Pulse Width Modulation (PWM) Cornerstone Electronics Technology and Robotics II

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1 Pulse Width Mdulatin (PWM) Crnerstne Electrnics Technlgy and Rbtics II Administratin: Prayer PicBasic Pr Prgrams Used in This Lessn: General PicBasic Pr Prgram Listing: Lab 1 pwm1 as a.pdf file: Lab 2 hpwm1 as a.pdf file: Lab 2 hpwm2 as a.pdf file: Lab 3 hpwm3 as a.pdf file: Lab 4 pwm_hpwm1 as a.pdf file: Pulse Width Mdulatin (PWM): Intrductin: Electric mtr speed is cntrlled by increasing and decreasing the effective vltage t the mtr. Mre vltage and the mtr rtates faster, less vltage and the mtr slws dwn. The instinctive way t cntrl mtr speed is t cnnect a rhestat between the mtr and the pwer supply t adjust the vltage, but this methd has several shrtcmings which will be discussed in this lessn. A better methd f managing mtr speed is t switch the pwer t the mtr n and ff very quickly. Rather than slwing a mtr dwn by reducing the mtr supply vltage frm the full rated vltage, PWM prduces digital pulses at the full mtr rated vltage. Pulse Width Mdulatin, r PWM, is a technique fr creating the series f n-ff pulses. This n-ff square wave pattern changes the prtin f the time the signal is n versus the time that the signal is ff (Figure 1). Figure 1: Sample Pulse-Width-Mdulatin (PWM) Signal Wavefrm 1

2 Prblems Using a Rhestat t Cntrl a Mtr: As nted abve, t reduce the speed f a mtr is seems natural t place a rhestat between the mtr and the pwer supply, but this methd has sme inherent prblems: One difficulty with this methd is that the vltage drp acrss the resistr represents energy lst in the frm f heat which is a waste f valuable energy, especially frm a battery pwer surce (Figure 2). Figure 2: Mtr Cntrl Using a Rhestat (NOT Recmmended) Mtr trque is directly related t the vltage supplied t the mtr. The rhestat reduces the vltage t the mtr which prprtinally reduces the trque the mtr delivers. Anther shrtcming is this when the mtr is running and yu set the rhestat fr a very slw speed then restart the mtr, the mtr may nt rtate. It takes mre energy t start a mtr than t keep it running. Duty Cycle: Definitin fr ur purpses: The percentage f time a mtr is n. Frmula definitin f duty cycle: Duty Cycle = 100% x Pulse Width/Perid Where: Duty Cycle in (%) Pulse Width = Time the signal is in the ON r high state (sec) Perid = Time f ne cycle (sec) Figure 3: PWM Signal Wavefrm Terms When the duty cycle is 0%, the lad (mtr) is fully ff; when the duty cycle is 100%, the lad is fully n. 2

3 Examples: Figure 4: Examples f Several Duty Cycles The lessn cntinues n the next page. 3

4 Example Duty Cycle Calculatin: A PWM wavefrm is +12 vlts fr 40 us and 0 vlts fr 10 us (Figure 5). What is the duty cycle fr the PWM signal? Perid = Pulse Width + Time OFF Perid = 40 us + 10 us Perid = 50 us Duty Cycle = 100% x Pulse Width / Perid Duty Cycle = 100% x (40 us / 50 us) Duty Cycle = 80% Figure 5: Duty Cycle Example Calculatin What is the frequency f this wavefrm? Frequency = 1 / Perid Frequency = 1 / 50 us Frequency = 1 / sec Frequency = 20,000 Hz r 20 khz Theretical Average Vltage: The actual vltage f a PWM signal depends upn the lad. Frmula: Theretical Average Vltage = Vltage Full x Duty Cycle Example frm Figure 5: Figure 6: Average Vltage f Duty Cycle Example Average Vltage = 12 Vlts x 80% Average Vltage = 9.6 Vlts 4

5 Details abut PWM: Since the mtr is at full vltage during the ON pulse, the mtr runs at full trque during the ON pulse. A 25% duty cycle reduces the pwer applied t the mtr clse t 25%, yet the speed may nt be reduced t 25% f the maximum speed. A PWM signal is at a fixed frequency. A very lw PWM frequency will make the mtr rtate in a sequence f 'jerks', a slightly higher frequency will cause the mtr t make an audible humming sund. The frequency f a PWM mtr signal shuld be 20 khz r mre t ensure that the mtr whine is utside the nrmal human hearing range (20 20,000 Hz). If yur mtr driver circuitry uses MOSFETs, the PWM frequency shuld never exceed the switching speed f the MOSFET. Because f the weight f the mtr armature and its inertia, the mtr speed wn't vary nticeable between each n and ff pulse, prvided the pulses are shrt enugh and clse enugh tgether. Pulse-Width Mdulatin (PWM) is a way f cntrlling the pwer f an electric circuit that wastes very little electrical energy. The signal is fed thrugh a transistr switch which has little resistance while in the ON state. Pwer MOSFETs generally have a drain t surce resistance in the ON-state (R DS(ON) ) measured in the hundredths f an hm (Figure 7). Since the resistance is s small, little energy is cnsumed by the transistr switch while in the ON-state. Figure 7: The Drain t Surce Resistance in the ON-state is Measured in the Hundredths f an Ohm Check ut hw yur mtr cntrller cpes with frward and reverse. Sme cntrllers use the PWM fr speed and anther pin t set directin (frward r reverse). Other cntrllers achieve it all in the ne PWM signal e.g. duty cycles < 50% are reverse and > 50% are frward. 5

6 New PicBasic Pr Cmmands: PWM Frmat: PWM Pin,Duty,Cycle Outputs a pulse width mdulated pulse train n Pin. The Duty cycle fr each PWM cycle ranges frm 0 (0%) t 255 (100%). This PWM cycle is repeated Cycle times. Pin may be a cnstant, 0-15, r a variable that cntains a number 0 15 (e.g. B0) r a pin name (e.g. PORTA.0). The Cycle time f PWM is dependent upn the scillatr frequency. If a 4MHz scillatr is used, each Cycle is abut 5ms lng. If a 20MHz scillatr is used, each Cycle is abut 1ms in length. Defining an OSC value has n effect n PWM. The Cycle time always changes with the actual scillatr speed. If yu want cntinuus PWM utput and the PICmicr MCU has PWM hardware, HPWM may be used instead f PWM. Pin is made an utput just prir t pulse generatin and reverts t an input after generatin stps. The PWM utput n a pin lks like s much garbage, nt a beautiful series f square waves. A filter f sme srt is necessary t turn the signal int smething useful. An RC circuit can be used as a simple D/A cnverter: Example: PWM 7,127,100 Sends a 50% duty cycle PWM signal ut Pin RB7 fr 100 cycles Perfrm Pulse Width Mdulatin LAB 1 pwm1.pbp HPWM: Frmat: HPWM Channel,Dutycycle,Frequency Outputs a PWM signal using the PICs PWM hardware which is available n sme PICs including the PIC16F88. The default HPWM Channel 1 n the 16F88 is RB0. In the specificatin sheet, it is referred t as CCP1. RB3 is an alternative pin fr CCP1, but the PIC must be recnfigured befre this pin can be used. See the green PicBasic Pr Cmpiler manual by micrengineering Labs, Inc. fr details. The Dutycycle fr each HPWM cycle ranges frm 0 (0%) t 255 (100%), similar t Duty fr the PWM cmmand. Frequency sets the desired frequency f the PWM. The lwest frequency fr the PIC16F88 at an scillatr setting f 4 MHz is 245 Hz and the highest is 32,767 Hz. The HPWM cmmand runs in the backgrund f yur prgram, meaning it will cntinue t run while the prgram is executing ther cmmands. Cmplete Pulse Width Mdulatin LAB 2 hpwm1.pbp Mtr Calibratin: Since ur rbtic cars are equipped with differential drive, it is essential that bth mtrs perate at the same rpm when navigating frward r backward. The dc mtrs must be calibrated t ensure bth mtrs rtate at the same rpm. Perfrm Pulse Width Mdulatin LAB 3 PWM Calibratin Perfrm Mtr Cntrl Pulse Width Mdulatin LAB 4 Using PWM fr Speed Cntrl with the SN

7 Crnerstne Electrnics Technlgy and Rbtics II Pulse Width Mdulatin LAB 1 pwm1.pbp Purpse: The purpse f this lab is t acquaint the student the PicBasic Pr cmmand PWM and hw t make basic cnnectins f a mtr t a PIC prgrammed with PWM. Apparatus and Materials: 1 Breadbard with +5VDC and +12VDC Pwer Supply 1 PIC16F88 1 1K Resistrs 1 4.7K Resistr 1 2N2222 NPN Transistr 1 1N5817 Schttky Dide 1 12 Vlt DC Mtr Prcedure: Wire the circuit belw n yur breadbard: Open pwm1.pbp frm yur flder and dwnlad t the PIC. The pwm1.pbp prgram changes the mtr speed t three levels. Run the prgram and bserve the mtr speed changes Nw save pwm1.pbp as pwm10.pbp. Experiment by changing the values f Duty first, and then Cycle in the PWM cmmand. Circuit fr pwm1.pbp 7

8 Crnerstne Electrnics Technlgy and Rbtics II Pulse Width Mdulatin LAB 2 hpwm1.pbp Purpse: The purpse f this lab is t acquaint the student with the cmmand HPWM and hw it runs in the backgrund while the prgram executes ther cmmands. Apparatus and Materials: 1 Breadbard with +5VDC and +12VDC Pwer Supply 1 PIC16F88 1 1K Resistrs 1 4.7K Resistr 1 2N2222A NPN Transistr 1 1N5817 Dide 1 12 Vlt DC Mtr The Class Used the Jamec # Gearhead 72 RPM Mtr Prcedure: Wire the circuit as shwn belw. Lad hpwm1.pbp int the PIC16F88. The hpwm1.pbp prgram runs the HPWM cmmand in the backgrund while executing ther PicBasic Pr cmmands. Take nte that the mtr cntinues t run as the prgram executes the ther prgram cmmands. Circuit fr hpwm1.pbp Nw save hpwm10.pbp as hpwm10.pbp and change the Dutycycle values. Open hpwm2.pbp and lad int the PIC16F88. This prgram changes the value f the Dutycycle frm 90 t 255 and then t 0. The mtr speed respnds accrdingly. 8

9 Crnerstne Electrnics Technlgy and Rbtics II Pulse Width Mdulatin LAB 3 PWM Calibratin Purpse: The purpse f this lab is t acquaint the student calibrating mtr rtatinal speeds driven by PWM. Apparatus and Materials: 1 RPM Meter 1 Breadbard with +5VDC and +12VDC Pwer Supply 1 PIC16F88 1 1K Resistrs 1 4.7K Resistr 1 2N2222A NPN Transistr 1 1N5817 Schttky Dide 2 DC Mtrs f the Same Mdel Prcedure: Use the same circuit that was used in Lab 1 fr Lab 3. Circuit fr PWM and HPWM Calibratin Mtr 1 Calibratin with PWM Cmmand: Label the mtrs Mtr 1 and 2 and cnnect the pwer supply psitive lead t the + terminal n Mtr 1 and the negative lead t the ther terminal n Mtr 1. This will be cnsidered frward fr Mtr 1. Make sure the car des in fact travel frward, nt in reverse. Using pwm10.pbp, empirically determine the smallest Duty value befre Mtr 1 stps rtating. This number will be used as the smallest Duty value in the remaining discussin. 9

10 Calculate Input Values: Divide the range frm the smallest Duty value t 255 int 9 almst equal parts. Fr example, if the smallest Duty value is 140, subtract 140 frm 255 t yield 115. Divide 115 by 9 t get 12.77, r runded, 13. Start the input values at 140. Write each f these input values dwn. Nw add 13 t 140 t get the secnd input value, 153. T calculate the remaining input values, cntinue adding 13 t the previus ttal until yu arrive at apprximately 255. In this example, the input values wuld be: 140, 153, 166, 179, 192, 205, 218, 231, 244, and 257. Setting the Calibratin Graph Scales: Set the hrizntal scale frm yur smallest Duty value (at the graph rigin) t 255. Adjust the placement f the 255 value s that the lines n the scale make sense when pltting the ther input values. Prgram the PIC16F88 with the Duty value 255 s yu can determine the highest rpm that yu will measure. Set the vertical scale using this rpm value as the maximum value. Again, adjust this maximum value s the lines n the scale make sense. Fr each input value, measure the rpm f Mtr 1 and plt the crdinates n the calibratin graph. Label this plt as Mtr 1 Frward. Switch the plarity f the mtr leads and repeat the whle calibratin prcess fr Mtr 1 in reverse. Plt the results n the same calibratin graph as Mtr 1 Frward. Mtr 2 Calibratin with HPWM Cmmand: Cnnect the psitive lead t the - terminal and the negative lead t the + terminal n Mtr 2. This will be cnsidered frward fr Mtr 2. Repeat the whle calibratin prcess fr Mtr 2 except use hpwm3.pbp. Plt the results n a new calibratin graph and label this plt as Mtr 2 Frward. Switch the plarity f the mtr leads and repeat the whle calibratin prcess fr Mtr 2 in reverse. Plt the results n the same calibratin graph as Mtr 2 Frward. Save these plts fr mtr calibratin in the cming weeks. 10

11 Crnerstne Electrnics Technlgy and Rbtics II Pulse Width Mdulatin LAB 4 Using PWM fr Speed Cntrl with the SN Purpse: The purpse f this lab is t have the student use PWM t change the speed f their rbtic car. Apparatus and Materials: 1 Rbtic Car Platfrm 2 Gearhead DC Mtrs, Jamec # SN Quadruple Half-H Driver, Pllu # LS04 Hex-Inverter 1 PIC16F88 8 1N5817 Dides 1 4.7K Resistr 4 10K Resistrs Ohm Resistrs 2 - LEDs uf Capacitr Prcedure: Wire the fllwing circuit n the rbtic car breadbard. This is the identical circuit that was used in the H-Bridge lessn. Prgram the PIC16F88 with pwm_hpwm_sn pbp. 11

12 Challenge: Using the calibratin data just cllected, prgram the rbtic car t travel frward alng the straight taped line. Use the calibratin graphs t make the rbtic car travel at ½ its maximum speed. Prgram the rbtic car t fllw the straight taped line in reverse. 12

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