IBM Platform Technology Symposium

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1 IBM Platform Technology Symposium Rochester, Minnesota USA September 14-15, 2004 Remote control by CAN bus (Controller Area Network) including active load sharing for scalable power supply systems Authors: Daniele Sabbatini : Software Design Engineer Angelo Nicolini : Technology and Quality Director ROAL Electronics s.p.a. Via Jesina 56/A 60022, Castelfidardo ITALY 1

2 Remote control by CAN bus (Controller Area Network) including active load sharing for scalable power supply systems Abstract: In modern power supply systems, connectivity, diagnostic and remote control are needed. Past and current designs take advantage of RS232, RS422, I 2 C-bus, and others well known communication protocols. The CAN-bus was originally designed for the automotive industry, but recently it has become popular in the industrial process control too. This paper will discuss why and how the CAN-bus is able to improve performances in power management, and a practical implementation will be presented. 2

3 CAN-bus overview - CAN-bus was first developed by BOSH in 1986 and V2.0x is the latest issue - There are two ISO standards for CAN:ISO up to 125Kbit/s ISO up to 1Mbit/s - CAN specification states an asynchronous serial communication protocol -It allows point-to-point communications in a multi-master environment - Can acts like Ethernet, it uses CSMA/CD & AMP ( Carrier Sense Multiple Access / Collision Detection with Arbitration on Message Priority) - Communications are broken in messages, the message concept works like a broadcast, so that the communication isn t address based but contents based - The message ID classifies the message payload, so that receiving nodes accept or discard the message in function of its data type - The communication reliability is ensured by a 15 bit hardware checksum control, without software overhead 3

4 Advantages using CAN bus in power supply systems - Safe multi-master environment : each of all nodes can become master on the fly - Intrinsic error detection and automated retransmission handled directly in hardware - The broadcast criteria allows to add new functions without reconfiguring the network and without changes to the already installed nodes - Noise Immunity : The bus media is a balanced differential line, avoiding ground noise and currents effects, it allows to displace various power supplies around the system, optimizing space and cooling without short return cables (ground plane) constraints - Low cost : due to the large diffusion of CAN in automotive and industrial control, a wide range of dedicated peripherals and all-in-one microcontrollers are currently available and cheap - Know-How : Consolidated knowledge, certificated software libraries and powerful diagnostic and developing tools allow us to manage and solve design issues and to speed up the debug phase 4

5 Intrinsic limitations - Collisions and Arbitrating can make the communication timings not strictly deterministic. You must take care of the average bus load in order to guarantee enough bandwidth to time-sensitive communications. - Due to the Bitwise Arbitrating Technique, the end-to-end propagation delay must be lesser than 25 50% of the bit time, thus, the maximum bus physical length is limited by the desired bit rate and vice versa. - The physical bus is in all aspects a so called transmission line, thus his nominal impedance must be respected for the whole path, if not, reflections take place. For this reason the bus must be deployed linearly on the field, star or ring topologies are not allowed. The bus must be well terminated on both ends with a resistive dummy load identical to the bus line nominal impedance. 5

6 Proposed implementation The proposed implementation is based on a 8 bit microcontroller with built-in CAN controller interfaced to the physical bus (balanced twisted pair) through a standard Bus Transceiver I.C. uc characteristics 32Kb Flash ROM 1Kb SRAM 16 MHz CISC Core 48 I/O Lines 4 x 8 bit PWM 5 Timers 16 x 10 bit ADC SCI, SPI, CAN serial ports Transceiver characteristics Fully ISO (1Mbit) compliant Bus Transients Protected (Automotive Specs) High Common Mode Rejection Slope Control (for Bus EMI reduction) Thermally Protected Low Power Stand-by mode Up to 110 nodes on the same Bus In order to guarantee a reliable 100 meters Bus operation, considering the desired functions and consequent Bus Data Flow, a good trade-off was obtained developing a proprietary CAN-bus high level communication protocol that allows to connect up to 3 groups of 3 units on the same bus running at 125Kb/s. 6

7 CAN-Bus Remote Control Functions Power On / Off Output voltage and current monitoring Output adjust Current limitation adjust Internal temperature monitoring Alarms and status indications VAC Input Identification (digital labeling) Errors and faults history Working life counter Converter Primary Analog Control Primary VAC Voltage Sense Converter Secondary Current Sense Voltage Sense Analog Control Secondary Output Adj. Current Lim Current Share Ctrl Power ON / OFF Temperature Monitoring uc & CAN BUS FAN VDC Output Voltage & Current monitoring CAN-Bus Link Fan Speed Monitoring & Control To Previous Power Fan speed monitoring & control Active current sharing 7 To Next Power

8 Current Sharing Over CAN-bus detail Within a group, one power supply become the communication master and starts collecting the actual output current of each unit. Hence, following the highest current algorithm, it calculates the target current and sends a broadcast current sharing message to the group. Each unit captures the current sharing message and adjust its own output voltage in order to obtain the current balancing. CAN-Bus From The Power Stage Output Current OUT Transceiver uc Target Current Level To the voltage control loop In general, the communications master and the current sharing master are independent, and its designation is fully dynamic. In case of fault another unit became the communication master and handles the whole process. 8

9 Unit Selection Remote control panel Output monitoring Internal Temperature Current Sharing Activity ON /OFF & Configuration Status & Alarms 9

10 CAN-Bus Connectivity developed product family Input Vac Single output W, 12V Version, 16.4W / Inch W, 48V Version, 20.5W / Inch 3 Multiphase digital PFC (patent pending) Interleaved DC-DC converter Secondary synchronous rectification CAN-Bus management 10

11 Conclusions - A new product family with CAN-Bus connectivity has been introduced offering the followings advantages : A high noise immunity current sharing system High reliability remote control Easy power system scalability Expandable multiple monitoring system Easy software control user interface Suitable for Hi Power 48V, 24V or 12V Bus System management 11

12 Thank you for your attention 12

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