Sensorless Brushless DC Motor Control with the Z16FMC MCU
Contents
1. PH2_ANATO D D S NAA AAA Ui ia SA ie SRESSE8055S88885 PAO_TOIN PAO 8 SI PA1_TOOUT EE Ba oF Ht c s Oa 000 acta a fir 7 aq aaa aa Pe IF Poz PAM 50 PAO TOINTTOOUT ao PATISDA 31 LeS PC2_nSS Bilao Men ac PDG CTS f 39 PC3 SCK PA6_SCL RESET 52_ PC2 SS k POS SCK 35 PD7_PWML2 PA7_SDA RESET 539 RESET PD7 PWM2L l 38 GND PES Srl VDD1 VSS4 PES PAI7 0 PES 55 PE4 PES F3 PES VCC_3v3 17 0 GND C3 PES PES 25 PE7 PEZ hi B7 V993 PE 34 PE2 VDD3 LE S sare EE 7 60_ PEO VDD2 T PG7_T20UT_PWMLO Poro PD1_PWML1 61 VSS Z H TEF PC6_T2IN_PWMHO PCO TUN PD1 PWMIL Z PC6 T2IN T2ZOUT PWMOH 052 PDO PWM1H 225 DBG Hg as XOUT 2239 Z PC1ITIOUTICOMPOUT H7 c yi XIN ee 55 52 2 PCO TIN TIOUT CINN c LSTI ANEE PC5_MISO 1 3 SSSSSSSSSSE5 PCS T2IN_PWMHO BCE T ILI T EE PC7 TOUT PWMLO b ke ETIT ET 20 MHz gt StoaoaaaaaaaaaAaaAaS Ss S al T B pF F e a Ji 899999 aaae PB6_ANA6_OPINP PEO PET 7 z pi 4 T PES 5 6 R ji gt VREF BL 8 le PES a sk EER Z la m 1 SS EERIE Bl PH3_ANA11_CPINP FET FFL Sos 15 16 zleze zeaz E HDRVPIN sis SS EIIZ lt N SS w w w w w we EI IE Pf Pe Pal Sa aaa aaa aa voc_sva PB3_ANA3_OPOUT B B voc_sva 1 12pF C6 PDO_PWMHi PWMH1 pwu cr PB7_ANA7_OPINN PD1_PWMLt PWMLT BWR aE PD2_PWMH2 PWMH2 BWR voc_sv3 PD3_ DET DEI 1 HP 2 PD4_RXD1 ere PD5_TXDT TXDI oh C8 10uF PD6_nCTSI CIS NT PD7_PWMLE PWM OL c9 10 11 12 13 14 15 16 17 18 bi DBG BB 4k R7 S 1 22 uF p2. GND 54 235 26H35 az Sy aja afz gjo Lf 35 33 sje S S BG 89 39 37 38720 47 39 40 AS 43 41 42 Fag JP2 25143 44 aE ANAO 1 2 ANAI T 46 Fag ANA ay eta ANAS e 9 3 oe PAZO ANAT 313 Ma ANAS mj 2 PAO TOIN ANAT 718 6 S ANAS B35 ST PAT TO VOC_ava yj 8 n GND GND 55 93 54 55 PA2_DEO PC4 MOSI we Be PC5 MISO 57135 BS ea PWMH2 13 14 PWML2 59 60 PWMH2 PCS_SCK 15113 146 PC2_nSS PwML2 59 60 pung PWNHT 1713 16 18 POS T2IN PWMHo HDR PIN 2x30 GND T917 38 20 Pc7 12007 PWMLO c PWMLI 217 22 PAZ pwm C BeTa asel 22 Pag PD6_nOTSt orsi pey PDS 25 23 6 PD4_RXD1 eae Tin Ee PD5_IXDI mja 9 PCO_TiIN PAO 2975 58 30 GND it PAT 31 32 BET POO RTE za e PGS So PCO_T1IN PM HED 3533 Ms AS_TXDO PCi TOUT I E SE ae PC2_nSS GND 39 37 Srg 477 89 40 Fg E we Tas 41 42 Pag BE ke pas so 46199 44 Fag NC PCE_T2IN_PWMHO PA7 SDA yje 48 ag cno PWMLO a9 47 s ue ae RESET 3 PH3_ANA11 RESET TEE aa 55 E 56 57 58 NC 57 58 NC VCC_3v3 59 29 go E0 we HDRIPIN 2x30 7 B ANA 11 0 g PHI ANA U 9 25 26 Z PHO_ANAB 23 25 26 Pag PBO_ANAO aj IT PBT ANAT TS 22 30 PB4 ANAL 77 19 208 PB5 ANAS yje me PBE ANAS iS fz PB7_ANA7 mS nfz PB3_ANA3 a reme PB2_ANA2 7 C E E PH2_ANATO 3 6 PHS ANAT 3 5 8 7 MDS INTERFACE VREF yi A VREF 1 2 Zilog Confidential All Rights Reserved eso fest fos2 baa aa 35 css a css c39 fao pa DRPINEI Zilog N A RouE RouE p otuF pour bou batu pour pour por pour Rou bour 6800 Santa Teresa Bivd zilo
3. IK I 96C0960 001 Figure 12 3 Phase Motor Control Application Board 2 of 3 Application Note Zilog Embedded in Life Ani IXYS Company AN031103 0412 Page 18 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life Ani IXYS Company UNUSED POWER INTERFACE JP2 VB CS RG io 1 ii TH CL SS LALA ojs g gt SI ped NJS be a Ea 1 Rag bh r loo fu 1 eo ico D FN G G M 1 fy E 1 AA Ol jen n Ina j cn rad D n D n joo fua io D HEADER 20 25 HEADER 30x2 SM 3 PHASE MOTOR CONTROL APPLICATION BOARD Document Number 96C0960 001 Date Thursday June 09 2005 BE Figure 13 3 Phase Motor Control Application Board 3 of 3 AN031103 0412 Page 19 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog imbedded in AnEITXYS Company Appendix B Flowcharts This appendix displays flow charts that diagram the Main Function and the Read and Write APIs Figure 14 shows the main control loop Peripheral Initialization Enable Interrupts Main Loop Application Code Figure 14 Initialization and Application Code Space The Back EMF sensing loop is shown in Figure 15 tO_intrp Back EMF ISR every TimerO time out forms Ph
4. counts counts F clock _ Speed constant TimerPrescale Speed_count Frequency to Electrical cycles Commutation Angular Frequency Revolutions per Commutation cycles per cycles Timer cycles Integrator Conversion per cycle sec radians cycle sec rev cycle unitless radians Hertz Timer cycles sec Figure 17 Back EMF Sensing Using the Phase Locked Loop Algorithm Phase Detector Filter Ud s Kd e s Uf s Ud s F s Figure 18 Proportional Integral PI Filter Representation for Back EMF Sensing ANO31 103 0412 Page 22 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life AnEITXYS Company Table 2 Back EMF Sensing Phase Locked Loop An ie Divider Ratio Rj R2 N volts rad Ki aoo speed current speed of motor lt i l 1 519 t numeric constant F s E iy tT numeric constant Kspeed A 5 Kd F s z Kd Ko oll ADCcounts fclock 2 2 Vref Prescaler 6 N Kspeed 2 2n fclock speed count maz count mar counts at max speed 2 6 N Oma Prescaler max Maximum motor speed rad sec ADCeounts Omax Vref speed count max S42 5 0 0 Ln Closed Loop Transfer Function Ko i 5T st s Kd Ko t Kd Ko Open Loop Gain 5 5 T We begin with the transfer function of the Proportional Integral PI Filter in the s plane ANO031103 0412 s _1 st F s R s ST Page 23 of
5. files contained in AN0311 SC02 are enhanced versions of AN0311 SCO1 that allow users to easily change parameters to accommodate differing motor types Revision History Each instance in the following table reflects a change to this document from its previous version For more details refer to the corresponding pages or appropriate links provided in the table Revision Page Date Level Description Number Apr 2012 03 Corrected source code figure references 1 6 8 Mar 2011 02 AN0311 SC02 source code added to encompass 1 22 multiple motor types correction to TimerPrescale data in PLL flow Figure 17 Dec 2010 01 Original issue All ANO031 103 0412 Page 1 of 26 Features Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life AnEITXYS Company The power saving features of this Z16FMC application include e Smooth S curve motor start up with reduced starting current e Sensorless back EMF control using Phase Locked Loop feedback e Microcontroller based overcurrent protection e Selectable speed or torque setting e Selectable speed or torque control e Selectable control of motor direction e UART Interface for PC control e LED for max speed indication e LED for motoring running indication s LED for fault indication Discussion The Z16FMC Series Flash microcontrollers are based on Zilog s advanced ZNEO 16 bit CPU core The ZI6FMC MCU family of devices set a new stan
6. otuF Raup pour p oiuF otur p otuF p oluF p oiuF p otuF bour p INTERFACE 5K i i i p ji k GND ji i ji 1 2 RESET 7j AE DBG 20 513 4 Le M MCU 5 6 000pF z HDRVPIN 2x3 s Zilog Confidential All Rights Reserved Zilog A 6800 Santa Teresa Bivd zilo g San Jose CA 95119 Ta 408 513 1500 LTE Website www zilog com ie zi6FMC MDS BOARD age MCU k SES T Document Number 9601299 001G pa UNCONTROLLED WHEN PRINTED UNLESS STAMPED CONTROLLED COPY IN RED BY DOCUMENT CONTROL A ate Monday November 08 2010 pra 3 o 5 5 4 3 2 if Figure 8 Z16FMC Motor Control MDS Module 2 of 2 AN031103 0412 Page 14 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life Ani IXYS Company Figure 9 shows the schematics for the MDS board s power and serial interfaces s z z z i P2 2 VCC_3v3 A E CON DC be w AYA bup Paur Sa g vE E g C1 5 26 5 a lt E CONSOLE Ge C2 pauF puf D 6 7 P3 D Rup c2 ka Ee k PE PA 5o Btn tiout HZ ee TT a GND 12 toi aour ae ee L e X nd Lo BR nere 18 our ii TE H USER Pas RxDo 10 aaa B e gt DB9 Female VCC 3v3 td en P 20 NG aq NC SP3222EBC
7. 0 is used for the Time Stamp function as well as for updating the commutation period if necessary t nl Tek Stop SHE 5 00 V 2 9 10 00 1 Figure 3 Cycle By Cycle Shutdown ANO031103 0412 Page 6 of 26 Testing Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life AnEITXYS Company This section provides information about how to run the code and demonstrate this applica tion including the equipment used to build the implementation its configuration and the results of its testing Equipment Used The following equipment is used for the setup the first five items are contained in the Z16FMC Series Development Kit Z16FMC28200KITG Zilog Z16FMC MDS Module 99C1299 001 Zilog 3 Phase Motor Control Application Board 99C0960 001 Opto Isolated USB Smart Cable to connect the PC to the Z16FMC Series Development Board LINIX 3 Phase BLDC motor 24VDc 30W 3200RPM 45ZWN24 30 5 V DC power supply for the Z16FMC MDS Module 24 V DC power supply for BLDC motor Digital Oscilloscope or Logic Analyzer Hardware Setup ANO031103 0412 Figures 4 and 5 illustrate the application hardware connections Page 7 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog LINIX 3 Phase BLDC Motor Opto isolated USB Smart Cable n 3 Phase MC Application Board Z16FMC MDS 2NEO MOS Module THREE PHASE MO
8. 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life AnEITXYS Company Next by using the bilinear transform identity 22 1 1 2 Fiz 72 Us Riz 2 1 Tz ya When multiplying by Tz T the calculations that follow are Fix YE _ BR Ta Riz 2t z 2t T 2t5 27 z z F z lt L em 2 2 R z z z z agzR z a R z where T 2t T 2 ag Jr and s d 1 Y z z z agR z a z Riz Collecting terms and dividing by z yields the following result y n yin 1 agr n ar n 1 ANO031103 0412 Page 24 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life AnEITXYS Company When writing this computation as a computer program it takes the form of a recursive fil ter with the coefficients AO and Al YO Y1 A0 RO Al RI where ANO031103 0412 YO Current output Y1 Output at the last sample period RO Current ADC sample of Back EMF phase voltage Vgys 2 R1 Most recent sample of Back EMF from ADC AO a0 Al al Page 25 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note S En AnEITXYS Company Customer Support To share comments get your technical questions answered or report issues you may be experiencing with our products please visit Zilog s Technical Support page at http sup
9. A C C RESET lt VCC_3v3 D2 R10 R11 PAO_TOIN 1 KER 1 1 2 1 RED PA 7 0 198 10K RESET PAO_TOIN PAO Ld Bp 12 PA1_TOOUT le PA1_TOOUT 1 1 2 DEO PA3_nCTSO YELL PA4 RXDO 100 PA6_SCL D4 R13 PA7_SDA PA2_DEO 1 A GREEN 100 R15 B 10K B R16 PA7_SDA POWER amp RS232 100 R17 PCO PCO_T1IN VCC_3v3 100 EG1218 STOP RUN dl GND q H vec 3 3V Zilog Confidential All Rights Reserved N TPI TP2 Zilog C gt 6800 Santa Teresa Byd Zilo g San Jose CA 95119 ka 408 513 1500 BIKYS Website www zilog com Wa Z16FMC MDS BOARD power and RS232 UNCONTROLLED WHEN PRINTED UNLESS STAMPED CONTROLLED COPY IN RED BY DOCUMENT CONTROL itis e x Date Monday November 08 2010 Bheat 4 o 5 s z s z i Figure 9 Z16FMC MDS Board Power and RS 232 Connections AN031103 0412 Page 15 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life AnEiLXYS Company z a E z 7 Ji zi ha y 476 VeC_3v3 715 6 hs cup 9 7 8 10 Tt 9 Hr Tse ura enn 75 13 a TL sav mji 18 R 13117 18 Fag D a 5 18 a2 21 22 23 24 25123 2725
10. Application Note Zilog Embedded in Life Sensorless Brushless DC Motor An EXIXYS Company Control with the Z16FMC MCU AN031103 0412 Abstract This application note discusses the closed loop control of a 3 phase brushless direct cur rent BLDC motor using the Z16FMC Family of Microcontrollers MCUs The Z16FMC product family is designed specifically for motor control applications featuring an on chip integrated array of application specific analog and digital modules The result is fast and precise fault control high system efficiency on the fly speed torque and direc tion control as well as ease of firmware development for customized applications This document further discusses ways in which to implement a sensorless feedback con trol system using a Phase Locked Loop along with back EMF sensing Test results are based on using the Z16FMC Modular Development System MDS module a 3 phase motor control MC application board and a 3 phase 24 VDC 30 W 3200RPM BLDC motor with internal Hall sensors gt Note The source code files associated with this application note AN0311 SC01 and AN0311 SC02 were tested with version 4 12 of ZDSII for ZNEO MCUs Subsequent releases of ZDSII may require you to modify the code supplied with this application note The sample project included in ZDSII v4 12 and the firmware in the Rev D or earlier ver sion of the Z16F28200KITG Development Kit were preprogrammed with ANO311 SCO1 The source code
11. TOR 7 T USB SmartCable or F Ethernet SmanCable Ji ts f Na Ra b S Ka L JI 24VDC inputs Figure 5 3 Phase BLDC Hardware Setup with Z16FMC MDS Module AN031103 0412 Page 8 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life AnEITXYS Company Figure 6 displays the proper port settings in the HyperTerminal emulation program COM1 Properties ar Port Settings Bits per second 57600 y Data bits 8 z v Parity None v Stop bits 1 v Flow control None v Restore Defaults Figure 6 HyperTerminal Display Settings Procedure Observe the following steps to test the 3 Phase Sensorless BLDC Motor Control Applica tion demo program to the Z16FMC MDS Module 1 Install the ZDSII ZNEO version 4 12 or newer software on your PC 2 Connect the Opto Isolated USB Smart Cable to the PC To install the driver of the Opto Isolated USB Smart Cable refer to the installation guide of the Opto Isolated USB Smart Cable included in the Z16FMC Series Development Kit Connect the Hardware Setup as shown in Figures 4 and 5 4 Power up the Z16FMC MDS board using the 5 VDC adapter included in the kit 5 Open the ANO0311 SCO1 project in ZDS II for ZNEO ANO031103 0412 Page 9 of 26 10 11 12 13 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog
12. ase Locked Loop Commutation Update every other interrupt Back EMF Sensing and PLL Filter opposite interrupt from Com Update Figure 15 Initialization and Application Code Space ANO31 103 0412 Page 20 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life AnEITXYS Company A flow chart of the PWM loop is shown in Figure 16 This PWM loop can also be used for specific application code such as communications or additional user interfaces pwm_timer_isr Main Loop ISR every PWM reload 50us Current Loop PWM duty cycle control 500uUs update LED Status 50us update and Blink 0 4 sec update Torque current command from ADC 2ms update filtered Direction Switch 7 5ms update filtered Figure 16 Current Loop and Timed Housekeeping ANO031103 0412 Page 21 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life AnEITXYS Company Appendix C Back EMF Sensing Phase Locked Loop The Phase Locked Loop Back EMF algorithm implemented to provide a smooth start up of the motor is shown in Figures 17 and 18 Additional details about the specific formulas in these figures are shown in Table 2 a description of these calculations follows ADC PI Filter unitless Back EMF Neutral Back EMF Divider volts radian unitless counts volt R ADC counts radians volts 1 volts V counts
13. bedded in Life AnEITXYS Company From the main c source file choose the following mode for the Motor Control appli cation define LOOP_SELECT_VALUE lu Ou torque loop lu speed loop Compile the application and download the code to the ZI6FMC MDS module Stop the debug mode from the IDE disconnect the Opto Isolated USB Smart Cable and switch off the power supply to the Z16FMC development board Connect the 24V DC supply source to the MC application board Ensure that the RUN STOP switch on the Z16FMC development board is in the STOP position First apply power to the Z16FMC development board supply then apply power via the 24V supply to the MC application board Set the RUN STOP switch on the Z16FMC development board to RUN Additionally observe the following points If SPEED mode is selected the speed of the motor can be varied by adjusting the potentiometer on the Z16FMC development board If TORQUE mode is selected the motor speed is decreased with application of force on the shaft of the motor The direction of rotation of the motor is set by changing the position of the direction switch on the Z16FMC development board You can now add your application software to the main program to experiment with addi tional functions gt Note While debugging your code ensure that the Opto Isolated USB Smart Cable controls the reset pin of the MCU After debugging and running your code detach th
14. ckwise RPM rotation When the motor is loaded mechanically by e Potentiometer R10 at minimum value holding the shaft speed initially decreases then picks up gradually current increases e Green LED blinks e RUN STOP switch in RUN position e Motor begins rotating at a speed of 3890 e Direction switch set to a counterclockwise RPM with no load rotation e Green LED blinks e Potentiometer R10 at maximum value e RUN STOP switch in RUN position e Motor begins rotating at a speed of 1250 e Direction switch set to a clockwise direction RPM at no load e Motor stops rotating upon holding the shaft Constant current consumption of 60mA e Green LED blinks Toraue e RUN STOP switch in RUN position e Motor starts rotating at a speed of 1250 q e Direction switch set to a counterclockwise RPM at no load direction e Motor stops rotating upon holding the shaft e Constant current consumption of 60mA e Green LED blinks e RUN STOP switch in STOP position e Motor is in idle mode e Yellow LED blinks Summary This Application Note described the closed loop control of a sensorless BLDC motor using the advanced on chip integrated features of the Z16FMC MCU The Z16FMC prod uct line is ideally suited for such applications providing for a seamless start up of the motor from an idle mode to full operational speed on the fly reversal of the direction of rotation an extremely fast fault detection cycle and a lower total solution cost These fea tur
15. dard of performance and efficiency with up to 20 MIPS performance at 20 MHz It supports 16 bit internal and external bus widths and provides near single cycle instruction execution The Z16FMC s external interface allows seamless connection to external memory and peripherals A 24 bit address bus and a selectable 8 bit or 16 bit data bus allows parallel access up to 16 MB Up to 128 KB internal Flash memory is accessible by the CPU 16 bits at a time to improve processor throughput Up to 4KB of internal RAM provides storage of data variables and stack operations Figure 1 displays a block diagram of the Z16FMC MCU architecture ANO031103 0412 Page 2 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life AnEITXYS Company Figure 1 The Z16FMC MCU Architecture In each of the Z16FMC products the novel device architecture allows for realization of a number of enhanced control features Time Stamp for Speed Control e Integrated Operational Amplifier e Multi Channel PWM Timer Time Stamp for Speed Control Most microcontrollers use at least one dedicated comparator to detect the zero crossing of the input AC voltage signal so that the output driving pulses can be synchronized and ANO31103 0412 Page 3 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note a adjusted to properly regulate the motor speed An alternative approach based on Z
16. e Opto Isolated USB Smart Cable from P3 of the Z16F28200KITG to free the Reset pin and apply a power cycle to reset the MCU from debug mode Result This Motor Control application was tested with the Z16FMC MDS board connected to Zilog s 3 phase motor control application board The BLDC motor specifications are AN031103 0412 Manufacturer Linix Motor type 3 wire 3 phase brushless DC motor Voltage rating 24V Power rating 30W Maximum speed of rotation 3200RPM Page 10 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Z v pa AnEITXYS Company Observations that we noted about speed and torque are indicated in Table 1 Table 1 Speed and Torque Observations Function Description Observation e RUN STOP switch in STOP position e Motor is in idle mode e Yellow LED blinks e RUN STOP switch in RUN position e Motor starts rotating e Direction switch set to a clockwise rotation When the motor is loaded mechanically by e Potentiometer R10 at minimum value holding the shaft speed initially decreases then picks up gradually current increases e Green LED blinks e RUN STOP switch in RUN position e Motor starts rotating with no load e Direction switch set to a clockwise rotation Green LED blinks Speed e Potentiometer R10 at maximum value e RUN STOP switch in RUN position e Motor starts rotating at a speed of 1280 e Direction switch set to a counterclo
17. es along with the powerful ZNEO CPU core and some of the best development tools AN031103 0412 Page 11 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life AnEITXYS Company available in the industry result in less complex board designs and reduced design cycle time References ANO031103 0412 The following documents are associated with the Z16FMC Series of Motor Control MCUs each is available for download on www zilog com e ZI16FMC Series Motor Control MCU Product Specification PS0287 e ZI16FMC Series Motor Control Development Kit User Manual UM0234 e ZI16FMC Series Motor Control Development Kit Quick Start Guide QS0079 e Zilog Developer Studio Il ZNEO User Manual UMO171 e ZNEO CPU Core User Manual UMO188 e Sensorless Brushless DC Motor Control with Z8 Encore MC Microcontrollers Appli cation Note AN0226 Page 12 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life a AnD IXYS Company Appendix A Schematics Figures 7 and 8 show basic block and MCU schematics respectively for the ZI6FMC Motor Control MDS Module 5 z z z 7 D D PCO POWER amp COMMUNICATIONS MDS INTERFACE PAI7 0 PA 7 0 PC 0 Ai pr 7 lorr Po pag Ora i na PEST R peset S ANAD 1 01
18. g 4 J 4 J 1 San Jose CA 95119 pae 408 513 1500 DIKYSC Website www zilog com Me 216FMC MDS BOARD Page ps INTERFACE UNCONTROLLED WHEN PRINTED UNLESS STAMPED CONTROLLED COPY IN RED BY DOCUMENT CONTROL eee wow x Date Monday November 08 2010 Bhett_5 of 5 S a z z 1 AN031103 0412 Figure 10 MDS Board Interfaces Page 16 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life Ani IXYS Company Figures 11 through 13 display the schematics for the 3 Phase Motor Control Application Board 3 PHASE POWER STAGE BA FA NG N 9 BUS E SA FUSE at IRFZ48 95 IRFZ48 Our SUV Q4 GATE BL IRFZ48 O4uF 50V 33004F 50V QG S300uF 50V GATE_AL IRFZ48 HEATSINK TEMP SENSOR TI Heru R4 NTC ADK 96C0960 001 F HE Figure 11 3 Phase Motor Control Application Board 1 of 3 3 PHASE MOTOR CONTROL APPLICATION BOARD Document Number AN031103 0412 Page 17 of 26 BEMF DIVIDERS PHASE A PHASE PHASE C RB R10 R12 150k 150k 150k VAs vB R7 R9 R11 10 00k 10 00k 10 00k NGC 33V lt 12V SUPPLY L1 LAE Sensorless Brushless DC Motor Control with the Z16FMC MCU GATE DRIVE D1 BAV19 MEUS 4 IR2101 D2 BAY19 221 GATE BH 221 GATE BL gt gt IR2101 D3 gt BAV19 BE Ts Ta
19. ilog s motor control MCU eliminates the need for this comparator by instead employing an ana log to digital converter ADC in conjunction with a timer In this case the ADC samples the AC line voltage with the timer running in the background When the ADC samples the line voltage s zero crossing it reads the timer count and writes the result to a register As a result the timers are cued for the output Pulse Width Modula tion PWM pulses to efficiently regulate the speed of the motor This time stamp approach results in a very simple and cost effective solution for smooth operation of the motor in steady state Integrated Operational Amplifier Appliance controllers almost invariably monitor motor speed by sensing the current through the windings using sensor and sensorless techniques in conjunction with the ADC Ordinarily sampling instances by the ADC are synchronized by the MCU With this process an external operational amplifier is often used to convert the current signal to a voltage signal the ADC next samples the voltage signal and outputs the result to the pro cessor The processor then synthesizes the PWM outputs to control motor speed In the case of the Z16FMC Family of Microcontrollers an on chip integrated operational amplifier eliminates the requirement for an external component thereby reducing overall system cost Multi Channel PWM Timer The Z16FMC features a flexible PWM module with three complementary pairs or
20. o suggest possible uses and may be superseded ZILOG INC DOES NOT ASSUME LIABILITY FOR OR PROVIDE A REPRESENTATION OF ACCURACY OF THE INFORMATION DEVICES OR TECHNOLOGY DESCRIBED IN THIS DOCUMENT ZILOG ALSO DOES NOT ASSUME LIABILITY FOR INTELLECTUAL PROPERTY INFRINGEMENT RELATED IN ANY MANNER TO USE OF INFORMATION DEVICES OR TECHNOLOGY DESCRIBED HEREIN OR OTHERWISE The information contained within this document has been verified according to the general principles of electrical and mechanical engineering Z8 Z8 Encore Z8 Encore XP and ZMOTION are trademarks or registered trademarks of Zilog Inc All other product or service names are the property of their respective owners ANO31 103 0412 Page 26 of 26
21. plementation of this critical sensing function without the requirement for an additional comparator ANO31 103 0412 Page 4 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life AnEITXYS Company Pl Driver RL Driver et Driver A B BLDC MOTOR DH o fo EZA Driver IF Driver nk Driver 5 n j 7FAULT PWM TO DRIVERS Z MT CURRENT TEMP BEMP A 3 v vAvBvc SE VRE H Multiplexing Sample amp Hold Figure 2 A 3 Phase BLDC Motor Control System The algorithm for Back EMF sensing is based on an implementation of a Phase Locked Loop PLL as shown in Figures 3 and 4 and described in Appendix C Back EMF Sens ing Phase Locked Loop This algorithm is especially advantageous during startup result ing in a very smooth increase in the motor speed as well as nearly instantaneous reversal of direction of rotation on command as outlined below With a conventional approach during the start up sequence power is applied to the wind ings in order to place the rotor in a known starting position followed by commutation and start of Back EMF sensing and control In contrast the PLL based approach implemented herein makes it possible to lock the Back EMF signal from the onset of the start up phase without the requirement for initial placement of the rotor in a specific posi
22. port zilog com To learn more about this product find additional documentation or to discover other fac ets about Zilog product offerings please visit the Zilog Knowledge Base at http zilog com kb or consider participating in the Zilog Forum at http zilog com forum This publication is subject to replacement by a later edition To determine whether a later edition exists please visit the Zilog website at http www zilog com AN Warning DO NOT USE THIS PRODUCT IN LIFE SUPPORT SYSTEMS LIFE SUPPORT POLICY ZILOG S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES OR SYSTEMS WITHOUT THE EXPRESS PRIOR WRITTEN APPROVAL OF THE PRESIDENT AND GENERAL COUNSEL OF ZILOG CORPORATION As used herein Life support devices or systems are devices which a are intended for surgical implant into the body or b support or sustain life and whose failure to perform when properly used in accordance with instructions for use provided in the labeling can be reasonably expected to result in a significant injury to the user A critical component is any component in a life support device or system whose failure to perform can be reasonably expected to cause the failure of the life support device or system or to affect its safety or effectiveness Document Disclaimer 2012 Zilog Inc All rights reserved Information in this publication concerning the devices applications or technology described is intended t
23. six independent PWM outputs supporting deadband operation and fault protection trip input These features provide multiphase control capability for a variety of motor types and ensure safe operation of the motor by providing immediate shutdown of the PWM pins during a fault condition Theory of Operation In a brushless DC motor the rotor is comprised of permanent magnets while the stator windings are similar to those in poly phase motors For a detailed discussion of BLDC motor fundamentals as well as closed loop control using sensorless techniques refer to the Motor Control Electronics Handbook by Richard Valentine McGraw Hill NY 1998 In sensor based control applications the Hall elements are integrated and are used to detect the position of the rotor for drive synchronization In contrast sensorless control employs the detection of Back EMF signals which are generated induced by specific phase windings to synchronize the timing of the control loop A block diagram of the BLDC motor control system based on the Z16FMC MCU is shown in Figure 2 In a 3 phase commutation arrangement at any given instance only two phases are energized The back EMF voltage is in turn generated in the unenergized phase winding and the zero crossing of this induced voltage is detected for synchronization of the subsequent closed loop control events As discussed earlier the innovative time stamp feature of the Z16FMC MCU provides for robust efficient im
24. tion Moreover this approach significantly reduces any erratic movement of the motor during start up or a reversal of direction During normal operation following the start up period phase torque current mode control is achieved via sensing of the voltage generated across a sense resistor in the motor drive ANO031103 0412 Page 5 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life AnEITXYS Company circuit This voltage is routed to the on chip integrated ADC after which data processing by the CPU based on a predefined computational algorithm results in the regulation of the PWM commutation signal period s As discussed earlier another key feature of the Z16FMC MCU is the direct coupling of the on chip integrated comparator to the PWM module to enable fast cycle by cycle shut down during an overcurrent fault event Oscilloscope generated waveforms representing this sequence of events are shown in Figure 3 In conjunction with the integrated on chip hardware blocks the 3 phase BLDC motor control software developed herein allows for ease of programming to achieve the desired closed loop control characteristics The routines that enable the sensing of the motor s Back EMF and current are all interrupt driven It is critical that the highest interrupt prior ity is assigned to the Back EMF sensing event for subsequent synchronization of the com mutation events In this case Timer
25. ube ANAJ 1 0 POWER amp COMMUNICATIONS aaa gt PWML1 rua Prodi S 1 4 PWMH1 FAB gt RESET RESET 8 s INTERFACE MCU TOP Zilog Confidential All Rights Reserved Zilo i P cael zilo g N San Jose CA 95119 408 513 1500 An D SYS Company Website www zilog com Te Zi6FMC MDS BOARD Pee op Size Rev B R Document Number 96C1299 001G UNCONTROLLED WHEN PRINTED UNLESS STAMPED CONTROLLED COPY IN RED BY DOCUMENT CONTROL a Monday November 08 2070 Shoat 3 a5 A 7 5 a a z Figure 7 Z16FMC Motor Control MDS Module 1 of 2 AN031103 0412 Page 13 of 26 Sensorless Brushless DC Motor Control with the Z16FMC MCU Application Note Zilog Embedded in Life Ani IXYS Company 5 4 3 2 1 PBO ANAO TOINO ANAO PF PB1_ANAT_TOIN1 PEB2_ANAZ_TOIN2 ANA lais alles sisi PE3_ANA3_OPOUT alae maa SS PBA ANAJ gae fers SEa PB5 ANAS ANAS voc_ava la elsisis Is PB6_ANA6_OPINP O SPS KRESKI Ee PB7_ANA7 OPINN
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