BLDC 868 v52

Drives & Control June 2003A. Jansen1

Brushless DC Motor Control

withC868 and

CAPCOM6


Agenda Basics of a BLDC Motor

TopologyBLDC Motor with Hall Sensors

BLDC Motor with Hardware BEMF-Detection

BLDC Motor Sensor less Control

Switching Pattern for Driving a BLDC

How to use the CAPCOM6E for a BLDC

Introduction CAPCOM6E for BLDC purpose

CAPCOM6E & ADC


Electrical Motor Types

ElectricMotor types

AC

Asynchronous Synchronous

Induction

StepperSynchronousPMSM Switched Rel.

DC


BLDCBasics


Basics of a BLDC Motor

DC Motor with 3 Brushes

VW

UU

VW

+

-

3-Phase Brush-less DC Motor

According to the theory of DC machine, the motor rotational speed can be written as follows:

N = ( Ud - I R ) / (Ke )While,

“N” stands for the motor rotational speed“Ud” stands for the DC voltage applied to the motor windings“R” is the pure resistance of the winding while “I” stands for the winding current “Ke” is the magnet coefficient while “” stands for the motor magnetic flux

From the above formula, there are two methods to change the speed of DC motor: One is to change the DC voltage of the motor windings (Ud), the other one is to change the magnetic flux of the motor (). As the BLDC motor has permanent magnet rotor, only the first method can be used in practical application. The principal of generating variable DC voltage is to use PWM for chopping: change the duty cycle of the PWM voltage, proportionally change the DC voltage.

N

S


How an Inverter Turns a BLDC (1)

C+

B-

11

0

A’

B’

B C

C’

A

NS



C+

B-

11

0

A’

B’

B C

C’

A

NS



C+

B-

A’

B’

B C

C’

A11>>0

0

N

S



C+

A-

10

0

A’

B’

B C

C’

A

NS



B+

A-

A’

B’

B C

C’

A

N

S

1>>00

0



B+

A-

A’

B’

B C

C’

A

NS

1>>00

0


BLDC with Hall Sensors – Switching Pattern

Typical Switching Pattern for a BLDC Hall Sequence depends on motor construction Output pattern levels depends on inverter topology


BLDC withHall Sensors


BLDC with Hall Sensors -- Topology Typical Circuit Block Diagram

Hall Sensors detect the position Over current protection and control via ADC

Hall Sensor

C868

+-

HV Driver

V+

M otorCC60CO UT60

CC61CO UT61

CC62CO UT62CTRAP

CCPOS2

CCPOS1

CCPOS0


Block Diagram CAPCOM6E for BLDC Usage

channel 0

channel 1

channel 2

T12

capture/com pare input / output control

CC62

COUT

62CC

61CO

UT61

CC60

COUT

60

CTRA

P

channel 3T13

CCPO

S0

222

com pare

capture

trapcontrol

1

port control

CCPO

S1CC

POS2

3

noisefilter

com pare m ulti-channel control

com pare


H ardw are N oiseS uppression

ch0 gets capturedvalue for act. speed

ch1 com parefor phase delay

ch2 com parefor tim eout

C C 6x

act. speedC C 60

phase delayC C 61

tim eoutC C 62

C O U T6y

110001C C P O S 2

C C P O S 0 1 1 1 0 0 0

C C P O S 1 0 0 1 1 1 1

C aptureE vent

R esets T 12

Usage of CAPCOM6E to Control a BLDC (1)

BEMF-Detection/Hall Signals

HW-noise filter on CCPOSx inputs (BEMF-signals)


H ard w are N oiseS uppression




C C 6x

act. speedC C 60

phase delayC C 61

tim eoutC C 62

C O U T6y

110001C C P O S 2

C C P O S 0 1 1 1 0 0 0

C C P O S 1 0 0 1 1 1 1

C aptureE vent

R esets T 12




automatic reset of T12 with interrupt

actual speed by capture ch0






C C 6x

act. speedC C 60

phase delayC C 61

tim eoutC C 62

C O U T6y

110001C C P O S 2

C C P O S 0 1 1 1 0 0 0

C C P O S 1 0 0 1 1 1 1

C aptureE vent

R esets T 12






phase delay function on ch1






C C 6x

act. speedC C 60

phase delayC C 61

tim eoutC C 62

C O U T6y

110001C C P O S 2

C C P O S 0 1 1 1 0 0 0

C C P O S 1 0 0 1 1 1 1

C aptureE vent

R esets T 12






phase delay function on ch1

time out function on ch2


Usage of CAPCOM6E – Hall Sensor Mode (1)

Hall n n+1

Hall n+1 n+2

0 0

0 0

1

1

0

1 0H2H1H0

? ?startDead T ime Counterafter edge detection

CCPOSx Inputs for Hallsensor Interface

MCMOUTSH / MCMOUTSL SW programmable state machine



Hall n n+1

Hall n+1 n+2

0 0

0 0

1

1

0

1 0H2H1H0

? ?noise C orrect

expectedHall E vent

comparevalid level

afterDTC count down

CCPOSx Inputs edge detection triggers Dead Time

Counter

MCMOUTSH / MCMOUTSL compare CCPOSx level with programmed

value



Hall n+1 n+2

Hall n+1 n+2

0 0

0 0

1

1

0

1 0H2H1H0

? !noise C orrect

expectedHall E vent

setCHE -flag

CCPOSx Inputs MCMOUTSH / MCMOUTSL switch to next state on valid edge by

hardware



prepare next state

Hall n+1 n+2

Hall n+2 n+3

0 0

0 0

1

1

0

1 0H2H1H0

? ?wait onedge

CCPOSx Inputs wait on edge

MCMOUTSH / MCMOUTSL prepare next state by software


Usage of CAPCOM6E – Modulation Control (some Choices)

T12.COUT0

M ODT13out

M CM OUTH.1

CTRAP#

1

11

A-1

T12.COUT0

M ODT13out

M CM OUTH.1

CTRAP#

1

11

A-T12.COUT0

M ODT13out

M CM OUTH.1

CTRAP#

1

01

A-

T12.COUT0

M ODT13out

M CM OUTH.1

CTRAP#

11

A-

T12.COUT0

M ODT13out

M CM OUTH.1

CTRAP#

1

10

A-1


Usage of CAPCOM6E – Generate the PWM Pattern for BLDC

T12.COUT2

M ODT13out

M CM OUTH.5

CTRAP#

1

0>0>0>1>1>0>01

T12.CC2

M ODT13out

M CM OUTH.4

CTRAP#

1

1>1>0>0>0>0>11

T12.COUT1

M ODT13out

M CM OUTH.3

CTRAP#

1

1>0>0>0>0>1>11

T12.CC1

M ODT13out

M CM OUTH.2

CTRAP#

1

0>0>1>1>0>0>01

T12.COUT0

M ODT13out

M CM OUTH.1

CTRAP#

1

0>1>1>0>0>0>01

T12.CC0

M ODT13out

M CM OUTH.0

CTRAP#

1

0>0>0>0>1>1>01

1

1

C+

B-

C-

B+

A+

A-

H2H1H0

1



T12.COUT2

M ODT13out

M CM OUTH.5

CTRAP#

1

0>0>0>1>1>0>01

T12.CC2

M ODT13out

M CM OUTH.4

CTRAP#

1

1>1>0>0>0>0>11

T12.CO UT1

M ODT13out

M CM OUTH.3

CTRAP#

1

1>0>0>0>0>1>11

T12.CC1

M ODT13out

M CM OUTH.2

CTRAP#

1

0>0>1>1>0>0>01

T12.CO UT0

M ODT13out

M CM OUTH.1

CTRAP#

1

0>1>1>0>0>0>01

T12.CC0

M ODT13out

M CM OUTH.0

CTRAP#

1

0>0>0>0>1>1>01

1

1

C+

B-

C-

B+

A+

A-

H2H1H0

1



T12.CO UT2

M O DT13out

M CM O UTH.5

CTRAP#

1

0>0>0>1>1>0>01

T12.CC2

M O DT13out

M CM O UTH.4

CTRAP#

1

1>1>0>0>0>0>11

T12.COUT1

M O DT13out

M CM O UTH.3

CTRAP#

1

1>0>0>0>0>1>11

T12.CC1

M O DT13out

M CM O UTH.2

CTRAP#

1

0>0>1>1>0>0>01

T12.COUT0

M O DT13out

M CM O UTH.1

CTRAP#

1

0>1>1>0>0>0>01

T12.CC0

M O DT13out

M CM O UTH.0

CTRAP#

1

0>0>0>0>1>1>01

1

1

C+

B-

C-

B+

A+

A-

H2H1H0

1



T12.COUT2

M ODT13out

M CM OUTH.5

CTRAP#

1

0>0>0>1>1>0>01

T12.CC2

M O DT13out

M CM OUTH.4

CTRAP#

1

1>1>0>0>0>0>11

T12.CO UT1

M O DT13out

M CM OUTH.3

CTRAP#

1

1>0>0>0>0>1>11

T12.CC1

M O DT13out

M CM OUTH.2

CTRAP#

1

0>0>1>1>0>0>01

T12.CO UT0

M O DT13out

M CM OUTH.1

CTRAP#

1

0>1>1>0>0>0>01

T12.CC0

M O DT13out

M CM OUTH.0

CTRAP#

1

0>0>0>0>1>1>01

1

1

C+

B-

C-

B+

A+

A-

H2H1H0

1



T12.CO UT2

M O DT13out

M CM O UTH.5

CTRAP#

1

0>0>0>1>1>0>01

T12.CC2

M O DT13out

M CM OUTH.4

CTRAP#

1

1

T12.CO UT1

M O DT13out

M CM OUTH.3

CTRAP#

1

1>0>0>0>0>1>11

T12.CC1

M O DT13out

M CM OUTH.2

CTRAP#

1

0>0>1>1>0>0>01

T12.CO UT0

M O DT13out

M CM OUTH.1

CTRAP#

1

0>1>1>0>0>0>01

T12.CC0

M O DT13out

M CM OUTH.0

CTRAP#

1

0>0>0>0>1>1>01

1

1

C+

B-

C-

B+

A+

A-

H2H1H0

1

1>1>0>0>0>0>1



T12.CO UT2

M O DT13out

M CM O UTH.5

CTRAP#

1

0>0>0>1>1>0>01

T12.CC2

M ODT13out

M CM O UTH.4

CTRAP#

1

1

T12.CO UT1

M ODT13out

M CM O UTH.3

CTRAP#

1

1>0>0>0>0>1>11

T12.CC1

M ODT13out

M CM O UTH.2

CTRAP#

1

0>0>1>1>0>0>01

T12.CO UT0

M ODT13out

M CM O UTH.1

CTRAP#

1

0>1>1>0>0>0>01

T12.CC0

M ODT13out

M CM O UTH.0

CTRAP#

1

0>0>0>0>1>1>01

1

1

C+

B-

C-

B+

A+

A-

H2H1H0

1

1>1>0>0>0>0>1


Usage of CAPCOM6E – Modulation and Synchronization

CorrectHall Event

M CM P

M CM PS

to m odulationselection

6

write by software6T12pm

T13pm

T12c1cm

T13zm

Flag

T12zm

direct

T12om

SW -Triggerno action

Reset

MC MOUTS L

MC MOUTL



CorrectHall Event

M CM P

M CM PS


6


T13pm

T12c1cm

T13zm

Flag

T12zm

direct

T12om


Reset

MC MOUTS L

MC MOUTL



CorrectHall Event

M CM P

M CM PS


6


T13pm

T12c1cm

T13zm

Flag

T12zm

direct

T12om


Reset

MC MOUTS L

MC MOUTL



CorrectHall Event

M CM P

M CM PS


6


T13pm

T12c1cm

T13zm

Flag

T12zm

direct

T12om


Reset

MC MOUTS L

MC MOUTL



0 0 0

1 1 0 1 0 0

1 0 00 1 0

0 1 1 0 0 0

0 1 0

MCMOUT S L

MCMOUTL

MCMOUTS H

MCMOUT H

C+

B-

11

0

A’

B’

B C

C’

A

N

S



0 0 0

1 0 0 0 0 0

1 0 00 1 0

0 1 1 0 0 0

0 1 0

MCMOUT S L

MCMOUTL

MCMOUT S H

MCMOUTH

C+

B-

A’

B’

B C

C’

A11>>0

0

N

S



0 0 1

1 0 0 0 0 0

0 0 00 1 0

0 1 0 0 1 0

0 1 0

MCMOUT S L

MCMOUTL

MCMOUTS H

MCMOUT H

C+

A-

10

0

A’

B’

B C

C’

A

NS



0 0 1

0 0 0 0 0 1

0 0 00 0 0

0 1 0 0 1 0

0 1 1

MCMOUTS L

MCMOUTL

MCMOUTS H

MCMOUTH

B+

A-

A’

B’

B C

C’

A

N

S

1>>00

0


BLDCSensor less


BLDC in Theory – Back Electro Magnetic Force

Theory UP = (R x i) + (L x di/dt) + eP

where"UP" stands for phase voltage"R" stands for winding resistance"i" stands for actual phase current"L" stands for phase inductance"di/dt" stands for changment of phase current over time"eP" stands for electromagnetic voltage caused by magnet

whilei = 0 and di/dt = 0:UP = eP

by measuring UPa position detectionis possible

iavai

30°

ibvbi

120°


BLDC in Reality (1) – BEMF vs. Current

iav

ai

Real BEMF Voltage and Current: shape depends on magnets, motor speed, voltage


BLDC in Reality (2a) – BEMF vs. Current

Zoom In: BEMF is only visible at active switching

PhaseCurren

t

BEMFVoltag

e


BLDC in Reality (2b) – BEMF vs. Current

Current Commutation in a Coil Freewheeling diode conducts

PhaseCurren

t

BEMFVoltag

e

V+

G ND

CurrentFlow

M otor

V+

G ND

Current FlowFreewheeling

Diode

M otor


BLDC in Reality (3) – All Important Signals

PhaseCurren

t

BEMFVoltag

e


BLDC Sensor less with Hardware BEMF-Detection

Typical Circuit Block Diagram Comparators and RC-Filter detect the BEMF zero

crossing for position detection

C868

RCFilter

virtualStar

-+

-+

-+

+-

HV Driver

V+

M otorCC60COUT60

CC61COUT61

CC62COUT62CTRAP

CCPOS2

CCPOS1

CCPOS0


BLDC Sensor less Using ADC

Typical Circuit Block DiagramUse simple resistor divider and ADC for position detection

C868

+-

HV Driver

V+

M otorCC60COUT60

CC61COUT61

CC62COUT62CTRAP

AN2

AN1

AN0

BEM FDetection


CAPCOM6E & ADC Synchronize ADC on T13

T13 period match can trigger the ADC equidistant sampling of analog

signals exact timing guaranteed by hardware no timing jitter due to software

delays

f(n-1) f(n) f(n+1)

f(n+2)

conversionchannel 0

T13

analogsignal

ADC

start sam plingby hardware


CAPCOM6E & ADC Synchronize T13 on

T12 T13 performs delay

for stable measurement

T13 period match triggers ADC

Useful for Current Measurement E.g. induction

machine

Compare value

T12

T13

CC6x

PhaseCurrent x

synchronizeT13 on T12cm

S tart ADC whensignal is stable after aprogrammable delay


CAPCOM6E & ADC T13PM triggers ADC

Delay between T13PM and high voltage switching event due to driving circuit

Useful for Voltage or Current Measurement E.g. BEMF detection Sample shortly

before power device is switched off (BEMF is noise free)

BEM Fsignal

IGBTdrainvolt.

CC6x

T13Modulation for

Block-Commutation

Delay due toIGBT driv ing circuit

IGBT ’s gate signal

V oltage signal atcurrentless phase

for position detection

S tart ADC sampling


CAPCOM6E & ADC T13PM triggers ADC

Delay between T13PM and high voltage switching event due to driving circuit

Useful for Voltage or Current Measurement E.g. Current in DC link

path Sample shortly before

power device is switched off (current is noise free)

IGBTdrainvolt.

CC6x

T13Modulation for

Block-Commutation

Delay due toIGBT driv ing circuit

IGBT ’s gate signal

DC LinkCurrent

S tart ADC sampling


BLDC Sensor less Using ADC T13 used for

ModulationADC trigger

T12 used for Phase delay

Software (for 60° sector)

With every T13PMthe BEMF voltage is sampled and compared to a BEMF-wave table

When crossing a limit the software generates a CHE-event (1)

Speed reference is captured and phase delay for T12ch1 is calculated

At T12ch1 the pattern for the next sector is switched (2)

BEM FVoltagePhaseC

T13

T12

CurrentPhase C

CurrentPhase A

M easureBEM F-Voltage(Phase C)

M easureDC-Link Current

(Phase A)

M easureVoltage(PhaseB)

1 2

AnalogCom pareValue

Com pareValueT12_ch1


BLDC Sensor less with Current Control T13 used for

ModulationADC trigger

T12 used for Phase delay

Software (for 60° sector)

With every T13PM the ADC alternatively samples BEMF voltage Phase current

The current set value can be controlled by adjusting the PWM duty cycle

BEM FVoltagePhaseC

T13

T12

CurrentPhase C

CurrentPhase A

M easureDC-LinkCurrent(Phase A)

M easureBEM FVoltage(Phase C)

M easureDC-Link Current

(Phase A)

M easureBEM FVoltage(PhaseB)

M easureDC-LinkCurrent(Phase C)

1 2

Com pareValueT12_ch1

AnalogCom pareValue

ControlCurrent Value


BLDC Sensor less Scope Shots

Port pin toggles when BEMF is below limit

BEMFVoltag

e

PhaseCurren

t


Application: Line powered Industrial Drives

Power: 750 W Current: max. 5 A AC Input Voltage: 110 to 264 VAC

Features: 8-bit MCU: C868 with on-chip 8 kB SRAM,

with 8-bit ADC and powerful PWM module CoolSet: TDA61831G instead of a

transformer for 12V supply 6 rugged IGBT DuoPacks EEPROM: 8 kB to store program + stand

alone boot option Optically Isolated Serial Interface to

PC for SW development + boot from PC option

Protection: shut down protection for over current and over temperature

Extension for alternative MCU like XC164 or TC1775

SW environment: Keil Compiler + Debugger or Mini Debugger (free software)

Board can be used for current/torque or speed control

Supports Hall-Effect sensors or sensor-less control

High Voltage 3-Phase Brushless DC / Induction MotorReference Design and Development Kit


Low Voltage 3-Phase Brushless DC / Induction MotorReference Design and Development Kit

Application: Industrial & Automotive Drives

Power: 1.2 kW Current: max. 50 A Voltage: 12 - 24 V DC

Features: 8-bit MCU: C868 with on-chip 8 kB SRAM,

with 8-bit ADC and powerful PWM module 3-Phase Bridge Driver: TLE6280G 6 OptiMOS MOSFETs EEPROM: 8 kB to store program + stand

alone boot option RS232: Interface to PC for SW

development + boot from PC option Protection: shut down protection for

over current and over temperature Extension for alternative MCU like

XC164 SW environment: Keil Compiler +

Debugger or Mini Debugger (free software)

Board can be used for current/torque or speed control

Supports Hall-Effect sensors or sensor-less control

BLDC 868 v52

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