 MST_SC_OR_PWM_H Output For stepper motor Microstepping ON K16 1 Trapezoidal Form 0 Sinusoidal Form For brushed or brushless motor PWM ON 1 ON 0 OFF MST_OR_BD_BL_H Output For stepper motor K4 Microstepping ON OFF 1 ON 0 OFF For Brushed Brushless motor 1 Brushed motor 0 Brushless motor STEPPER_OR_BDBL_H Output Motor Select K3 Ishnatek Confidential 1 Stepper Motor 0 BLDC Motor 59 support ishnatek com MCDB User s Manual RUN_H Output Motor Start Run F2 BEMF_COMP_A Input BEMFA DB Comparator output Ll BEMF_COMP_B Input DB Comparator output L3 BEMF_COMP_C Input BEMFB DB Comparator output M2 RANGE_SELECT_H Output Stepper Motor Range Select G14 ON 1440 RPM OFF 720 RPM SYS_RESET Input System Reset Pulse through Switch SW6 L15 FAULT_OT Output Over Temperature Fault Detection N2 Output PhaseA High Side Signal J
42. generates a Back Electromotive Force The rotor position is inferred based on the induced voltage on the inactive winding The Zero Crossing of the BEMF 15 a significant point for commutation Back EMF is proportional to the angular velocity of the rotor magnetic field generated by rotor magnets and the number of turns of stator windings Current has to be commutated in phase with BEMF to get optimal control and maximum torque per current Startup On start command the rotor is first aligned to a known position in DC excitation mode At low speeds BEMF is low hence zero crossing detection becomes difficult hence the motor is started in a forced commutation mode this can also be referred to as open loop mode As is a function of rotor rpm the BEMEF is initially zero when the rotor is still So measurable BEMF should be generated to be able to self commutate close loop mode When a sufficient BEMF is generated we can shift to auto commutation In every commutation Three phase step one winding is positive one winding negative and the third is floating The back EMF zero crossing detection enables position recognition Detect zero crossing of for the winding that is floating in order to commutate to next step sequence A resistor network is used to step down sensed voltages to a 0 5 level Zero crossing detection is done using external comparators by synthesizing a Star reference point Neutral point of the motor is unavail
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44. ignal is applied to both sides of the Mosfet Pair Care is taken in the design to ensure that there is enough dead time between the two signals in the Mosfet bridge and avoid any short circuit current AB AC BC BA CA CB AB AC 1 2 3 4 5 6 1 2 am Ahigh as U pP 1 2 BS Bhigh Bow LE BB HH Chigh iit NEM Figure 6 2 7 3 PWM to low side Phase PhaseA L PhaseB PhaseB_L PhaseC PhaseC Table 6 2 7 3 Phase sequence when PWM to both sides Ishnatek Confidential 41 support ishnatek com MCDB User s Manual 6 2 7 4 Complementary PWM In this case the PWM signal is applied in a complementary fashion to the high and low side of the bridge simultaneously The freewheeling current flows through the mosfet instead of the body diode This technique gives improved for low speed applications The offset voltage caused by body diode is eliminated Controller design to assure safe dead times in order to prevent short circuit currents AC BC BA CA CB AB AC 4 5 6 1 2 Ahigh Ee B 4 Alow Bhigh Blow BN Chigh Clow E mm Figure 6 2 7 4 Complementary PWM Phase PhaseA_H PhaseA_L PhaseB_H PhaseB_L PhaseC_H PhaseC_L Phasel 2221 Table 6 2 7 4 Complimentary PWM phase sequence Ishnatek Confidential 42 support ishnatek com MCDB User s Manual
45. in electrical installations or machinery Instructions about the setup and use of the ISH ACT MCK Starter Kit must be strictly observed at all times 0 1 3 Operation After disconnecting the board from the voltage supply several parts and power terminals must not be touched immediately because of possible energized capacitors or hot surfaces 0 1 4 Important Notice to Users While every effort has been made to ensure the accuracy of all information in this document Ishnatek Systems and Actel assumes no liability to any party for any loss or damage caused by errors or omissions or by statements of any kind in this document its updates supplements or special editions whether such errors are omissions or statements resulting from negligence accident or any other cause 0 2 Required Skills In order to profitably use the ISH MCDB R3 Motor Control Starter Kit you should be acquainted with several skills ranging from hardware design to software design In particular you should possess the knowledge about Electrical Motors and FPGA Programming Ishnatek Confidential 4 support ishnatek com MCDB User s Manual 1 0 Introduction Features e Supports o Stepper Motor 4 Wire 5 Wire as well as 6 Wire Configuration Full Step Half Step Mode Micro Step Mode Sinusoidal Trapezoidal Option 8 16 32 Microsteps o Brushless DC BLDC Motor Provision for 4 One Phase or 2 Two Phase or 1 Three Phase OR 1 Four Phase BLDC M
46. k motor needs to be forcibly driven in openloop acceleration phase initially so that back emf of considerable magnitude is generated Once enough BEMF is generated the motor is shifted to closeloop i e motor is driven as per BEMF feedback In case BLDC DRIVE For Sensored Commutation Use HALL Mode For SensorLess Commutation use the BEMF Option PWM When PWM ON is selected we can have speed control using RPM UP and RPM DN The Duty Cycle and consequently the average voltage to the Motor winding are altered to increase or decrease the speed of the motor When PWM OFF is selected the RPM is at its maximum per applied voltage In that the case the RPM can be varied only with External Motor Supply voltage Make sure the motor voltage does not exceed the specifications PWM MODE SELECT A BLDC Motor can run in four modes 1 Complimentary in this mode free wheeling current flows through MOSFETS and PWM is applied to high side MOSFET drivers The complimentary mode consumes a lot of current at low speeds this mode is not recommended for use and only a BETA feature High Side PWM is applied to only high side MOSFET drivers Low Side PWM is applied to only low side MOSFET drivers 4 Both Sides PWM is applied to high side as well as low side MOSFET drivers wh MOTOR DRIVE HALL This option is for motors having Hall sensors for auto commutation This option is for motors that do not have sensors and need to be driven using BEMF
47. log control through potentiometer This control is used to select drive for stepper motor or drive for dc motor Brushed or Brushless Motor 0 Brushed or Brushless Motor support ishnatek com CTR_REG_6 ADDRESS 2 0 110 Read Write MCDB User s Manual Bits Name Description 3 0 Reserved Reserved 7 ADDRESS 2 0 111 Read Only Bits Name 3 2 1 0 Description These two bits indicate the current in motor windings Ampere 00 Current lt 0 5A 01 2 0 5A lt Current lt 1A 10 1A Current lt 2A 11 Current 2A 1 0 OT 1 0 These two bits indicate the temperature of motor Degree C 00 Temperature lt 30 01 30 lt Temperature 40 10 40 lt 50 11 Temperature gt 50 Ishnatek Confidential 58 support ishnatek com 9 APPENDIX MCDB User s Manual 9 1 Appendix A AFS600 FG256 Pin List Signal Name Input Description Fusion Output Pin RxD Input RS232 Receive F3 TxD Output RS232 Transmit Fl CW_OR_CCW_H Output Motor Direction Control J6 1 Clockwise 0 Counterclockwise ATRETURN89 Input Temperature Sensor Return T12 AT Input Temperature Sensor R12 1 Input Over Current Sense Voltage Input P6 1 Input Over Current Sense Current Input M7 AVO Input RPM Control Analog M6 AV2 Input Scaled down BEMF voltage
48. n Board Daughter Board Checks e JP20 and JP21 on daughter board are closed Current Sense e Pin3 of J6 CS OUT on daughter board connects to Fusion Pin 7 by removing jumper JP51 on Fusion Board Pin 2 of JP51 Pin4ofJ6 VM LOW OUT on daughter board connects to Fusion Pin by removing jumper JP49 on FUSION board Pin 2 of JP49 Wire From Board Pin Names Color Code Fusion Pin Daughter Board CABLE C Pin3 of J6 VM CS OUT Brown M7 Pin 2 of JP51 Pin 4 of J6 VM LOW OUT Black P6 Pin 2 of JP49 There is sense resistor Rs 10 milliohm provided on the low side of the power drive The current that flows through this sense resistor is discontinuous as the signal is chopped at the PWM frequency The current flows during the ON time of the power stage and is zero during the OFF time If you need to measure average current you will need to create your own hardware This feature is not supported on the daughter board 3 1 2 4 Connections for Temperature Sensing If Fusion Kit is programmed with mcdb rev3 ts cs stp Remove Jumpers JP68 and JP62 on Fusion Board Daughter Board Checks e JP18 and JP19 on daughter board are closed Temperature Sense Pin 1 of J6 T RTN on daughter card connects to Fusion pin R12 by removing jumper 7 627 on FUSION board Pin 2 of JP62 Pin 2 of J6 T SIG on daughter card connects to Fusion pin T12 by removing jumper JP68 on FUSION board
49. n yet 3 1 2 Fusion Starter Kit Setup Remove the following short links on the Fusion Starter Kit JP51 JP49 JP68 JP62 JP34 JP30 and JP37 3 1 2 1 RPM Control using Analog Potentiometer A Potentiometer connected to Pin and to Fusion Pin M6 On the Fusion Kit can be used to control the speed when in analog control mode 3 1 2 2 Connections for BEMF drive using Fusion ADC If Fusion Kit is programmed with mcdb rev3 adc drive stp Remove Jumpers JP34 M9 JP30 N7 and JP37 N9 on Fusion Board Daughter Board Checks JP14 JP15 JP16 and JP17 on daughter board are closed Scaled Motor Voltages e Pin 12 of J5 on daughter board connects to Fusion pin M9 by removing jumper JP34 on FUSION board e Pin 11 of 75 on daughter board connects to Fusion pin N7 by removing jumper JP30 on FUSION board e Pin 10 of J5 on daughter board connects to Fusion pin N9 by removing jumper JP37 on FUSION board CABLE D 4 Open single Leads Orange left unconnected Wire From Color Code Fusion Pin Daughter Board CABLE D Pin 12 of J5 Black M9 Pin 11 of J5 Brown N7 PH_B_BEMF Pin 10 of J5 Red _ _ Ishnatek Confidential 7 support ishnatek com MCDB User s Manual 3 1 2 3 Connections for current sensing If Fusion Kit is programmed with mcdb rev3 ts cs stp Remove Jumpers JP51 and JP49 on Fusio
50. nce of phase voltages the motor windings must be supplied with for proper commutation For a 4 wire 6 wire motor there are 2 windings provided One winding is powered while the current in the other winding is gradually dropped to zero reversed and then ramped up again The sequence and period will define the speed of commutation In the case of 6 wire Stepper Motor Figure 4 1 2 additional wires are provided A center tap from each of the windings is brought out externally A high wattage resistor is required on board to dissipate the power in the windings Refer to motor specifications for exact values of to be used Rext Rext Figure 6 1 4 Wire 6 Wire 2 Phase Stepper Configuration In the case of 4 wire or 6 wire Stepper motor four vectored inputs are used to directly control which switches are open or closed in the push pull stage In some motors the inputs may be encoded while others may control subsystems such as the analog to digital converter in a microstepping interface A control vector is defined as the state of each logic input and control trajectory is defined by the sequence of states used to commutate the rotor The control trajectory remains the same for both types of motors Note There could be different control trajectory for different motor designs please make the design changes accordingly to conform to motor specification Ishnatek Confidential 25 support ishnatek com MCDB User
51. ng or decreasing speed respectively when in digital control mode Ishnatek Confidential 51 support ishnatek com MCDB User s Manual STEPPER CONTROLS e STEP TYPE Stepper motor can be run in FULL STEP HALF STEP or MICRO STEP mode Full Step Mode In this case the stepper motor rotates by 1 8 degrees per STEP Click i e 200 Full Steps for one complete revolution of the motor shaft Half Step In this mode the stepper motor rotates by 0 9 degrees per STEP Click i e 400 Half Steps for one complete revolution of the motor shaft Microstep Mode Microstepping can be done using Trapezoidal method or sine method with 8 16 and 32 microsteps im MicroStepping Options MICROSTEPSIZE MICROSTEP TYPE 6 TRAPEZOIDAL 16 Steps 8 82 Steps SINUSOIDAL Stepper Motors can give very high precision in angle of rotation and commonly used in Automation and Motion Control Applications RANGE SELECT For different motors maximum RPM rating is different so two ranges are provided In one case we get a maximum of 1440RPM and in another case we get maximum 720RPM In microstep mode Range select does not affect the speed range e STEP When you click on STEP you can single step the stepper motor in full or half step mode Single step does not work in Microstepping mode Ishnatek Confidential 52 support ishnatek com MCDB User s Manual BLDC CONTROLS Note In case of BEMF feedbac
52. ntary 5 39 KHz MICROSTEP 5 BEMF High Side 78KHz RANGE SELECT 1 Tow Site C 156KHz Stepper 2900 RPM PWM Both Sides 312KHz Stepper 1450 RPM C PWM OFF E 1 ClockWise ANALOG CounterClockWise DIGITAL ES Divide by N SPEED 9 STOP 2 Temperature Update Initialize Motor Parameters Shunt Current Communication Port The first step to start communication with daughter board is to set up the COM Port Com Port Settings Please verify the COM number assigned for the virtual com port generated by the OS when the RS232 to USB cable is plugged in Control Panel gt System gt Device Manager gt COM Port Also make sure all associated drivers for the USB to RS232 Interface cable is loaded prior to using this interface Ishnatek Confidential 47 ishnatek com MCDB User s Manual iw Communication Control Properties 218 File values Actual Values Comm Port DTR Enable Handshaking In Buffer Size Input Len Input Made Null Discard Qut Buffer Size Parity Replace R Threshold RTS Enable Settings 5 Threshold Ishnatek Confidential 0 Text Mode Tue 2 04 5 2 48 Recommended Values 2011 True 2 comRTS 1024 0 0 Text Mode True 512 1024 2 1 True 9600 8 1 support ishnatek com MCDB User s Manual
53. ons for PWM_GEN_FREQUENCY provided in hardware and software PWM_FR_SEL 1 0 PWM_GEN_FREQUENCY 00 39 KHz 01 78 KHz 10 156 KHz 11 312 KHz 6 2 4 Speed Control The speed of the motor is directly proportional to the applied voltage By varying the average voltage across the windings the rpm can be altered This is achieved by altering the duty cycle of the base PWM signal Maximum speed is achieved when PWM is OFF In that case the mosfets are ON 100 of the commutation period When PWM is turned ON then the speed is proportional to the duty cycle setting The duty cycle modification can be done through Analog or Digital mechanism Analog Control of RPM An external potentiometer and the Fusion s internal 8 10 12 Bit ADC is used to alter the Duty Cycle of the base PWM base clock The 8 bit Duty cycle value is fed to the design to adjust the duty cycle and hence control the speed of the motor Digital Control of RPM A fixed internal 8 bit register is incremented or decremented upon receiving the RPM RPM commands from the switches onboard or through the software interface This alters the duty cycle and hence the speed of the motor 6 2 5 Fault Protection Over Current Protection A very small valued shunt resistor 10 milliohm is put in series of the low side of the bridge and the negative terminal of the Motor Power supply These two signals are fed to Fusion s analog quads to measure the curren
54. otor Sensored Drive e Using Hall Effect Sensors provided on Motors Sensorless Drive e Using on board comparators OR e Using Fusion ADC threshold flags Brushed Drive Support One Brushed Motor with Direction Speed Control Direction Control Clockwise or Counterclockwise Rotation e Basic Functions Start Stop Step Full or Half Stepping in case of Stepper Motor RPM RPM Increase Decrease RPM Analog Digital Control Features e Four Acceleration Settings for various motor types Fast 208 milliseconds Medium High 312 milliseconds Medium Low 520 milliseconds Slow 3 74 seconds e Support Four PWM Modes PWM high side of Mosfet Bridge PWM on low side of Mosfet Bridge PWM both sides of Mosfet Bridge Complementary through Mosfet Bridge BETA Feature Hardware Software Control Access to all above features through keys switches on board Equivalent controls are provided also through software Software Interface using on board USB to RS232 bridge e High Output Current up to 10 e Over Current Over Temperature Protection through Shutdown Pin of the Mosfet Driver Ishnatek Confidential 5 support ishnatek com MCDB User s Manual 2 Contents and System Requirements Motor Control Daughter Board Rev 3 0 Requirements o Fusion Starter Kit AFS600FG256ES Not Provided 40 Pin FRC Connector To Fusion Starter Kit Provided 12 Pin Straight Connector To Fusion Starter
55. s are active the third phase is inactive or floating This mechanism has built in dead time and assures that the two Mosfets in the same bridge are not active at the same time The commutation sequence as shown above will be AB AC BC BA CA CB AB AC and repeats there on Notice that during AB sequence the upper side of the A bridge is active while the lower side of B bridge is active So current flows from DC through A high side to motor winding across A and B passes through low side of B bridge and to DC Similarly for all other phases The commutation timing is determined based on the position of the rotor In case of Sensored drive Hall effect sensor digital outputs determine the position of the rotor which can be used to move to the next logical sequence In case of Sensorless drive the on the floating winding is used to detect the rotor position and move to the next logical sequence to commutate the motor Ishnatek Confidential 37 support ishnatek com MCDB User s Manual 6 2 7 PWM Modes e average phase voltage is modulated to control the speed of the motor e Higher the average Voltage higher the RPM This can be achieved using PWM logic A Simple 8 Bit PWM Block is used Duty Cycle Digital Control Internal 8 Bit Duty Cycle counter Incremented or decremented using and RPM keys on board Analog Control Potentiometer setting selects the 8 bit Duty Cycle value Period Counter Period Count
56. se external keypad to control RUN signal command to Fusion JP6 STOP from the Daughter Close Connects Key STOP from the daughter Board board Open Disconnects Key STOP from the daughter board When Open user can use external keypad to control STOP signal command to Fusion JP7 STEP from the Daughter Close Connects Key STEP from the daughter Board board Open Disconnects Key STEP from the daughter board When Open user can use external keypad to control STEP signal command to Fusion JP8 from the Daughter Close Connects Key from the Board daughter board Open Disconnects Key RPM from the daughter board When Open user can use external keypad to control signal command to Motherboard JP9 from the Daughter Close Connects Key from the daughter Board board Open Disconnects Key RPM from the daughter board When Open user can use external keypad to control RPM signal command to Fusion JP10 DIR from the Daughter Close Connects Key DIR from the daughter Board board Open Disconnects Key DIR from the daughter board When Open user can use external keypad to Ishnatek Confidential 18 support ishnatek com MCDB User s Manual control DIR signal command to Fusion A_D from the Daughter Close Connects Key _ from the Daught
57. t from the Motor s power supply using Potential differential method A threshold current flag is generated from Fusion which could cause the Shutdown pin of the Mosfet driver to go active and switch off the Ishnatek Confidential 35 supportQ ishnatek com MCDB User s Manual Mosfets The Shutdown pin of the Mosfet driver is currently tied to OFF position If you wish to use this feature you will need access to the code and do the alterations Over Temperature Protection A junction temperature of the transistor is used to measure the temperature in the vicinity of the Mosfets If the Mosfets are running hot then the Fusion s Analog Quad block dedicated for temperature sensing would raise the threshold flag to indicate over temperature A threshold temperature flag is generated from Fusion which could cause the Shutdown pin of the Mosfet driver to go active and switch off the Mosfets The Shutdown pin of the Mosfet driver is currently tied to OFF position If you wish to use this feature you will need access to the code and do the alterations Ishnatek Confidential 36 support ishnatek com MCDB User s Manual 6 2 6 Commutation Typical 3 Ph Current Waveforms b Figure 6 2 6 Six Step Commutation Waveform Figure 4 shows the commutation sequence for a typical 3 Ph BLDC Motor Each phase is active for 120 electrical degrees At any given time step interval notice that only two phase
58. tor 8 16 or 32 for same rpm Pulse Width Modulation PWM technique is used to implement Micro step mode by varying the duty cycle of the applied voltage Step Dutycycle Value Dutycycle Value Dutycycle Value No 32 Steps 16 Steps 8 Steps 9 1 05 2 05 2 05 2 2 1 11 31 19 61 38 3 31 19 61 38 4 63 4 4 29 8 55 92 5 61 38 4 63 92 6 78 47 4 83 B4 63 7 8C 55 EB 92 61 38 8 63 98 05 2 9 B4 70 FA 98 10 C6 77 92 11 D4 83 D4 83 12 EO 88 B4 63 13 EB 92 8C 55 14 F4 95 61 38 15 FA 98 31 19 16 FE 100 05 2 17 100 18 98 19 4 95 20 92 21 EO 88 22 D4 83 23 C6 77 24 70 25 63 26 8 55 27 78 47 28 61 38 29 4 29 30 31 19 31 1 11 32 05 2 Table 6 1 1 3 Duty Cycles for 32 16 8 Microstep options Ishnatek Confidential 27 support ishnatek com MCDB User s Manual 6 1 1 3 1 Sinusoidal Microstepping Method In this mode the Stepper commutation sequence is applied as shown below One Sequence A_HIGH A_LOW B_HIGH B_LOW C_HIGH C_LOW D_HIGH D_LOW A being Energized while D is being De Energized 8 16 32 Steps Figure 1 1 3 1 Sinusoidal Microstepping Method PWM frequency during Microstepping Both Sinusoidal and Trapezoidal is generated as follows PWM Frequen
59. ttings 4 1 BLDC Acceleration Settings In the current setup for Maxon EC45 Flat use MEDIUM HIGH or MEDIUM LOW setting for acceleration 4 2 BLDC Motor using Analog Drive While running the BLDC motor in Sensorless Mode and using Analog Drive make sure the Potentiometer R50 on the Fusion Kit connected to AVO or pin M6 is at its maximum The LED s on Fusion Kit D1 to D8 will reflect the value of the Potentiometer setting the value will be Hex FA D8 MSB and D1 LSB In case of sensored drive this Potentiometer can be at any position and the motor will start and run at the speed set by the Potentiometer 4 3 Stepper Motor using Analog Drive In the case of Stepper there are only 16 steps for speed control The 4 MSB bits of the analog ADC outputs as reflected by the LED s D4 D1 control the divide by N ratio of the applied frequency to the stepper drive circuit While running the stepper motor using Analog Drive make sure the Potentiometer R50 the Fusion Kit connected to or pin M6 is at its maximum The LED s on Fusion Kit D4 to D1 will reflect the value of the Potentiometer setting 4 4 Stepper Motor Anomalous Behavior When the RPM setting is at C or 12 and the settings are Full Step and Range_Select is OFF the Stepper motor stutters This is due to the applied frequency matches to the resonance frequency of the motor based on the winding inductance and resistance This is particul
60. ve A BLDC Motor is a synchronous motor with no damping or starting windings Three logic signals are decoded to determine the next winding sequence A Three Phase Motor requires three push pull stages In each of the six possible states two outputs are active at a given time current flows in only two windings of the stator Each state translates to electrical sectors Figure 6 2 Push Pull stages of a 3 phase bldc drive Simple Control Technique would be to sense the change in the state of the position of the rotor and apply the next step state for commutation In case sensors are provided the position is known by reading the Hall sensors to determine the next state Pulse Width Modultation PWM is used for speed control 6 2 1 Sensored Drive Hall Effect Sensors Motor is commutated based on the signals given by the Hall Sensors mounted at various positions inside the motor Hall outputs change very 60 electrical degrees The state of the control switches and the Hall sensor signals are scanned continuously A new voltage vector control trajectory is applied to the BLDC Motor based on the Hall sensor signal conditions This mechanism is known as commutation The Hall position sensors sense the actual rotor position The hall outputs are monitored by the controller and appropriate commutation sequence is applied to assist in commutating the motor The speed of the motor is varied by making use of PWM outputs on the output voltages Typi
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