3-Phase BLDC/PMSM Low- Voltage Motor Control Drive
Contents
1. E TP35 V deb MOTOR tea n 2 o TPIT BEMF B He 1 R20 0 R25 12 50 754 R29 TP42 GND 2 2 1993 10 8 1095 0 RI 035 C34 1 i H i 4 i 5 a 3 D18 um 9 s 018 We 8 706 51 8707 01 8 081 95 7 RES R86 ROT 5 3 3V go zo ce 2 e n 22 Ee 2 ti a co 3 phase Drive Freesca a S x 003150 9 Tp36 7 5 Ya Y 5 vs Y 6 ile ens 2 8 S N ca Ss 4 a os of Rem te gt 22 go go 888 4 We ane TPI g SS a 4 23 m Desmo LI wA N AB 2 amp 3 27 a RSR3 818815 27742 amp PWM BT TOLER SI 2 1 L Z 1 TP28 3 lo R93 J10 USB u5 Gs n s 49 mE 2 CB 2 05 0 52 0 705 D8 R63 x 8 So z 1915 o 2 2 TP24 09 0 Rea les J9 D L______ ooo TP44 amp xcd 0 D GNDA xz BEMF_A 1 2 cio D Ci4 R60 CIS 548 J8 Idebs xc RO 555 o FE od 22 J T 1 2 1 2 197 qe 5 4 CAN Rx 3 R28 5 5 0 R31 2 100 1 TP18 lt a 5 y 8 1 55 om H2. INSIWd 2Q18 HDR1x3 MOSFET Drivers DCB Pos Gate AT Source CT IRESET DRV_EN sense DCB1 ISS sense DCB2 MISO MOSI Gate AB Gate BT Gate BB Gate CT Gate CB Sense DCB1 Sense DCB2 Phase A Phase B Phase C sense A1 sense A2 sense B1 sense B2 sense C1 sense C2 DCB pos DCB neg GND LSFET J1 3 3VA Motor 1 65V_REF lt u 8 GNDA e Phase m DCB_pos Power Circuit Phase B Phase C sense A1 sense A2 sense B1 sense B2 sense C1 sense C2 DCB pos BEMF sense C BEMF sense B BEMF sense I sense C sense B sense sense DCB 2 V sense DCB sense DCB gt sense DCB out B x GNDA SCLK sense DCB out LSFET BEMF sense C BEMF sense B BEMF sense A sense C I sense I sense A sense DCB 2 GND LsFET Analog sensing 4 ____ oo 5V lt 8 gt a V sense DCB INT 5 sense DCB MicroHeaders amp others circuits n T 3 3VA 3 3 5V GNDA Q1 CON 2 TB og 3 DCB pos 1 FQD11P06 2 R1 J2 1M J3 1 POWER JACK 12 50V 5A DCB pos 3 3V 3 3VA 1 65V REF Power Supplies
3. REG RODEO EN cie HEC rite ARR ETT TT TT LT las S me sasa Motor connected Tu stus plos E ERI Gh teeta ge Soke re era Power Supply Input Connectors J2 and 3 CAN Header Encoder Hall Effect Interface Daughter Board Connectors J7 8 USB Controller BDM 9 USE Connect JTO et p a e dob do Chapter 4 Design Consideration ee eee TOT T TTL eee T T TL IT cai Bus Voltage and Current Overcurrent Undervoltage and Other Safety Pa aa jr Pere a a rer Phase Current qt RR oases D ree sth pneu Test Foints ang LED INGHILTERRA Power Supplies and Voltage Reference Pd par b P RR GRE Re dua 5 dno do 0j AP FS FB VA PONSI SUPP 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 4 9 4 10 4 11 4 12 Ericodet Hall Effect
4. 24 56 38 oai sonda Elda MRR ee 39 USB Lu dx 40 Control SWIIPB AES v late 40 Appendix 3 Phase BLDC PMSM Motor Control Drive Schematics Appendix B Bill of Materials Appendix C 3 Phase BLDC PMSM Low Voltage Motor Control Drive Layouts 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor List of Tables Table 2 1 Electrical 5 a 19 Table 3 1 Motor Connector J1 Signal Descriptions 22 Table 3 2 CAN Header Signal Descriptions 22 Table 3 3 Encoder Hall Effect Interface J6 Signal Descriptions 23 Table 3 4 Daughter Board Connector J7 Signal Descriptions 23 Table 3 5 Daughter Board Connector J8 Signal Descriptions 24 Table 3 6 USB Controller BDM Header J9 Signal 26 Table 3 7 USB Connector J10 Signal Descriptions 26 Pans Lel ibiza sad ER A Oa Re fe lo hdc eg eke 55 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 9 3 Phase BLDC PMSM Low Voltage Motor Cont
5. 1 65 V Reference Source 4 9 Encoder Hall Effect Interface 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 38 Freescale Semiconductor CAN Interface The 3 Phase BLDC PMSM Low Voltage Motor Control Drive contains an encoder hall effect interface The circuit is designed to accept 3 3 V to 5 0 V encoder or hall effect sensor inputs Input noise filtering is supplied on the input path for the encoder hall effect interface Filtered signals are then connected to the controller daughter board connector J8 Figure 4 11 contains the encoder interface 5V ANA NI gt gt 5V 45V DNA NN J6 24 OHM I ae 470PF o o o 5V NI L AVNA Index Figure 4 11 Encoder Hall Effect Circuitry 4 10 CAN Interface The board contains a CAN interface The main part of the interface is CAN controller PCA82C250 The PCA82C250 is the interface between the CAN communication controller and the physical bus The device provides differential transmit capability to the bus and differential receive capability to the CAN controller The CAN interface is compatible with ISO 11898 and allows a maximum data transfer rate of 1 Mbit s The CAN transceiver is short circuit protected transient bus protected thermal protected RFI and EMI immunized The CAN transceiver is connected via CANTX and CANRX signals to the daughter board connector J7 Bus signals CANL and CANH are connected
6. GNDA Figure A 1 Board Overview 1 9 4 0 5 10104 WSIWd 2Q18 9seud e sense A1 1 sense A2 I sense B1 sense B2 I sense C1 I sense C2 la R2 TP2 t R3 R4 ANN ANN lat 1 6K 220 OHM ci R6 ANN 220 U1B R7 7 5K R10 1 65V ref GNDA MC33502DG t 47PF R12 co AA ANN ai 220 OHM 16k R13 7 5K gt 3 3VA R14 Ic TP8 t RIS R16 Ic 1 6K TRU 220 OHM MC33502DG 47PF R17 gt 7 ANN NN oi 220 OHM 186 R19 7 5K 4 1 65V_REF Figure A 2 Analog Sensing Phase Current Sensing I sense 1 65V 1 65V Imax TP4 Imax 4A 1 65V 1 65V 0 Imax Imax 4A sense B 1 65V 1 65V Imax 4A sense C Imax sense DCB out Idcb s 1 5 MC33502DG sense DCB 1 65V 1 65V Imax Imax 4A o 3 3VA GNDA GNDA 3 3VA I 0 3 3VA 1 65 _ o 1 65V REF 3 3VA 3 3VA o o 0 1UF 0 1UF GNDA GNDA 9v JojonpuooluJeg 0 5 10104 INSIWd 2Q18 Phase A 3 3V 8 Phase 3 BEMF sense A Phase B 3 3V Phase B 3 BEMF sense B P
7. they do not directly measure the phase current However given phase voltages for all three phases phase current can be constructed mathematically from the lower phase leg values The measurement circuitry for one phase is shown in Figure 4 4 Referencing the sampling resistors to the negative motor rail makes the measurement circuitry straightforward and inexpensive Current is sampled by resistor R85 and amplified by the differential amplifier U1B 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 32 Freescale Semiconductor Test Points and LED Indication This circuit provides a voltage output suitable for sampling on A D inputs The MC33502DG is used as a differential amplifier With R2 R7 R3 R5 and R4 R6 the gain is given by A R2 R4 EQ 4 2 The input voltage is shifted up by 1 65 V REF to accommodate both positive and negative current swings A 400 mV voltage drop across the shunt resistor corresponds to a measured current range of 4 A As a source for 1 65 V REF we use the voltage divider described in chapter 4 8 5 1 65 V Reference The gain of this operational amplifier is 4 12 with the 1 65 V offset in other words the output 1 65 V corresponds to 4 A The output is connected to the daughter board connector J8 la TP2 sense A1 SN S N lat 220 OHM TP3 22 las 1 65V 1 65V Imax TP4 Imax 4A ____ sense A I sense A2 220 OHM 3 3VA 1 65
8. 0805 ANY ACCEPTABLE o TPE ON 3 250 2 i00nF 100Vsize 1206 ANY ACCEPTABLE x cscs 2 100 780 6 1 ANY ACCEPTABLE 1 TOO size HTS ANY ACCEPTABLE 2 47uF 63VsizeC ANY ACCEPTABLE cay i i00uF t6VsizsE ANYACCEPTABLE n 100 p 7100 V size 0805 ANY ACCEPTABLE conven EERE HDR 1x3 MOLEX 09 65 2038 CON 2 TB LUMBERG INC KRM 02 SWITCHCRAFT RAPC712X TYCO ELECTRONICS _ 21929227 TYCO HDR 1X5 MOLEX 22 27 2051 J7 J8 87407 110 87407 110LF TYCO ELECTRONICS size 2012 TOK 22012 rost Wurth Elektronik 744778920 FAIRCHILD 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 alo Freescale Semiconductor 55 Table B 1 Parts List DESIGNATORS QUANTITY DESCRIPTION MANUFACTURER PART NUMBER 200 MA 40 V NPN size 507 23 secc MMBT2969ALTIG 7 5 100 V MOSFET size FAIRCHILD 2202 6 SOIC 8 SEMICONDUCTOR R1 R60 2 1 MO Resistor 1 8 W 1 ANY ACCEPTABLE size 0805 2 7 10 13 14 1 7 5 Resistor 1 8 W 1 ee dis ANY ACCEPTABLE R3 R5 R8 R1 R15 R18 220 O Resistor 1 8 W 1 Meme 5 s p ANY AC
9. 29 Freescale Semiconductor Bus Voltage and Current Feedback 4 3 Bus Voltage and Current Feedback Figure 4 2 shows the circuitry that provides feedback signals proportional to bus voltage and bus current Bus voltage is scaled down by a voltage divider consisting of R23 R27 and R104 The values are chosen in such way that a 36 3 V bus voltage corresponds to 3 3 V at output V sense DCB The V dcb is scaled at 91 mV per V of the DC bus voltage and is connected to the daughter board connector J8 pin 9 V sense DCB An additional output V sense DCB 2 provides a reference used in zero crossing detection The V dcb 2 is scaled at 45 5 mV per V of the DC bus voltage and is connected to the daughter board connector J8 pin 10 V sense DCB 2 Bus current is sampled by resistor R88 in Figure A 9 and amplified in the MC33927 s operational amplifier Figure 4 2 This circuit provides a voltage output suitable for sampling on A D analog to digital inputs The MC33927 s operational amplifier is used as a differential amplifier for bus current sensing With R82 R83 R102 R103 and R81 R84 the gain is given by A R81 R82 R102 EQ 4 1 The output voltage is shifted up by 1 65 V REF to accommodate positive and negative current swings A 400 mV voltage drop across the sense resistor corresponds to a measured current range of 4 A The AMP OUT signal is internally connected to the overcurrent comparator of the MC33927 and provides an over
10. 3 3V 3 u7 LM2594HVM 5 0 1 GND ADJVOUT1 i 2 VIN FB A VIN zg NC1 VOUT3 SE OUT B R 0 OHM 84 NC2 VOUT4 1uH dla C35 8 588 MC33269D 33 C39 040 ca C42 43 An 4TUF 68 0UF o o 222 D18 C37 C38 TM 47UF 0 1UF OUR 0 1UF 100PF MURS120T3 100UF 0 1UF e 1 7vcvv 2 END END END END END GNDA Grounds Connection GND GND GND GND GNDA GNDA TP39 TP40 41 TP42 TP43 TP44 3 3VA 5V 1 65 REF GND 1 65 RERO R90 TP38 R91 GNDA 68R e 820 OHM 1830 N 4 065V REF Big 3 3VAo m HSMG c170 WA LED Green 1 68R 5 0 1UF J ND E N Z GND GNDA GNDA GNDA Figure A 10 Power Supplies 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 54 Freescale Semiconductor Appendix B Bill of Materials Table B 1 Parts List DESIGNATORS QUANTITY DESCRIPTION MANUFACTURER PART NUMBER C1 3 C5 47 pF 100 V size 0805 ANY ACCEPTABLE C4 C5 C9 C10 C12 C13 C17 C23 C27 C29 C31 16 100 nF 100 V size 0805 ANY ACCEPTABLE C38 C40 C42 C44 x 6 3 470pF i00Vsize0805 ANYACCEPIABLE __ 4 22uF 25Vsize0805 ANY ACCEPTABLE x cacos 2 22pF 100VsizeoB05 ANY ACCEPTABLE x i0uF 16Vsize0805 ANYACCEPTABLE x 1 47 6 size 0805 ANY ACCEPTABLE cia 1 4017725 0805 ANY ACCEPTABLE x 2052 142 26
11. 5 48 15 10R 10R RST _o o o o ome IRESET RST 42 D12 MBRO520LT1G PWM AT PB HS S R72 15 HO Ral PWM_CT 38 ANN gt Gate BT PC BOOT S Meo PWM_AB PA LS PC HS G a 10R 10R PWM BB PB LS PC HS S 1 PWM CB PC_LS PC_LS_G Source BT ISS cs HT MOSI 2 ETA 013 MBROSZOLTIG SCLK 4 SCLK PHASEA L R73 R74 MISO SO ncs N NC5 2 AMP_P DOT 10R 10R OW 33 014 4 MBRO520LT1G 28 R76 5 R75 AMP OUT 24 OUT 5 gt gt Gate Sand gt 3 3V 852222 A S 33vo aa 9 zz 1UF 1 0K Em 550000 Source c23 15 0K MC33927 D15 MBROS20LT1G 0 1UF oc 3 09v 8 3 75 GND gt Gate CB 1 65 REF 10R 10R 7 3 3VA R81 7 5K DC Bus Current Sensing Di R102 R82 DCB pos IL OoDCB pos Sense DCB2 gt nn AN p AMPIE ma QUT 33 1 0 3 3v 220 OHM C45 sense DCB out die 4TPF R83 R84 3 3V_ 03 3VA 1 Sense DCB1 NN NANA AMP OpAmp is within A 220 OHM eu 1 65 _ O 1 65V REF DCB pos DCB pos VLS CAP VLS CAP 5 VIS VDD VDD GND E C25 aL coe cor cog c29 GND_LSFET 22uF 0 1UF 22UF 0 1UF 22UF 0 1UF 22UF SUD END LSFET LSFET GND LS
12. ANRX PWM AB GND PWM BB PWM_CB INT TOGGLE SWITCH TOGGLE SWITCH ON2 UP SWITCH DOWN SWITCH SER LED 9 19 RESET 87407 110LF RESET 3 3V SW4 A A1 R58 GND GND 4 7K B BI gt C13 0 1UF J8 O 3 3VA sense A O sense B sense O BEMF_sense_A GNDA BEMF_sense_B 04 BEMF sense C V sense DCB sense DCB 2 sense DCB O4 ENC PhaseA ENC PhaseB Index DRV 78S MOSI SCLK MISO 3 3V 3 3VA GND GNDA 87407 110LF GND 33 GND GNDA Figure A 6 Micro Headers amp Other Circuits Daughter Board Connectors amp RESET OG ejeoseoJ4 0 5 10104 INSIWd 2Q18 3 3V 33V 33V T R94 9 R95 TxD RxD 10K 10K TP21 TP22 PTBO ve m PTBO MISO2 ADPO PTEO TXD1 M 24 PTB1 MOSIZ ADP1 8 PTE1 RxD1 25 pTB2 SPSCK2 ADP2 5 PTE2 TPM1CHO PTB3 SS2 ADP3 PTE3 TPM1CH1 3 gt 2L PTB4 KBIP4 ADP4 PTE4 MISO1 2 gt 28 PTB5 KBIP5 ADP5 PTE5 MOSI1 x PTES SPSCK1 14 PTE7 SS1 D ALI PICO SCL 41 PTC1 SDA 42 2 PTFO TPM1CH2 gt 43 PTC3 TxD2 PTF1 TPM1CH3 4 PTF4 TPM2CHO 44 PTCSIRXD2 2 1 CON USB 29 PTDO ADP8 ACMP PTGO KBIPO 30 PTD1
13. PMSM Low Voltage Motor Control Drive Rev 0 24 Freescale Semiconductor Signal Descriptions Table 3 5 Daughter Board Connector J8 Signal Descriptions Continued Pin Signal Name Description 9 V sense DCB E N signal that measures bus voltage It is scaled at 8 09 V per V of DC 10 V sense DCB 2 ee signal that measures bus voltage It is scaled at 8 09 V per V of DC 11 sense DCB Analog sense signal that measures bus current It is scaled at 8 09 V per A of DC bus current 12 ENC PhaseA Encoder or hall sensor phase A input pin logic 13 ENC PhaseB Encoder or hall sensor phase B input pin logic 14 ENC Index Encoder index or hall sensor phase C input pin logic 15 DRV EN 3 phase bridge gate driver enable signal 16 SS SPI pin chip select pin for 3 phase bridge driver 17 MOSI SPI pin master out slave in pin for 3 phase bridge driver 18 SCLK SPI pin clock source pin input for 3 phase bridge driver 19 MISO SPI pin master in slave out pin for 3 phase bridge driver 20 GND Digital and power ground 1 2 GNDA e 43 3VA CANTX 3 4 CANRX sense A 13 sense DCB PWM AT O 5 6 O PWM_AB sense C O 5 BEMF_sense_A 7 8 PWM BB BEMF sense B 7 BEMF sense C CT 9 V sense 19 V sense DCB 2 sense 11 ENC_PhaseA TxD 0 13 RxD ENC_PhaseB O 13 ENC_Index TOGGLE SW
14. that proper operation is difficult to achieve The BLDC Motor Control Drive is designed with switching times at the higher end of this range to minimize noise Anti parallel diode softness is also a primary design consideration If the anti parallel diodes in an off line motor drive are allowed to snap the resulting di dts can cause noise management problems difficult to solve In general the peak to zero di dt should be approximately equal to the di dt applied to turning off the anti parallel diodes The FDS3672 MOSFETS used in this design are targeted at this kind of reverse recovery 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 28 Freescale Semiconductor 3 Phase Bridge 18457 Si _ Jv z19esa4 a SH 90 V 2192504 MIS 029 bo 4 sod LZ6EEOW O N9d 10 1 20 1nO LON ZON 9ON V3SVHd 987199 66 5 SH _ 9 SH od lt 1008 Od 9 ST S SH 8d 1v 9 SH 8d 1008 9 S1 Vd S SH Vd 9 SH Vd 1008 Wd INI AZt LVEA 4 1 Phase Output Figure 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0
15. 3 Phase BLDC PMSM Low Voltage Motor Control Drive User Manual Rev 0 04 2009 e freescale com 27 freescale semiconductor 3 Phase BLDC PMSM Low Voltage Motor Control Drive User Manual by Petr Frgal Freescale Semiconductor Czech System Center To provide the most up to date information the revision of our documents on the world wide web will be the most current Your printed copy may be an earlier revision To verify that you have the latest information available refer to www freescale com The following revision history table summarizes the changes contained in this document For your convenience the page number designators have been linked to the appropriate location Revision History Revision Date Level Description Number s 10 2008 0 Initial release N A 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 3 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor Figure 1 1 Figure 1 2 Figure 1 3 Figure 2 1 Figure 3 1 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 4 7 Figure 4 8 Figure 4 9 Figure 4 10 Figure 4 11 Figure 4 12 Figure 4 13 Figure A 1 Figure A 2 Figure A 3 Figure A 4 Figure A 5 Figure A 6 Figure A 7 Figure A 8 Figure A 9 Figure A 10 Figure C 1 Figure C 2 Figure C 3 Figure C 4 List of Figures System CODO Dace ROCA C
16. 4 A full scale Both bus and phase leg currents are measured An overcurrent trip point is set at 3 75 A There are controller daughter boards available with these controllers MC56F8013 23 LQFP32 MC9S08ACI6 LQFP44 e MCESIAC256 LQFP80 MC9808MP16 LQFP48 56 8006 LQFP32 More controller daughter boards are planned Check the website www freescale com for more information 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 17 Electrical Characteristics INPUTS ENCODER HALL EFFECT MOTOR J2 J3 J6 J1 USB SWITCHES 3 PH MOSFET USB SCI amp BRIDGE BRIDGE LEDs CAN MOSFET DRIVERS PH LAYER 2 5 m gt SIGNAL CONDITIONING SUPPLIES DC BUS PHASE voltages and currents 5V 3 3V 3 3VA BEMF DAUGHTER BOARD Legend Module J Connector Figure 2 1 Block Diagram 2 2 Electrical Characteristics The electrical characteristics in Table 2 1 apply to operations at 25 C with a 24 V DC power supply voltage Maximal value of the input voltage can be higher than 24 V A 50 V maximal input voltage value is allowed but the DC bus and BEMF sensing circuits need to be modified The divider resistors in these circuits need to be changed to change sensing range up to 50 V if required It prevents scaled quantities exceed
17. 75 GND 1 65V REF ND ND ND LsFET 3 3VA ldcb 5 O R81 7 5K DC Bus Current Sensing mE R82 MBROS20LT1G A Sense DCB2 AME 1 6K AMP OUT I sense 220 OHM R103 4 R83 RE 1 657 1 659 Imax Sense DCB1 KAR ANA AMP N OpAmp is within 3PP A Imax 4A 220 OHM mens ped 7 5K Figure 4 2 Bus Feedback 4 4 Overcurrent Undervoltage and Other Safety Functions The MC33927 provides overcurrent and undervoltage functions Figure 4 2 Bus current feedback is filtered to remove spikes and this signal is fed into the MC33927 current comparator Therefore when bus current exceeds 3 75 A all six output transistors are switched off Once a fault state has been detected all six gate drivers are off until the fault state is cleared by the low level on RESET pin or by switching the board off Then you can switch the power stage on The undervoltage function is implemented internally The MC33927 s supply voltage is sensed internally If this voltage is lower than 8 V the hold off circuit is evaluated and an interrupt is generated if set 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 31 Back EMF Signals The MC33927 safety functions keep the driver operating properly and within safe limits Current limiting by itself however does not necessarily ensure that a board is operating within safe thermal limits The MC33927 has a thermal warning feature If the temperatu
18. ADPS ACMP PTG1 KBIP1 gt 33 PTD2 KBIP2 ACMPO PTG2 KBIP6 GND PTG3 KBIP7 XTAL PTGA XTAL 2 IRQ TPMCLK EXIAL IRESET JM 3 BKGD MS RESET E aes 36 BKGD MS E VUSB33 3 3V D 2 9 USBDN 2 8 USBDP R61 33 OHM NNN NNW D 555 TP23 MC9S08JM60CFGE R62 33 OHM D8 R63 HSMG C170 270 OHM GND TP24 D9 R64 3 3V 3 3V 3 3V 2 1 Ane HSMY C170 270 OHM E cm cb 4 TUF 0 47UF Figure A 7 Micro Headers amp Other Circuits USB SCI Bridge 3 3V 10 0uF 0 1UF J9 e BKGD MS 1 2 o 3 55 4 RESET JM Lo 04 6 o 3 3v HDR 2X3 3 3V GND R59 0 OHM C15 22PF 22PF sv GND 1 9 4 19 0 5 10104 WSIWd 2Q18 9seud e VLS CAP DCB pos DCB pos vis R65 0 OHM PWM AT PWM AB U6 10R 10R 25 TP26 R68 Source AT DRV_EN EN1 399 8657 10K PWM BT pwm ORV EB REE 7008 iE INT D11 MBRO0520LT1G TP27 0 1 gt gt amp gt 870 5 48 64 25 mE HS G 47 A AA gt Gate PA HS
19. B D2 lt ve 0 3 3V 270 0HM 5 170 LED Yellow U4C PWM2 74AC14 D3 b G ND 270 OHM 5 170 LED Yellow U4D PWM3 74 14 RSI E v 270 _ HSMY C170 LED Yellow U4E PWMA 05 b 0 ND 270 HSMY C170 LED Yellow U4F PWM5 56 06 CB lt 5 gt AX 2 270 5 170 LED Yellow Figure 4 6 PWM LED Indication 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 36 Freescale Semiconductor Power Supplies and Voltage Reference 4 8 Power Supplies and Voltage Reference The 3 Phase BLDC PMSM Low Voltage Motor Control Drive contains devices that require various voltage levels of 5 V or 43 3 V 4 8 1 Input Power Supply The bus can be supplied from two input connectors J2 and the J3 power jack The power source should be able to deliver at least 4 A The DC bus has reverse polarity protection The MC33927 driver is supplied directly from the DC bus The 5 V power supply is served from bus voltage CON 2 TB OB C34 0 1UF POWER JACK 12 50V 5A Figure 4 7 DC Bus Input Circuitry 4 8 2 5 V Power Supply The 5 V level is generated by means of the LM2594HVM switching step down regulator see Figure 4 8 which generates this level from bus voltage This converter can supply up to 500 mA This voltage level se
20. CEPTABLE R4 R6 R9 R12 R16 R17 1 6 Resistor 1 8 W 1 Bene ANY ACCEPTABLE R20 R23 R25 R29 4 30 Resistor 1 8 W 1 ANY ACCEPTABLE size 0805 1 R22 R28 R31 3 3 kO Resistor 1 8 W 1 ANY ACCEPTABLE size 0805 R27 R104 21 1 5 Resistor 1 8 W 1 ANY ACCEPTABLE size 0805 R32 R36 R39 R41 1 Resistor 1 8 W size 0805 ACCEPTABLE R33 R37 R42 24 Resistor 1 80 W size 0805 ACCEPTABLE id de i E 1 8 kO Resistor 1 8 W size 0805 ANY ACCEPTABLE 120 Resistor 1 8 W size 0805 ANY ACCEPTABLE R40 R59 R65 R89 0 Resistor 1 8 W size 0805 ANY ACCEPTABLE R44 R47 R49 R51 R54 R56 R63 R64 270 Q Resistor 1 80 W size 0805 ANY ACCEPTABLE 4 7 Resistor 1 8 W size 0805 ANY ACCEPTABLE R61 R62 33 O Resistor 1 8 W size 0805 ANY ACCEPTABLE O a ad x e 10 Resistor 1 8 W size 0805 ANY ACCEPTABLE Bug uU 10 kO Resistor 1 8 W size 0805 ANY ACCEPTABLE ERCIM R77 1 1 Resistor 1 8 W 1 96 ANY ACCEPTABLE Size 0805 i size 0805 ANY ACCEPTABLE WELWYN R85 R88 100 MQ Resistor 1 size 2512 COMPONENTS LR2512 R10FW LIMITED R90 R93 SW1 SW2 680 Resistor 1 8W 1 ANY ACCEPTABLE size 0805 820 Resistor 1 8 W size 0805 ANY ACCEPTABLE 20 mA 32 V Touch Key C amp K COMPONENTS KSC621JLFS 20 mA 20 V Toggle Switch 3 state COMPONENTS TL39P0050 20 mA 32 V Touch Key C amp K COMPONENTS KSC341J LFS TP1 TP45 _
21. E S SAN S D Res e 1 252 TP31 2 1004 14 so 155 E 12 19 20 20 mas 5 Spas CI R37 8 6 8 E i 8 vo MOST R43 642 RAI z go 3 TP34 0 i m H s 5 4 0 Gos R96 R97 TP40 2122 0 dn Gp TP39 su TOGGLE 9 2 g UP 1542 DOWN d oz 22 2 DI 0203 04 05 06 Rss DI pig map ode PM 0 i 2 3 4 5 PWM USER I T 3 a4 _ 4 Figure C 3 Board Silkscreen Top Layer 1 9 4 9 0 10002 10104 WSIWd 2Q18 1 12 50 5 J2 Ji MOTOR J3 J10 USB J9 BDM J8 J7 1 J6 ENCODER J4 CAN J5 1 20 19 20 19 Figure C 4 Board Silkscreen Bottom Layer 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 64 Freescale Semiconductor 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 G
22. FET LSFET END END Figure A 8 MOSFET Drivers ejeoseoJ4 0 5 10104 INSIWd 2Q18 DCB pos DCB neg GND LSFET r 9 9 ooo Wana IGN Q3 Q4 Q5 MEE Gate A Gate BT Gate CT FDS3672 FDS3672 FDS3672 Lee Lee C32 Ts Phase 4 Phase_B Phase C33 ooo 100 0 1UF Q6 Q7 Q8 m MEE MENT Gate AB Gate BB Gate CB FDS3672 FDS3672 FDS3672 aN Lee Lee I sense 1 A I sense B1 A sense C1 2 R85 R86 2 R87 0 1R 0 1R 0 1R ___ sense I sense 2 e e ANI R88 0 1R LSFET Sense DCB1 Sense DCB2 Figure A 9 Power Circuit LSFET 1 9 4 0 5 10104 5 C36 1 65V REF 3 3V 3 3VA 5V GND GNDA D17 V dcb 45V lt 3 3V TP35 TP36 TP37 5V us MBR0520LT1G
23. High level CAN voltage input output 5 GND Power supply ground 6 No Connect 7 No Connect 8 No Connect 9 No Connect 10 No Connect 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 22 Freescale Semiconductor Signal Descriptions 3 2 4 Encoder Hall Effect Interface J6 The 3 Phase BLDC PMSM Low Voltage Motor Control Drive contains an encoder hall effect interface for position and speed sensing The encoder hall effect interface is located on the right edge of the board The circuit is designed to accept 3 3 V to 5 V encoder or hall effect sensor inputs Input noise filtering is supplied on the input path to the encoder hall effect interface Table 3 4 shows the encoder hall effect interface pin description Table 3 3 Encoder Hall Effect Interface J6 Signal Descriptions Pin Signal Name Description 1 5V Supplies power from the board to either encoder or hall sensors 2 GND Encoder or hall sensors ground 3 PHASE A Encoder or hall sensors phase A input 4 PHASE B Encoder or hall sensors phase B input 5 INDEX Encoder index or hall sensors C input 3 2 5 Daughter Board Connectors J7 and J8 Signal inputs and outputs for interconnection with different types of daughter boards are situated on two 20 pin connectors located on the board s front side Figure 3 1 shows pin assignments This figure shows the physical layout of the connectors The physical view a
24. ITCH 1 O 15 O TOGGLE_SWITCH_ON2 DRV_EN D 15 ISS UP_SWITCH O 17 O DOWN SWITCH MOSI 0 17 SCLK USER LED O 19 RESET MISO D 19 GND Figure 3 1 J7 and J8 Connector Physical View 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 25 Signal Descriptions 3 2 6 USB Controller BDM Header J9 It serves for updating the software for JM60 Signals are described in Table 3 6 The BDM header J9 is not populated Table 3 6 USB Controller BDM Header J9 Signal Descriptions Pin Signal Name Description 1 BKGD MS Background debug pin 2 GND Digital ground 3 No Connect 4 RESET JM RESET signal 5 No Connect 6 3 3V Digital 3 3 V power supply 3 2 7 USB Connector J10 USB connector J10 serves for connecting the controller to the host PC via a virtual serial port Signals are described in Table 3 7 Table 3 7 USB Connector J10 Signal Descriptions Pin Signal Name Description 1 No Connect 2 UDSBDN Negative USB differential signal 3 UDSBDP Positive USB differential signal 4 GND Digital ground 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 26 Freescale Semiconductor Chapter 4 Design Consideration 4 1 Overview The 3 Phase BLDC PMSM Low Voltage Motor Control Drive is designed for software development In addition to the hardware needed to run a motor a variety of feedback signals that facilitate control algorithm
25. R REOR Ree Rae 12 3 Phase BLDC PMSM Low Voltage Motor Control 13 3 Phase BLDC PMSM Low Voltage Motor Control Drive Setup 15 Bock Dagia ROS Sede Saga 18 J7 and Connector Physical 25 dioc i 000 2 29 co PC pm 31 Back EMF Sensing Phase de Phase Guirent DEBIDO uy CHR C CARERE uha 33 up ns ee eer er 36 Bicester 36 Bus Input COIS auda 37 ERES eee ees NERIS RR 37 3 3 5 VA Power 38 1 65 V Reference 38 REESE 39 MD 40 Gontrol SE babi See ce Ls 41 1 44 Analog Sensing Phase Current Sensing 1 45 Analog Sensing Back EMF Sensing 1 46 Micro Headers amp Other Circuits Encoder Hall Sensor 4 1 47 Micro Headers amp Other Circuits Switches User and PWMLEDs 1 48 M
26. V REF R90 TP38 68R e hd gt R93 68R C44 0 1UF GNDA GNDA Figure 4 4 Phase Current Sensing 4 7 Test Points and LED Indication Some voltages and currents of the 3 Phase BLDC PMSM Low Voltage Motor Control Drive can be sensed whilst some are connected to the daughter board connector pins Those are back EMF voltage phase current bus power voltage half of bus power voltage bus current PWM signal for all six switches of the 3 phase power bridge and other control signals The four test points are located near the corners of the board and provide a GND signal digital ground for easy oscilloscope attachment As mentioned in previous chapters the board contains more grounds analog and digital The 3 Phase BLDC PMSM Low Voltage Motor Control Drive contains 45 round shape test points to allow the user to easily check the voltage of all important points 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 33 Test Points and LED Indication TP1 Idcb s Bus current output test point scaled at 0 413 V per A of bus current B and shifted by 1 65 V TP2 Ia Phase A current sense resistor test point for node I sense Ia Phase A current sense resistor test point for node sense A2 TP4 Ia s Phase A current output test point for node I sense scaled at 0 413 V per A of phase current A and shifted by 1 65 V TP5 Ib Phase B current sense resistor test point
27. _ __ j i ON Operational Amplifier SOIC 8 SEMICONDUCTOR MC33502DR2G 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 56 Freescale Semiconductor Table B 1 Parts List DESIGNATORS QUANTITY DESCRIPTION MANUFACTURER PART NUMBER PHILIPS u f 6 R FRA FREESCALE 8 bit HCS08 Controller LOFP 44 22 REESSALE MC9S08JM60CFGE 3 Phase ca Driver 54 FREESCALE NATIONAL LM2594HVM 5 0 NO ON Voltage Regulator SOIC 8 SEMICONDUCTOR MC33269D 3 3G 8 MHz Crystal HC49 RAKON A140E 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 57 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 58 Freescale Semiconductor Appendix C 3 Phase BLDC PMSM Low Voltage Motor Control Drive Layouts 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 59 Figure C 1 Board Top Layer 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 2 Board Bottom Layer Figure C Freescale Semiconductor 61 c9 ejeoseoJ4 0 5 10104 INSIWd 2Q18
28. current triggering function A discussion about overcurrent limiting follows in chapter 4 4 Overcurrent Undervoltage and Other Safety Functions In addition the AMP OUT is connected to the daughter board connector J8 pin 11 I sense DCB The shunt resistor is represented by a 0 1 0 resistance Welwyn SMD precision resistor the same as the phase current measurement resistors 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 30 Freescale Semiconductor Overcurrent Undervoltage and Other Safety Functions VLS CAP DCB pos DCB pos vpp vis R65 d 0 OHM U6 055 aan R68 gt gt 9 DRV 398 855 19K EN2 ge gt INT gt INT R98 5g gt 8 5 PA Hs PA HS 5 46 HS 5 1 15 6 TP13 ND 4 RST PB BOOT 4 PB Hs PA HS PB HS S 27 DCB pos PB HS PB LS PC HS 8 R23 PC BOOT PA LS PC HS IK PB 15 PC HS S 36 PC LS IS 3 3V 8 DC Bus 36 3V CS lt V sense DCB 2 SI PHASEB 10 SCLK PHASEA V 5 RT S So TP45 1 5 AMP_N AMP_N Nee 1 657 DC Bus 2 18 157 AMP_P 6 AMP P Nea 80 us NC3 V_sense_DCB 2 a NC2 2 NC1 R104 4 5 UP UE AMP OUT 1 5K R77 R78 Pao OC OUT gt 3 3VO ANA ANN 86 2222 i 7 9 220666 1 0K gt c23 15 0K T dd MC33927 0 1UF 3 GNDA 8 3 09v 8 3
29. development are provided A set of schematics for the drive appears in the following section Circuit descriptions for the drive appear in 4 2 3 Phase Bridge through 4 12 Control Switches One phase leg of the 3 phase bridge is examined in 4 2 3 Phase Bridge Bus voltage and bus current feedback are discussed in 4 3 Bus Voltage and Current Feedback Safety functions are highlighted in 4 4 Overcurrent Undervoltage and Other Safety Functions Back EMF signals appear in 4 5 Back EMF Signals Phase current sensing is discussed in 4 6 Phase Current Sensing The test points description and LED description are in 4 7 Test Points and LED Indication all power supplies and voltage reference are described in 4 8 Power Supplies and Voltage Reference Encoder circuitry is described in 4 9 Encoder Hall Effect Interface The CAN physical layer interface is discussed in 4 10 CAN Interface The USB interface appears in section 4 11 USB SCI Bridge and finally push buttons and the toggle switch are described in 4 12 Control Switches 4 2 3 Phase Bridge The output stage is configured as a 3 phase bridge with MOSFET output transistors It is simplified considerably by an integrated gate driver that has an overcurrent undervoltage and other safety features Figure 4 1 shows a schematic of one phase At the input pull down resistor R99 sets a logic low in the absence of a signal for the low side transistor Open input pull down is important because the power transistor
30. eescale Semiconductor data sheets and or specifications can and do vary in different applications and actual performance may vary over time All operating parameters including Typicals must be validated for each customer application by customer s technical experts Freescale Semiconductor does not convey any license under its patent rights nor the rights of others Freescale Semiconductor products are not designed intended or authorized for use as components in systems intended for surgical implant into the body or other applications intended to support or sustain life or for any other application in 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 a lt gt freescale semiconductor Freescale and the Freescale logo are trademarks of Freescale Semiconductor Inc All other product o
31. eescale Semiconductor Chapter 3 Pin Description 3 1 Introduction Inputs and outputs are located on nine connectors and headers available on the board Three pin motor connector J1 Two power supply input connectors J2 and J3 CAN header J4 Encoder hall effect connector J e Two 20 pin daughter board connectors J7 and J8 USB controller BDM Background Debugger Monitor tool header J9 USB connector J10 Pin descriptions for each connector and header are identified in the following information Figure 3 1 shows the pin assignments for the daughter board connectors J7 and J8 Table 3 4 and Table 3 5 show the signal descriptions The 3 Phase BLDC PMSM Low Voltage Motor Control Drive contains several connectors and headers that serve for the connection of a power supply for motor phases connection and other functions The input power supply attached to the J2 or J3 input must be in the range of 12 50 V DC The output for the motor is done by the three way connector J1 See 3 2 1 Motor Connector J1 for more details Each connector and header is labelled from the bottom side of the board 3 2 Signal Descriptions Pin descriptions are identified in this subsection 3 2 1 Motor Connector J1 Power outputs to the motor are located on connector J1 Phase outputs are labelled A B and C Table 3 1 contains pin assignments Section 1 4 Setup Guide shows how to connect the motor On a permanent magnet synchronous motor any o
32. erman 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 China Ltd Exchange Building 23F No 118 Jianguo Road Chaoyang District Beijing 100022 China 86 10 5879 8000 support asia freescale com For Literature Requests Only Freescale Semiconductor Literature Distribution Center 1 800 441 2447 or 303 675 2140 Fax 303 675 2150 LDCForFreescaleSemiconductor hibbertgroup com Information in this document is provided solely to enable system and software implementers to use Freescale Semiconductor products There are no express or implied copyright licenses granted hereunder to design or fabricate any integrated circuits or integrated circuits based on the information in this document Freescale Semiconductor reserves the right to make changes without further notice to any products herein Freescale Semiconductor makes no warranty representation or guarantee regarding the suitability of its products for any particular purpose nor does Freescale Semiconductor assume any liability arising out of the application or use of any product or circuit and specifically disclaims any and all liability including without limitation consequential or incidental damages Typical parameters that may be provided in Fr
33. etup 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 15 TFI Setup Guide 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 16 Freescale Semiconductor Chapter 2 Operational Description 2 1 Introduction Freescale s 3 Phase BLDC PMSM Low Voltage Motor Control Drive is a 3 phase power stage that will operate with DC input voltages in the range 12 24 V 4 A Together with the daughter boards it provides a software development platform that allows algorithms to be written and tested without designing and building any hardware It supports a variety of algorithms for PMSM and brushless DC BLDC motors The 3 Phase BLDC PMSM Low Voltage Motor Control Drive contains reverse polarity protection circuitry MOSFET gate drive circuits analog signal conditioning low voltage power supplies and bridge MOSFETs The power devices do not need to be mounted on a heatsink Figure 2 1 shows a block diagram The daughter board is connected via two 20 pin rib cage connectors J7 and J8 Figure 3 1 shows pin assignments for the daughter board connectors Power connections to the motor are made on output connector J1 Phase A phase B and phase C are labelled A B and C Power requirements are met by a single external 12 V to 50 V DC power supply Either input is supplied through connector J2 or J3 All connectors are marked on the bottom side of the board Current measuring circuitry is set up for
34. f the 3 phase windings can be connected here For brushless DC motors you must connect the wire color coded for phase A into the connector terminal labelled A and so on for phase B and phase C 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 21 Signal Descriptions Table 3 1 Motor Connector J1 Signal Descriptions Pin Signal Name Description 1 C Supplies power to motor phase C 2 B Supplies power to motor phase B 3 A Supplies power to motor phase A 3 2 2 Power Supply Input Connectors J2 and J3 The power supply input connectors labelled J2 and J3 are located at the left back corner of the board They accept DC voltages from 12 V to 50 V 5 A maximum The J2 connector is a two wire connector the J3 connector is a 2 1 mm power jack for plug in type DC power supply connections The power supply polarity label for connector J2 is located on the bottom side The board has reverse polarity protection Power applied to the board is indicated by a green color 5 V LED This LED is the nearest one located to the reset switch 3 2 3 CAN Header J4 This shows the CAN Controller Area Network bus header pin description The CAN interface is located on the left edge of the board Table 3 2 CAN Header J4 Signal Descriptions Pin Signal Name Description 1 No Connect 2 No Connect 3 CANL Low level CAN voltage input output 4 CANH
35. for node I sense TP6 Ib Phase B current sense resistor test point for node I sense B2 TP7 Ib s Phase B current output test point of node I sense B scaled at 0 413 V per A of phase current B and shifted by 1 65 V 8 Ic Phase C current sense resistor test point for node sense TP9 Ic Phase C current sense resistor test point for node I sense C2 TP10 Ic s Phase C current output test point of node I sense C scaled at 0 413 V per A of phase current C and shifted by 1 65 V TP11 BEMF A Back EMF phase A test point TP12 BEMF A s Back EMF phase A test point scaled at 91 mV per V of phase voltage A TP13 V dcb Bus voltage test point TP14 BEMF B Back EMF phase B test point TP15 V dcb s Bus voltage test point scaled at 91 mV per V TP16 BEMF B s Back EMF phase B test point scaled at 91 mV per V of phase voltage B TP17 BEMF C Back EMF phase C test point TP18 BEMF s Back EMF phase C test point scaled at 91 mV per V of phase voltage TP19 CANTX TX signal for CAN physical layer TP20 CANRX RX signal for CAN physical layer TP21 TxD TxD signal for SCI communication between JM60 and daughter board controller TP22 RxD RxD signal for SCI communication between JM60 and daughter board controller TP23 signal activity on TxD signal TP24 signal activity on RxD signal TP25 PWM AT PWM control signal for top transistor gate of phase A
36. hase C 3 3V 8 Phase C 3 BEMF sense C BEMF A 11 BEMF s TP12 BEMF B TP14 BEMF B s TP16 BEMF_C TP17 BEMF_C_s TP18 6 3V M 6 3V 6 3V R25 30K R28 3 0K GNDA DCB pos V dcb TP13 23 V dcb s 30K TP15 V dcb 2 s R27 TP45 1 5K 3 3V DC Bus 36 3V V sense DCB 1 65V DC Bus 2 18 15V _ a V sense DCB 2 R104 1 5K GNDA Co GNDA Figure A 3 Analog Sensing Back EMF Sensing 1 9 4 Lv 0 5 10104 WSIWd 2Q18 9seud e 5V R32 10K R33 R34 ANA gt gt PhaseA 1 8K 240HM s 470PF 5V GND R36 10K R37 R38 45V gt gt 9 1 8 J6 240HM c oli 470PF 042 5 5V HDR_1X5_M END R41 10K R42 R43 gt gt Index 1 8K 240HM 470PF 5V 5V li 9 0 1UF 2 2UF END CANH 120 OHM HEADERICAN bus termination J5 HDR 1X2 M R39 R40 CANTX CANRX TP19 TP20 SS NIT us 10K 0 OHM CANTX TXD 8 RS 7 CANH CANRX gt gt canl E VREF 2 PCA82C250TD 5V SET GND 0 1UF SV GND Figure A 4 Micro Headers amp Other Circuits Encoder Hall Sensor amp CAN 8v Jojonpuooruueg e5
37. hase bridge driver 13 TxD TxD signal between the JM60 and daughter board 14 RxD RxD signal between the JM60 and daughter board TOGGLE _ ROCCE 15 SWITCH ON1 Toggle switch input switch in position ON1 TOGGLE _ ee 3s 16 SWITCH ON2 Toggle switch input switch in position ON2 17 UP SWITCH Up switch input 18 DOWN SWITCH Down switch input 19 USER LED User LED signal 20 RESET RESET signal only for controller on daughter board and 3 phase bridge driver JM60 reset signal is connected only on BDM connector Table 3 5 Daughter Board Connector J8 Signal Descriptions Pin Signal Name Description 1 GNDA Analog power supply ground 2 3 3VA Analog 3 3 V power supply Analog sense signal that measures the current in phase A It is scaled at 50 V per A 3 sense A of DC bus current Analog sense that measures the current in phase B It is scaled at 0 563 V per A of 4 sense B DC bus current Analog sense signal that measures the current in phase C It is scaled at 0 563 V per 5 sense C A of DC bus current 6 BEMF sense A Analog sense signal that measures phase A back EMF It is scaled at 8 09 mV per V of DC bus voltage 7 BEMF sense B Analog sense signal that measures phase B back EMF It is scaled at 8 09 mV per V of DC bus voltage 8 BEMF sense C Analog sense signal that measures phase C back EMF It is scaled at 8 09 mV per V of DC bus voltage 3 Phase BLDC
38. icro Headers amp Other Circuits Daughter Board Connectors amp RESET 1 49 Micro Headers amp Other Circuits USB SCI Bridge 1 50 MOSFET DIIM8IS TI or 1 51 FONT o raioane i tnae e ELFE 1 52 au E 1 53 eerd a C 60 Board Bonom Laver ux ch eere qase exeat C 61 Board Silkscreen Top LASER dor EA C 62 Board Silkscreen Bottom C 63 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 5 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 1 1 L2 1 3 1 4 2 1 3 1 3 2 3 2 1 3 2 2 3 2 3 3 2 4 3 2 5 3 2 6 ded 4 1 4 2 4 3 44 4 5 4 6 4 7 4 8 4 8 1 4 8 2 4 8 3 4 8 4 4 8 5 Table of Contents Chapter 1 Introduction 3 Phase BLDC PMSM Low Voltage Motor Control Drive About Vite ROBA RR RR ORE CM ee eee ae Chapter 2 Operational Description o tn re ee re ddr d ed e D E pd ED eRe E ecu doc Electrical Charsclenslie8 eee gence eae Chapter 3 Pin Description IRIS WENO 5 5 ahs
39. ing the maximum allowed input voltage value on the controller input pins WARNING If an input voltage higher than 24 V is applied the controller daughter board can be damaged 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 18 Freescale Semiconductor Electrical Characteristics Table 2 1 Electrical Characteristics Characteristic Symbol Min Typ Max Units DC input voltage Vac 12 24 V Quiescent Current loc TBD mA Logic 1 Input Voltage 1 5 1 7 V Logic 0 Input Voltage ViL 0 9 1 V Input Resistance Rin 10 kQ Analog Output Range Vout 0 3 3 V Bus Current Sense Voltage Icense x 413 mV A Bus Current Sense Offset loffset 1 65 V Bus Voltage Sense Voltage VBus 91 mV V Bus Voltage Sense Offset Voffset 0 V Bus Continuous Output Current Ic 3 75 A Total Power Dissipation per MOSFET Pp TBD W Dead Time set by SW MC33927 0 15 us Full sensing range 3 3 V corresponds to 36 3 V Overcurrent threshold is set at this level The values were measured at 25 C for other temperatures the values may be different Default dead time is 15 us Dead time depends on the timebase of the MC33927 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 19 Electrical Characteristics 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 20 Fr
40. main board powers the controller daughter board Plug a standard AB type USB cable into your PC and into the 3 Phase BLDC PMSM Low Voltage Motor Control Drive Then install the USB driver onto your PC to enable using FreeMASTER Follow the instructions in the USB driver install doc to properly install the USB driver WARNING If an input voltage higher than 24 V is applied the controller daughter board can be damaged 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor Setup Guide Freescale Semiconductor 3 Phase BLDC PMSM Low Voltage Motor Control Drive Optional J9 Power Supply Connector for gt Controller USB controller J3 Daughter board 4 10 USB C c Power Connector Supply 12 24 V Daughter board J7 g Connectors Daughter board BDMJTAG Connectors Connector Leni EE J4 Phase C 1 Motor CAN Phase 2 n pyl a Connector Controller Daughter board is plugged into Phase A 3 Di the 3 Phase BLDC PMSM Low Voltage ce Motor Control Drive c 45V GND HALL A ENCODER PHASE A HALL B ENCODER PHASE B HALL C ENCODER INDEX Hall Encoder Connector 10010 Figure 1 3 3 Phase BLDC PMSM Low Voltage Motor Control Drive S
41. n LED 6 PWM LED diodes and SCI activity LED diodes Up down toggle switches Reset push button 1 2 About This Manual Key items are in the following locations in this manual Setup instructions 1 4 Setup Guide Schematics Appendix A 3 Phase BLDC PMSM Motor Control Drive Schematics Pin assignments Chapter 3 Pin Description 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 11 About This Manual Pin by pin description 3 2 Signal Descriptions Description of reference design aspects of the board s circuitry Chapter 4 Design Consideration BDM or JTAG EOnCE INTERFACE WORKSTATION CONTROLLER DAUGHTER BOARD BLDC PMSM LOW VOLTAGE MOTOR CONTROL DRIVE Figure 1 1 System Configuration 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 12 Freescale Semiconductor Warnings 59 TT ut n 1 OW freescale Cd be p of i 14 m A mo d 3 si wy 5 B 2 A natu Figure 1 2 3 Phase BLDC PMSM Low Voltage Motor Control Drive 1 3 Warnings This development tool set operates in an environment that includes rotating machinery Be aware Wear safety glasses avoid ties and jewelry use shields Powe
42. r devices and the motor can reach temperatures hot enough to cause burns 1 4 Setup Guide Setup and connections for the 3 Phase BLDC PMSM Low Voltage Motor Control Drive main board are straightforward A controller daughter board connects to the main board via two 20 pin daughter board connectors The system can be powered by a 12 24 V DC power supply For safety reasons and ease of making measurements use a regulated DC power supply Limit the power supply to under 5 A Figure 1 3 depicts a complete setup 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 13 Setup Guide The step by step setup procedure is as follows 1 Plug controller daughter board into the main board Connect the motor connector to the output connector J1 located along the back edge of the board Phase A phase B and phase C are labelled on the bottom of the board For BLDC motors it is important to put the wire color coded for phase A into the connector terminal labelled A and so on for phase B and phase C Connect an encoder or hall sensor connector to the encoder hall sensor interface 16 Connect a current limited DC power supply to connector J2 or J3 located on the left back edge of the board The input voltage range is 12 24 V DC Current limit should be set for less than 5 A Only one power input is required Apply power to the main board The green power on LED D19 located on the front edge lights The
43. r service names are the property of their respective owners The ARM POWERED logo is a registered trademark of ARM Limited ARM7TDMI S is a trademark of ARM Limited Java and all other Java based marks are trademarks or registered trademarks of Sun Microsystems Inc in the U S and other countries The Bluetooth trademarks are owned by their proprietor and used by Freescale Semiconductor Inc under license Freescale Semiconductor Inc 2004 All rights reserved BLDCPMSMUM Rev 0 04 2009
44. re rises above 170 C on one of the three detectors then an interrupt is generated if set The MC33927 driver has also other safety features such as desaturation detection phase error framing error write error after the lock and exiting RESET AII these features can be configured through SPI to trigger interrupts Detailed information is available in the driver datasheet 4 5 Back EMF Signals Back EMF signals are included to support sensorless algorithms for BLDC motors and dead time distortion correction for sinusoidal motors Referring to Figure 4 3 which shows circuitry for phase A the raw phase voltage is scaled down by a voltage divider consisting of R20 and R22 Output from this divider produces back EMF sense voltage BEMF sense A Resistor values are chosen such that a 36 3 V of phase voltage corresponds to a 3 3 V A D input The BEMF sense A is led directly to the daughter board connector J8 pin 6 without any offset correction see Figure A 6 The V sense DCB and V sense DCB 2 are provided by the R23 R27 and R104 resistor divider from the bus voltage see Figure 4 2 BEMF_A 11 fpf gt R20 BEMF A s 30K TP12 3 3V 8 Phase A 36 3V BEMF sense A f R22 3 0K x GNDA Figure 4 3 Back EMF Sensing Phase A 4 6 Phase Current Sensing Sampling resistors provide phase current information for all three phases Because these resistors sample the current in the lower phase legs
45. rol Drive Rev 0 10 Freescale Semiconductor Chapter 1 Introduction 1 1 3 Phase BLDC PMSM Low Voltage Motor Control Drive Outline Freescale s 3 Phase BLDC Brushless DC PMSM Permanent Magnet Synchronous Motor Low Voltage Motor Control Drive is a 12 24 V DC 4 A off line power stage that as a main board together with a daughter board creates a single unit for developing BLDC PMSM motor control applications With one of the available daughter boards accommodating a selected microcontroller it provides a ready made software development platform for one third horsepower off line motors Feedback signals are provided that allow a variety of algorithms to control 3 phase PMSM and BLDC motors Figure 1 1 shows an illustration of the system architecture Figure 1 2 is a picture of the main board The board features Power supply voltage input 12 24 V DC extended up to 50 V see chapter 2 2 Electrical Characteristics for details Output current 4 A Power supply reverse polarity protection circuitry 3 phase bridge inverter 6 MOSFET s 3 phase MOSFET gate driver with overcurrent and undervoltage protection 3 phase and DC bus current sensing shunts DC bus voltage sensing 3 phase back EMF voltage sensing circuitry Low voltage on board power supplies Encoder hall sensor sensing circuitry Motor power and signal connectors 2 connectors for daughter board connection CAN physical layer USB interface User LED power o
46. rves the MC33269D linear regulator encoder and CAN physical layer interface If the LM2594HVM converter operates properly the D19 green LED is lit V dcb 5V TP35 TP36 Figure 4 8 5 V Power Supply 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 37 Encoder Hall Effect Interface 4 8 3 3 3 V Power Supply An important voltage level for this board is 3 3 V This voltage level is obtained from the MC33269D linear voltage regulator and can supply up to 800 mA Figure 4 9 The 3 3 V level is used to supply the on board logic inverter and JM60 controller It is connected to the daughter board connector J7 D17 4 3 3V U8 MBRO520LT1G e GND ADJVOUT1 VIN VOUT2 2 NC1 VOUT3 8 2 VOUT4 MC33269D 3 3 Figure 4 9 3 3 VA 5 VA Power Supply 4 8 4 3 3 VA Power Supply The 43 3 VA power supply is drawn from the 43 3 V level by passive filtering through Lland L3 see Figure 4 9 Maximum current load should not exceed 200 mA This voltage level serves the on board operational amplifiers and voltage reference It is also connected to the daughter board connector J8 4 8 5 41 65 V Reference The 1 65 V reference is generated from the 43 3 VA level simply by the voltage divider see Figure 4 10 This reference serves to shift the DC bus and phase current sensing values It can sink up to 30 mA 3 3VA 1 65V REF TP38 GNDA GNDA Figure 4 10
47. s 13 0 5 10104 INSIWd 2Q18 3 3V SW1 2 KSC621J 3 3V R48 4 7K Sn R50 2 1 8K KSC621J 3 3V sw3 R96 TL39P0050 4 7K R97 TOGGLE SWITCH lt lt 1 8K GND GND uis GND 3 3V I gt gt DOWN SWITCH 3 3V R52 4 7K R53 gt gt TOGGLE SWITCH_ON2 1 8K 3 3V 9 gt R55 270 OHM N D7 HSMG C170 WW USER LED LED Green N R57 q Q2 USER MMBT2369ALT1G 4 7K GND PWM AT AB lt PWM PWM PWM CT CB lt 3 3V 42 0 1UF 270 OHM HSMY C170 LED Yellow PWM1 U4B 14 D2 1 2 ANZ 4 0 3 3V 270 HSMY C170 LED Yellow U4C PWM2 74AC14 R49 D3 ANA 1 po 270 OHM 170 LED Yellow PWM3 74 14 54 1 2 4 0 3 3V 270 HSMY C170 LED Yellow U4E 14 05 270 OHM HSMY C170 LED Yellow PWM5 74AC14 R56 D6 4 2 270 HSMY C170 LED Yellow Figure A 5 Micro Headers amp Other Circuits Switches User and PWM LEDs 1 9 4 6v 0 5 10104 WSIWd 2Q18 9seud e LIGHT TOUCH PUSH BUTTON 0 3 3V
48. s must stay off in the case of a broken connection or an absence of power on the daughter board Gate driver inputs are 3 V compatible A Freescale device the MC33927 supplies the gate drive The MC33927 also provides undervoltage hold off and overcurrent Undervoltage hold off threshold value is 8 V The MC33927 has an implemented dead time insertion which can be configured using SPI The default dead time value is typically 15 Current limiting and undervoltage hold off are discussed further in 4 4 Overcurrent Undervoltage and Other Safety Functions One important design decision in a motor drive is the selection of gate drive impedance for the output transistors In Figure 4 1 resistor R69 R70 diode D11 and the MC33927 nominal 100 mA current sinking capability determine gate drive impedance for the lower half bridge transistor A similar network is used on the upper half bridge These networks set the turn on gate drive impedance at approximately 100 Q and turn off gate drive to approximately 100 mA These values produce transition times of approximately 285 ns Transition times of this length represent a carefully weighed compromise between power dissipation and noise generation Generally transition times longer than 250 ns tend to get power hungry at non audible 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 27 3 Phase Bridge PWM rates transition times under 50 ns create di dts so large
49. see Figure 4 13 Two push buttons up down are directly connected to the daughter board connector J7 One push button RESET is provided for setting the daughter board controller RESET input pin to logic level low The RESET signal is connected to the 3 phase driver and to the daughter board connector J7 A toggle switch is connected to the daughter board connector J7 too This toggle switch has 3 stable positions two on states in edge positions and one off state in the middle position 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 40 Freescale Semiconductor 3 3V 9 R45 4 7K S R46 1 ANY SWITCH 1 8K KSC621J YT 3 3V 9 R48 4 7K s R50 1 ANY DOWN SWITCH 1 8K KSC621J ND 3 3V 3 3V sw3 R96 TL39P0050 R52 4 7K 4 7K R97 R53 TOGGLE SWITCH ON1 lt lt 1 8K 1 8K GND RESET 3 3V 5 4 GND C20 LIGHT TOUCH PUSH BUTTON 0 1UF GND Figure 4 13 Control Switches 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 gt gt TOGGLE SWITCH ON2 RESET Control Switches Freescale Semiconductor 41 Control Switches 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 42 Freescale Semiconductor Appendix A 3 Phase BLDC PMSM Motor Control Drive Schematics 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 43 vv ejeoseoJ4 0 5 1010
50. ssumes that the board is oriented in such way that its title can be read from left to right Table 3 4 and Table 3 5 contain lists of signal descriptions for connectors J7 and J8 Table 3 4 Daughter Board Connector J7 Signal Descriptions Pin Signal Name Description 1 GND Digital and power ground 2 3 3V Digital 3 3 V power supply 3 CANTX CAN transmit data input 4 CANRX CAN receive data output 5 AT Gate drive signal for the top half bridge of phase A A logic low turns on phase A s top switch Gate drive signal for the bottom half bridge of phase A A logic high turns phase A s 6 PWM AB bottom switch on 7 PWM BT Gate drive signal for the top half bridge of phase B A logic low turns on phase B s top switch 8 PWM BB Gate drive signal for the bottom half bridge of phase B A logic high turns phase B s bottom switch on 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 23 Signal Descriptions Table 3 4 Daughter Board Connector J7 Signal Descriptions Pin Signal Name Description 9 PWM CT Gate drive signal for the top half bridge of phase C A logic low turns on phase C s top switch 10 PWM CB Gate drive signal for the bottom half bridge of phase C A logic high turns phase C s bottom switch on 11 OC Overcurrent signal from 3 phase bridge driver 12 INT Interrupt signal from 3 p
51. st point TP41 GND Ground test point TP42 GND Ground test point TP43 GNDA Analog ground test point TP44 GNDA Analog ground test point TP45 V dcb 2 s Half of bus voltage test point scaled at 45 5 mV per V This board also contains ten LEDs as indicators D1 PWM AT indication LED activated on low level D2 PWM AB indication LED activated on high level D3 PWM BT indication LED activated on low level D4 PWM BB indication LED activated on high level D5 CT indication LED activated on low level D6 PWM CB indication LED activated on high level D7 User LED diode for user defined purposes activated on high level D8 Indicated communication activity on TxD pin D9 Indicated communication activity on RxD pin D19 Indicates that the 5 V level is properly generated 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 35 Test Points and LED Indication For more details see Figure 4 5 3 3V 5V R91 820 OHM D7 HSMG C170 USER LED LED Green D19 HSMG C170 LED Green Q2 USER LED MMBT2369ALT1G GND 2 R55 270 OHM Figure 4 5 LED Indication For more details see Figure 4 6 U4A 74 14 R44 TP23 D8 R63 2 1 PTBO HSMG C170 270 OHM TP24 D9 R64 2 1 4 1 HSMY C170 270 OHM PWMO 270 HM HSMY C170 LED Yellow GND PWM1 U4
52. test point on connector J7 pin TP26 AB PWM control signal for bottom transistor gate of phase A test point on connector J7 pin TP27 PWM BB PWM control signal for bottom transistor gate of phase B test point on connector J7 pin 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 34 Freescale Semiconductor Test Points and LED Indication TP28 PWM CT PWM control signal for top transistor gate of phase C test point on connector J7 pin TP29 PWM BT PWM control signal for top transistor gate of phase B test point on connector J7 pin TP30 CB PWM control signal for bottom transistor gate of phase C test point on connector J7 pin TP31 SS Chip select signal for SPI communication TP32 MOSI MOSI signal for SPI communication TP33 SCLK Clock signal for SPI communication TP32 MISO MISO signal for SPI communication TP35 V dcb Bus voltage test point TP36 5V This point is the output of the U7 switching step down inverter It serves as the power supply for the on board encoder and CAN physical layer interface TP37 3 3V This point is the output of the U8 linear voltage regulator It serves as the power supply for the on board logic inverter and JM60 controller and as the source for generating 43 3 VA It is connected to the daughter board connector J7 TP38 1 65V_REF Reference voltage test point TP39 GND Ground test point TP40 GND Ground te
53. to the CAN bus header J4 Shorten the jumper terminal J5 to attach the bus end termination resistor This resistor ensures that data will not be reflected at the bus end The schematic diagram of the CAN is in Figure 4 12 3 Phase BLDC PMSM Low Voltage Motor Control Drive Rev 0 Freescale Semiconductor 39 USB SCI Bridge 120 OHM CANTX CANRX TP19 TP20 PCA82C250TD Figure 4 12 CAN Interface 4 11 USB SCI Bridge The 3 Phase BLDC PMSM Low Voltage Motor Control Drive provides a USB interface by the use of USB level converter circuitry referred to in the USB SCI bridge schematic diagram in Figure A 7 The core of the USB interface is the MC9S08JM60 controller and it s universal serial bus USB device controller The USB device controller module is based on the Universal Serial Bus Specification Rev 2 0 and provides a single chip solution for full speed 12 Mbps USB device applications The USB level converter transitions the SCI UART s 3 3 V signal levels to USB compatible signal levels and connects to the host s serial port via the standard USB connector J10 The pinout of the USB connector is listed in Table 3 7 To enable proper working of the serial interface code for the USB SCI bridge should be loaded in the JM60 controller LED diodes D8 and D9 indicate communication activity 4 12 Control Switches Three on board push button switches and one toggle switch are provided for the user s program control
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