User Manual: - Allied Motion
Contents
1. Figure 36 System Diagram bath the current and velocity contrat eoe two main gal must be achive a Keep the uat Gin this case curent in the molo phases and velocity of the rotor as close as possible o the target setpoint The refered steady an acceptable response to a chan pe in setpoint This is called the dynamic To achieve these two goals second order infinite impulse response filter quad compensator is used 1o approximate a chassie PID control oop MA Biquad Compensator PID control Log cun be approximated in the discrete time domain by a 2 oder ier wih the flowing zona aee function Equation 1 Transfer Function Biquad Compenator Domain YO Beime eB no transfer function has the following block diagram w Figure 37 Biquad Filter Diagram Motion Tock Taw Ari 7 2018 seams Ro Page 37 of 39 Kisa fed Motion User Manusi Qua Calculating Filter Coeficients DPD automatically caleulates the filter coefficients and An from the chassie PID control lop gains and Ka Biquad coefficients are values deseribed in QUIS format with exponent value Most good digital signal processing texas contain a description ofthe QLIS numerical formt The transfer function af the PID compensator in thes domain is Equation 2 Transfer Function PID Compensator s Domain 62. et Tage een Fos dele na sal fem to racy pur en ing Cue Samulu 1t erty ipa io 09 ote ge Var Supr pte Te cut ante qa s tte gin Pek Canet and egere do Te as apocert cle que Mobi aa Cure lici Maton Techslagies lc Api 17 2018 Jueces Page 240f 39 Motion 1112 Velocity Stimulus Velocity Stimulus Tool allows the user to command mato velocity from the interface Refer to the following and tible for instructions T Puise amplitude sliders onn Pulse frequency slider Figure 2 Velocity Stas Tool Table 3 Velocity Stimulus Tool Instructions Sing Coa moie pron s coe must ecc riso been Host corii ticum Te dete ne sal Yon Do racy pu Suus vo satan soma e325 Pas io me gren Matan Vect ETEN a ve ci hem TE ante sider vict angle genas spare gin Mata Vac Tue Suspe command to wave any TE eger The 2s percentage ge timum Vez Maias Apel 17 2018
3. F To find out how PID gains are related to quad gains assume that s approximation of bilinear transformation Then transforming Equation 2 ote 2 domain yids Equation 3 Transfer Function PID Compensator Domain He Ri hy Ue 3o and by comparing Equation 1 and 3 Equation 4 Biquad Compenstor Coefficient A Equation 5 Biquad Compensator Coefficient Az Equation iud Compensator Be Equation 7 Biquad Compenstor Coefficient Cs 2 Equation 8 Compenstor Coefficient Equations through how each of the five quad filter coefficients ane calculated from the classic PD control lop gs s Ky ind hose value are input ough for boh the curent and velocity control loops Motion ilis con Ari 1 2015 siamo 2 Page 38 of 39 Aed Motion User Manil DPFlex Os 150 Contacts and Service For technical support ses oc service repa please visi our website andar cona NORTH AMERICA 1 888 302 5543 E mail inquiry alliedmotion com EUROPE S46 1 100 E mail ingusy albedmotin com ASIA 852 2607 4038 E mail com 160 Revision History Table Revision History TENSON DESCRIPTION OF CHANGE DAE Re Removed TAGS age HOP OBS Riad wang dices wring ncn and rout lat and tnc ect lici Mon Toca
4. The Registers allows the user to retrieve and save DPFIx settings as files and to load those senings non volatile memory Abo ie the Registers Form o configure the drive Start mode Note that changes to the Auto Start einge vill uke effect afler selecting Update Registers disconnecting the drive fom DP and then power cycling the Alii Motos Technologies Tac efie April 1 2015 Page 33 0f 39 Motion User DPFlex Ger Table 4 Registers Form Instructions eme DESCRIPTION usur i a WR aT TEE a ating Sve eee beso dore odp eed by Fra Tous Sarup ui asp When e deis ened 1 wi communis FE mair wia u rque sort deina by sralo Input analog signal mintan ge o Burgen EAA seant output deina by Fas Vct inputa vaka er Tre saring curent curent aed e To mone th ts sia postor Tns caent must be ge ough arcs Sate perta o me nott s had Sahay ee et Pe s did Tr 100 narum acy commana of 3125 it Pars o t od vier Cure he str suci ead nor i order a mowe Horis ci sl posto Ths caer age nah
5. overcame te eta oth er pls Sire ses meer EXT Save pei eS SET DFE ron EE run STI 138 Output The digital output can be configured to be either sped indicator or a fault ear When configured to be spoed indicator tbe output will change once every 60 degrees When configured io be a auh indicator the digital output wil activate When a drive fault occur Deren z sen eor Figure 34 Digital Output Form Aled Motion Teck EET Api 7 2018 Page Mac Motion User Manual DPFlex Gen 2 the Oscilloscope m t lake one DPD features a fourchannel ocio actual performance To display the digital cai Tonis menu choose Oscilloscope Tuning Tool Tm A33 1 Guam Esp os l Fm wem necp m Figure 3 Ovellncope Allied Motion Technologie Apei 17 2015 Motion User Manil DPFlex Os Tabie S Instructions ELA DESERTON GAT aa CH Use a aa marge Sats apt ISTRY Saeco ge a ag ae uc ge Gn pre Ea Waste spay re par vn be dare on Seen og 100 gven
6. Choosing Tuning Tool wil display the Oscilloscope and the Velocity Stimulus forms Note that these formis can he arranged as desired and their positions saved by using the View Save Window command The fens can then be restored ta their saved positions any time by choosing View gt Restore Windows emm T Figure 25 Velocity Compenstor Tuning Tools When tuning the velocity loop make sure the monar shaft is connected in the required Jud that the load is fre to move and move safely and that the motor self will ut Fake Werau a tage at etat rives Pat melo move e pear sti prope and carage oeque riy proe To manually ture the velocity lop gains in the Velocity Stimulus Forms choose Pulse Set the desired values Far velocity pulse and Then select Stat 10 apply the velocity command tothe motor In the Oscilloscope Form choose Aut to Str iggering Aer a few seconds the Oscilloscope will display the ve in green and the actual in red the elo Alied Motion Technologie Apei 17 2015 Page 300639 Motion User Manual DPFlex Gen 2 ixl ua mmm Figure 2 Oscilloscope Velocity Loop Tuning E The Inputs Fra allow in DPD the dive i be monitored Note that while monitoring the input pins vou ed
7. pma thermal pol Tor hest removal rom tbe PCB the surface directly beneath the power MOSPETS Tocated between the two mounting bol locations ast maintain the fatness and spatial dimension requirements as given by the following figure Figure 8 Mounting Surface Considerations DPFlex PCB Assembly lisi Motion Technologien lc iis con 17 205 siamo Page 1 of 39 Allied Motion Mana Qu allure to mest the flatness specification wil ead poor thermal beat out af the PCB and may lead to premature shutdowns of he deive or complete failure of the sembly Adequate thermally conductive material beneath the drive i essential for Proper operation product Failing o provide either increased surface area capable te maximum expected power dissipation or a sufficient bulk thermally Conductive material will require the de rating of the DPFlex for reliable operation Refer to the power curve for the product assembly thatthe mounting surface s designed Tor Not that the recommended minium thermal area s only for meeting he minimum thermal transfer requirements This surface can be extended othe outer edges af the along the centerline of the mounting holes If this extension i made be Bernal interface material need tw be extended to those additional areas as wel In addition to observing the constraints on the mechanica clearances and interface
8. Pied Motion 2 User Manual DPFlex Gen 2 Sensorless Brushless Motor Drives Document Number 34 2003 R2 lici Motion Technologien lc ES April 1 2015 samo ga Motion User Manual Gen 2 Table of Contents TE 58 Inspection Upon Receipt B Sensorless Drive Technology a Understanding Commutation 32 SixSiep Trpersidal Commutation 1 43 Sensorless Sep Commutation 5 AO Special Considerations for Sensorless Commutation 9 85 Sensorless Startup Power Cabling Cabling 93 Communications Cabling 11 Mounting Guidelines for the DPFlex PCB Assembly 11 1 Mechanical Integration Testing BUNT e RR 021 Included Software 1022 Installing ne Solar 123 Connecting to the DPF 7 124 Saving Configurations EI Alii Moos Techn mew com Ari 7 2018 siamo Ro Motion User Manual DPElex Gen 2 us Loading New Firmware 140 Creating Applleations na us rn na Similis Took 1211 Cusen 1312 Velocity S mulus Motor Parameters 1321 Motor Verifi
9. de motor the defined Motor Peak Current in order to saturate the motor phases Note that if Motor Verifiestion fails i is likely that the Mate Curen set 03 high value To resolve increase the Motor Peak Current sening Aler the tool has finished close the Verification Tool and save the Configuration parameters to the DPFlex s non volatile memory by navigating o Registers gt Update Registers in the System Navigation Tree 133 Current Compensator current is a control loup nested inside of the discrete velocity loop that ensures the targeted eurent setpoint is achieved and maintained The Conpensate Fem displays the current pains set for the target mator Kalso enables the user to re calculate the pains based on e moto parameters or to tune the tains manually using DP Ds tuning tob muero msn wem m Tm of teena Lm Figure Curent Compensator Form Choosing Tuning Tools wil display the Oscilloscope and the Curent Stimulus foem that these fom can be arranged desired and their positions saved hy using he View Save Windows command The fae can then be restored w their saved positions any time by choosing View Restore Windows lici Motion Technologien lc Judi April 1 2015 samo ga Page 27 of 39 Figure 25 Current Compensatr Tuning Tools Wien tuning he current loop make sur
10. time between sector transitions at ow notar speeds The Ping Method guarantees unidireetional motor start whieh i independent af motur conditions Thus the system robust wth respect to system lod conditions Wiring For information regarding terminal assigaments and function product datasheet To ensure operation of the DPFls your application mas meet following requirement CAUTION GENERAL WARNING Fale con whe Istas aoe za Power Cabling Use twa 16 AWG 105 twisted cables with at east one twist per centimeter made as shat as possible ro connect the DC power supply to the DPFls Connect 30 fast blow fase between the positive voltage from the DC power supply and Doo de DPF Jis recommended that additional capacitor placed across on the close as possible to the connectors Rule af thumb sizing fortia capacitar is 30 pF per ampere fe DPFlex s rated current Cables running o and from this added capacitor should be twisted together using 1 vs or more per centimeter M entra capacitance is used recommended that a pre charge crt be used to imit the ines eurent caused when charging this capacitate The limiting resistor sould then he shred out using a relay or some other appropriate means Spot ground the drive ibl Motor Cabling Use three 16 AWG 105 C twisted cables with at least one twist made as th
11. SLOT DIMENSIONS TD uS Ei A E Ed Figure 9 Dimensions Metal Compression Clip l Figure 0 Dimensions Rubber Compression Sirip Altenately mounting hardware kits can be ordered fram Allied Mato which bo compression elip the Berquist banal interface material and two 8632 3 16 inch length machine screws When mounting the PCB mast be taken thut no mare than LE Non Dind of toque be applied to screws during assembly Alt Motion Technologien lc April 1 2015 samo ga Page 17 of 39 Motion Qu completing the integration af the PCB into the target location an insulation et Should performed o verify thar the electrical insulation i mot been breached The unit Should also be tested under lodo verify adegit thermal interface has been provided 120 Getting Started m Included Software The software provided with the DPFlex dive includes DPD a Microsoft Windows based pplication that enables a user to configure monitor the drive and a 0580 ver that enables PC to communicate with the drive through standard USB port To install and run the DPD and USB driver software a PC is needed with the following minimum requirements Windows XP with SP2 or higher A USB port or an RS 232 serial communication port capable af 115200 bps 133 MHz or higher Penti
12. of Pom es 0 obe cape erac e cope tt he he Dg fea alea charge eg re aea part captura 10 ma EI ae AHN and number Ports ote otn 10 Fran ghe Peine per tion Te Boe wil Da plat ores as Charges eg 10 ms Zio oi een Te aR Tia a aTe aa GU as para tape co apy ae HEP Qs ACD o Dep sein Ey ic ae RATE FE 140 Control Theory amp Implementation Te dive and motor system can be modelled as shown in the diagram below Except for the lan the molor ad is Joad all f he Blocks inthe diagram of the DPFex Note hat the and velocity control Logs within the DPFex fom a nested pair with the Velocity Toop outputing curent command to the curent lop and the current loop outing curent io he noto Forte sake af this analysis onl the inner current op s shown in the diagram note that the velocity loop surounding the current op shares an identical tutu Also the plant ie taken to be the RL transfer function fa BLDC motor lici Maias lc Jade alid Api 17 2018 Aded Motion User Manil DPF Gen 2 OA
13. other rwo in the negative polarity BLDC matan ate by six 60 degree steps during sach full 360 degre electrical cycle Because the transition from one septo he ext ie discrete the waveform of e field shaped ike a trapezoid Figure 1 Siz Step Commutation Phase Current and Back EMF commutation is simple ad can be used fo many types of BLDC motors The simplicity of the method makes it an atractive choice far commutation even at bigh speed Motion Toca Ari 7 2018 Tae ew Page 7039 Motion Dern Sensorless Commutator Once the af the motors spinning fast the induced bck EMF volage caused byte tne varying magnet linking the stator windings can be messed by the drive This magnet produced from the permanent magnets of the roe is possible to use this information o commute the motar without any other position Feedback information This i what is meant by the tenin sensores it the absence af any physical positon feedback devices in the motor During commutation the coils that are energiad are the two that yield the developed electromagnetic toque Foe a WYE connecte toto the third coil is off and so the back voltage can be measured at its phase terminal Each of the tds coils is energized ON for 120 electrical degrees andi ten de energized OFF For 60 electrical degrees Thi
14. 6 Revision History 40 Pretace This maul describes the installation and operation of DPFlex Gen 2 sensores brushless motor iver manufactured by Motion Technologies Inc Every effort has been made to ensure accuracy of in this manual However Allied Motion assumes no responsibility Tor any errors oeonision The information contained win this document is regularly reviewed and we welcome your critical evaluation ad suggestions for improvement Allied Motion reserves the ight to modify ll documentation without prior notice to download the most recent revision ofthis manual from the company website Tis manua supplied to the user with the understanding thatit will not reproduced duplicated or disclosed in whole i part without the expres written permission of Allied Maton Technologies Table 1 Applicable Allied Motion Products S PART ROMER DESCRIPTOR So Inspection Upon Receipt Motion products are thoroughly inspected and tested before leaving the factory Albough products are packaged with extreme care s important tha the user complete thorough inspection of the product upon Examine the condition of the shipping container and materials If damage is found notify the Commercial carier involved Iris the user s responsibility to file any damage clams Wit the carrier Our products shipped EXW e
15. Ael 12015 siamo ga Page 10 0f 39 Motion Dx ns Figure 13 Installation Install Driver Connecting to the DPFlex To configu the DPFex deive using the installed DPD software it iste connected W power 10 a mator und to the C Connect the DPFlex tothe PC by plugging one end of the USB Ato into the USB port of the USE UART adapter cable Pag the fies end af the USB A to cable imo 2 USB on the PC Note that the USB driver has not been installed the PC will ancha device driver install wizard when it detects the adapter cable Use be wiza install he driver rom the driver directory on the DP D CD The plug th Toe end of the adapter cable into the seal communications connector o the drive then siart DPD When stars it opens a blank System Navigation Tree which is used to create and manage DPFex configurations Figure 14 DPD System Navigation Tree Fled Motion April 1 2015 com Page 20139 Aed Motion Mana Dern Qa To add a DPF configuation rightclick the Systm banh in the System Tree and choose Connection or double click the System branch DPD hen displays the Interact Torm which lists defined connections Choose m Figure 15 Interact Furm DPD then displays the Connection Infi Form I he port to which the DPFle controll
16. Figure 30 Inputs Form Allis Motion Technologie n pm Anil 17 2015 siam Aed Motion er Mana De na Tue Analog Input indicator shows the percentage of input voltage acto the unalog When 05V is selected O V seles tom 1004 When 20k por is Selected 033 V rom 1003 Teo digital inputs are availible the Digita input 1 provides an ences signal and digia input 2 signals direction Note that moto direction cannot be changed Aer the DPF has been enabled Input One and Input indicators turn bright ed when signal voltage is applied across the corresponding inputs Use the drop down configure the digita inputs to b either Active High Active Low Faits sehe Sans tto view the operational of the DPFlex and motar Choose Refresh to update the display with the current status Choose Cle Faults to clear the display upate the tts None that fauls are also cleared by power cycling the dive Figure 31 Faults Status Form Use the Configure tsb to adjust fault setings states warnings and eror messages Set by entering ales for temperature cumen and Cols ners and volts respectively Choose Apply to save senings Alii Moron Tecnologie ne April 1 2015 EIS Page 32 of 39 User DPFlex Gen 2 Figure 32 Faults Configure Form 137 Registers
17. Sane alata com Ail 17 2015 Page 10639
18. Moon Technologien Ari 1 2015 samo ga Page 12 of 39 fed Motion Mana Dern Qu Mounting Guidelines for the DPFlex PCB Assembly Tie DPR has also been designed to allow installstion of the printed bound PCB assembly alone Note that the assembly requires an optimal heatsink in onder to realize is all ouput power ruing The following guidelines have been provided to allow designers who Wish n incorporate the DPFlex PCB assembly imo their own packaging achieve maximam mechanical robustness and greatest out performance DISCLAIMER The standard housed DPFIex Gen 2 drive as shipped from the Alied Motion bas been tested aalst and found to comply with the requirements the EN 6180 5 1 standard when installed according to the guidelines described in this manal Although Permitted DPFlex Gen 2 drive PCB assembly alame and its associated mounting hardware When used in any other configuration may no longer be compliant with the EN 618051 standard in the end use application Sinse high temperatures can be reached an the board as weli av on any surface lo contact With the ret board Aled Motion Technologies Ine tikes responsibility for any damages ox injury caused by the particular selection or application of the beatin thermal paste mounting method or caused by improper In eases where the standard housed DPFlex Gen 2 drive not used the installer must affix the te
19. User Manual Judices alid Aed Motion Manusi Qu 152 Motor Parameters Use the Motor Fors to input the motors number of pole pairs pole motor the number pole paies s three td its rated peak current Chose Apply moror parameters By default the DPD software automatically set of current lop gis for the DPFles targeting optimal control abour a ad point of 20 of the Motor Peak Curent I during operation the motor is expected to operate above this 20 cree the percentage to reflect the application spi load point Note that while the Moto Verification process provides intial current gains some cases these should be fine tuned using the Current Compete Figure 2 Motor Form 1321 Motor Verification Tool CAUTION GENERAL WARNING Fale Pat he cin pcs excavated slo Pes an ur fay aye conan ane dane pee Alter the appropiate motor parameters have heen appli choose Start 1o he Motor Verification process Figure 23 Mator Verification Toal Motion Technologien ilis con 17 2015 Page 260 39 Motion Mana Dx Qua During the Motor Verification process the DPD software detects the mator s inductance and resistance vales and determines the appropriate sensorless Startup setings To accomplis his the wll output
20. age 13 of 39 Aded Motion mom Bes rien mi Sie oo m AER 8 d Figure 6 Dimensions DPFlex PCB Assembly In dion to the clearance requirement on the of the bod there isa minimum supporting outer requirement that is necessary fr proper mechanical support of the assembly Fae to include this edge may lead to additional stresses being ced on the PCB which could cause component failures A minum af 0 635 0 025 in supporting must extend underneath the PCB Starting from the nominal board edge location This edge must not extend any further nder the PCB o risk of an electrical short may occur minimum creepage and clearance specifications may be breached Tor specified regulatory agencies Refer to the following figure far details on ede dimensions and tolerances Note that the supporting Sae requitement is teal Tar the two edges are perpendicular to the connectar side edge ofthe PCB so the use af an economical extrusion can be used to decrease manufacturing costs if desired Alii Motion Technologien lc Acl 12015 samo ga Page Aded Motion Dern Qa emm a f Figure 7 Edge Dimensions and Tolerance DPFlex PCB Assembly Because the primary purpose of the mounting surface is to provide
21. cation Current Conpensatr Velocity Compenstoe Register Cup Using the Oscilloscope 140 Control Theory amp Inplementatin ua Biquad Compensatar Calculating Fiter e e eee 2 16 Contacts and Service D Alii Motion April 1 2015 com Page 30039 Motion Manusi Equstion 1 Transfer Function 2 Doms E Equation 2 Transfer Function PID Congensatr Equation 3 Transfer Function Congensatr Domain Equation 4 Biquad Compenstor Coefficient Lm Equstion 5 Conpensta Coefficient Equation 6 Biquad Conpenstr Coefficient y E Equation 7 Biquad Compemater Coeficient E Equation 8 Biquad Compensatar Coefficient s Sees etai 200 Figures uel Sis Sep Commutation Phase Current and EME 1 Figure 2 Six Sep Commutation Sequence Figure 3 Power and Motor Wiring Diagram LLL ue 4 Power Dissipation Curve DPFlex 24 V 30 A n iure S Sule Operating Area DPHes 24 V 30 Model n Figure 6 Dimensions DPFlex Assembly eee Figure 7 Edge Dimensions and Tolerance DPFex PCB V Mounting Consdertions DPFlex PCB Assembly 9 Dimensions Metal Compresion Ci n 10 Dimensions Rubber Compression Sup Figure 11 Mai
22. e the melor shaft is connected t the required fiiere Pa rein o anacan safey mat he melo move whe per esti and carage 1 manually tune the current lop gains ia the Form choose Curent Mode and Pulse Set the desired values fr curent pulse frequency and amplitude Then select Stat to apply to the motor In the Oscilloscope Form choose Aut to start triggering a fev seconds ie Oscilloscope wil display the curent sous in green and tbe actual curent draw in red Adjust the cent pains such that rise time ringing and overshoot are minimized Alied Techn es ne Apei 17 2015 User Manual DPFlex Gen 2 THEO 4 5 M Gua 502 Figure 26 Oseloscope Current Loop Tuning 134 Velocity Compensator The velocity loop is a discrete which issues curent command o the curent such that he desired velocity setpoint is achieved and maintained The Velocity Compensator Form displays the velocity gains set far th mock allows the user 1o Tune the pains manually using DI Ds ning B a Figure 2 Velocity Conpematar Form Alied Motion Technologie Apei 17 2015 flied Motion User Manual DPFlex Ger
23. ependent and therefore Applicable atali speeds at which the boc EME of the rota can be detected by the dive XA Special Considerations for Sensorless Commutation During he process af commutation current in one phase must drop to zero and be transferred to the phase that is just coming ON Because of the faet are coils not mutually coupled 110 and tht each coil has its own leakage reactance there will be a portion af time albeit brief where all see coils have eurent in them During this period lime an accurate back EMF cannot obtained fom the volage sense circuit on the curl Immediately after commutation the drive wil shut OFF the phase voltage and wait unt t determines that an bck EMF signal can be obtained iom he analo input dedicated to hock EME sensing in the OFF phase Mt is only afler this has been successfully detected thar tbe drive will begin to use the measured back EMF for commutation purposes Since DPFlex monitors the Back EME feedback and activates the back EMF sensing iil dhe no parameter associato with the cl col current taster MS Sensorless Startup Ache induced hak EMF is proportional to speed a sensorless controller needs means of finding the rotar position stal in onder to start the motor and accetta cel high eed to be able t0 detect tbe back EMF voltage Startup is undoubtedly the biggest hurdle for any sensorless cono algorithm Conventional methods drive a current throug
24. er is connected displayed in the Por drop down list choose Scan Poris DPD S en scan the foe serial or the adapter the USB port doet not appear in the list check the following ems and re scan that he driver installed that the USB cables are properly connected In the Port drop down lis choose the port to which the DPFlexeomolle is connected S Figure 16 Connection Info Form gt Choose Test to confi the connection to the conwoller is working I the ls hock the following tems and reest tht the communication cables ae properly connected th the DPFlex conl s powered Choose accept the connection or Cancel 10 the operation The Interact Form now the connection to contol Alt Moon Technologien lc iis can Apel 17 2015 Page 2 of 39 Aed Motion Mana Dern Qa ee rem Figure 17 Interact Form Wih Enabled Connection Chose to accept the controller connection configuration or Cancel to abort the operation DPD updates the Syster Navigation Tree for the new configuration Figure 18 DPD System Navigation Tree With Enabled Connection Each configuration shows the enabled COM port and provides access to the Following items Tools Motor Curent Compensator Velocity Conpeneuur Inputs Faults Registers and Digital O
25. h the windings in onde to force the toa known position t ensure proper molo can cause up to IND degrees moor rotation in the direction opposite to that whieh is actually desi Also the required to orient the rotor depends on the inertial and tonal load ofthe motor dhe initia curent orient the moto to gh there may be overshoot and Singing in the system I the curent i to lov the motor may not siart at all Sucha stem is not robist with respect to system Jod condis More method determine rotor position sed on the motor phase saturation inductance change The drive generates six short and opposing current pulses thut drive the motor phases into saturation The dive the atr rtc positon based on the saturation inductance change in cach phase Allied Motion eer to this procedure as the Ping Method The rotar remains stationary during the iil ping period because the pulses are short and in opposing sequence In most cases the molo reaches Alii Motion Technologien Ic iss aliua con Page of 39 Motion Mana Qu before the next commutation sector change far the tke over In a few cases usually if tbe load on the matri extremely heavy ping process while the motor rotates at low speeds below the back EMF threshold Tiss possible because the ping period time is negligible with respect
26. mperature warning label on o near the motor controller in cleat visible location Mechanical Integration During design of the heatsink for the PCB assembly be sure to consider the following Clearance between the PCB and surrounding aneas must be checked to ensure interferences do not occur ut maximum tolerances as this might induce unexpected stresses on the PCB that could affect component reli Clearances between the mounting surface and specified PCB locations must meet minimum egued regulatory agency specifications far electrical lances or Lt ma 0 0305 in The mounting surface designated as the hema transfer surface must meet given Names specifications so sto prevent raised surfaces from interfering wih eat address he clearance requirements between the mounting ares and the edge ofthe PCB ts soconmended provisions be made a minimum of 10 0 0394 in o clearance fom the edge of the PCB to area surrounding the PCB mounting locaton The PCB wl typically hae a tolerance of 0762 0 030 in and 200 mom 00 in oo the ote edge dimensions Refer to the following figure far details clearance and tolerance requirements providing the recommend clearance it Wil accommodate any variations in manufacturing process that might occur and will facilitate the installation of the PCB during sssembly while ensuring PCB reli Aled Mos Toca malin Ari 17 2015 saan Ro P
27. n Menu racha Figure 12 asain lastall DPD iue 13 Installation Utility USB Driver 20 Figure 14 DPD Systm Navigation Tree Figure 15 Interact SNNT Figure 16 Connection Ilo Form S de Figure 17 Interact Form Wit Enabled Connecti iue 18 DPD System Navigation Tee With abled Connection Figure 19 DPFlex Form Figure 20 Current Simili Too Figure 21 Velocity Stimulus Tool c Aen iue 2 Motor Fem iue 23 Motor Verification Toa Figure 24 Curent F r Figure 25 Conpensatr Tuning Figure 26 Oscilloscope Curent Loop Tuning nos iue 27 Velocity Conpersat Form iue 28 Velocity Compensto Tuning Tool Figure 29 Oscilloscope Velocity Loop Tuning s Figure 30 Inputs Fen don iue 31 Faults Status Figure 32 Configure Form Figure 33 Registers Form Alii Moon Technologien Ic isis con April 17 2015 siamo ga Page tof 39 Allied Motion Mana Qu Figure Digital Output Eme 35 Oscilloscope MURAT 36 System Diagrams iue 37 Fier Diagram Tables Table 1 Applicable Allied Motion Products 5 able 2 Current Stimulus Tool Intructionc 3 Velocity Instructions 6 Buc nen Table 4 Registers Table 5 Oscilloscope Instructions NELSON NANI able
28. ort as possible to conc the motor to the Motion iss con 17 2015 Page 100f 39 Motion User Manual DPFlex Gen 2 DPFlex 11 Figure 3 Power and Motor Wiring Diagram 93 Communications Cabling The signal cables for 1 must be less than 1 meter in length Use a USB cable to connect the PC to the USB UART adapter The serial communications connector on the deive uses TTL signals I communication with the deive from device using standard RS 232 signals is desired a means to comert the signal level bermeen the va devices mast be provided lici Motion Technologien lc Ilion co 17 2015 Page I of 39 E lied Motion er Maa DF Qa Power Dissipation The generates eat as power is consumed during operation Note thst the DPFlex requires optimal heatsink i adr to eiae its full output power rating Therefore heatsink the plate af the wing the following power dissipation curve a5 guide Noe that the power dissipanion curve was generated with balanced 3 phase sinusoidal curent 100 H Fundamental and a 20 KH switching frequency Past Curent per Prane Figure 4e Power Dissipation Curve DPFles 24 V 30 A Model Figure 5 Safe Operating Area DPFles 24 V 30 Modet Alii
29. s pattern repeated again and again every 180 electrical degrees and the current is switched in direction at each 180 degree segment PW Figure 2 Commutation Sequence The tack EME voltage induced while in the OFF phase undergoes polarity revera during time the plase is FF bias voltage the voltage of the neural point of he WYE connection Mall the drive should shut OFF ci she induced back EME that coit is undergoing a polarity reversal The should then be re energized once the voltage has changed polariry ad at coil can contribute t tongue production n der to do is te controller samples the voltage of the OFF phase once the curent in that has dropped to zero Once it detects that the tor x is generating a back of the proper polarity i shuts OFF the coil that is just beginning to though this voltage reveal process and energizes th that just iid this process Alt Moon Technologien lc Acl 12015 samo ga Page 8039 Allied Motion Manusi Qu The dive uses the physical properties motor to assess when the me for switching is appropriane The motor back constant Ke af te motar is used to how much us there is per pole By integrating the induced buck EMF vilae i the OFF phase and waiting for the proper amount of Au to accumulate the drive can commute the appropiate time Since is conan it is speed ind
30. surfaces as explained above ii necessary to use a electrically isolating neta material inserted between the oct at the specified thermal transfer surface underneath the PCB and a compression clip to guurnee proper operation of the DPFlex The thera interface material must be selected to have a Tow thermal resistance while Fling in voids bereen the mounting surface and the and providing 1100 VDC isolation Allied Moon recommends using the Berquist GAP PAD GPVOS OX ACL 0 5 002 iny dick thermal interface material The material must extend poss the mounting surface by minimum af 1 27 sm 0 05 i or the PCB edge Whichever is es to ensure hat ao cot will occur between the PCB races and the thermally conductive mounting surface The thermal interface material should provide close fit clearance holes for the mounting serews to sufficient insulation material around those locations the thermal interface neil has een installed a compression clip must be fied o 1p ofthe PCB board above the power MOSFETS o ensure that adequate pressure is fined on the board o minimize terial resistance and provide mechanical nosti An example design af a compression metal clip and compresion rubber stip efer ro allowing figures lici Motion Technologien Inc Acl 12015 ga Page 16 0f 39 Motion te Maa DF Qa oN
31. ton s DP D software foc Miersof Windows 2000XP Vita is wet configure and program the drive t provides seup and configuration tools along With motor verification ad perfarmance lys is suitable for a wide range of applications including control of fans pumps compressors centrifuges drills mills conveyors office and medical equipment automotive Subsystems and many others See datasheet for Further explanation o produet fts benefits and specifications lici Motion Technologien Inc ilis alein Acl 12015 ga Page 6039 Motion Mana 38 Sensorless Drive Technology Understanding Commutation Torque in an lec motor is the result f the interaction between two magnetic one from the rotor and the other from the stator These wo magnet elds nus move in Sequence with eich eter to produce torque Sequeatially contmlling curent hough e molor so as to produce ripe is what is commutation To accomplis ts the uses a senseless trapezoidal commutation method whieh relies on the hack electromotive foree EMF fr position sensing She Step Trapezoidal Commutation In this method there ane only two af ie phases of stator coils energized by the DC source at any one given time To complete ane electrical cycle or magnetic field rotation very phase is energized four times two in the positive polarity
32. um compatible microprocessor A least 6 of RAM 50 MB available hard drive storage SVGA or higher resolution Installing the Software The software is packaged on a CD ROM containing the DID and USB t seral driver or may e dowloaded rom the company website To run the instalation liy insert tbe CD your CD ROM drive Walt for the utility touto ran If the installation does not automatically ran open Be SETUP EXE program fundin the oot ofthe CD lici Motion Technologien lc April 1 2015 com ga Page 18 of 39 Aded Motion Dern Ga Figure 11 Italis Uil Main Menu To install DPD in tbe installation utility choose Install DP D The installation utility launches the DE D instalation wizard Follow the instructions in the wizard to install Not thst an Open Database Connectivity driver be stale on the PC do not have one yo can one by running he TYPEXE program in the 7 directory found on CD Uli Install DPD Tons the serial driver in the lon uty choose USB seri Deriver The uly launches the dave installation wizard I you want change where the driver is installed choose Browse to select another locaton Then choose Next to instali the driver or Cancel to abort the operation Motion con
33. utput 124 Saving Configurations save a DPFlex configuration choose File gt Save the configuration hat not been previously saved DP wil display a browser by which to seleet puth and file for the configuration file To creste a new configuration choose Fike gt New I the curent configuration has ac been saved DID wil prompt to either save or discard the configuration To open a configuration choose File gt Open DPD wil display a browser Select the pth and name Tor he desired configuration and choose Open Ald Moon Technologien Ic Api 1 2015 samo ga Page 22 of 39 Motion ae Mana Dern 125 Loading New Firmware To load mew and view system properties right click the Gen2_DPFlex COM leaf in the navigation ee and chose ers or double click the leaf BPD then displays the DPFex System Properties Fom Figure 19 DPFI Properties Form The Properties Form displays the following controller information the supply voltas dise temperature tbe firmware version including date and tme of compilation and the DPFlevscureat voltage ratings To load new firmware lick Show Details Now DPD will then present a browser by which to select the appropriate path and fle nane Creating Applications This chapter describes how to configure and deploy te for a particular aplication tich includes ho
34. w to configure te for a specifie motor tune the current and velocity comro lops check the digital and analog inputs configure the digital output monitor and clear ve fauls ad use the DPD digital oscilloscope Stimulus Tools The Stimulus Tool allow the user to conl either motor current teque velocity from the interface Before using Stimulus Tools be sure to successfully complete Mutor Verification process see Mots Parameters for instructions nd input appropriate and Velocity loop gains see Curent and that the Moto Verification process will provide ial curent oop dins however in some cates these senings should be Fine tune using the Current Compost Alii Motion Technologien Api 1 2015 com samo ga Page 23 of 39 Motion 1114 Current Stimulus User Manual The Stimulus Tool allows the user to comand motar curent orange from the DP D interface Refer 1 the following and abe fr instructions Pulse amplitude siders mitt Pulse frequency slider lr Ss Tool Table 2 Current Stimulus Toa Instructions DESCRIPTION Was Pei Cre sean Te netra pact a His eer Curt slo T arent mede cuen tro he melor tthe nor rl mies Us PAE e gta
35. x works unless other asrangements have been made Allied Mation is not Yor carrier mishandling Fled Motion Teck Judice Ari 7 2018 Page of 39 Motion Mana Qu uem eeupmen can propery carece posta uae ah Te leoni br canon cerem WANG Rat al vee anes ter consent ust Oca poten ido Tae He VOLTAGE We es ae gong ups ea he eve amd can be dangerous Te vcr td abe removed win 1e power on nd Pen by and ned coron a em comptent ep m Hor SURFACE Whe es he heat sh and ar components can teme vary at Thee eodd net be Pen rl and apod egos Overview The system includes the following components the product datasheet this user manual the DPFex drive DP D commissioning software eabling for connecting a DPFex drive to power motor and personal computer PC The drive provides one andor velocity contral rotary brushless DC BLDC mates at performance levels exceeding those of conventional Hall sensor drives detects motar rator position at stall through an innovative algorithm based molo inductance measurement thus no commutation sensors re requi The may be integrated moror e g imo the bell end or mounted separately Alied Mo
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