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Sensored BLDC Sinusoidal Drive Controller for Refrigerator
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TI DesignsSensored BLDC Sinusoidal Drive Controller
forRefrigerator Fans
Design OverviewThe DRV10970 is an integrated, three-phase
BLDCmotor driver for home appliances, fans, and
othergeneral-purpose motor control applications. Theembedded
intelligence, small form factor, and simplepin-out structure reduce
the design complexity, boardspace, and overall system cost. The
integratedprotections improve the system robustness andreliability.
The design is targeted for fans inrefrigerators.
Design Resources
TIDA-00919 Tool Folder Containing Design FilesDRV10970 Product
FolderDRV5013 Product Folder
ASK Our E2E Experts
Design Features• Output Stage of DRV10970 Consists of Three
Half
Bridges With Rdson of 450 mΩ (With Each HalfBridge Capable of
Delivering 1-A RMS and 1.5-APeak Current)
• Cost-Effective Single-Side Board Design– Small Form Factor
Board With Hall Sensors– Speed Control Through External PWM
Control
• 180° Sine Wave Commutation Algorithm Helps forHigh Efficiency,
Superior Acoustic Performance,and Low Torque Ripple
• Automatic Drive Angle Adjustment EnablesOptimized
Efficiency
• Supports Single Hall- and Three Hall-BasedApplications
• Features Such as PWM Speed Input, DirectionReversal, FG
Output, and Motor Lock Indicator
Featured Applications• Cooling Fans• Small Appliances•
General-Purpose BLDC Motor Drivers
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Key System Specifications www.ti.com
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An IMPORTANT NOTICE at the end of this TI reference design
addresses authorized use, intellectual property matters and
otherimportant disclaimers and information.
1 Key System SpecificationsA refrigerator is a very common
household appliance which consists of a main compressor motor and
amotor for a circulation fan. The circulation fan serves as a
blower that rotates cold airflow throughout theunit to keep it
cold. The fan for a refrigerator is typically a sensored brushless
DC (BLDC) motor, whichrequires an electronic controller. The
TIDA-00919 reference design is a ready platform for driving such
afan motor.
This reference design is a cost-effective, small-form-factor,
three-phase sinusoidal motor drive forsensored BLDC fan motors
specified up to a maximum current of 1 A RMS at 18 V maximum.
Unlike mostsensored drivers, the DRV10970 drives a motor with a
180° sinusoidal commutation, which results in lowtorque ripple,
better acoustics, and a high drive efficiency. The speed input
command can be utilized in theform of a pulse width modulation
(PWM) input and a direction control by controlling a pin high or
low.
Table 1 lists the key system specifications for the design.
Table 1. Key System Specifications
PARAMETER SPECIFICATIONDC input voltage 12 V
Rated power capacity 15 WSpeed input PWM
Operating ambient temperature –20°C to 50°CInverter efficiency ≥
97% at rated load
Protections Overcurrent, overtemperature, and short circuit
The drive board has been designed for a small form factor in
consideration of the small factors of theappliance fans. Because
the motor driver has sensors, the printed-circuit board (PCB) is
typically housedinside the motor, which explains the requirement
for placing Hall sensors on the board. The low-costrequirement also
confines the design to a single-side board.
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www.ti.com System Description
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2 System DescriptionThe use of permanent-magnet brushless DC
motors continue to gain prominence in the field because oftheir
high efficiency, low maintenance, high reliability, low rotor
inertia, and low noise as compared to thebrushed motor counterpart.
A brushless permanent-magnet motor has a wound stator, which is
apermanent magnet rotor assembly. These types of motors generally
use internal or external devices tosense rotor position. The
sensing devices provide logic signals for electronically switching
the statorwindings in the proper sequence to maintain rotation of
the magnet assembly.
The DRV10970 is an electronic drive which is used to
sinusoidally control the drive of a sensored BLDCmotor. The system
operates at 12-V power and provides the motor terminal outputs. The
designimplements Hall sensors because the electronic components are
placed inside the motor for mostsensored BLDC motors. The system
also accepts user inputs such as direction and speed also in
additionto providing some feedback, such as lock detection and
speed feedback.
3 System Design TheoryThe DRV10970 device controls three-phase
BLDC motors using a speed command (PWM), direction (FR)interface,
and Hall signals from the motor. The device is capable of driving
up to 1-A RMS and 1.5-A peakcurrent.
When the DRV10970 device powers up, it starts to drive the motor
in trapezoidal communication modebased on Hall sensor information.
If all three Hall sensors have been connected, the commutation
logicrelies on all three Hall sensors. If a U-phase Hall sensor is
the only sensor connected (VHP is floating),then the DRV10970
device starts to drive the motor in a single Hall sensor mode.
After six electrical cycles, the device switches to sinusoidal
drive mode if the CMTMOD pin is not floating.If the motor has a 0°
placement for the Hall sensor (set on the CMTMOD pin accordingly),
the DRV10970device automatically adjusts the driving angle based on
the feedback from the motor. The DRV10970device optimizes the
efficiency regardless of the motor parameters and the load
conditions.
This automatic function that drives the angle adjustment can be
disabled by the DAA pin. A fixed drivingangle is available for the
user to optimize the motor drive efficiency if this automatic
function has beendisabled.
The PWM input duty cycle commands the steady-state motor speed,
which converts to an average outputvoltage of VM multiplied by the
duty cycle. A floating PWM pin functions as the full-speed command.
TheFR input can be used to control the direction of motor
rotations. The user can adjust the rotationaldirection while the
motor is spinning. The device has a time delay (TLOCK_EX) before
reversing direction.
The FG output is aligned with a U-phase Hall sensor signal,
which indicates the motor speed. If the motorhas been locked by an
external force for TLOCK_EN, then the RD output is asserted to
indicate the motor lockcondition and DRV10970 retries after the
TLOCK_EX period, which is determined by the capacitor on theRETRY
pin.
When the motor is not spinning (either in lock condition or PWM
= 0), the state of the phases are selectedby the BRKMOD pin. The
phases can be maintained floating (coasting condition) or pulled
down to GND(braking condition).
The DRV10970 device enters sleep mode when the PWM has been
driven low for TSLEEP time and internalcircuits including
regulators are turned off and the power consumption is less than 35
µA.
Overcurrent, current limit, thermal shutdown, and undervoltage
protection circuits prevent systemcomponents from being damaged
during extreme conditions.
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OUT3
VCC1
GND2
U2
DRV5013ADQLPGM
OUT3
VCC1
GND2
U4
DRV5013ADQLPGM
OUT3
VCC1
GND2
U3
DRV5013ADQLPGM
GND
U_HP
W_HP
V_HP
10kR6
10kR8
10kR7
U_HN
W_HN
V_HN
W_HP
V_HP
U_HP
0.1µF
C3
0.1µF
C4
0.1µF
C5
VINT
DNP
DNP
DNP
System Design Theory www.ti.com
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3.1 Single-Side DesignThe design targets the use of a
single-side board because of the extremely cost-sensitive
application.
With the constraint of a single-side board, the GND connection
is routed to multiple places throughout theboard. To avoid the
noise associated with ground loop on current sense and VINT, a
provision has beenestablished to connect an optional resistor R13
of 0 Ω, which acts as a jumper if required.
3.2 Hall Sensor ConnectionsHall sensors and their connections
are very important parameters to consider while driving a
sensoredBLDC motor. The DRV10970 device has been designed to work
with Hall sensor elements as well as thelatched output types of
Hall sensors. Apart from working with these sensor types, the
DRV10970 alsoworks with different Hall sensor placements and with
single hall mode and three-hall mode as well.
The TIDA-00919 design has three DRV5013 Hall sensors (U2, U3,
and U4), which are of the single-ended, latch output type. The
supply to the Hall sensors travels through VINT from the DRV10970
device,which is 5 V. Three Hall sensors are placed at 120°
mechanical apart in the slot made for the rotor (seeFigure 1).
Because the device has been designed to operate as differential
input Hall sensor outputs, thedesign requires the creation of a
reference point when being supplied with single-ended Hall
sensoroutputs. This reference is created as VINT / 2 by a simple
resistor divider formed by R3 and R5. Thisreference connects to all
the negative terminals of the Hall sensor connections as Figure 2
shows.
Figure 1. TIDA-00919 Board Image Figure 2. Hall Sensor
Connections
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LOCK _EX 6 RETRYT 15.36 10 C= ´ ´
( )ILIM_ THR CLLIMIT
CS
V AI
R
´=
BRKMOD CMTMOD
DAAVINTVINT
10k
R12
10k
R11
10k
R10
VINT
FR
10k
R9
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The three capacitors C3, C4, and C5 filter the noise on the Hall
sensor outputs. The Hall sensors aretypically located inside the
motor; for this reason, the user can connect the Hall sensor
outputs acrossthese capacitors if it is not feasible to mount the
complete board inside the PCB. Take the appropriatelevel of care
with the reference in this configuration. If using the board
directly inside the motor and theHall sensors require mounting on
the component side (the design is on the top side), the user must
modifythe Hall sensor pinout.
3.3 Hardware SettingsThe DRV10970 is capable of driving a BLDC
motor in sinusoidal or trapezoidal way. The user can setother
features by hardware, such as adaptive angle adjustment and brake
mode adjustment. Configurethe required settings by making the
appropriate placements of R9 to R12, as Table 2 details and Figure
3shows.
Table 2. Drive Settings
FUNCTION SETTINGS RESISTOR
Commutation modePlace R11 Sine drive with 30° Hall placement
Remove R11 Trapezoidal driveBrake mode Place R9 Coasting
mode
Adaptive angle adjustPlace R12 10° drive angle adjustment
Remove R12 Auto-drive angle adjustmentDirection control Remove
R10 Direction reversal
Figure 3. Hardware Settings
The current sense resistor helps to set the current limit during
operation. The current sense resistor iscalculated by Equation 1
(refer to the datasheet for more details).
where• VILIM_THR = 1.2 V (typical)• ACL = 25000 A/A (typical)
(1)
During a fault condition, the device stops the drive and
attempts to drive the motor again after a certaintime. The
capacitor CRETRY determines this retry time, which is controlled by
the charging and dischargingof the cap with VRETRY_H (1.2 V) and
VRETRY_L (0.6 V) and source and sink current at 10 uA typical(see
Equation 2 and Figure 4).
where• TLOCK_EX is in seconds (2)
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FG
PWMPWMFG
CPP9
CPN10
CS17
PWM19
RETRY22
FR23
DRV10970PWP
FRRETRY
PWM
CS
CPP
CPN
GND
GND 0.1µFC8
24.0kR4
0.1µFC7
System Design Theory www.ti.com
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Figure 4. Current Sense and Retry Circuit
With the constraint of a single-side board, the GND connection
is routed to multiple places throughout theboard. To avoid the
ground loop on current sense and VINT, utilize the optional
resistor provision on theboard. If the GND noise is too much to
handle for the current sense and VINT circuit, R13 can be addedon
the board.
3.4 ControlThe design has a provision for controlling user
inputs through connections (Figure 5).• PWM: A PWM input (frequency
range of 15 kHz to 100 kHz) is used to control the speed of the
motor
during runtime.• FG: The FG signal provides the electrical speed
of the motor by toggling an open-drain output, which
has already been pulled high to VINT on the board.
Figure 5. Control Inputs
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www.ti.com Block Diagram
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4 Block Diagram
Figure 6. TIDA-00919 Block Diagram
4.1 Highlighted ProductsThe design contains a three-phase,
sensored, sinusoidal BLDC driver (DRV10970) and three Hall
sensors(DRV5013).
4.1.1 DRV10970The DRV10970 is an integrated, three-phase BLDC
motor driver for home appliances, cooling fans, andother the
general-purpose motor control applications. The embedded
intelligence, small form factor, andsimple pinout structure reduce
the design complexity, board space, and system cost. The
integratedprotections improve the system robustness and
reliability.
The output stage of the DRV10970 device consists of three half
bridges. Each half bridge is capable ofdriving up to 1-A RMS and
1.5-A peak output current. When the device enters sleep mode, it
consumes atypical 35-μA of current.
The advanced 180° sine-wave commutation algorithm is embedded
into the device that achieves highefficiency, low torque ripple,
and superior acoustic performance. The automatic driving angle
adjustmentfunction achieves the most optimized efficiency
regardless of the motor parameters and load conditions.
The DRV10970 has been designed for Hall sensor-based
applications. The differential Hall signal inputsare detected by
the integrated comparators. The device supports single Hall-based
applications and threeHalls-based applications. The single Hall
sensor mode reduces the system cost by eliminating two
Hallsensors.
The device implements a standard control interface which
includes PWM input (speed command), FGoutput (speed feedback), FR
input (forward and reverse direction control), and RD output (motor
lockindicator).
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Block Diagram www.ti.com
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The DRV10970 supports both 30° and 0° Hall sensors (with respect
to the corresponding phase back-electromotive force [BEMF]). The
device implements a trapezoidal drive mode to address the
higherpower requirement.
The DRV10970 device determines the motor lock condition based on
the absence of hall input switching.The device re-attempts to spin
the motor after an adjustable auto-retry time, which can be
configured by acapacitor connected to the RETRY pin.
The device incorporates multiple protection features such as
overcurrent, undervoltage, overtemperature,and locked rotor
conditions to improve the system robustness.
The DRV10970 is packaged in a thermally enhanced 24-pin TSSOP
package (eco-friendly: RoHS and noSb/Br).
4.1.2 DRV5013The DRV5013 device is a chopper-stabilized Hall
effect sensor that offers a magnetic sensing solutionwith superior
sensitivity stability over temperature and integrated protection
features.
The magnetic field is indicated through a digital bipolar latch
output. The integrated circuit (IC) has anopen-drain output stage
with a 30-mA current sink capability. A wide operating voltage
range from 2.5 V to38 V with reverse polarity protection up to –22
V makes the device suitable for a wide range of
industrialapplications.
Internal protection functions have been provided for reverse
supply conditions, load dump, and outputshort circuit or
overcurrent.
Device features• Digital bipolar-latch Hall sensor• Superior
temperature stability
– BOP ±10% overtemperature• High sensitivity options (BOP and
BRP)
– +2.7 / –2.7 mT (AD)– +6 / –6 mT (AG)– +12 / –12 mT (BC)
• Supports a wide voltage range– 2.5 to 38 V– No external
regulator required
• Wide operating temperature range– TA = –40 to 125°C (Q)
• Open-drain output (30-mA sink)• Fast 35-µs power-on time•
Small package and footprint
– Surface mount 3-pin SOT-23 (DBZ)• 2.92 mm × 2.37 mm
– Throughhole 3-pin TO-92 (LPG)• 4.00 mm × 3.15 mm
• Protection features– Reverse supply protection (up to –22 V)–
Supports up to 40-V load dump– Output short-circuit protection–
Output current limitation
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www.ti.com Getting Started
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5 Getting StartedThe hardware is capable of exploring all the
available features of the DRV10970 device.
5.1 Hardware SettingsBefore connecting the motor to the board,
the user must be aware of the Hall placement if the Hall signalsare
being externally provided to the board. Configure the following
required hardware settings beforegetting started with the hardware
(see Table 2 as well).• CS: Check whether the onboard resistor is
correct as per the expected motor current. Change this
resistor if required.• BRKMOD: Check R9 to confirm if either
must be present for the appropriate brake mode.• CMTMOD: Check R11
for the appropriate commutation mode. A provision has been provided
to either
pull the pin high or keep it floating.• DAA: The DAA settings
can be changed while in three-Hall sensor mode by using R12.• Hall
sensor: Depending on the type of Hall sensors and placement in the
motor, connect the Hall
sensors (if they are being provided externally). Take note of
the Hall sensor pinout, as thisconfiguration depends on the way
that the PCB has been used inside the motor.
5.2 StartAfter having correctly implemented the hardware
settings, connect the power supply to the board andmotor connected
to U/V/W terminals on the board.
Switch on the power supply and apply the PWM input to the PWM
jumper for speed control. The FGoutput shows the speed as an
electrical frequency.
5.3 RuntimeChange the speed command through the PWM input and
observe the speed feedback on the FG pin.
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Test Setup www.ti.com
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6 Test SetupThe board was tested with a Hurst motor number
DMB0224C10002. The board was supplied by anAgilent E3634A power
supply at 12 V. The following waveforms have been captured using
the TektronixDPS4034 oscilloscope. The power supply setting was
kept at 12 V with a current limit of 3 A. Figure 7shows an image of
the test setup.
Figure 7. Test Setup
7 Test Data
7.1 DRV10970 Driving With Three-Hall Mode
Figure 8. DRV10970 Driving Motor With Three-Hall Mode
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www.ti.com Test Data
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7.2 DRV10970 Driving With Trapezoidal Mode
Figure 9. DRV10970 Driving With Trapezoidal Mode
7.3 DRV10970 Ph-Ph Short and Recovery
Figure 10. DRV10970 Ph-Ph Short and Recovery
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Test Data www.ti.com
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7.4 Thermal Image at 18-V, 1-A Load
Figure 11. Thermal Image at 18-V, 1-A Load
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www.ti.com Design Files
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8 Design Files
8.1 SchematicsTo download the schematics, see the design files
at TIDA-00919.
8.2 Bill of MaterialsTo download the bill of materials (BOM),
see the design files at TIDA-00919.
8.3 Layer PlotsTo download the layer plots, see the design files
at TIDA-00919.
8.4 Altium ProjectTo download the Altium project files, see the
design files at TIDA-00919.
8.5 Gerber FilesTo download the Gerber files, see the design
files at TIDA-00919.
8.6 Assembly DrawingsTo download the assembly drawings, see the
design files at TIDA-00919.
9 References
1. Texas Instruments, DRV10970 3-Phase Brushless DC Motor
Driver, DRV10970 Datasheet (SLVSCU7)
10 TerminologyBEMF— Back-electromotive force
BLDC— Brushless DC motor
ESD— Electrostatic discharge
FET— Field-effect transistor
MOSFET— Metal-oxide-semiconductor field-effect transistor
PWM— Pulse width modulation
RMS— Root mean square
RPM— Rotations per minute
11 About the AuthorJASRAJ DALVI is an applications engineer at
Texas Instruments, where he is responsible for developingreference
design solutions and control algorithms for motor control
applications. He completed hisBachelors of Engineering degree in
Electrical Engineering from University of Pune, India and his
PostGraduate Diploma in Marketing Management at S.I.B.M. in Pune,
India.
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failure to meet ISO/TS16949.IMPORTANT NOTICE
Mailing Address: Texas Instruments, Post Office Box 655303,
Dallas, Texas 75265Copyright © 2016, Texas Instruments
Incorporated
Sensored BLDC Sinusoidal Drive Controller for Refrigerator
Fans1 Key System Specifications2 System Description3 System Design
Theory3.1 Single-Side Design3.2 Hall Sensor Connections3.3 Hardware
Settings3.4 Control
4 Block Diagram4.1 Highlighted
Products4.1.1 DRV109704.1.2 DRV5013
5 Getting Started5.1 Hardware Settings5.2 Start5.3 Runtime
6 Test Setup7 Test Data7.1 DRV10970 Driving With Three-Hall
Mode7.2 DRV10970 Driving With Trapezoidal Mode7.3 DRV10970 Ph-Ph
Short and Recovery7.4 Thermal Image at 18-V, 1-A Load
8 Design Files8.1 Schematics8.2 Bill of Materials8.3 Layer
Plots8.4 Altium Project8.5 Gerber Files8.6 Assembly Drawings
9 References10 Terminology11 About the Author
Important Notice