Introduction of ACIM and PMSM Motor Control

Transcription

1 June, 2010 Introduction of ACIM and PMSM Motor Control FTF-IND-F0487 Charlie Wu Senior Member, Technical Staff Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink

2 Abstract Intelligent motor control can reduce the energy consumption in AC induction and permanent magnet synchronous motors by 30 percent or more. This session introduces inverter-based motor control principles and demonstrates a three phase permanent magnet synchronous motor control. Participants gain knowledge of the application and overview of Freescale motor control portfolio. Participants discover the use of Freescale's CodeWarrior development environment for code development assistance and debugging. Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 2

3 Agenda Electric Motor Type Classification Vector Control of AC Motors: Principle of Operation Position Sensor Elimination: Sensorless Speed Vector Control Freescale Motor Control Solution Enablement and Development Tools Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 3

4 Electric Motor Type Classification ELECTRIC MOTORS ASYNCHRONOUS AC SYNCHRONOUS DC VARIABLE RELUCTANCE Induction Sinusoidal Brushless Reluctance SR Stepper Permanent Magnet Surface PM Stator same Difference in Rotor Construction Wound Field Interior PM If properly controlled: Provides constant torque Low torque ripple Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 4

5 Global Motor Control Markets and Applications Appliance Typical Motor Type Washing machine/dishwasher/dryer ACIM, PMSM Refrigerator/Freezer BLDC Shaver DC Drills DC Vacuum Cleaner SR Industrial Factory automation Stepper Robotic systems Universal, BLDC Compressors ACIM, PMSM Fans BLDC Air conditioning ACIM, BLDC, PMSM Elevators ACIM Shutters BLDC Gates DC Surveillance platforms DC Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 5

6 Typical Motor Control MCU Peripherals Function Timer: PWM signals < 20Khz Dead time insertion Commutation (mask-out) ADC triggering Fault control ADC Measure current Delay block Set ADC measurement at specific times Position decoder Quadrature decoder inputs if not sensorless Position decoder 6 ch PWM timer Fault inputs Prog delay 12 bit ADC Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 6

7 Choosing Your MCU Depends Upon The same application may have different performance if implemented on different MCUs The peripheral features can significantly impact performance of target application, not CPU only Application Features should be considered Type of motor Current control Type of load Speed control and/or position control Operational mode Number of PID controllers Minimal speed Fault control Maximal speed System Cost! Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 7

8 Agenda Electric Motor Type Classification Vector Control of AC Motors: Principle of Operation Position Sensor Elimination: Sensorless Speed Vector Control Freescale Motor Control Solution Enablement and Development Tools Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 8

9 Understanding the Motor Basics DC Motor Torque Establishment DC Motor Principle The stator of a Permanent Magnet DC Motor is composed of two or more permanent magnet pole pieces Right Hand Rule I = Current Flow B = Magnetice Field The rotor is composed of windings which are connected to a mechanical commutator. In this case, the rotor has three pole pairs Brush DC motor control is simple: Apply voltage Commutation occurs mechanically Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 9

10 Simple Model of a DC Motor Applied Voltage + V d I d Resistor R Inductor L + - Back EMF E = K e Φω - DC Motor Equivalent Circuit Dynamic Motor speed: V ω = d Id R L di dt Ke Φ d Speed is increased by increasing the voltage Torque is controlled by controlling the current Direction is determined by the direction of the current Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 10

11 Asynchronous v. Synchronous 3-phase winding on the stator distributed or concentrated Assumed sinusoidal flux distribution in air gap Different rotor construction and consequences ACIM Squirrel cage (rugged, reliable, economical) No brushes, no PM Low maintenance cost Synchronous Rotor with permanent magnet High efficiency (no rotor loses) Synchronous motor rotates at the same frequency as the revolving magnetic field Asynchronous means that the mechanical speed of the rotor is generally different from the speed of the revolving magnetic field ω Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 11

12 Trapezoidal v. Sinusoidal PM Machine Sinusoidal or Sinewave machine means Synchronous (PMSM) Trapezoidal means Brushless DC (BLDC) motors Differences in flux distribution Six-Step control v. Field-Oriented Control Both requires position information BLDC Motor Control 2 of the 3 stator phases are excited at any time 1 unexcited phase used as sensor (BLDC Sensorless) Synchronous Motor All 3 phases persistently excited at any time Sensorless algorithm becomes complicated Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 12

13 AC Induction Motor The STATOR windings are distributed around the stator to produce a roughly sinusoidal distribution When three phase ac voltages are applied to the stator windings, a rotating magnetic field is produced The ROTOR also consists of windings or, more often, a copper squirrel cage An electric current is induced in the rotor bars which also produce a magnetic field Notice the rotor slip! The Rotor does not quite keep up with the Rotating Magnetic Field of the stator. Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 13

14 Permanent Magnet AC Motor This motor exhibits a smoothly rotating magnetic field where the magnetic gradient of the stator flux is illustrated by the color shading. There is no commutation to cause motor jerking. But how do you create such a smoothly rotating magnetic field???? Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 14

15 3-Phase AC Voltage Generation on a per Phase Basis Each phase is considered a Half H-Bridge Complementary PWMs are used Dead-time is needed to prevent shoot through 50% duty cycle Zero voltage on phase winding Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 15

16 Sinusoidal PWM Generation ACIM / PMSM 100% Phase A Phase B Phase C 75% Duty Cycle 50% 25% 0% Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 16

17 Sinusoidal PWM Generation ACIM / PMSM 100% Phase A Phase B Phase C 75% Duty Cycle 50% 25% 0% Decrease Frequency to the motor Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 17

18 Sinusoidal PWM Generation ACIM / PMSM 100% Phase A Phase B Phase C 75% Duty Cycle 50% 25% 0% Decrease Increase Voltage to the motor Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 18

19 Sinusoidal PWM Generation ACIM / PMSM 100% Phase A Phase B Phase C 75% Duty Cycle 50% 25% 0% Decrease Frequency to the motor Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 19

20 Sinusoidal PWM Generation ACIM / PMSM 100% Phase A Phase B Phase C 75% Duty Cycle 50% 25% 0% Increase Frequency to the motor Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 20

21 Space Vector Rotation Sequence A B C A A Rotating Space Vector B C This is how the rotating magnetic field is made A To reverse rotation direction, swap the connection of any two phases or sequence the field in the opposite direction. B C Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 21

22 Principle of Field Oriented Control (Vector Control) All is about magnetic fields interaction Rotor Magnetic field Stator Magnetic field The torque/force is produced when both fields form an non-zero angle Having the stator magnetic field leading the rotor magnetic field forms an electric motor Then FOC is to control the torque By the field angle By strength of the rotor magnetic field By strength of the stator magnetic field Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 22

23 Principle of Field Oriented Control (Vector Control) All is about magnetic fields interaction Rotor Magnetic field Stator Magnetic field The torque/force is produced when both fields form an non-zero angle Having the stator magnetic field leading the rotor magnetic field forms an electric motor Then FOC is to control the torque By the field angle By strength of the rotor magnetic field By strength of the stator magnetic field Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 23

24 Principle of Field Oriented Control (Vector Control) All is about magnetic fields interaction Rotor Magnetic field Stator Magnetic field The torque/force is produced when both fields form an non-zero angle Having the stator magnetic field leading the rotor magnetic field forms an electric motor Then FOC is to control the torque By the field angle By strength of the rotor magnetic field By strength of the stator magnetic field Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 24

25 Principle of Field Oriented Control (Vector Control) All is about magnetic fields interaction Rotor Magnetic field Stator Magnetic field The torque/force is produced when both fields form an non-zero angle Having the stator magnetic field leading the rotor magnetic field forms an electric motor Then FOC is to control the torque By the field angle By strength of the rotor magnetic field By strength of the stator magnetic field Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 25

26 Principle of Field Oriented Control (Vector Control) All is about magnetic fields interaction Rotor Magnetic field Stator Magnetic field The torque/force is produced when both fields form an non-zero angle Having the stator magnetic field leading the rotor magnetic field forms an electric motor Then FOC is to control the torque By the field angle By strength of the rotor magnetic field By strength of the stator magnetic field Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 26

27 Principle of Field Oriented Control (Vector Control) All is about magnetic fields interaction Rotor Magnetic field Stator Magnetic field The torque/force is produced when both fields form an non-zero angle Having the stator magnetic field leading the rotor magnetic field forms an electric motor Then FOC is to control the torque By the field angle By strength of the rotor magnetic field By strength of the stator magnetic field Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 27

28 Electric Variables in Vector Representation The q axis is the axis motor torque along which the stator field must be developed Axis of phase b +a The d axis refers to the direct axis of the rotor flux -c N -b +b S Rotation +c Axis of phase a Rotor made from permanent magnets Axis of phase c -a Stator windings Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 28

29 FOC Principle Vector Representation Field-Oriented Control (Vector Control) Full motor torque capability at low speed Better dynamic behavior Higher efficiency for each operation point in a wide speed range Decoupled control of torque and flux Short-term overload capability Four quadrant operation Accurate position and velocity signals required Stator current and magnet flux space vectors in the DQ rotating reference frame and electromagnetic torque production T = c ψ i = c ψ i sin e r s r s s ( ) max T i e i = 0 d γ = 90 o ( γ ) Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 29

30 How Do We Control a 3-Phase AC Process? Phase A Phase B Phase C Measured Variable (i.e Current) 3-Phase to 2-Phase α β Stationary to Rotating d d q 3-Phase qac Control Process Rotating to Stationary Control Process α β Control Variable (i.e Voltage) Modulation Phase A Phase B Phase C 3-Ph AC 2-Ph AC 2-Ph DC 2-Ph AC 3-Ph AC DC Convert it to a 2-Phase DC Process!! Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 30

31 How Do We Control a 3-Phase AC Process? Phase A Phase B Phase C 3-Phase to 2-Phase α β Stationary to Rotating d q Control Process d q Rotating to Stationary α β Modulation Phase A Phase B Phase C 3-Ph AC 2-Ph AC 2-Ph DC 2-Ph AC 3-Ph AC DC Convert it to a 2-Phase DC Process!! Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 31

32 Creating Space Vector (3ph 2ph Transformation) The space-vectors can be defined for all motor quantities β B B Ψ s Ψ c Three Phase Stator A Ψ b Ψ a A α C C Because the space vector is defined in the plain (2D), it is sufficient to describe space vector in 2-axis (α,β) coordinate system some times also 2-phase system Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 32

33 Creating Space Vector (3ph 2ph Transformation) The space-vectors can be defined for all motor quantities β B B Ψ s Ψ c Three Phase Stator A Ψ b Ψ a A α C C Because the space vector is defined in the plain (2D), it is sufficient to describe space vector in 2-axis (α,β) coordinate system some times also 2-phase system Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 33

34 Reference Frames The Magic to Convert AC to DC Reference frames Stationary - α, β Rotating rotor speed - d, q y y β α x x All rotating quantities are rectified when viewed from reference frame that rotates synchronously with rotor Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 34

35 i d i q Controlling the Fields and are handled independently. Since the comparison is performed in the rotating frame, motor AC frequency is not seen. Thus, they are treated as DC quantities! ACIM (i d 0) Commanded i d is set to induce a field in the rotor. It is typically held constant unless field weakening is desired. PMSM (id = 0) Commanded i d is set to zero since all the d-axis flux need is supplied by the permanent magnets in the rotor. PMSM or ACIM This is how much torque we want! (commanded) i d + i d i q i q (measured) + (commanded) (measured) - - error(t) error(t) PI PI v d v q i d i q can be used to weaken the field in both ACIM and PMSM machines controls amount of instantaneous torque generated by the motor Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 35

36 Proportional Integral Derivative (PID) Controller The PID controller corrects the error between a measured variable and a desired set-point The PID controller calculation involves 3 separate parameters Proportional Determines the reaction to the current error Integral Determines the reaction based on the sum of recent errors (i.e. steady state error) Derivative Determines the reaction to the rate at which the error has been changing The weighted sum of these three actions is used to adjust the process via a control element such as the position of a control valve or the power supply of a heating element or the voltage to a motor A fast response may require rapid calculation of the PID output and this can force the use of a higher performing CPU core (i.e. DSC, ColdFire, or PPC) Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 36

37 Transformation Calculations i i 3-phase Stationary to 2-phase Stationary (Forward Clark Transform) sα sβ 3 2 = i i i sa sb sc i sb i sq i sβ i s 2-phase Stationary to 3-phase Stationary (Reverse Clark Transform) i i i sa sb sc = i i sα sβ θ rf i sd i sa i i sd sq 2-phase Stationary to 2-phase Synchronous (Forward Park Transform) cosθ rf = sinθ rf sinθ cosθ rf rf i i sα sβ i sc i i sα sβ i sα 2-phase Synchronous to 2-phase Stationary (Reverse Park Transform) cosθ rf = sinθ rf sinθ cosθ rf rf i i sd sq Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 37

38 FOC Transformation Summary Phase A Phase B Phase C 3-Phase to 2-Phase α β Stationary to Rotating d q Control Process d q Rotating to Stationary α β Modulation Phase A Phase B Phase C 3-Ph AC 2-Ph AC 2-Ph DC 2-Ph AC 3-Ph AC DC Stationary Reference Frame Rotating Reference Frame Stationary Reference Frame ALL of these operations can be done on the Freescale DSC Family in about 20 us! Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 38

39 Put It All Together θ d Stationary to Synchronous Frame i d i q = 0 i d i q PI Regulators i a i b i c v d v q θ d Synchronous to Stationary Frame Current Measurement v a v b v c Field Orientation! PWM Module Motorola Dave s Control Center M 6 Transistor Power Stage θ d Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 39

40 FOC Principle Block Diagram Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 40

41 Shunt resistors voltage drop measured Phase Current Measurement S/W calculation of all 3 phase currents needed; e.g. Phase A current sensing is true when bottom switch (transistor) is conducting Simultaneously 2 channels sampled at the same time 12-bit resolution Single conversion time: 1.7 (8.5 ADC clock cycles) Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 41

42 Feedback signals proportional to bus voltage DC Bus Voltage Measurement Bus voltage is scaled down by a voltage divider Values are chosen such that a 400-volt maximum bus voltage corresponds to 3.24 volts at output V_sense_DCB. Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 42

43 Agenda Electric Motor Type Classification Vector Control of AC Motors: Principle of Operation Position Sensor Elimination: Sensorless Speed Vector Control Freescale Motor Control Solution Enablement and Development Tools Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 43

44 Rotor Position Sensor Elimination Introduction FOC requires accurate position and velocity signals Conventional motion control systems uses resolvers or encoders Sensor, wirings, connectors increase the cost of the system and decrease the reliability Application Sensorless PM Motor Control In Lower overall drive cost by eliminating mechanical position sensor Cost sensitive application Increase system performance for the same price Increase position resolution in collaboration of estimator and low cost position sensor Increase system performance Back-up sensor Independent position sensing together with mechanical Safety critical application Increase system redundancy Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 44

45 Sensorless PMSM Control Rotor position estimation is needed Sensorless techniques for rotor position estimation Low speed range position estimation: Speed 0rpm up to 20% nominal speed Techniques based on motor inductance saliency Medium and high speed position estimation: Speed range from 5-10% up to 100% of nominal speed: Speed range of the fridge, air-conditioning applications Where the variable reluctance deviation (saliency) is smaller then BEMF effect BEMF/Flux reconstruction using state observers Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 45

46 Sensorless Methods for PM Motors Classifications of Sensorless Algorithms Utilization of Magnetic Saliency rotor position detected by tracking magnetic saliency carrier signal superimposed to main voltage excitation Calculating an Appropriate Motor Model Proper motor parameters, voltage and current required Issue at zero and low speed estimation Measured current low, distortion by inverter non-idealities Parameter deviation becomes significant with lowering speed Combination of two sensorless algorithms covering the entire speed range Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 46

47 Sinusoidal PM Motor Model in αβ Stationary Frame Salient v. Non-Salient Machine Model in αβ stationary frame Stator Voltage Equations u sα Rs 0 i sα s 0 ψ sα u = sβ 0 R i + s sβ 0 s ψ sβ Stator Flux Linkages of Non-Salient Machine ( θre) ( θ ) ψ sα Ls 0 isα cos ψ PM ψ = sβ 0 L + i s sβ sin re Stator Flux Linkages of Salient Machine ( ) ( ) ( ) Δ ( ) Saliency Inductance Matrix and Rotor Angle Calculation ( ) ( ) ψ sα L+ΔL cos 2θre ΔL sin 2θ i re sα cos θre ψ PM ψ = sβ L sin 2θre L L cos 2θ i + Δ re sβ sin θre ( θre ) ( θre ) ( θ ) Δ ( θ ) L+ΔL cos 2 ΔL sin 2 L = ΔL sin 2 re L L cos 2 re L 2θ re tan + L = arc L11 L22 s position dependency d dt Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 47

48 Sinusoidal PM Motor Model in DQ Rotating Frame Salient v. Non-Salient Machine Model in DQ rotating frame Stator Voltage Equations usd Rs 0 isα s ωre ψ sd u = sq 0 R i + s sβ ωre s ψ sq Stator Flux Linkages of Non-Salient Machine ψ sd Ls 0 isd 1 ψ PM ψ = sq 0 L + i s sq 0 Stator Flux Linkages of Salient Machine ψ sd Ld 0 isd 1 ψ PM ψ = sq 0 L + q i sq 0 L the average inductance & ΔL the zero-to-peak differential inductance L = L d + L q 2 Δ L = L d L 2 q L d L q s d dt Direct & Quadrature Inductance Not Equal Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 48

49 Extended Back EMF Definition Computation of position dependent information is contained in two unknown voltage vectors conventional u e and u rel Symmetrical inductance matrix is formed in dq frame then 2*θ e is eliminated in αβ frame Y term is extension of conventional back EMF u i i sin θe sin 2θe cos 2θe i α R α pl α 0 ke re 2 re p L α u = β i + ω ω β i + + β cos( θe) cos( 2θe) sin( 2θe) i β { ( ) u pld Ld L α iα q ω e iα sin( θe ) R {( Ld Lq)( eid iq) ke e} u = ω ω β i + β { ( L ) i + + cos( e ) d Lq ωe pl d β θ uur 123 uur ur uur X ( ) uur uur uur uur uuuuur u u u u u S R L E REL ( ) ( ) us ur Y Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 49

50 Sensorless Method in High Speed Region Since back EMF is not included in the observer model, the current observer acts as a state filter for Back EMF. State filter bandwith limits the performance of the method. Inverse tangent function With two inputs of the extended EMF estimates Yields unfiltered rotor angle without any speed information Angle tracking observer Noise on the position estimate can be filtered out without adding lag to the estimate within its bandwidth Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 50

51 Rotor electrical position extraction by Position and Speed Extraction Inverse tangent function with two inputs of the extended EMF estimates Yields unfiltered rotor angle without any speed information Angle tracking observer Noise on the position estimate can be filtered out without adding lag to the estimate within its bandwidth ( ˆ θ ) ( ˆ θ ) E ˆ ˆ sin α = E e E ˆ ˆ cos β = E e Ê α Ê β Ê atan Ê α β θˆe ˆe θ e sα e sβ ( ˆ ) θ ˆ θ = sin θ θ e e e e + + K s s + sin ( Θ ) K 2 Θ(s) cos( Θ ) Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 51

52 Sensorless Speed Control in Entire Speed Range Speed Control Loop PWM Generation Position Estimation Speed Estimation Current Control Loop Software Portion Hardware Portion Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 52

53 Agenda Electric Motor Type Classification Vector Control of AC Motors: Principle of Operation Position Sensor Elimination: Sensorless Speed Vector Control Freescale Motor Control Solution Enablement and Development Tools Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 53

54 Freescale Motor Control Solution Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 54 54

55 Freescale Motor Control Processors High-end Motor Control MMIPS < 0.5 1W Mid-range Motor Control MMIPS < 0.5 1W MPC553x MCF5234 MC56F83xx DSC56F802x/3x DSC56F801x DSC56F800x DSC56F824x/5x MC56F82xx MPC5604P Low-end Compact 6 30 MMIPS < 0.5W MC9S12XH MC9S08AW MCF51AC256 MC9S08AC128 MC9S08MP16 MCF51xx MC9S08xx Analog PoE MC34670 H-bridges MC33880, 87, MC33926, 32 Signal Conditioning MC33972, 75 Power Supply MC34727, 26 Linear Regulator MC33742, MC33910, 11,12 Pre-driver MC33937 In Development Power e200 DSC 16-bit S08 8-bit Analog Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 55 55

56 Freescale Single Chip Soultion Strategy High Speed DSP Core Serial Peripherals Control Peripherals CPU:56800E Flash Memory EEPROM RAM CANs I2Cs SPIs SCIs PWMs Multi Function Timers Tick Timers (PIT) Clock System PLL OSC HS_CLK Sys_CLK Sys_Bus Internal ROSC Cross Bar Interconnection Vbus 3.3V On-Chip Regulator COP SIM LVI POR 12bit ADC ACMPs DACs System High System Clock System Clock Power Source Data/Control Signal Freescale Technology Single Power Supply Advanced DSP Core Scaleable product portfolio with full enablement Internal inter-module Connections How are you doing this today? Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 56

57 MC9S08MP16/12 Smoother, Safer and Lower Cost BLDC Motor Control Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink

58 Core Ind. version: 50MHz (25MHz bus), -40to105C, 28SOIC, 32LQFP, 48LQFP Auto version: 40MHz (20MHz bus), -40to125C, 48LQFP 2.7V to 5.5V operating range Memory 16KB Flash / 1KB SRAM Features 2x FlexTimers (6ch + 2ch) automatic fault protection, supports up to 50MHz CLK, selectable input capture, output compare, edge- or center-aligned PWM; dead time insertion 3 Analog Comparators h/w sample trigger from PWM module allowing comparison at any point in cycle 2x Programmable Delay Blocks (PDB) 12-ch 12-bit ADC 3.5 us conversion, h/w trigger from PWM module allowing conversion at any point in cycle Programmable Gain Amplifier (PGA) 8-bit Modulo Timer Module (MTIM) LIN SCI, SPI, IIC 3x 5-bit DAC used as a 32 tap voltage reference RTC with periodical timer interval interrupt Software Programmable Internal Clock Source 2 low power modes Power Management Controller (PMC) 3x 8-bit KBI POR/LVI supports 4 interrupt priority levels Background Debug Mode Interface/ICE System Protection Cyclic Redundancy Check Generator (CRC) Watchdog Timer with Independent Clock Source SPI SCI IIC 8-bit MTIM 3x 5-bit DAC RTC MC9S08MP16/12 S08 50MHz CPU 16KB Flash 1KB RAM CRC Generator ICS COP BDM/ICE 13ch, 12-bit ADC & Temp Sensor 6ch+2ch FlexTimer with PWM functions Programmable Gain Amplifier Programmable Delay Blocks (x2) 3x High Speed Analog Comparators Device Package RAM ADC PGA IIC I/O 10K# SRP MC9S08MP16 48LQFP 1KB 13ch $1.30 MC9S08MP16 32LQFP 1KB 12ch $1.20 MC9S08MP16 28SOIC 1KB 8ch $1.10 MC9S08MP12 28SOIC 512B 8ch $1.06 Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 58

59 Smoother, Safer and Lower Cost BLDC Motor Control MC9S08MP16 Key Messages An 8-bit MCU that delivers smooth, safe, Sensorless BLDC motor control for < $1 volume) across a wide speed range of Industrial, Consumer and Automotive applications. Dedicated for Motor Control Safety and System Cost Reduction Broad Motor Control Ecosystem Increased precision and reduced s/ware complexity FlexTimer module (first on S08): dedicated motor control peripheral providing dead-time insertion and fault protection in h/ware, ADC triggering, and paired channel PWM signal generation Smoother sensorless BLDC motor operation 3x Analog Comparators & 12-bit, 2.5 us ADC: can take measurements of high resolution zerocrossing back-emf. PWM cycle can be reset at each commutation boundary to reduce speed dithering in high-speed applications. High ADC resolution enables fast, precise monitoring of system voltages and currents. No ext. comparators and safer motor operation 3x Analog Comparators: in conjunction with the 16-bit PWM FlexTimer fault inputs, provide fast, accurate over-current shutdown protection by driving PWMs to a safe state No ext. op-amps and wide load/speed range Programmable Gain Amplifier: eliminates need for external op-amps by amplifying low level signals such as motor current readings from a low resistance shunt. Dynamically adjusts gain to maintain high resolution A/D readings over a wide range of motor loads and speeds. Off-the-shelf design resources Extensive catalogue of free Motor Control Reference Designs, Application Notes, Software Algorithms, & Libraries covering all motor topologies and performance levels. Cycle time reducing development tools Complimentary C/Warrior Special Edition IDE (32KB) with intuitive Processor Expert Rapid Application Development Tool. Freemaster Remote Real-Time Control and Monitoring Tool. Reduced CPU loading Programmable Delay Block (PDB): efficient and accurate timing of ADC measurements enabling low cost current reconstruction in PWM applications. Also functions as an independent timer to enable Digital Power Factor Correction for HID Light Ballast and Motor Control Applications Compelling entry-level solution Small footprint 28-48pin SOIC and LQFP packages with automotive qualified high temperature option. Resale pricing from <$ volume Enhanced system integrity for safety-critical applications implementing IEC60730 Independently clocked COP and Cyclic Redundancy Check Engine: CLK failure protection and memory content validation No external crystal / resonator Internal Clock Source (ICS): 1.5% accuracy when receiving messages over a LIN bus using the SCI module. Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 59 Complete motor control system solutions Complimentary Analog products: MC ph FET Pre-Driver, MC33880/87 & MC33926/32 H-bridges. Global Motor Control Centres of Excellence Dedicated regional customer design support from concept to delivery (reference design, algorithm, library and driver development)

60 56800/E Family Combining Signal Processing and Controller Functionality Traditional Microcontroller Designed for Controller Code Compact Code Size Easy to Program Inefficient Signal Processing Traditional DSP Engine Designed for DSP Processing Designed for Matrix Operations Complex Programming Less Suitable for Control Instructions Optimized for Controller Code, DSP, Matrix Operations Compact Assembly and C Compiled Code Size Easy to Program Additional MIPS Headroom and extended addressing space Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 60

61 56800E Core Architecture PC LA LA2 HWS FIRA FISR SR OMR LC LC2 PROGRAM CONTROLLER BIT MANIPULATION UNIT EOnCE/JTAG TAP INSTRUCTION DECODER INTERRUPT UNIT LOOPING UNIT A B C D Y0 Y1 X0 AGU M 01 N 3 MAC and ALU R0 R1 R2 R3 R4 R5 N SP Multi-bit Shifter DATA ALU XAB1 XAB2 PAB PDB CDBW CDBR XDB2 Program Memory up to 4 MByte size Data Memory up to 32 MByte size IP-Bus Interface External Bus Interface Shadowed registers; supports execution of fast interrupts Registers available only on the 56800E core Instruction Fetch: PAB PDB - 21 bits (4MB) - 16 bits 1st Data Access: XAB1-24 bits (32MB) CDBR - 32 bit CDBW - 32 bit 2nd Data Access: XAB2 XDB2 Operations Performed: - 24 bits (32MB) - 16 bits 1st - PAB / PDB 2nd - XAB1 / CDBR- CDBW 3rd - XAB2 / XDB2 Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 61

62 56800E Digital Signal Controller Core Summary Dual-Harvard architecture Three simultaneous accesses to program and data memory Eight-stage execution pipeline 155 basic instructions with up to 20 address modes Large address spaces Efficient peripheral interfacing through IP-BUS Interface Fast interrupt support Powerful register sets Shadow registers Single-cycle bit parallel multiplier-accumulator (MAC) Load of two data from memory in the same clock cycle Modulo addressing for circular buffer in no additional time Loops with no overhead Relocatable interrupt Vectors Base Address (VBA) Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 62

63 Cost Effective 56F8000 Solutions 56F8011/56F8013/56F K - 16KB Program Flash 4kB Program/ Data RAM 56800E Core 32MHz JTAG/EOnCE 56F8011/56F8013/56F8014 System Integration Module (SIM) Interrupt Controller PLL Relaxation OSC Voltage Regulator COP Power-On-Reset Power Supervisor Package: 32LQFP In Production Up to 26 GPIOs 1 x SCI 1 x SPI 1x IIC 3-4ch 12bit ADC 3-4ch 12bit ADC Synch 4Ch 16bit Timer 6-ch PWM Output 32 MIPS Performance 12K -16 K Bytes Program FLASH 4 K Bytes Program/Data RAM Tunable Internal Relaxation Oscillator Software Programmable Phase Locked Loop Up to 96 MHz Peripherals Timers and PWMs Up to 6-Output PWM Module with up to 4 Programmable Fault Inputs Selectable PWM frequency for each complementary PWM signal pair Two 12-bit ADCs with up to 8 Inputs, 1.125us conversion rate Synchronization between PWM and ADC Four 16-bit General Purpose Programmable Timers Computer Operating Properly Timer Serial Ports: SCI, SPI, I2C Up to 26 GPIOs Versatile pin usage Low Power Consumption 59mA Max and.026ma Min JTAG/EOnCE Debug Port Industrial and Automotive temp Cost Effective Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 63

64 56F8023/56F8025/56F8036/56F KB - 64KB Program Flash 4kB-8KB Program/ Data RAM 56800E Core 32MHz JTAG/EOnCE System Integration Module (SIM) Interrupt Controller PLL Relaxation OSC Crystal OSC Voltage Regulator COP Power-On-Reset Power Supervisor 2 x 12 bit DAC Package 32 LQFP, 44LQFP, 48LQFP, 64LQFP In Production 56F8000 Family Expansion 56F8023/56F8025/56F8036/56F8037 Features Up to 53 GPIOs 2 x QSCI 2 x QSPI 1xIIC 1x MSCAN 3xPIT 8ch 12bit ADC 8ch 12bit ADC Synch 8Ch 16bit Timer 6-ch PWM Output 2 x Comparators 32 MHz/32 MIPS 56800E Core V Operation 32K-64K Bytes Program FLASH 4K-8K Bytes Program/Data RAM Flash security Tunable Internal Relaxation Oscillator Software Programmable Phase Locked Loop Up to 96 MHz Peripherals Timers and PWMs 6 Output PWM Module with 4 Programmable Fault Inputs Selectable PWM frequency for each complementary PWM signal pair Two 12-bit ADCs with up to 16 Inputs, 1.125us conversion rate Up to Two 12-bit Digital to Analog Converters Two Analog Comparators Synchronization between PWM and ADC 4 or 8 16-bit General Purpose Programmable Timers 1 or 3 Programmable Interval Timers (PIT) Computer Operating Properly Timer 2-Queued Serial Communications Interface 2-Queued Serial Peripheral Interface Optional MSCAN I 2 C Communications Interface Up to 53 GPIOs Versatile pin usage JTAG/EOnCE Debug Port Lead Free Green Packages Industrial and Automotive temp Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 64

65 12-16KB Program Flash 2KB Program/ Data RAM 56800E Core 32MHz JTAG/EOnCE System Integration Module (SIM) Interrupt Controller PLL Relaxation OSC Voltage Regulator COP Power-On-Reset Power Supervisor In Production Less than $2.00 in Volume Ultra Low cost 56F8000 member: 56F8002, 56F F8002, 56F8006 Crystal OSC 1 Period Int Timer Up to 40 GPIOs 1 SCI 1 SPI 1 IIC 2 x 16bit Timers 3 x Analog Comparators 2 x Programmable Gain Amplifiers 12ch 12bit ADC 12ch 12bit ADC Synch Programmable Delay Block 6-ch PWM Output 28SOIC, 32SDIP, 32LQFP, 48 LQFP 32 MHz/32 MIPS 56800E Core V Operation 12K - 16K Bytes Program FLASH with Flash security 2K Bytes Program/Data RAM Tunable Internal Relaxation Oscillator and 32KHz clock Phase Locked Loop (PLL) Up to 96 MHz Peripherals Timers, PWM & Hi-SCI 6 Output PWM Module with 4 Programmable Fault Inputs Programmable Dead timer insertion Programmable PWM generation for Power supply apps Multiple PWM Frequency outputs Two Programmable Gain Amplifiers with x2, x4, x8, x16 gains (Clocked in order to cancel input offset) Two 12-bit ADCs with up to 24 Inputs, 2.5us Per conversion Programmable Delay Block provides precise control of ADC/PGA sample times relative to PWM reload cycles Three High Speed Analog Comparators 2 multiple function Programmable Timers Computer Operating Properly Timer One Periodic Interval Timer (PIT) 1 High Speed Serial Communication Interface (Hi-SCI) 1 Serial Peripheral Interface (SPI) I 2 C Communications Interface Up to 40 GPIOs Versatile pin usage JTAG/EOnCE Debug Port Lead Free Green Packages Industrial temp: -40C 105C Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 65

66 56F8000 Series Feature Summary 56F F8006 Performance 32MHz/MIPs 32MHz/MIPs 32MHz/MIPs 32MHz/MIPs 32MHz/MIPs 32MHz/MIPs 32MHz/MIPs 32MHz/MIPs 32MHz/MIPs Temperature Range (V) -40C~105C -40C~105C -40C~105C -40C~125C -40C~125C -40C~125C -40C~125C -40C~125C -40C~125C Voltage Range 1.8V - 3.6V 1.8V - 3.6V 3.0V - 3.6V 3.0V - 3.6V 3.0V - 3.6V 3.0V - 3.6V 3.0V - 3.6V 3.0V - 3.6V 3.0V - 3.6V Voltage Regulator On-Chip On-Chip On-Chip On-Chip On-Chip On-Chip On-Chip On-Chip On-Chip Program/Data Flash 12KB 16KB 12KB 16KB 16KB 32KB 32KB 64KB 32KB / 64KB Program/Data RAM 2KB 2KB 2KB 4KB 4KB 4KB 4KB 8KB 4KB /8KB Program Security Yes Yes Yes Yes Yes Yes Yes Yes Yes Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 66 56F F F F F F F8027/37 OnChip Relaxation Osc Yes Yes Yes Yes Yes Yes Yes Yes Yes PLL Yes Yes Yes Yes Yes Yes Yes Yes Yes COP (Watchdog) Yes Yes Yes Yes Yes Yes Yes Yes Yes PWM (96Mhz Clock) 1 x 6ch 1 x 6ch 1 x 6ch 1 x 6ch 1 x 5ch 1 x 6ch 1 x 6ch 1 x 6ch 1 x 6ch PWM Fault Inputs bit ADCs 2 x 8ch 2 x 12ch 2 x 3ch 2 x 3ch 2 x 4ch 2 x 3ch 2 x 4ch 2 x 5ch 2 x 8ch 12-bit DACs 0 0 No No No (Pinned out) Analog Comparator 3 3 No No No Prog Gain Amp 2 2 No No No No No No No 16-bit Timers Prog. Interval Timers 1 (RTC) 1 (RTC) No No No GPIO (max) (+/-8mA) * 26* 26* 26* 35* 39* 53* IIC QIIC 1 - QIIC 1 - QIIC 1 - QIIC SCI (UART)/LIN Slave 1 - SCI 1 - SCI 1 - SCI 1 - SCI 1 - SCI 1 - QSCI 1 - QSCI 1 - QSCI 2 - QSCI SPI (Synchronous) 1 - SPI 1 - SPI 1 - SPI 1 - SPI 1 - SPI 1 - QSPI 1 - QSPI 1 - QSPI 2 - QSPI CAN No No No No No No No MSCAN MSCAN JTAG/EOnCE Yes Yes Yes Yes Yes Yes Yes Yes Yes Power Consumption IDD = 45.6mA;IDDA = 4.5mA IDD = 42mA; IDDA = 13.5mA IDD = 48mA; IDDA = 18.8mA IDD = 48mA; IDDA = 18.8mA Package 28SOIC 32LQFP (.8p) 32LQFP 32LQFP 32LQFP 32LQFP 32LQFP 44LQFP 48LQFP 64LQFP 32SDIP 48LQFP * 5V tolerance I/O

67 MC56F82xx (Anguilla Black) 32 / 48 / 64KB Program Flash 6 / 8kB Data RAM 56800E Core 60MHz 512byte EE (8 b) JTAG/EOnCE System Integration Module (SIM) ICE + BDM Interrupt Controller Breakthrough Features: High Speed PWM module 520ps duty cycle resolution High speed ADC with Programmable Gain Amplifiers Inter-module Cross Bar 8ch 12bit ADCA 8ch 12bit ADCB CRC Crystal Oscillator SPI PLL Relaxation OSC Voltage Regulator COP COP POR IIC LVI 44LQFP, 48LQFP, & 64LQFP Prog Gain Amp Ax1,2,4 Prog Gain Amp Bx1,2,4 8-ch High Res PWM 1ch 12bit DAC 3 5bit DAC 3 Analog Comparators 2 x QSCI 1 x QSPI 2x IIC/SMbus 1 x MSCAN 8Ch 16bit Timer Inter-module Cross Bar 60 MHz/60MIPS From 56800E Core V Operation 64K/48k/32k Bytes Program FLASH 8K/6K Bytes Program/Data RAM Flash security 8Mhz/100Khz Tunable Internal Relaxation Oscillator Software Programmable Phase Locked Loop Up to 60 MHz Peripherals Timers and PWMs 8 Output PWM Module ( 520ps PWM duty cycle resolution) 2-12-bit ADCs with total of 16 Inputs: 500ns conversion rate Built-in Programmable Gain Amplifiers with 1x, 2x, 4x, gains 1 12-bit Digital to Analog Converter 3 5bit Digital to Analog Converters 3 - Analog Comparators 8 16-bit Enhanced General Purpose Multifunction Programmable QTimers Cyclic Redundancy Check Generator (CRC) Computer Operating Properly Timer 2- Queued High Speed Serial Communications Interface (QSCI) 1-Queued Serial Peripheral Interface (QSPI) 1 MS-CAN Bus 2 - I 2 C/SMbus Communications Interface Up to 54 GPIOs Inter Module cross-bar JTAG/EOnCE Debug Port Lead Free Green Packages Industrial temperature:-40c to 60MHz Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 67

68 Temperature Range (V) 56F824x/5x Series Feature Summary 56F F F F F F8257 Performance 60MHz/MIPs 60MHz/MIPs 60MHz/MIPs 60MHz/MIPs 60MHz/MIPs 60MHz/MIPs -40C~105C -40C~105C -40C~105C -40C~105C -40C~105C -40C~105C Voltage Range 3.0V - 3.6V 3.0V - 3.6V 3.0V - 3.6V 3.0V - 3.6V 3.0V - 3.6V 3.0V - 3.6V Voltage Regulator On-Chip On-Chip On-Chip On-Chip On-Chip On-Chip Program/Data Flash 48KB 48KB 48KB 64KB 64KB 64KB Program/Data RAM 6KB 6KB 8KB 8KB 8KB 8KB Program Security Yes Yes Yes Yes Yes Yes OnChip Relaxation Osc Yes Yes Yes Yes Yes Yes PLL Yes Yes Yes Yes Yes Yes COP (Watchdog) Yes Yes Yes Yes Yes Yes eflexpwm Channels 1 x 6ch 1 x 6ch 1 x 9ch 1 x 6ch 1 x 6ch 1 x 9ch HiRes PWM Channels 6ch 6ch 6ch 6ch 6ch 6ch FlexPWM Channels 3ch 3ch PWM Fault Inputs bit ADCs /w PGA 2 x 3ch 2 x 3ch 2 x 4ch 2 x 3ch 2 x 4ch 2 x 5ch 12-bit DACs Analog Comparator /w 5bir DAC Ref Crossbar Module Yes Yes Yes yes Yes Yes 16-bit Timers Prog. Interval Timers No No No No No No GPIO (max) (+/-8mA) 35* 39* 54* 35* 39* 54* IIC /SMBus SCI (UART)/LIN Slave 2- QSCI 2 - QSCI 2 - QSCI 2 - QSCI 2 - QSCI 2 - QSCI SPI (Synchronous) 1 - QSPI 1 - QSPI 1 - QSPI 1 - QSPI 1 - QSPI 1 - QSPI CAN No No No MSCAN MSCAN MSCAN JTAG/EOnCE Yes Yes Yes Yes Yes Yes Package * 5V tolerance I/O 44LQFP Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 68 48LQFP 64LQFP 44LQFP 48LQFP 64LQFP

69 Agenda Electric Motor Type Classification Vector Control of AC Motors: Principle of Operation Position Sensor Elimination: Sensorless Speed Vector Control Freescale Motor Control Solution Enablement and Development Tools Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 69

70 Low Cost High Value CodeWarrior Development Studio Single Development Environment & License for: S08 Core 56800/E Core ColdFire Core Multi-tiered pricing structure Flexible low cost pricing based on memory usage License prices include 1 year maintenance Provides free 24/7 CodeWarrior support Processor Expert with Free drivers and libraries 11 premium libraries are Free with object code CodeWarrior USB Tap or 1-wire BDM Low cost high performance Universal Serial Bus interface for debugging CodeWarrior Development Studio IDE with optimizing C compiler Sophisticated Project Manager Graphical source level debugger Editor and file/folder compare functions Instruction-set simulation A free Special Edition permanent license up to 64 KB code size! Intelligent software development kit Processor Expert 56F8006 Software Development Tools EVEN MORE VALUE 56800QEDL QEDesign Lite Filter (FIR, IIR, etc ) emits code for the IDE Extensive SW libraries built into IDE Motor Control Mathematics Signal Processing Voice Processing Modem Encryption Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 70

71 Graphical Setup Tool (ProcessExpert and QuickStart) GCT Plug-in Module Application constant calculation and scaling Output constants generated into header file Custom page coded in HL/Java/Excel Application parameters modified only from one place Simplify customer application design start Required GCT version 2.4 and higher Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 71

72 3-ph BLDC/PMSM Low Voltage Motor Control Drive Kit being prepared for manufacturing at DevTech Usage: Motor Control Techniques Development Brushless DC Motor Drives Permanent Magnet Synchronous Drives High-End Control Algorithms Development and Demonstration Board Features: Power supply voltage input V DC extended up to 50 V Output current 4A(tested) 3-phase bridge inverter (6 MOSFET s) 3-phase MOSFET gate driver(mc33927 or MC33937) with over-current and under-voltage protection 3-phase and DC-bus-current-sensing shunts DC-bus voltage and 3-phase back-emf voltagesensing circuitry Encoder/hall sensor sensing circuitry 2 connectors for daughter board connection USB interface with MC9S08JM60 User LED, power-on LED, 6 PWM LED diodes and SCI activity LED diodes Up, down, toggle switches and Reset push-button Daughter Boards MC9S08AC16 MC9S08MP16 MC56F8013/23 MC56F8006 MCF51AC256 Anguilla Black (in prototype) MCF51AG128 (in prototype) Pictus (in development) Daughter Board Connectors Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 72

73 NEW 3-ph BLDC/PMSM High Voltage Motor Control Drive Usage: Motor Control Techniques Development Brushless DC Motor Drives Permanent Magnet Synchronous Drives AC Induction Motor Drives SMPS applications High-End Control Algorithms Development and Demonstration Board Features: Input Voltage Vac, 50/60Hz Optional Voltage doubler for input voltage 115Vac Output Power 1kW 3-phase IGBT inverter bridge with over-current protection (Fairchild IGBT power module) 3-phase motor current sensing DC-Bus current and voltage sensing Galvanic isolated SCI / USB interface User LED Power-on LED Encoder/Hall Sensor and tacho generator interface DC-Brake resistor switch with terminal BEMF sensing PFC control signal terminal PCI type of interface connector (separated analog and digital signals) Daughter Boards: MC9S08MP16 MC56F8006/8013 MC56F8257 PCI Daughter Board Connectors Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 73

74 Freescale Embedded Software Libraries Target Devices/Platforms: S08 MCF56F80xx MCF51xx Range of Applications: Digital Control Systems Motor Control (BLDC, PMSM, AC) Highlights/Descriptions: Software modules implemented in assembly Optimized for speed C-callable interface Easy to use Fully documented Public Deliverables: Documentation General Function Library (GFLIB) contains math, trigonometric, look-up table and control functions. These software modules are basic building blocks. Motor Control Library (MCLIB) contains vector modulation, transformation and specific motor related functions to build digitally controlled motor drives. General Digital Filter Library (GDFLIB) contains filter functions for signal conditioning. Advanced Control Library (ACLIB) will contain functions to enable building the variable speed AC motor drive systems with field oriented control techniques without position or speed transducer (available soon). ACLIB User Application SW MCLIB On-Chip Drivers System Infrastructure FMaster* Support GDFLIB GFLIB FSLESL External App.* Support *Optional APPLICATION Application SW Libraries On-Chip Driver On-Chip Peripherals PINS External HW External Connection s Processor Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 74

75 Motor Control Functions: Motor Control Library Clark Clarke Transformation algorithm ClarInv Inverse Clarke Transformation algorithm Park Park Transformation algorithm ParkInv Inverse Park Transformation algorithm DecouplingPMSM Cross-coupling voltages to eliminate dq axis coupling (only of PM synchronous motor) ElimDcBusRip Elimination of the DC-Bus voltage ripple SvmStd Appropriate duty-cycle ratios needed for generating the given stator reference voltage using a Standard Space Vector Modulation (SVM) technique SvmU0n As SvmStd, but using termed SVM with O000 Nulls SvmU7n As SvmStd, but using termed SVM with O111 Ones SvmAlt Special standard SVM SvmSci General sinusoidal modulation with injection of the third harmonic PWMIct General sinusoidal modulation Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 75

76 PMSM Sensorless Vector Control 56F8025 Key Features Sensorless Control of Permanent Magnet Synchronous Motor based on Back-EMF Observer Application based on MC56F80XX digital signal controller 3-phase AC/BLDC High Voltage Power Stage with 1-ph. line input 50/60Hz Industrial Permanent Magnet Synchronous Motor with braking mechanism Initial rotor position detection using high frequency injection Full torque at motor start-up Field weakening at high speeds Application based on C-callable library functions (GFLIB, GDFLIB, MCLIB, ACLIB) Current control loop execution time: 38us Speed control loop with Field weakening execution time : 11us Flash: ~ 6KB, RAM ~ 1.5KB FreeMASTER based control pages Fault Protection Description This application presents a motor control technique of permanent magnet motor (PM motor) without a need to use a rotor position transducer. This technique particularly targets horizontal axis (H-axis) washing machine with belt drive in fractional horsepower range The PM motor control solution is based on field oriented control (FOC) with implemented speed control loop. This includes inner current control loop achieving good torque control performance. To maximize converter efficiency and minimize its rating, current loop. Even such sensorless control technique can be realized on lowcost 32-MIPS digital signal controller. Application is a single chip solution based on MC56F80XX digital signal controller series The demo consists of the 3-phace PM motor, control board based on MC56F8025 and high voltage power stage. Featured Products MC56F80xx Key Markets Industrial Drives Appliance Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 76

77 PMSM Sensor/Sensorless Vector Ctrl MCF51AC256 Key Features NEW Vector control of PMSM using the Quadrature Encoder as a position sensor Vector control with speed closed-loop Two algorithms implemented: Encoder based position and speed measurement Sensorless position and speed estimation using Back-EMF Observer Start from any motor position (with rotor alignment) 4-quadrant operation 3-shunt current sensing Wide speed range FreeMASTER Control Interface Fault protection over-current, over-voltage, under-voltage Description This application demonstrates an advanced design of a 3-phase Permanent Magnet (PM) synchronous motor drive that is controlled sensorless or using an encoder. It is based on Freescale Semiconductor s MCF51AC256 controller. The concept of the application is a speed closed loop PM synchronous drive using a Vector Control technique. It serves as an example of a PMSM control. The application uses the Freescale libraries (GFLIB, MCLIB, GDFLIB, ACLIB) that contained algorithms already compiled and optimized in assembler. This application utilizes a 3-phase power stage equipped with Freescale gate driver and a Freescale chip that creates a virtual COM port via USB for the Freemaster communication. The application contains very attractive graphical gauges web page control for the Freemaster software plus many real time charts to explain the behavior of the system. Featured Products S08MRxxx Key Markets Appliance Dishwasher pump drives Washing machine High-end pumps and Fans Industrial Drives Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 77

78 Application HW Setup HW is modular it consists of Freescale universal motor control boards 56F8025CB Controller Board High Voltage 3-phase Power Stage Motor TG SBL3 JTAG for Debugger RS232 FreeMaster Connection Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 78

79 Application Memory Usage Application with MC56F8025 Sensorless PMSM FOC Control - Open loop start-up - Model based estimator - Field Oriented Control - Field Weakening.p_flash_ROM 2975 d [Words] B9F h.x_internal_ram 623 d [Words] 26F h # Memory map: v_addr p_addr size name p_flash_ROM p_flash_ROM (1069-4CA)=00B9F 0050E9 0050E p_flash_ROM p_all_internal_RAM x_all_internal_RAM 0087E0 0087E p_internal_RAM 0087E0 0087E p_internal_RAM C3.x_internal_RAM 0050F p_internal_RAM_ximage 00F000 00F x_onchip_peripherals FFFF00 FFFF x_EOnC\ # Memory map: Freemaster = 004CA(.p_flash_ROM) = 00554(.x_internal_RAM) 0047C text FFMSTR_Init 004C A.text FFMSTR_AddressToBuffer 00016E 0004E2.bss Fpcm_pOwnRecBuffer 0006C bss Fpcm_bUseExAddr Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 79

80 Application Timing Application based on MC56F8025 Computational performance Pulse width modulation running at 20[kHz] with dead-time 1μsec FOC current loop running at 10[kHz] (100[μsec]) Speed Control Loop running at 1[msec] Field Weakening with proper desaturation Anguilla dedicated s/w library used GFLIB (General Functions) GDFLIB (Digital Filtering) MCLIB (Motor Control) ACLIB (Advanced Control sensorless) FOC current loop takes 55 Speed control loop 17 Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 80

81 Application Tuning for Customer Motor The FreeMaster Communication/Control Tool running on a PC comp FreeMaster control page for application control and tuning Selection The Required Block Tuning Graphical Control Window Parameters View and Set Window Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 81

82 FreeMaster Measurements(1) Constant Speed 3000rpm Operation: speedmotorsens Sensed speed speedmotorestim Estimated speed speedmotorerror Estimated -sensed speed sincosest.cos Estimated Angle cosine sincossens.cos Measured Angle cosine sincoselscalarerr Angle error [degree] smobemfstruct.cur.beta.f16.h Estimated current Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 82

83 FreeMaster Measurements(2) Motor Start-up from 0 to 1000rpm: speedmotorsens Sensed speed speedmotorestim Estimated speed speedmotorerror Estimated-sensed speed sincosest.sine Estimated Angle sine sincossens.sine Measured Angle sine sincosgen32hl.sin.f16.h Open loop generated Angle sine sincoselscalarerr Angle error [degree] smobemfstruct.cur.alpha.f16.h Estimated current isalphabetacompens.alpha Measured current Reg. U.S. Pat. & Tm. Off. BeeKit, BeeStack, CoreNet, the Energy Efficient Solutions logo, Flexis, MXC, Platform in a Package, Processor Expert, QorIQ, QUICC Engine, SMAROS, TurboLink 83