DC-Motor-Driver-42A
Contents
1. DIP switch setting for Right Mix Mode 00001100 Exponential and MCU Mode are turned off 3 For the first time the direction and mixing side left right of the motor must be checked to make sure it 1s correct Follow the steps below to set up the motor mixing side and direction 1 ii iii Turn on the RC transmitter first and followed by the driver Push the speed channel stick to maximum forward position and hold it Both motors should run with full speed now Ignore the direction of the motors for the moment Still holding the speed channel stick in maximum forward position push the direction channel stick to left at the same time The left motor should run slower than the right motor If this is not so power off the driver and change the DIP switch setting of mixing side for both motor After that start from step l again iv Push the direction channel stick to right The right motor should run slower than the left motor This means the mixing side of the motor 1s set correctly v Now we want to make sure the motor direction is correct Push the speed channel stick to maximum forward position and center the direction channel stick Both motor should run in the forward direction If this is not so reverse the polarity of the motor connection vi Push the speed channel stick to maximum backward position and center the direction channel stick Both motor should run in the backward direction This means the motors are runn2. Input 1 controls the overall speed as well as forward backward movement of the robot Input 2 controls the left right or pivot movement of the robot In left mix mode the motor will be slowed down when the robot is commanded to turn left and vice versa SW8 must be set to 0 Single Mix Mode Right Mix Mode This mode should be selected for the right motor of the robot differential drive system Input 1 controls the overall speed as well as forward backward movement of the robot Input 2 controls the left right or pivot movement of the robot In right mix mode the motor will be slowed down when the robot is commanded to turn right and vice versa SW8 must be set to 0 Off The speed is linear with the input signal This is for low to medium speed motor Exponential Mode On The response to input is exponential and this soften the control around the center zero speed point This is suitable fo high speed and very sensitive motor Off Motor stops when the input signal is 2 5V Motor moves 1 one direction when the input is lt 2 5V and in another directio hen the input is gt 2 5V Sign Magnitude Mode On Input 1 controls the speed of the motor Motor stops whe the input is OV and run at full speed when the input is 5V Input 2 is digital input and it controls the direction of the motor SW2 must be set to 0 0 OFF 1 ON X Don t Care Left Right is just for reference only Actual side of the motor may depends on t
3. a e a o 4 Vion Logic Input High Leve _ _ 3 SS C5 Mor Logic Input Low Level o o os v i Depends on the room temperature oe Must not exceed I second 4 0 BOARD OR PRODUCT LAYOUT f i sE q oer w y Ys P 6 i 8 ETELICIE Beli sii ia A qa Bi i ii zo Y 7 a TaT pat t Components on MDS40A and their functions Dean T Connector Male Connect to power source For high current application please solder the wire directly to the pad at bottom layer LED A Turns on when the output A is high and output B is low Indicates the current flows from output A to B Terminal Block Connect to motor Reverse the polarity if the motor direction is incorrect LED B Turns on when the output A is low and output B is high Indicates the current flows from output B to A 5 LED STAT Status LED Turn on when the motor is running Turn off otherwise 6 LED ERR Error LED The number of blinks is corresponding to the error Number of Blinks Off Over current is detected and curren Over Current marcas limiting is operating Over Temperature The board temperature is too high MOSFET Driver Error Error detected by the MOSFET driver 7 Test Button B When this button is pressed current flows from output B to A and motor will turn CCW or CW depending on the connection 8 Test Button A When this button is pressed current flows from o
4. High Current DC Motor Driver Manual 1 0 INTRODUCTION AND OVERVIEW This driver is one of the latest smart series motor drivers designed to drive medium to high power brushed DC motor with current capacity up to 82A peak and 42A continuously MOSFETs are switched at 16 KHz to ensure quiet operation and no annoying whining sound Besides it also equipped with a microcontroller unit to provide some smart features such as multiple input mode current limiting and thermal protection The driver can also be hooked up with another similar unit and operates in pair This make driving a robot with differential drive a truly plug and play experience Some of the features for the driver are summarized as below e Bi directional control for a single brushed DC motor e Support motor from 7V to 25V e Maximum current up to 82A peak 1 second 42A 5 minutes or 30A continuously e 16 KHz switching frequency for quiet operation e Reverse polarity protection e LiPo battery low voltage warning e Thermal protection e Current limiting base on temperature e Multiple input modes RC Analog PWM Simplified Serial and Packetized Serial e On board push button for manual operation 3 0 PRODUCT SPECIFICATION AND LIMITATIONS Dimensions inom hum 3 tH toCcwoerc rp Byz as F of 7 a a3 i h 7 7 Eer 100mm a a PP Imax Maximum Continuous Motor Current 2 5 minutes gt 20 minutes gt eee itid Aa
5. RC transmitter must be turn on before power up the driver RC Input mode is selected by setting all the SW1 SW4 to 0 Down SW5 SW8 can be configured depending on the requirement of the user Input Mode e RC Input Mode SW5 SW6 0X Single Channel Mode The motor speed and direction are controlled by a single RC channel connected to Input 1 Motor stops when the input signal is at the center point Input 2 is not used in this mode Left Mix Mode This mode should be selected for the left motor of the robot differential drive system Input 1 controls the overall speed as well as forward backward movement of the robot Input 2 controls the left right or pivot movement of the robot In left mix mode the motor will be slowed down when the robot is commanded to turn left and vice versa Right Mix Mode This mode should be selected for the right motor o the robot differential drive system Input 1 controls the overall speed as ell as forward backward movement of the robot Input 2 controls the left right or pivot movement of the robot In right mix mode the motor will be slowed down when the robot is commanded to turn right and vice versa Off The speed is linear with the input signal This is for low to medium speed motor Exponential Mode On The response to input is exponential and this soften the control around the center zero speed point This is suitable for high speed and sensitive motor Off The c
6. dentify the polarity of Dean T connector There are and marking on the Dean T connector 2 Cut and remove the wire insulator If user needs to solder the wire directly from battery to Dean T connector solder one terminal at a time and leave another one wrapped 3 Cut the shrinking tube to 2cm each Slide in the shrinking tube into the wire The shrinking tube is used to protect the connection at the Dean T terminal 4 Solder the wire to Dean T connector Be careful while soldering and make sure the polarity 1s correct 5 Cover the connection with shrinking tube and supply heat to it The shrinking tube will shrink and cover the connection neatly as shown below User may use soldering iron to heat the shrinking tube 6 Continue with another terminal Steps to solder the wire directly to the pad at bottom layer are shown below 1 Identify the polarity of power terminal There are and marking at the bottom layer of MDS40A 2 Cut and remove the wire insulator Solder one terminal at a time and leave another one wrapped 3 Solder the wire to the pad at the bottom layer Be careful while soldering and make sure the polarity is correct 4 Continue with another terminal 5 Below is an example of power cable being soldered directly to the bottom layer 6 0 MOTOR CONNECTION Similar to the power supply connection to the motor can be made either via the terminal block or it can be so
7. enter point will be calibrated upon power up Timeout occurs after lost of signal for 100ms and the motor will be stopped for safety On The center point is fixed at 1 5ms and the timeout feature is disabled Motor will continue to run with previous speed if new signal is not detected This is useful when a microcontroller is used to control the motor The microcontroller does not need to send the pulse continuously to the driver Instead it only needs to send a single pulse when the speed or direction of the motor needs to be changed 0 OFF 1 ON X Don t Care Left Right is just for reference only Actual side of the motor may depends on the RC transmitter Table below shows the commonly used DIP switch settings for RC mode MLE Semis DIP eRC Mode ON o o D g q o g g Single Channel Mode a a By Gb LE AS TA te eExponential Off E e MCU Mode Off 00000000 O DIP eRC Mode F olo o o A eSingle Channel Mode a o LEL a a TA te eExponential On e MCU Mode Off 00000010 O DIP eRC Mode F on a Left Mix Mode 11 2 81 amp day TA e e Exponential Off e MCU Mode Off 00001000 DIP eRC Mode T H a H H H eRight Mix Mode ial Off 3 4 678 e Fxponentia Li e MCU Mode Off 00001100 Figures below show the connection in RC mode for Single Channel Mode Input 1 is connected to either a RC Receiver or a microcontroller generating the RC pulse RC Tranamitter gt ee ee RC Receiv
8. er Microcontroller 8 2 ANALOG PWM INPUT MODE In Analog PWM input mode the speed and direction of the motor is controlled by the analog voltage or PWM signal The valid input range is 0 5V and it s very easy to control by using a potentiometer For example the motor can be controlled by a joystick or foot pedal with potentiometer NOTE The Analog PWM signal to stop the motor 2 5V if Sign Magnitude mode is off OV otherwise must be available when the driver is turned on Else the driver will show Input Error until the correct signal is available Analog PWM input mode is selected by setting SW3 to 0 Down and SW4 to 1 Up SW1 SW2 and SW5 SW8 can be configured depending on the requirement of the user SW1 Sw2 00 Off The input is analog signal The filter capacitor is not connected and the input signal is not filtered SW1 is for Input 1 hile SW2 is for Input 2 On The input is PWM signal The filter capacitor is connected and the input signal is low pass filtered to be an analog signal SW1 is for Input 1 while SW2 is for Input 2 SW2 must be set to 0 if Si nitude mode is turned on SW5 SW6 OX Single Channel Mode The motor speed and direction are controlled by a single channel connected to Input 1 Motor stops hen the input signal is at the center point Input 2 is not used in this mode Left Mix Mode This mode should be selected for the left moto of the robot differential drive system
9. ether to a single microcontroller UART port Besides that the driver also incorporates an Auto Baud feature in Packetized Serial mode When the driver is first powered up the host microcontroller must send a header byte Decimal 85 to the driver The driver will then calculate the baud rate automatically based on this character After that driver is ready for command and the baud rate cannot be changed without power off and on again NOTE 1 When the driver is powered up and waiting for the header byte the error LED will blink and indicate that there is input error driver may take up to 500ms to start up after power is applied Sending the header byte for auto baud during this time period may cause undesirable results Please allow a one second delay between applying power and sending the header byte Packetized Serial mode is selected by setting SW1 SW2 to 0 Down and SW3 SW4 to 1 Up SW5 SW8 are used to select the address SW1 SW4 Input Mode 0011 Packetized Serial Mode SW5 SW8 0 OFF 1 ON X Don t Care A packet consists of 4 bytes and the format is shown in the following table Byte Name Value Decimal 1 Header_ 85 To indicate the start of packet sed to identify the driver when multiple units are connected 2 Address O 15 together The address byte must match the address configured ith the DIP switch Command p 355 Value 127 stops the motor O is full reverse and 255 is full forward 4 Chec
10. he Input signal Table below shows the commonly used DIP switch settings for Analog PWM mode DIP Switch DIP e Analog Mode T a E H a H H eSingle Channel Mode 1 2 SG by Ge FF e e Exponential Off 00010000 eSign Magnitude Mode Off O DIP ePWM Mode i H p H a H i eSingle Channel Mode Ta aA aO es eExponential Off eSign Magnitude Mode On 10010001 ON DIP ePWM Mode SEE Sy eLeft Mix Mode 2 Bi Zo Gy 7 fe eExponential Off eSign Magnitude Mode Off 11011000 ON DIP ePWM Mode i B E B E l g E T J g g eRight Mix Mode o 4b GY T te e Exponential Off eSign Magnitude Mode Off 11011100 Figure below shows the connection of Analog PWM mode for Single Channel Mode Setting Up Driver for Differential Drive System This example is based on the RC input mode However it can be applied for the Analog PWM input mode as well 1 Set up the connection for two units of the driver as shown below _ pmm 2 Set the DIP Switch to operate in RC mode Driver for left motor must be set as left mix mode and driver for right motor must be set as right mix mode Exponential can be turned on or off for both motor but both motor must have the same exponential setting MCU mode should be turned off for both motor Dils aRagERS 74 Sh Gh bb oe DIP switch setting for Left Mix Mode 00001000 Exponential and MCU Mode are turned off DIP J TE 7 yy bey 8 Tf Ce
11. ing in the correct direction and the setting process has been completed 8 3 SIMPLIFIED SERIAL MODE In Simplified Serial mode driver is controlled by using the UART interface Input 1 is the UART Rx pin and Input 2 is the Slave Select pin The Slave Select must be HIGH in order for the driver to receive the UART command If the Slave Select pin is set to LOW all the UART data will be ignored This feature allows multiple driver to be connected together to a single microcontroller UART port The Slave Select pin is internally pulled high and it may be left unconnected if not used A single byte of data is all you need to control the speed and direction of the motor Sending byte 127 stops the motor 0 is full reverse and 255 is full forward Simplified Serial mode is selected by setting SW1 SW2 and SW4 to 0 Down and SW3 to 1 Up SWS is not used in this mode and SW6 SW8 are used to select the UART baud rate Input Mode ee Simplified Serial Mode Baud Rate ART Baud Rate 0 OFF 1 ON X Don t Care Figure below shows the connection to multiple driver in Simplified Serial Mode 8 4 PACKETIZED SERIALMODE In Packetized Serial mode driver is controlled by using the UART interface Input 1 is the UART Rx pin and Input 2 is not used in this mode To control the motor data sent to the driver must be in 4 bytes packet format which includes a header address command and checksum Up to 16 units of driver can be connected tog
12. k to warn the user However the power to the motor will be maintained and will not be cut out Thus it is the user s responsibility to stop the motor and replace the battery to avoid further damage to the battery If the other type of battery is used to power the board the LiPo under voltage warning will still be shown In this case user may ignore the warning and he she needs to estimate when to replace the battery by him herself Over Current Protection Error LED blinks 4 times If over current is detected for more than 1 second the current limiting feature will kick in and limit the motor current to the over current threshold 40A by default The current limiting only starts working after 1 second to allow a higher startup current for the motor when it starts running The actual over current threshold 1s depending on the temperature of the board d Over Temperature Protection The driver 1s equipped with a temperature sensor to monitor its operating temperature It will gradually lower down the over current and current limiting threshold base on the temperature as shown below Temperature Range C Over Current Threshold A o o S A 110 120 130 140 8 0 INPUT MODE 40 When the driver is powered up both STAT LED and ERR LED will blink together for 10 times After that the input mode will be read from the DIP switch and retained as long as the driver is powered If you wish to change the input mode you
13. ksum 0 255 The value for checksum must be the result of Header Address Command Figure below shows the connection to multiple drivers in Packetized Serial Mode Microcontroller
14. ldered directly to the bottom layer pad NOTE For application where the current is gt 20A it s recommended to solder the wire directly to the pad at bottom layer Steps to connect the motor via terminal block 1 Open the cover for terminal block 2 Remove the screw from the terminal block 3 Wrap the wire of DC motor around the screw 4 Put back the screw into terminal block and tighten the screw gt 5 Repeat step 2 4 for another wire of DC motor 6 This is an example connection of DC motor via terminal block Steps to solder motor connection directly to the bottom layer pad 1 Cut the motor wire and remove the insulator 2 Solder the wire to the pad at the bottom layer 3 Continue with another terminal as shown below 7 0 SAFETY FEATURES Driver incorporates some safety features which make it a robust and reliable motor driver Below are the detailed descriptions for each feature a Reverse Polarity Protection Unlike the other motor driver in the market Driver incorporates 2 extra MOSFET for reverse polarity protection Hence user no longer will see smoke coming out from the board if the power supply is connected at wrong polarity LiPo Under Voltage Warning Error LED blinks 3 times Upon power on driver will automatically detect the number of cells for the LiPo battery If the input voltage falls below 3 3V per cell during operation the error LED will blin
15. utput A to B and motor will turn CW or CCW depending on the connection Input channel 2 Input channel 1 5V output Do not connect to another 5V source Ground 10 Mode Selection DIP Switch Used to select the input mode 11 LED PWR Power LED Should be on when the board is powered 5 0 POWER SUPPLY Driver supports input voltage ranges from 7V to 25V The recommended power sources are e 6 18 cells NiMH or NiCd battery 2 6 cells LiPo or Li Ion battery 7V 24V sealed lead acid battery TV 24V power supply Must be in parallel with a battery with same voltage The power source can be connected to the driver either via the Dean T connector or soldered directly to the pad at the bottom layer NOTE 1 If a power supply that cannot sink current is being used the input voltage will rise when the driver is regenerating motor is slowing down Thus it is important to connect a battery with same voltage in parallel with the power supply to absorb the current generated by the motor Else the input voltage might rise to a level where Driver will be destroyed permanently 2 For application where the current is gt 20A it s recommended to solder the wire directly to the pad at bottom layer Steps to solder the wire to the Dean T connector are shown below The items needed to solder wire to Dean T connector are e Wire e Shrinking tube e Female Dean T connector 1 Before start soldering i
16. will need to change the setting on the DIP switch and power cycle the driver Turn it off and turn it on again In RC or Analog PWM Input mode two units of driver may be used together to control two motors in mixed mode This is useful to control the robot with differential drive system where one input controls the speed and forward backward direction of the robot while another input controls the left right direction of the robot Driver supports four different types of input mode The DIP switch settings for each mode and the function for input pin are summarized as below input Mode DIP Snitch T DIP Switch Descricon put fnput SW5 6 Single Mix Mode OX Single Mix Left RC 0000XXXX Mix Rien Speed Sign Analog PC eo Mix Left Magnitude is OFF PWM Mix Right Stee Lee Direction Sign Magnitude is ON Exponential Mode Sign Magnitude Mode Single Mode only SW2 must be 0 SW5 SW6 8 Simplified 0010XXXX ART Rx Slave Select Serial Packetized 0011XXXX _ SW5 8 ART Slave AddresstJART Rx JA Serial 0x00 OxOf 0 OFF 1 ON X Don t Care Left Right is just for reference Actual side of the motor may depends on the RC transmitter or analog PWM input 8 1 RC INPUT MODE In RC input mode the speed and direction of the motor is controlled by the signal from the standard hobby radio control transmitter and receiver or a microcontroller generating the similar signal NOTE The
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