TP Ftf2008 Motorctrl Part4

June, 2008
Hands-on Workshop: Motor Control Part 4 Brushless DC Motors Made Easy

AZ114
Eduardo Viramontes
Applications Engineer
TM
Freescale Semiconductor Proprietary Information. Freescale and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. Freescale Semiconductor, Inc. 2008.
Agenda
TM
Motor Anatomy
TM
Motor Anatomy
Brushed DC Rotor
Commutator
Stator
The
first electric motor was the Brushed DC Motor
Basic idea is to repel rotor from stator
TM
Motor Fundamentals
TM
Motor Fundamentals
N
+ _
S
+ _
TM
Motor Fundamentals
N
+ _
S
+ _
TM
Motor Fundamentals
S N S
_ +
N
_ +
TM
Motor Fundamentals
N N S
+ _
S
+ _
TM
Electric Motor Type Classification
TM

ELECTRIC MOTORS AC ASYNCHRONOUS SYNCHRONOUS DC VARIABLE RELUCTANCE
Induction
Sinusoidal
Brushless
SR
Stepper
Permanent Magnet Surface PM Interior PM Wound Field
Known as Universal DC motors or Brushed DC Motors

AC power Tools Washers, Dryers Garage Openers Blenders Vacuum Cleaners HVAC Toys
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10
Brushed DC Motors
Rotation due to electromagnetic force Continues rotation with multiple coils Undesirable effects due to friction and current reversing
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Induction
Sinusoidal
Brushless
Reluctance
SR
Stepper
Robots Traction Control Servo Systems Hard Drives Fans Sewing Machines Treadmills Industrial Machines
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12
Brushless DC (BLDC) Motors

The confusion arises because a BLDC Motor does NOT directly operate off a DC voltage source
Reverse design of brushed motors:

Magnet is on the rotor Inductors are on the stator
Benefits vs. Brushed

No mechanical commutator
(higher speeds)
Better torque/inertia ration

(higher acceleration)
Easier to cool
(Higher specific outputs)
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Brushed and Brushless Motors Comparison

Feature
Commutation Maintenance Life Speed/Torque Speed range Building Cost Control Control Requirements
Brushed DC motor
Brushed commutation Periodic maintenance is required Shorter Moderately Flat. Higher speeds produces higher friction and this reduces torque. Lower Mechanical limitations by the brushes Lower Simple A controller is required only when variable speed is desired
BLDC Motor
Electronic commutation based on Hall position sensors Less required due to absence of brushless Longer Flat Higher No mechanical limitation Higher Permanent magnets Complex and expensive A controller is always required
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Induction
Sinusoidal
Brushless
Reluctance
SR
Stepper
Washing Machines Vacuum Cleaners Machine tools Food Processors Fans Small Appliances
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Switched Reluctance
Both The
the rotor and stator have salient poles
stator winding is comprised of a set of coils, each wound to the stator
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Induction
Sinusoidal
Brushless
Reluctance
SR
Stepper
Cruise Control Air Vents Medical Scanners Gauges Office Equipment Printers Instrumentation
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Stepper Motor
These
motors turn as different voltages are applied to the different windings

Field
rotates in one direction while rotor moves in opposite direction of field

In It
this example, field rotates 60while rotor only moves 30
takes four complete cycles of the control system to rotate motor through one cycle. This is because the Rotor has 4 poles
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Induction
Sinusoidal
Brushless
Reluctance
SR
Stepper
Permanent Magnet Surface PM Interior PM Wound Field Get name from sinusoidial windings
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Brushless DC Motor Control

BLDC
Motor versus PMSM Motor
Both motors have identical construction. The difference is in stator winding only. The BLDC has distributed stator winding in order to have trapezoidal Back-EMF. The PMSM motor has distributed stator winding in order to have sinusoidal Back-EMF.
Phase B Phase B Phase C Phase C
Phase A Phase A
Trapezoidal Back-EMF voltage
Sinusoidal winding distribution

Source: Hendershot J. R. Jr, Miller TJE: Design of brushless permanent-magnet motors
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Induction
Sinusoidal
Brushless
Reluctance
SR
Stepper
Large Appliances HVAC Blowers Fan Pumps Industrial Controls Lifts Inverters
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Induction Machines
Invented over a century ago by Nikola Tesla
Stator same as BLDC Difference in rotor construction If properly controlled Provides constant torque Low torque ripple
No permanent magnets Think of it as a rotating transformer. Stator is the primary Rotor is the secondary Rotor current is induced from stator current
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AC Induction Motor Slip

Basic Principle: The stator is a classic three-phase stator with the winding displaced by 120 The rotor is a squirrel cage rotor in which bars are shorted together at both ends of the rotor by cast aluminum end rings The rotor currents are induced by stator magnetic field.
rotating Field ( s)
Indu ced
Torque
curr ent
The motor torque is generated by an interaction between the stator magnetic field and induced rotor magnetic field
NO BRUSHES, NO PERMANENT MAGNETS
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Induction
Sinusoidal
Brushless
Reluctance
SR
Stepper
Permanent Magnet Surface PM Interior PM Wound Field Unpractical for large motors yet practical in small sizes
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Reluctance
If
the rotating field of a motor is de-energized, it will still develop 10 or 15% of synchronous torque slots are cut into the conductor-less rotor of an induction motor, corresponding to the stator slots, a synchronous reluctance motor results like an induction motor but runs with a small amount of synchronous torque
If
Starts
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25
Freescale Roadmap for Motor Control
TM
BLDC In Depth: BLDC Motor Configurations

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27
Windings Electrical Connection - Star
A
A C
B C
Star connection
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Windings Electrical Connection - Delta
+ -
A B B
Delta connection
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BLDC motor configuration

4 pole pairs
S
N N
H3 B A H2 C B H1
N N
C S A
H1 H2 H3 1 0 1
30
S
TM
BLDC motor configuration
3 pole pairs
H1
9 coils
31
H2
N
S
TM
H3
External Rotor Different Motor Configurations
1 pole pairs
2 pole pairs
N
4 pole pairs
S
N N
H3
H1 B A H2 C A B H3 S C
H3 B A H2 C B H1
N N
A S H2 B
C N
C S A
H1
H1 H2 H3 1 0 1
H1 H2 H3 1 0 1
H1 H2 H3 1 0 1
32
TM
Internal Rotor Different Motor Configurations
1 pole pair
H3 A
2 pole pairs
B H1
4 pole pairs
B H3
H2
H2
H2
N
C A H3
H1 H2 H3 1 0 1
H1 H1 H2 H3 1 0 1
H1 H2 H3 1 0 1
33
N
S S
A
N
H1
TM
Six Step BLDC Motor Control

Voltage applied on two phases only It creates 6 flux vectors Phases are power based on rotor position The process is called commutation
Phases voltage
Power Stage
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34

Commutation example Stator field is maintained 60 120relative to rotor field ,
Before commutation
After commutation
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Six
Step BLDC Motor Control contd

1 2 R S 3 4 T c 5 6
1 1 0
Controller
Source: Eastern Air Devices, Inc. Brushless DC Motor Brochure
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Six
Step BLDC Motor Control contd

Hall a Hall b Hall c
PWM 1 PWM 3 PWM 5 PWM 2 PWM 4 PWM 6

0 60 120 180 240 300 360
Rotor Electrical Position (Degrees)
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Example
of commutation table
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38

Sinusoidal
BLDC motor control
iSb
All three phases are powered by sinewave shifted by 120
iS
iSa iSc
We are able to generate stator field to any position over 360
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Brushless DC Motor Control Summary

Six
step control versus sinusoidal control
Six step control

+ Simple PWM generation Ripple in the torque (stator flux jumps by 60 ) A little noise operation (due to ripple in the torque) + Simple sensor + +
Sinusoidal control
More complex PWM generation (sinewave has to be generated) Smooth torque (stator flux rotates fluently) Very quiet Requires sensor with high resolution
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Sensor Example: Hall Effect Sensor

Hall
effect sensor is a transducer that varies its output voltage in response to changes in magnetic field Hall sensors are used for proximity switching, positioning, speed detection and current sensing applications In this case, hall sensors are used in On/Off mode
Hall Sensor Everytime a magnetic field is sensed, a change in voltage can be detected Permanent Magnet
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Putting All Together
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Lab1
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How to Set Up the Boards

AC16 board
6.
Jumper J13 APMOTOR board
7. 8
LED array
3
2. BDM
1
3.
BLDC Motor
1. Power
Supply (9V DC)
J13
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Create a New CodeWarrior Project

1. Click on the Open Icon
2. Select the MC9S08AC16 MCU 4. Click next
3. Select P&E Multilink/Cyclone Pro
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45
Name Your CodeWarrior Project

1. Set new name for your project
2. Select Project Path
3. Click next
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Add Additional Files
1. Select AC16DaugherCard.h
2. Add To Project Files
3. Click next
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Processor Expert
1. Click next
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C Options
1. Click next
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PC-Lint Options
1. Click Finish
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New Project Set Up
1. Click On Make
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Commutation Table & Knowing Position with Hall Effect sensors
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Necessity of Knowing the Position

To

spin 3-phase BLDC motor:

Detect position/commutation Read commutation table Mask and swap phases
1 0 1 0 1 0
Signal sequence diagram for the hall sensors

60 H1 H2 H3 120 180 240 300 360
It is important to know the rotor position in order to maintain the rotating magnetic field
Supplied motor voltage

+
A-B
_ +
B-C
_ +
C-A
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3-Phase Inverter
Vb
Q1
Q2
Q3 A B C
With the 3-phase inverter, you can control which phases need to be fed in order to turn the motor
Q4
Q5
Q6
0v
Q1, Q2 and Q3 is where the current goes in the motor and Q4, Q5 and Q6 is where the current goes out of the motor
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Control of 3-Phase Inverter Determined on the Hall Sensor Position
A
N S
B C
C B
BLDC Motor
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A
N S
B C
C B
BLDC Motor
H1 1 1 1 0 0 0
H2 0 0 1 1 1 0
H3 1 0 0 0 1 1
Phase A +VDCB +VDCB NC -VDCB -VDCB NC
Phase B -VDCB NC +VDCB +VDCB NC -VDCB
Phase C NC -VDCB -VDCB NC +VDCB +VDCB
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A
S
B C
C B
BLDC Motor
H1 1 1 1 0 0 0
H2 0 0 1 1 1 0
H3 1 0 0 0 1 1
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A B C
N S
C A B
BLDC Motor
H1 1 1 1 0 0 0
H2 0 0 1 1 1 0
H3 1 0 0 0 1 1
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A B C
N S
C B
BLDC Motor
H1 1 1 1 0 0 0
H2 0 0 1 1 1 0
H3 1 0 0 0 1 1
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A B
S N
C B
BLDC Motor
H1 1 1 1 0 0 0
H2 0 0 1 1 1 0
H3 1 0 0 0 1 1
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A B C C B
N S
BLDC Motor
H1 1 1 1 0 0 0
H2 0 0 1 1 1 0
H3 1 0 0 0 1 1
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Lab 1
Make a program that On/Off transistors
TO DO:
Enable
moves the motor in the clockwise direction
Switch1 to enable commutations Enable 3-Phase Inverter LEDs will still reflect HALL Effect sensors Each time Switch1 is pressed, we will advance one step in the commutation table Commutation table will tell us which transistors to turn on When Switch1 is not pressed, turn OFF transistors
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Import Table Add Variables, Enable Switch1, Enable Inverter

extern unsigned char table_rotate[8]; unsigned char value; unsigned char commutation; void main(void) { EnableInterrupts; /* enable interrupts */ /* include your code here */ ENABLESWITCH(1); ENABLELED(1); ENABLELED(2); ENABLELED(3); ENABLE3PHASEINVERTER(); for(;;) {
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Wait for Switch1 to be Pressed

for(;;) { __RESET_WATCHDOG(); /* feeds the dog */ LED1_PIN = HALL_1; LED2_PIN = HALL_2; LED3_PIN = HALL_3; if(!SW1_PIN) { }
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Once Pressed, Advance Counter, Commutate

for(;;) { __RESET_WATCHDOG(); /* feeds the dog */ LED1_PIN = HALL_1; LED2_PIN = HALL_2; LED3_PIN = HALL_3; if(!SW1_PIN) { value++; if(value>=7) value = 1; commutation = table_rotate[value]; if(commutation & Q1_MASK) Q1 = 1; if(commutation & Q4_MASK) Q4 = 1; if(commutation & Q2_MASK) Q2 = 1; if(commutation & Q5_MASK) Q5 = 1; if(commutation & Q3_MASK) Q3 = 1; if(commutation & Q6_MASK) Q6 = 1; }
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Wait for Switch to be Released

if(commutation & Q3_MASK) Q3 = 1; if(commutation & Q6_MASK) Q6 = 1; while(!SW1_PIN) { __RESET_WATCHDOG(); LED1_PIN = HALL_1; LED2_PIN = HALL_2; LED3_PIN = HALL_3; } } IT IS IMPORTANT TO TURN OFF TRANSISTORS!
TURNOFFTRANSISTORS();
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Download and Run Code

1. Click On Run
4. Click On Run
2. Click On Connect on the Debugger 3. Click On Yes To Reprogram the MCU
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Lab2
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Lab 2
Make a program that On/Off transistors
move the motor in clockwise direction
TO DO: Enable Switch5 to enable commutations Check Hall Effect sensors to evaluate which commutation state motor is in When Hall Effect sensors changes state, transistors will commutate
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Add Variables, Enable Switch5

unsigned char pasthallsensors; unsigned char hallsensors; void main(void) { EnableInterrupts; /* enable interrupts */ /* include your code here */ ENABLESWITCH(5); ENABLESWITCH(1); ENABLELED(1); ENABLELED(2); ENABLELED(3); ENABLE3PHASEINVERTER(); for(;;) {
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Wait for Switch5 to be On

for(;;) { __RESET_WATCHDOG(); /* feeds the dog */ LED1_PIN = HALL_1; LED2_PIN = HALL_2; LED3_PIN = HALL_3; while(SW5_PIN) { } TURNOFFTRANSISTORS();
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Once On, Display and Check Hall Effect Sensors

while(SW5_PIN) { __RESET_WATCHDOG(); /* feeds the dog */ LED1_PIN = HALL_1; LED2_PIN = HALL_2; LED3_PIN = HALL_3; hallsensors = 0; if(HALL_1) hallsensors |= 0x04; if(HALL_2) hallsensors |= 0x02; if(HALL_3) hallsensors |= 0x01; if(pasthallsensors != hallsensors) { /* Do something */ }
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Once On, Display and Check Hall Effect Sensors

if(pasthallhensors != hallsensors) { pasthallsensors = hallsensors; value++; if(value>=7) value = 1; commutation = table_rotate[value]; IT IS IMPORTANT TO TURNOFFTRANSISTORS(); TURN OFF if(commutation & Q1_MASK) Q1 = 1; TRANSISTORS! if(commutation if(commutation if(commutation if(commutation if(commutation } & & & & & Q4_MASK) Q2_MASK) Q5_MASK) Q3_MASK) Q6_MASK) Q4 Q2 Q5 Q3 Q6 = = = = = 1; 1; 1; 1; 1;
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Download and Run Code

1. Click On Run
4. Click On Run
2. Click On Connect on the Debugger 3. Click On Yes To Reprogram the MCU
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Sensorless Sensing
Sensors
are expensive and take up space Several techniques can be used to determine the motor position/speed without an external device These techniques are based on the electrical characteristics of motors, mainly on their inductance characteristics:
Based on BEMF Speed range from 5-10% up to 100% of nominal speed

The BEMF must be high enough
Based
on Motor Inductance Saliency

Speed range from standstill to about 20% of nominal speed
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BEMF
-
BEMF is just an acronym for Back Electromagnetic Force Back electromagnetic force is a fancy term for the generator characteristics of a motor As has been shown not all phases of the motor are on at the same time BEMF voltage can be measured on the inactive phases of the motor The characteristics of the voltage curve generated by BEMF can tell the position/speed of the motor The method that will be exposed is the zero crossing method. When BEMF voltage equals zero, the motor is in a specific position By measuring the zero crosses against time, the speed of the motor can be determined
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BLDC Motor Back-EMF Shape
Phase A-B Voltage
Phase B-C Voltage
Phase C-A Voltage
Phase A
Phase B
Phase C
A CH4
0V
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Sensorless BLDC Motor Control with BEMF Zero-Crossing Detection
Appropriate Phase Comparator Output selected
Zero Crossing event detected
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Sensorless Commutation and BEMF

0 60 120 180 240 300 360 Rotor Electrical Position (Degrees)
Phase R Phase S Phase T
Zero crossings PWM 1 PWM 3 PWM 5
PWM 2 PWM 4 PWM 6
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BLDC Central Point is Not Accessible

3-phase
inverter and DC bus current measurement

Inverter Stage
Udcbus
Rshunt
HB1
A
Idcbus
V0
HB2
BLDC Motor
HB3
C
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80
Zero Crossing Sensing Reference

HB1
V0
+ + C
V0
HB2
+ HB3 + C
+ HB3 + -
HB3
UDCB reference
GND reference
Virtual CP reference
Udcbus
BLDC
Motor central point is not accessible
Rshunt Idcbus
B
V0
HB2
HB1
HB3
BLDC Motor
V0
HB2
+ -
HB1 + -
Udcb + -
HB1
HB2
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Zero Crossing Sensing using ADC

The
principle is the same as the HW topology, but more flexible

GND reference
HB1 ADC1 ADC2 HB3
C B
V0
Virtual CP reference
HB1 ADC1 ADC2 ADC3 ADC4
C
UDCB reference
HB1
A B
V0
V0
ADC2 ADC3 ADC4
HB2
HB2
HB2
ADC3
HB3
HB3
ADC1
Udcb
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Application Details
ADC
Measurement Back-EMF evaluation
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Back-EMF Detection Window
30
60
90
120
150
180
210
240
270
300
330
360
390 uVA uSa
- visible Back-EMF
detectable zero crossing
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Lab3
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85
Sensorless BLDC Motor Control using MC9S08AC

AC microcontroller
6 6 PWM 4 ADC inputs 3 Zero-cross detection circuit 3.3V Power supply
3
Application
PH A,B,C 3-phase inverter DC current sensing
3
Diagram
BLDC motor
APMOTOR board
3 outputs
Fault LED Direction LED Run/Stop status PB_A PB_B SW
9 Vdc
3 inputs
BDM
Freemaster on PC Read/set variables
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Sensorless BLDC Motor Control using MC9S08AC

MC9S08AC

Peripheral Utilization
Timer 1
6 channels: PWM modulation for BLDC motor (complementary bipolar)
Timer 2
Time base for commutation period measurement Channel 0: commutation Channel 1: timing of application
A/D Converter
DC bus current, phase voltages (zero-cross detection)
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PI Control
Proportional

Control
Error multiplied by constant Deals with present behavior
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PI Control
Integral

Control
Ads long-term precision Takes longer to settle, but provides better precision Deals with past behavior
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PI controller on AC MCU
These variables are used To tune the system
This is the control Algorithm inplemented In AC16 MCU for Motor control
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PWM and manual dead time insertion

PWM
Generation
TIMER
set to center aligned mode (TPM1SC:CPWMS=1)

Example:
PWM0: switching (duty cycle (50 - 100%) + dead time), negative polarity (TMP1CxSC:ELSnB =x,TMP1CxSC:ELSnA =1) PWM1: switching (duty cycle (50 - 100%) - dead time), positive polarity (TMP1CxSC:ELSnB =1,TMP1CxSC:ELSnA =0) PWM2: switching (duty cycle (50 - 100%) - dead time), positive polarity (TMP1CxSC:ELSnB =1,TMP1CxSC:ELSnA =0) PWM3: switching (duty cycle (50 - 100%) + dead time), negative polarity (TMP1CxSC:ELSnB =x,TMP1CxSC:ELSnA =1) PWM4: OFF PWM5: OFF
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Dead Time
Q1
Q1
Q4
Q4
a) Center aligned PWM, Q1 and Q4 change in the same instant, it can short circuit between Vb and GND
b) Center aligned PWM, Q1 and Q4 triggered with different PWM duty cycle avoiding that both transistors turn on at the same time.
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Application Details
ADC

Measurement
DC bus current, Back-EMF voltage Single result register only 3.5 us conversion time ADC measurement has to be synchronized with PWM
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Application Details
ADC
Measurement PWM -> ADC Synchronization
Overflow interrupt is used for PWM->ADC synchronization
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Application Details
ADC
Measurement Back-EMF evaluation
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FlexTimer in the MCF51AC

This part pending because dev board was delivered on April 29
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FlexTimer advantages
Supports up to 8 channels which can be synchronized in pairs for complementary signal generation. Dead time insertion supported by software. FTM can trigger ADC conversions automatically. Fault input supported by hardware (automatically turns of PWM pin outputs). Synchronized reloading of PWM duty cycle from several sources (ADC, analog comparator, software). Polarity for PWM output can be configured. Edge and center alligned PWM generation.
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Dead time insertion
Used to avoid to power devices to be turned on at the same time.

No CPU load generated to make dead time insertion. To configure simply enable dead time insertion bit and configure the number of timer counts of dead time, the rest is done by timer module.
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ADC Synchronization
Reduces CPU load by saving time needed to start conversions (to detect zero-crossings or instantaneous current. When doing back-EMF sensing measurements need to be made in certain timing windows. If measurements are always taken at the same times, control algorithm is more precise.
Timer Channel ISR t1 1 ADC conversion ADC Channel ISR t3 1 Process ADC data Manual start of ADC conversion t2
Timer Channel ISR Automatic start of ADC conversion t1 ADC conversion ADC Channel ISR t3 Process ADC data
Without hardware T = t1 + t2 + t3
trigger
With hardware trigger T = t1 + t3
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Related Session Resources

Sessions (Please limit to 3)
Session ID
AZ131 AZ121 AZ120
Title
Motor Control Part 1 Fundamentals and Freescale Solutions Motor Control Part 2 Solutions for Large Appliances and HVAC Motor Control Part 3 Solutions for Small Appliances and Health Care Applications
Demos (Please limit to 3)

Pedestal ID
312 214 706
Meet the FSL Experts (Please limit to 3)

Title Time Location
Demo Title
Large Appliance Demo 3-Phase PMSM Vector Control demo with Encoder Air Hockey Demonstration featuring the Flexis AC Products
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TM

TP Ftf2008 Motorctrl Part4

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June, 2008

Hands-on Workshop: Motor Control Part 4 Brushless DC Motors Made Easy

first electric motor was the Brushed DC Motor

Basic idea is to repel rotor from stator

Electric Motor Type Classification

Electric Motor Type Classification

Permanent Magnet Surface PM Interior PM Wound Field

Known as Universal DC motors or Brushed DC Motors

Electric Motor Type Classification

Permanent Magnet Surface PM Interior PM Wound Field

Brushless DC (BLDC) Motors

Reverse design of brushed motors:

Benefits vs. Brushed

Better torque/inertia ration

Brushed and Brushless Motors Comparison

Electric Motor Type Classification

Permanent Magnet Surface PM Interior PM Wound Field

the rotor and stator have salient poles

stator winding is comprised of a set of coils, each wound to the stator

Electric Motor Type Classification

Permanent Magnet Surface PM Interior PM Wound Field

motors turn as different voltages are applied to the different windings

rotates in one direction while rotor moves in opposite direction of field

this example, field rotates 60while rotor only moves 30

Electric Motor Type Classification

Brushless DC Motor Control

Motor versus PMSM Motor

Trapezoidal Back-EMF voltage

Sinusoidal winding distribution

Electric Motor Type Classification

Permanent Magnet Surface PM Interior PM Wound Field

AC Induction Motor Slip

Electric Motor Type Classification

Freescale Roadmap for Motor Control

BLDC In Depth: BLDC Motor Configurations

Windings Electrical Connection - Star

Windings Electrical Connection - Delta

BLDC motor configuration

BLDC motor configuration

External Rotor Different Motor Configurations

Internal Rotor Different Motor Configurations

Six Step BLDC Motor Control

Brushless DC Motor Control

Brushless DC Motor Control

Step BLDC Motor Control contd

Source: Eastern Air Devices, Inc. Brushless DC Motor Brochure

Brushless DC Motor Control

Step BLDC Motor Control contd

PWM 1 PWM 3 PWM 5 PWM 2 PWM 4 PWM 6

Rotor Electrical Position (Degrees)

Brushless DC Motor Control

Brushless DC Motor Control

BLDC motor control

Brushless DC Motor Control Summary

step control versus sinusoidal control

Six step control

Sensor Example: Hall Effect Sensor

Putting All Together

How to Set Up the Boards

Create a New CodeWarrior Project

2. Select the MC9S08AC16 MCU 4. Click next

3. Select P&E Multilink/Cyclone Pro