DSC MC56F84xxx in the motor control application
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1 Freescale Semiconductor Document Number:AN4625 Application Note Rev. 0, 10/2012 DSC MC56F84xxx in the motor control application by: Arendarik Stanislav 1 Introduction 3-phase high voltage or low voltage motors are used in large number of applications. The various types of motors require a various control algorithms, which are often very complex. Freescale offers a family of Digital Signal lers (DSC) MC56F84xxx dedicated for control of complex motor control algorithms. One of the latest DSC is 100MHz 32-bit MC56F For the successful control of the application the DSC peripherals must be utilized and properly connected to the power hardware control and feedback signals. 2 Key peripherals dedicated for motor control applications The two eflexpwm modules PWMA and PWMB for the control signal generation up to 12 output PWM channels 16-bit resolution for edge, center aligned or asymmetrical PWM Independent control of both edges of each PWM output Independently programmable PWM output polarity Independent top and bottom deadtime insertion Contents 1 Introduction Key peripherals dedicated for motor control applications Power Stage Structures Motor Inverter Interleaved PFC Stage and Measurement Hardware Connections Power Supply and DSC's JTAG Interface connection One 3-Phase Motor without PFC Stage One 3-Phase Motor with PFC Stage Two 3-Phase Motors with PFC Stage Conclusion Freescale Semiconductor, Inc.
2 Power Stage Structures Each complementary pair can operate with its own frequency and deadtime values The PWMA supports NanoEdge placement with 312 ps high resolution Two independent 12-bit high speed cyclic ADC for the analog signal measurements: 8-channel external input each 300 ns conversion speed Each ADC has ability to scan and store up to 8 conversion results 1 x 24-channel 16-bit SAR ADC 1 x 24-channel 16-bit SAR ADC One quadrature decoder Two periodic interval timers Two programmable delay blocks One 12-bit DAC Four high speed comparators with 6-bit DACs for comparator reference Dual inter-module crossbar switch enabling user configuration of data path between internal modules and between internal modules and GPIO pins. This DSC with large FLASH (up to 256 KB) and RAM (up to 32 KB) memories is running at 100 MHz. It is powered from 3.3 V power supply and it has the 5 V tolerant I/O pins. DSC is able to control two 3-phase motors together with one common power factor control (PFC) stage simultaneously. The suggested connections for the one or two 3-phase motors optionally with PFC stage are proposed below. 3 Power Stage Structures Let's start with the design of the key parts of typical power stage. Motor inverter Interleaved PFC and voltage feedback measurement. 3.1 Motor Inverter The basic hardware connection for one motor is shown in Figure 1. 2 Freescale Semiconductor, Inc.
3 Power Stage Structures 15V Gate drivers GAT GBT GCT GAB GBB GCB GAT GAB Q1 Q2 GBT GBB Q3 Q4 GCT GCB Q5 VoutB VoutC Q6 IsA IsB IsC Is_DCB Is_DCB R4 R1 IsA R2 IsB R3 IsC Figure 1. 3-Phase Motor Connection The Figure 1 shows the basic internal connection of the 3-phase power module typical for motor control application. The input gate driver block receives the control signals from the control DSC and generates the control signals for the IGBTs or MOSFETs. This stage is usually able to accept the control signals of the 3.3 V to 5 V level. The block of the gate drivers is powered from the 12 V to 15 V power supply (Vdd). The 3-phase bridge of the power MOSFETs or IGBTs is powered from the high voltage line (100V DC to 400V DC). 3.2 Interleaved PFC Stage The PFC stage is commonly used to improve the efficiency of the power consuming from the power line. The power factor is decreased by the current spikes when the capacitors are charged from the standard diode bridge rectifier. The PFC stage maintains the mains current nearly sine shape, thus the power factor is close to 1. Vin L1 D1 15V L2 D2 Q1 PWM1_PFC1 PWM1_PFC2 Dual gate driver Q2 C1 Is1_PFC Is2_PFC R1 Is1_PFC R2 Is2_PFC Figure 2. Interleaved PFC Stage The basic structure of the interleaved PFC stage is shown in Figure 2. The input to the PFC stage is the Vin voltage. It is the power line AC voltage rectified by the diode bridge. Vin is the pulsating DC voltage. This voltage is measured by the control DSC. The DSC generates the PWM control signals for the power MOSFETs in order to consume sine shape current from the power line. The high frequency switching currents are d by the current resistors R1 and R2, then amplified and measured by the ADC module of the DSC. The output voltage is usually stabilized at level about 380V DC. The voltage provides power for the motor inverter. Freescale Semiconductor, Inc. 3
4 Hardware Connections 3.3 and Measurement The current and voltage measurement is the key factor for the proper control of the motor. The currents of the each phase are d by the power current resistors. The voltage on the each sensing resistor is amplified by the measurement amplifier. The structure of this current amplifier is shown in The amplification factor is suggested to be lower than 10. levels are typically measured by the simple voltage divider, which scales the high voltage to proper level acceptable by the processor. The voltage for phase B and C are like for the phase A in 3.3VA Vin-RECT R5 R14 R15 V-DCB R11 R12 Vin R8 R9 V-A IsA IsA R1 C1 R2 R3 R4 U3 V V R7 C2 I-A C5 R16 C4 R13 C3 R10 1,65Vref R6 A A A A and current amplifier for phase A The input components R1, R2 and C1 form the noise filter. The voltage reference 1.65 V enables the measurement of currents of the both polarities. For the current measurement this reference voltage is equal to zero. Then the only positive current polarity is measured. At the output of this amplifier is the simply low pass filter which improves the measurement accuracy. The output of this filter is connected to the ADC input of the DSC. 4 Hardware Connections This section describes the DSC MC56F84xxx connections for the various configurations of the motor control application. The field oriented control (FOC) is mostly used for control of the 3-phase generic motors. The control algorithm requires the simultaneous (at the same time) measurement of the currents of the two phases of the 3-phase system. This task can be accomplished by the two ADC modules in the DSC. The measured values are processed by the DSC software algorithm. The control algorithm then generates the 3-phase PWM signals for the power stage control. The basic control algorithm is shown in Figure 4. 4 Freescale Semiconductor, Inc.
5 Hardware Connections wreq Ramp Speed control PI controller Field control west Q- control torque PI controller PI controller D- control flux q est Tracking observer Uq Ud a,b d,q Back-EMF observer Ua Ub /measured ripple elimination a,b d,q a,b,c PWM-C PWM-B PWM-A a,b I,a I,b a,b,c a,b la lb 3-phase power stage Figure 4. Basic Block for PMSM The control DSC MC56F84xxx is able to manage all these tasks for simultaneous control of the two motors with PFC stage together. The following sections describe the suggested hardware connection for one and two motor control with PFC stage. 4.1 Power Supply and DSC's JTAG Interface connection The DSC's power supply pins and JTAG connection for DSC is shown in Figure 5. Please meet the basic power supply rules for the layout design place the blocking capacitors as close to DSC's power supply pins as possible. 3.3V 3.3V C9 C10 C11 3.3VA A C12 C13 2.2u C14 2.2u C8 C15 2.2u VDD1 VDD2 VDD3 VDD4 VDDA VSSA VCAP1 VCAP2 VCAP3 VSS1 VSS2 VSS3 VSS4 VSS5 TDI TDO TCK TMS RESET R1 47k R2 47k J1 JTAG R3 47k MC56F84789_LQFP-100 Figure 5. DSC's power supply pins and JTAG connection. 4.2 One 3-Phase Motor without PFC Stage This is the simplest motor control application usually used for the low power (< 100W) application. The power limitation is due to valid regulation the only low power motor control applications can be used without PFC stage. Freescale Semiconductor, Inc. 5
6 Hardware Connections AC line Diode bridge 3-Ph. inverter PMSM Sensorless FOC control Application control Application SW DSC MC56F84xxx Figure 6. One Motor without PFC Stage The block schematic of the power circuit for the one motor control without PFC stage is shown in Figure 6. The power supply schematic is shown in Figure 7. 15V 3.3V 3.3VA L N PE RV1 Input filter DC AC1 AC2 DC C2 2n2 C3 2n2 C1 470u Auxiliary DC/DC C4 10u L1 C5 Bead L2 Bead C6 C7 2.2u A Figure 7. Power supply without PFC The measured currents and voltages are scaled by the voltage and measurement and connected to the control DSC as in Figure 8. 6 Freescale Semiconductor, Inc.
7 Hardware Connections I-A I-B V-A V-B I-DCB I-A I-C V-C V-DCB ANA0 ANA1 ANA2 ANA3 ANA4 ANA5 ANA6 ANA7 ANB0 ANB1 ANB2 ANB3 ANB4 ANB5 ANB6 ANB7 ANC16 ANC17 ANC18 ANC PWM1_D1 84 PWM1_D2 PWM2_AT PWM2_AB PWM2_BT PWM2_BB PWM2_CT PWM2_CB MOSFETs drivers Figure 1. VoutB VoutC MC56F84789_LQFP-100 Figure 8. Measurement and control signals for one 3-phase motor without PFC 4.3 One 3-Phase Motor with PFC Stage This configuration is often used for the high power motor control application. For higher power the interleaved PFC stage is used. AC line Interleave PFC 3-Ph. inverter PMSM Interleave PFC control Sensorless FOC control Application control Application SW DSC MC56F84xxx Figure 9. One Motor with PFC Stage The main 3-phase motor with the PFC stage connection is in Figure 9. The main power circuit for the one motor control with PFC stage connection is shown in Figure 10. Freescale Semiconductor, Inc. 7
8 Hardware Connections L N PE RV2 Input filter DC Vin-RECT Interleave PFC 15V 3.3V 3.3VA Figure 2. C21 AC1 2n2 L4 DC Auxiliary DC/DC Bead AC2 PWM1_PFC1 PWM1_PFC2 IPFC1 IPFC2 C22 2n2 C20 470u C18 10u C23 L3 Bead C24 A C19 2.2u Figure 10. Power supply with interleaved PFC stage The DSC power supply circuits and JTAG connection are the same as in previous configuration. It is shown in Figure 5. The measured currents and voltages are processed by the measurement and connected to the control DSC as in Figure 11. Vin-RECT PWM1_PFC1 PWM1_PFC2 Interleaved PFC stage Figure 2. Vin V-DCB I-PFC1 I-PFC2 I-A I-B V-A V-B I-DCB I-PFC I-A 33 I-C 34 V-C 36 Vin 42 V-DCB 30 I-PFC ANA0 ANA1 ANA2 ANA3 ANA4 ANA5 ANA6 ANA7 ANB0 ANB1 ANB2 ANB3 ANB4 ANB5 ANB6 ANB7 ANC16 ANC17 ANC18 ANC PWM1_D1 84 PWM1_D2 PWM2_AT PWM2_AB PWM2_BT PWM2_BB PWM2_CT PWM2_CB PWM1_PFC1 PWM1_PFC2 MOSFETs drivers Figure 1. VoutB VoutC MC56F84789_LQFP-100 Figure 11. Measurement and control signals for one 3-phase motor with PFC The difference to previous is only the PFC stage control PWMs and PFC currents measurement. 4.4 Two 3-Phase Motors with PFC Stage This configuration is mostly used in the heating, ventilating and air conditioning (HVAC) appliances. This configuration comprises the two PMSM with PFC stage as shown in Figure Freescale Semiconductor, Inc.
9 Conclusion 3-Ph. inverter motor 2 PMSM #2 AC line Interleave PFC 3-Ph. inverter PMSM #1 Interleave PFC control Sensorless FOC control Sensorless FOC control motor 2 Application control Application SW DSC MC56F84xxx Figure 12. Dual Motor with PFC Stage The hardware connection of the ADC and PWM pins of the control DSC is in Figure 13. Vin-RECT PWM1_PFC1 PWM1_PFC2 Interleaved PFC stage Figure 2. Vin V-DCB I-PFC1 I-PFC2 I1-A I1-B I2-A I2-B I-PFC1 V1-A V1-B I-DCB I1-A 33 I1-C 34 I2-A 36 I2-C 42 I-PFC2 30 V1-C Vin I-DCB2 V2-A V2-B V2-C ANA0 ANA1 ANA2 ANA3 ANA4 ANA5 ANA6 ANA7 ANB0 ANB1 ANB2 ANB3 ANB4 ANB5 ANB6 ANB7 ANC16 ANC17 ANC18 ANC19 PWM2_AT PWM2_AB PWM2_BT PWM2_BB PWM2_CT PWM2_CB MC56F84789_LQFP PWM1_PFC1 PWM1_D1 PWM1_D2 84 PWM1_PFC2 71 PWM2_AT 70 PWM2_AB 79 PWM2_BT 78 PWM2_BB 73 PWM2_CT 72 PWM2_CB MOSFETs drivers Figure 1. MOSFETs drivers Figure 1. VoutB VoutC VoutB VoutC Figure 13. Measurement and control signals for two 3-phase motors with PFC 5 Conclusion The application note suggests the proper connection of the DSC MC56F84xxx for motor control applications. Particularly it deals with ADC, PWM, current sensing and other necessary connections of pins of DSCs. Freescale Semiconductor, Inc. 9
10 Conclusion The main peripherals for this application are the ADC and PWM modules. The ADC module is used for all voltage/currents measurements. The ADC measurement moment must be properly set due to switching noise elimination. The ADC module provides many options for the right sampling time synchronization with the generated PWM signals. The PWM module generates the control signals for the power driver. The right consideration must be done for each application regarding the package pinout. The lowest pin count package (48 LQFP) meets the minimum requirements for one PMSM control. The largest package (100 LQFP) can be used for the dual motor control with PFC stage. The internal cross-bar supports flexibility for the final pinout configuration for the each package. 10 Freescale Semiconductor, Inc.
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Is Now Part of To learn more about ON Semiconductor, please visit our website at
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Distributed by: www.jameco.com 1-800-831-4242 The content and copyrights of the attached material are the property of its owner. Preferred Device Small Signal MOSFET 500 ma, 60 Volts N Channel Features
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