Real Time Development of MC Applications using the PC Master
Contents
1. 0 050 O 025 0 000 300 200 100 Flux Linkage Position deg el 0 000 HH Z 0 050 OUR Sa 0 100 BI T25 Time sec JV Auto stop Autorun Recorder is idle control page algorithm block description current item help recorder Unit Period appState APP_RUN ENUM 1000 omega_actual_mech 594 rpm 500 omega_required_mech 600 rpm 1000 u_de_bus 299 N 1000 theta_commutation_el 157 el degree 1000 4 gt r phase actual 24 1 ohms 1000 COMI speed 9600 bps Rec Idle Figure 4 3 Visualization of Phase Current Flux Linkage and Position Reference Using Scope 4 3 Setting Controllers Tuning Applications Almost any motor control application utilizes controllers Controllers are used for control of variables of both the motor control algorithm and the control of the application algorithm itself Motor speed current voltage flux linkage or motor torque are the most typical motor control variables Pressure load under pressure velocity temperature etc are examples of typical application variables System controllers need to be set up and tuned precisely to obtain optimal results for the control process Although theoretical analysis gives the preliminary values of the control parameters mostly they need to be tuned experimentally on a real system During the tuning both input and output variables of controllers need to be observed PC master software simplifies the tuning of the cont2. current is reconstructed For a such purpose the Recorder can be used to great advantage Real Time Development of MC Applications Rev 1 6 Freescale Semiconductor Preliminary Visualization of Measured Variables DC Bus Voltage Time T1 D1 PWM_T1 A pike Phase A D2 T2 z E i Time PWM_T2 gt lt sense S S R_sense dng pee Time sense Jp So GND wn to 4 ADC Sampling synchronized with PWM Figure 4 1 Shunt Resistors Current Sensors The Recorder enables the observation and reconstruction of the phase current measured by the ADC The Recorder read command is inserted into the ADC conversion completed interrupt routine recording the result of the ADC measurement and phase current reconstruction When the desired period 1s complete the measured profiles can be visualized on the Recorder window Figure 4 2 illustrates the visualized current profiles of a 3 Phase SR motor and the DC Bus voltage on the Recorder Each Recorder window can display up to eight recorded profiles This is extremely important when developing control algorithms for multi phase motors The start of the recording can also be triggered by a selected variable so the desired interval can be recorded It can be used e g when investigating the profiles of measured variables during motor start up or speed load transition Next the recorded data can be loaded into a table processor like MS Excel for further evaluation R
3. during motor operation It gives the possibility to visualize the course of the selected variables so the developer can effectively develop the application The tool enables creation of a demo to control the application that can be demonstrated to customers Overall the PC master software saves the cost of extremely expensive equipment like multichannel oscilloscopes and current probes Also it shortens development time significantly Those who deal with customers remotely will appreciate having the ability to control the application remotely through the Internet Real Time Development of MC Applications Rev 1 12 Freescale Semiconductor Preliminary On line Setting of Application Parameters and Variables 6 References The following materials were used to produce this paper 1 3 Phase SR Sensorless Motor Control Using 56F80x AN1932 Freescale Semiconductor Inc 2 Connecting Motor Controllers to the Internet Freescale Semiconductor Inc 3 PC Master Software Communication Protocol Specification Freescale Semiconductor Inc 4 PC Master Software Creation of Advanced Control Pages Freescale Semiconductor Inc 5 PC Master Software Usage Freescale Semiconductor Inc 6 PC Master Software User s Manual included in the SDK documentation Freescale Semiconductor Inc 7 Software Development Kit including PC master software is available at www freescale com Real Time Development of MC Applications Rev 1 Freescale S
4. stop the motor in order to access the memory of the processor and then let the motor run again The input and output variables can be observed by an oscilloscope The limiting factor of oscilloscope usage is that the real signals of the drive often differ from the signals measured by the processor The measured signals are affected by the sensing circuitry used by measurement noise and also by the offset and gain error of the analog to digital converter Generated signals are modulated by Pulse Width Modulation PWM so they need to be filtered in order to obtain the real value The filtering of the signals influences the precision of the measurement The usage of oscilloscopes for visualization of internal variables is quite limited The internal variables can be observed using a Digital to Analog Converter DAC Unfortunately such peripherals are not standard either at the motor control processor or at the motor control application board Another significant drawback of the traditional approach 1s the cost and availability of an oscilloscope and the necessary accessories like current probes Typically two channel oscilloscopes are available which is not enough for the development of a multi phase motor control system especially when it is desired to observe several internal and input output variables simultaneously In order to help the developers in the development of real time embedded applications Freescale has developed the PC master soft
5. which the failure of the Freescale Semiconductor product could create a situation where personal injury or death may occur Should Buyer purchase or use Freescale Semiconductor products for any such unintended or unauthorized application Buyer shall indemnify and hold Freescale Semiconductor and its officers employees subsidiaries affiliates and distributors harmless against all claims costs damages and expenses and reasonable attorney fees arising out of directly or indirectly any claim of personal injury or death associated with such unintended or unauthorized use even if such claim alleges that Freescale Semiconductor was negligent regarding the design or manufacture of the part freescale BOTOA CTO Freescale and the Freescale logo are trademarks of Freescale Semiconductor Inc All other product or service names are the property of their respective owners This product incorporates SuperFlash technology licensed from SST Freescale Semiconductor Inc 2005 All rights reserved AN1948 Rev 1 11 2005
6. Freescale Semiconductor Application Note Real Time Development of MC Applications using the PC Master Software Visualization Tool The PC Master Software Visualization Tool Simplifies the Development of Motor Control Applications in Real Time Radim Visinka l Introduction This Application Note describes the development of motor control applications using the PC master software visualization tool It is a software tool for development and debugging of embedded applications in real time It permits the reading modification and visualization of arbitrary variables or parameters of a target application The application note discusses the common difficulties faced in the development of a motor control application It presents the basic features of the PC master software tool The examples illustrate the usage of the tool for the development of motor control applications 2 Development of Motor Control Applications The motor control application represents a real time embedded application with a number of system variables and control parameters It processes both analog and digital inputs and generates mostly digital control outputs that control a power stage of the drive A number of application variables need to be observed and evaluated in real time in order to optimally develop set up and tune the control algorithm Freescale Semiconductor Inc 2002 2005 All rights reserved AN1948 Rev 1 11 2005 Contents 1
7. Introduction ee 1 2 Development of Motor Control Applications sese eee 1 3 The PC Master Software Visualization 1 Kee TTT 2 3 1 PC Master Software Introduction 2 3 2 PC Master Software Features 3 4 Development of Motor Control Applications Using PC Master OTT en AR 6 4 1 Visualization of Measured Variables 6 4 2 Visualization of Calculated Variables 8 4 3 Setting Controllers Tuning ADPliGatlONS 2 0c0ies0ccessaxssetazectaceindinadareses 9 4 4 On line Setting of Application Parameters and Variables 11 5 Conclusion cee ceeecceecceecceccceecceeceeeces 12 6 References ccsccesccosecesscossccssccesconscs 13 be Z freescale semiconductor The PC Master Software Visualization Tool Traditionally developers use code debuggers and oscilloscopes for the development of motor control applications Debuggers are used for visualization of the internal memory of the processor Oscilloscopes are chosen for visualization of the input and output signals Such traditional development is quite arduous Debuggers mostly do not allow visualization and change of the application variables at the run time of the target processor Also visualization of the selected variables as a time function is not possible Often debuggers require stopping the target processor to access the variables Such an approach is not applicable in motor control applications the developer cannot just
8. al motor speed in a negative direction 0 zero motor speed L maximal motor speed in a positive direction The real type transformation transfers such signed fractional type into a real mechanical speed displayed in rotations per minute RPM Thus the speed can be easily set and observed in PC master software The Scope window enables visualization of the variables of the target processor in a way similar to the way classical oscilloscopes do PC master software communicates with the target processor at predetermined intervals Each time it reads the selected variable and displays it as a course It enables the display of up to eight courses in a single Scope window The communication speed between the PC and the target controller depends on a number of selected variables in both the Scope and Variables windows Typically the variable is updated each 10msec The oscilloscope is useful for tracking variables that change relatively slowly The rate of their change should be comparable to the rate of variable updates in the Scope window A typical example is the speed of the motor The Recorder window enables the visualization of fast changing variables A small routine that resides in user code stores the selected variables in the on board memory buffer When the recording is finished they are loaded into the PC and displayed as a course The length of the buffer is limited by the accessible free on board data RAM The Recorder is very useful f
9. also allows the enumeration of the variables It is useful for displaying the status of the application or algorithm For examples of the real type transformation and the enumeration look at the variables listed in the Variable window in Figure 4 7 Real Time Development of MC Applications Rev 1 Freescale Semiconductor 11 Preliminary Conclusion B 3ph_srm_sensorless pmp PCMaster File Edit View Scope Item Project Help oO Hala loi z le elle 3 Phase SR Motor Contri DHE OS SpeedController SS LER PositionRecognition P lann da PhaseCurrent 2500 omega_required_mech omega_actual_mech LER Current Controller E Speed Scope 2250 2000 1730 1500 1250 T D a 1000 ep fou 500 250 E 6 7 Speed_stimulat Unit i appState APP_RUN ENUM 1000 omega_actual_mech 1631 rpm 500 omega_required_mech 1473 rpm 1000 u_dc_bus 300 y 1000 theta_commutation_el 115 el degree 1000 commands stimulators r_phase_actual 23 9 ohms 1000 Ready Not connected Scope Running Figure 4 7 Stimulation of Desired Speed 5 Conclusion PC master software puts into the developer s hands a tool that enables development of user s applications much faster and efficiently It enables you to see into the target processor without stopping the application This is extremely important for motor control applications where debugging and tuning needs to be done on line
10. are enables visualization of all variables using the Scope Recorder or Variable windows Visualization of the calculated variables can be shown on the sensorless control algorithm of SR motors The position estimation of the motor is based on the estimation of the phase flux linkage The correctness of the flux linkage estimation is a key factor in the sensorless drive performance During development of the algorithm the encoder position sensor is used as a position reference for the evaluation of the sensorless determination of the motor position The Recorder permits visualization of the calculated flux linkage together with the phase currents and with the reference position from the encoder see Figure 4 3 The shape of the calculated flux linkage can be compared with the theoretical analysis The individual parameters of the control algorithm can be easily modified to reach the desired behavior of the sensorless technique Real Time Development of MC Applications Rev 1 Freescale Semiconductor Preliminary Setting Controllers Tuning Applications oni 3ph_srm_sensorless pmp PCMaster 161 File Edit View Recorder Item Project Help saon Hala el gt a Sl fe el se al 3 Phase SR Motor Co E M SpeedController 0 019 347 669 ae EE e L EK _active psi_reference psi active counterEncoder 44 PositionRecogniti 1 00 LPA PhaseCurrent IL Current Controlle HZ DIES 0 25 0 00 0 075 Phase Current A
11. ble in processor memory Since any memory variable can be changed the developer is fully responsible for changing only the variables that do not cause the system damage The response of the system can be observed either in the Variables window or with the Scope or Recorder tool PC master software allows the simulation of a the selected variable in the time domain using Stimulator The Stimulator updates the selected variable automatically according to the table The stimulated variable is predefined in a simple table as a function of time see Figure 4 6 Figure 4 7 illustrates the stimulation of the desired speed and the drive response The developer can easily evaluate the response of the system to the change of the variable according to a predefined profile stimulator eee x Mame Speed _stimulator Stimulated variable Jomega_reqPCM_me me Approximate time step 10 ms fw Run inthe loop Tabular Value al Remove 3 seconds B00 5 seconds 1200 6 seconds 1200 7 seconds 1000 10 seconds 1000 12 seconds 000 15 seconds 2000 17 seconds 00 Time 18s 9 Value Eoo Set Cancel Figure 4 6 Setting of Speed Stimulator As it was mentioned in the PC master software description the variable can be transformed from the real type into more meaningful physical variable Thus a fractional number from the target processor can be easily transformed into RPM speed variables Volts Amps degrees etc PC master software
12. d soon Real Time Development of MC Applications Rev 1 2 Freescale Semiconductor Preliminary PC Master Software Features Figure 3 1 PC Master Software in Connection with Motor Drive 3 2 PC Master Software Features PC master software provides access to the target processor memory via an SCI communication The communication protocol on the base level reads writes the application variable out in the data memory of the target processor The PC master software can e control the application e read change application variables e scope slower variable courses e record fast variable courses e stimulate variables e send application commands with parameters e display help items like block diagrams of the application application characteristics etc e control the application remotely through the Internet Figure 3 2 illustrates the main PC master software window together with the examples of the Control Page the Variable window the Scope the Recorder and the help page from a real life motor control application Real Time Development of MC Applications Rev 1 Freescale Semiconductor 3 Preliminary The PC Master Software Visualization Tool Main PC master software window Peni 3ph_srm_sensorless pmp PCMaster laj x Fie Edit Yiew Explorer Item Project Help slalom Hala esal Sill Aaea ee ole l Tahoma Jp Rl O 2 Eal 3 Phase SR Motor Contro Applicatic of 3 Speed Scope 109 Start up ExtRa
13. eal Time Development of MC Applications Rev 1 Freescale Semiconductor H Preliminary Development of Motor Control Applications Using PC Master Software 4 2 BA 3ph_srm_sensorless pmp PCMaster lej x Fie Edit View Recorder Item Project Help I el S O tal elle lle lOS SZ 3 Phase SR Motor Co SpeedController 0 060 200 851 a fe Speed Scope i_active i_ discharge u dc bus fF PositionRecagniti 4 PhaseCurrent fF Current Controlle 0 75 z 0 50 5 O gt 0 25 oO ao 0 00 oul gt D 200 B 5 100 OD O 6 0 Pel Vl oO LS Oe SOs eae OOF dae Oe ei ei aae eis Time sec Recorder is idle M Auto stop T Autorun i control page algorithm block description current item help recorder il Period __ appState BPD RUN ENUM 1000 __ omega_actual_mech 582 rpm 500 __ omega_required_mech 600 rpm 1000 __ u_de_bus 297 y 1000 __ theta_commutation_el 157 el degree 1000 gt __ r_phase_actual 24 4 ohms 1000 Done COM1 speed 9600 bps Rec Idle Figure 4 2 Visualization of Phase Currents and DC Bus Voltage Using the Recorder Visualization of Calculated Variables During development of control algorithms it is necessary to visualize calculated variables their courses variations and mutual influences It is especially valuable for development of algorithms based on any kind of estimators PC master softw
14. emiconductor 13 Preliminary References Real Time Development of MC Applications Rev 1 14 Freescale Semiconductor Preliminary On line Setting of Application Parameters and Variables Real Time Development of MC Applications Rev 1 Freescale Semiconductor 15 Preliminary How to Reach Us Home Page www freescale com E mail support freescale com USA Europe or Locations Not Listed Freescale Semiconductor Technical Information Center CH370 1300 N Alma School Road Chandler Arizona 85224 1 800 521 6274 or 1 480 768 2130 support freescale com Europe Middle East and Africa Freescale Halbleiter Deutschland GmbH Technical Information Center Schatzbogen 7 81829 Muenchen Germany 44 1296 380 456 English 46 8 52200080 English 49 89 92103 559 German 33 1 69 35 48 48 French support freescale com Japan Freescale Semiconductor Japan Ltd Headquarters ARCO Tower 15F 1 8 1 Shimo Meguro Meguro ku Tokyo 153 0064 Japan 0120 191014 or 81 3 5437 9125 support japan freescale com Asia Pacific Freescale Semiconductor Hong Kong Ltd Technical Information Center 2 Dai King Street Tai Po Industrial Estate Tai Po N T Hong Kong 800 2666 8080 support asia freescale com For Literature Requests Only Freescale Semiconductor Literature Distribution Center P O Box 5405 Denver Colorado 80217 1 800 441 2447 or 303 675 2140 Fax 303 675 2150 LDCForFreescaleSemiconductor hibbertgro
15. functionality The individual components of the control page are linked to the appropriate variables of the target processor The control page can also be used for creation of the application demo Thanks to this unique approach anybody who can create HTML web pages can create the Control pages for PC master software as well Typical examples are the push buttons that start or stop the motor or the bar graph that sets displays the motor speed When the user clicks the push button on the control page screen the appropriate variable is updated in the target processor enabling control of the application The Variable window displays the selected variables or the memory location of the target processor The variable on the target processor can be directly set from the variable window Users can select the variable address variable type signed unsigned fixed point floating point signed unsigned fractional string variable size sampling period etc The important part of the setting is the real type transformation of the variables It enables transformation of the variable available on the target processor into a format that is more understandable for users The variables can be visualized in the variable window as well as in the control page see Figure 3 2 A typical example is the transformation of the variable omega actual that represents the motor speed At the target processor the variable is a signed fractional type scaled as maxim
16. ical example of the visualization of the measured variables is the measurement of motor phase currents Phase currents are measured by current sensors Figure 4 1 illustrates a typical configuration of one phase of a switched reluctance SR motor power stage It includes two power switches and two diodes per motor phase The shunt resistor is inserted into the current path of the motor phase The phase current is sensed as a voltage drop across the sense resistor The control signals of the individual transistors together with the actual current and the sensed voltage drop on the current sense resistor are shown as well As can be seen the phase current is not visible at the current sense resistor continuously and must be reconstructed by software For a reliable reconstruction of the shape of the phase current the measurement needs to be sampled in the center of the PWM pulse The zero current may be set to half of the ADC range so both the positive and the negative voltage drops on the phase current shunt resistors can be measured Proceeding like this the current can be reconstructed with required accuracy and credibility It is apparent that usage of the oscilloscope for the visualization of the measured current at the ADC input is quite limited We can see just PWM pulses on the oscilloscope screen Also it is important to evaluate what the actual value converted by the ADC is what the influence of the noise is and how successfully the phase
17. m ONLY 109 Flux Linkage ExtRam ONLY sof 8 Current Controller ExtRam ON Designed By Motorola Czech Systems Laboratories Roznov p Radh Czech Republic MA MOTOROLA 3 ph SR Sensorless Drive Control page 140 P it 2 600 rom 600 rpm Variable window aeoe Q arer MOTOROLA intelligence everywhere digital HE b 4 control page algorithm block description block description A Name value Unit Period gt appSpMode MANUAL ENUM 1000 appState _APP_RUN Saeed Fees Se eee RE OEE ey ENUM 1000 omega_actual_mech 1408 i O O O hyj LLL rpm 500 eaa renr M mech rpm 1000 J T Zi x x d n 7 x A rpm 1000 Z T H i pee eee v icon 3000 oMega_required_ mech omega_actual_mech sired 2500 L l os Z 2000 T T a ee T 0o 0 101 Hs sanar E1500 EN SEANA t 09 l l 08 4 o7 eg H Roe EN RaR e 05 I Sy 2 es ee el Ss E GE Es E Aes GS GE Gs OSes S eee p E our d S ow oo E ao a UL D1 kel T T E TT eae oe control pa Block ae seat D00 c g rege 1 Scope ae sabe 0 02 003 004 00s Time oar 0 08 0 09 010 O11 0 12 0 13 window Recorder window Help page Figure 3 2 PC Master Software Window Real Time Development of MC Applications Rev 1 4 Freescale Semiconductor Preliminary PC Master Software Features The Control Page enables control of the application It is created in HTML so it 1s easy to create all the desired
18. or tracking variables which change so fast that they cannot be tracked by the Scope A typical example is the motor current The Stimulator enables stimulation of the selected variables PC master software updates the variable in the target processor according to a predetermined variable profile Thus the response of the system can be observed and evaluated The stimulator is useful for both motor control and application development A typical example is the speed profile of the washing machine application The user can pre set the profile of the motor speed and evaluate the behavior of the drive without touching the motor control software Real Time Development of MC Applications Rev 1 Freescale Semiconductor 5 Preliminary Development of Motor Control Applications Using PC Master Software The Help Page enables the display of additional information the user might be interested in For example there can be a block diagram of the application description of the control algorithm or application description of the user interface of the application etc The help page is created in HTML A detailed description of PC master software including the PC master software settings detailed descriptions of the of the individual PC master software features a description of the communication protocol creation of PC master software control pages and remote control through the Internet can be found in the Application Notes listed in Section 6 4 De
19. riPIprm IntegralGainScale 22 DEC 1000 speedcCtriPIprm ProportionalGain 25000 gt DEC 1000 outputDutyCycle 28 4729 unit 1000 2 Ready Not connected Scope Bad Figure 4 5 Tuning the Speed Controller Using PC Master Software Real Time Development of MC Applications Rev 1 10 Freescale Semiconductor Preliminary On line Setting of Application Parameters and Variables The speed controller is a Proportional Integrational type PI controller that evaluates the required speed equired and the actual speed actual According to the speed error error it generates the desired output duty cycle The Scope window shows the required speed and the actual speed as the input variables as well as output duty cycle as the output variable of the controller see Figure 4 5 The response of the system to the change of the motor load is displayed The Variables window enables on line change of the individual parameters of the PI controller The developer can easily evaluate the response of the system and tune the controller parameters to get the optimal system performance 4 4 On line Setting of Application Parameters and Variables The development of an application often requires setting the application parameters and variables on line and evaluating the application behavior Since PC master software allows the changing of any variable in the memory of the target processor the task is pretty easy The developer can read and modify any varia
20. rollers in real time It enables visualization of the controlled variables modification of the control parameters on line and to immediately see the results The inputs and the outputs can be observed using the Scope or the Recorder On one hand the Scope can be used for slowly changing variables like for example motor speed On the other hand the Recorder can be used for fast changing variables like phase current Figure 4 4 and Figure 4 5 show a simple example of tuning a speed controller with help of the PC master software Scope Real Time Development of MC Applications Rev 1 Freescale Semiconductor Preliminary Development of Motor Control Applications Using PC Master Software Power Stage Processor Output Duty Cycle Speed Wrequired Controller Generator an 3ph_srm_sensorless pmp PCMaster File Edit view Scope Item Project Help Sujo E aaa aSa aa e Ael pe G 7 Ba K 2000 omega_required mech omega_actual_mech outputDutyCycle L asitionRecogniti 4 PhaseCurrent 4 Current Controlle 1500 1000 D a w 500 Le Re L Le s Le Output Duty Cycle ho AA ve FPP A A 49 50 51 52 53 54 set up parame of the controller R sec control page algorithm block description current item hely oscilloscope Name Value Unit Period speedcCtriPIprm IntegralGain 20000 DEC 1000 speedcCtriPIprm IntegralGainScale 22 DEC 1000 speedCt
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22. velopment of Motor Control Applications Using PC Master Software Let s illustrate the advantages of PC master software for real world motor control applications They are described in examples of common issues the developer is facing during the design of the applications The presented examples are based on the application 3 Phase SR Sensorless Motor Control Using 56F80x 1 First the visualization of the variables measured by an Analog to Digital Converter ADC is shown Then the visualization of courses of calculated variables 1s illustrated The setting of the controllers and tuning of the application with help of PC master software is presented Finally the on line setting of the application parameters and variables is demonstrated 4 1 Visualization of Measured Variables Precise analog measurement is a key factor for the implementation of almost any motor control algorithms Mainly the phase and or DC Bus voltages and currents are measured and utilized for the control algorithms Any inaccuracy in the measurement leads to control error and thus to the deterioration of drive performance PC master software enables the visualization of measured variables as they are converted by the Analog to Digital Converter The developer can evaluate the actual values and courses obtained from the analog to digital converter and can eliminate possible sources of inaccuracies Both the Scope or the Recorder can be used for the evaluation A typ
23. ware tool It enables access and visualization of the internal variables of the target processor and thus solves most of the difficulties the motor control developer faces 3 The PC Master Software Visualization Tool 3 1 PC Master Software Introduction PC master software was designed to make the development of motor control applications easier It provides the debugging diagnostic and demonstration tools needed for the development of real time algorithms and applications PC master software runs on a PC connected to the target processor via an RS232 serial interface A small program resident on the target processor communicates with the PC master software It provides access to any memory location of the target processor in real time Once the data are loaded into PC master software they can be visualized in a number of different ways The PC master software running on a PC uses Microsoft Internet Explorer as the user interface The detailed description can be found in the user s manual see 6 and in the dedicated application notes see 2 3 4 5 A basic block diagram is illustrated in Figure 3 1 PC master software is currently available for the 56F80x 56F82x and 5685x families The PC master software application is part of the Embedded Software Development Kit SDK 7 and may be selectively installed during the SDK installation Support for other processors including MC68HC08 MC68HCS12 and MPC500 families will be release
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