Brushless DC Motor (BLDC) Motor Control Using PIC18Fxx31

Brushless DC Motor Control Using
PIC18Fxx31 Microcontrollers
2003 Microchip Technology Inc. 1
2003 Microchip Technology Incorporated. All Rights Reserved. Brushless DC Motor Control Using PIC18Fxx31 Microcontrollers 1
Brushless DC (BLDC)
Motor Control
using
PIC18Fxx31
Microcontrollers
Agenda
G Overview of motor control solutions from Microchip
G PIC18Fxx31 peripherals for motor control
G BLDC motor control using PIC18Fxx31
G Open loop control
G Closed loop control using Hall sensors
G Closed loop control using Quadrature encoder
G Sensorless control
The agenda for this discussion is:
First we will discuss an overview of motor control solutions from Microchip
PIC18Fxx31 has many peripherals that are useful for motor control application. We
will discuss the major peripherals that are helpful in developing motor control
application.
Then we will discuss the Brushless DC motor control using PIC18Fxx31 devices in
open loop, closed loop with Hall sensors and closed loop with Quadrature Encoder
or also known as optical encoder. Finally we will see how a sensorless control of
BLDC motor can be implemented using PIC18Fxx31
At the end of this discussion, we will show few references that would be helpful for
you to understand BLDC motors and controls using PIC18Fxx31
Motor Control from Microchip
G Complete solutions for Stepper, Brushed DC,
BLDC, ACIM & SR motors utilizing PIC16, PIC18
and dsPIC
devices
G Microchip Op Amps and International Rectifier
drivers
G Provide everything a design engineer needs:
G Low-risk product development
G Lower total system cost
G Faster time to market
G Outstanding technical support
G Dependable delivery & quality
G Visit us at www.microchip.com/motor
Microchip Technology offers a broad product portfolio that provides a complete
system solution for your brushed DC motor, variable speed brushless DC motor,
AC induction motor, switched reluctance motor and stepper motor applications.
This includes the microcontroller with firmware to drive the motor, analog op amps
and comparators for sensors or feedback and power electronics from Microchip and
International Rectifier.
With our sophisticated development systems and technical documentation,
Microchip makes it easy for designers of all experience levels to complete a high
performance electronic motor control design quickly and cost effectively.
Microchip provides everything a motor control design engineer needs: low-risk
product development, lower total system cost, faster time-to-market, outstanding
technical support and dependable delivery and quality.
For access to Microchips complete motor control design resources,
visit the Motor Control Design Center at www.microchip.com/motor.
PIC18Fxx31 overview
PIC18Fxx31 family of microcontrollers have 4 parts, having 28-pin and 40-pin
packages with 8Kbytes and 16Kbytes of program memory. The major peripherals that are useful
in motor control are Power Control PWM or PCPWM, High-speed Analog-to-Digital Converter
and Motion Feedback module. These peripherals simplify the motor control algorithm to a great
extent.
The main features of PCPWM include:
Up to 8 channels output with independent or 4 pairs complimentary outputs
Up to 14 bits PWM of resolution
Center aligned or edge aligned PWM operation. Also known as symmetrical PWM or
asymmetrical PWM operation
Programmable dead band control for complementary outputs
Hardware Fault interface pins for fast PWM shut down in the event of fault.
Main features of high-speed ADC include:
Up to 9 channels input, with 2 Sample and Hold circuits
Simultaneous and sequential conversion capabilities with multiple channel selection
4 word deep FIFO with flexible interrupt settings
Main features of Motion Feedback Modules are:
Multiplexed Input Capture and Quadrature Encoder Interface (QEI) modules
In QEI, A, B and Index signals interface for measuring, position velocity and direction of
rotation
3 Input Capture pins with multiple modes for pulse width and frequency measurements -
Interrupt on change feature used for Hall sensor interface.
PIC18Fxx31 peripherals
G Power control PWM
G Up to 8 channels with up to 14-bit resolution
G Center aligned and edge aligned operations
G High-speed ADC
G Up to 9 channels with up to 200 Ksps
G 4 word FIFO buffer with flexible interrupts
G Motion feedback module
G Quadrature Encoder Interface (QEI) - QEA, QEB, Index
G Position and velocity measurement modes
G 3 Input Capture (IC) pins
G Pulse width and frequency measurement modes
PIC18Fxx31 family of microcontrollers have 4 parts, having 28-pin and 40-pin packages with
8Kbytes and 16Kbytes of program memory.
The major peripheral that are useful in motor control are Power Control PWM or PCPWM, high-
speed Analog-to-Digital Converter and Motion Feedback module. These peripherals simplify the
motor control algorithm to a great extent.
Main features of PCPWM include:
Up to 8 channels output with independent or 4 pairs complimentary outputs
Up to 14 bits PWM of resolution
Center aligned or edge aligned PWM operation. Also known as symmetrical PWM or
asymmetrical PWM operation
Programmable dead band control for complementary outputs
Hardware Fault interface pins for fast PWM shut down in the event of fault.
Main features of high-speed ADC include:
Up to 9 channels input, with 2 Sample and Hold circuits
Simultaneous and sequential conversion capabilities with multiple channel selection
4 word deep FIFO with flexible interrupt settings
Main features of Motion Feedback Modules are:
Multiplexed Input Capture and Quadrature Encoder Interface modules
In QEI, A, B and Index signals interface for measuring, position velocity and direction of
rotation
3 Input Capture pins with multiple modes for pulse width and frequency measurements -
Interrupt on change feature used for Hall sensor interface.
2003 Microchip Technology Inc.
Drive topology
VDC+
VDC-
(1)
(4)
(5)
(2)
(3)
(6)
H1
L1
H2
L2
H3
L3
Phase A
Phase B
Phase C
A brushless DC motor is a synchronous motor that finds numerous applications in
motion control. Appliance, automotive, aerospace, industrial automation, automation
are few industries to list. These come with different torque and voltage ratings. A
BLDC motor has windings on stator and alternate permanent magnets on rotor. BLDC
motors are electronically commutated based on the rotor position with respect to the
stator winding. This means, to run a BLDC motor an electronic drive is required.
Normally 3 Hall effect sensors mounted on the stator are used to determine the rotor
position. The Hall effect sensors give a combination of high and low signals when they
pass next to the rotor poles. With this combination, the commutation sequence is
determined.
A typical control circuit with 3 phase winding connection is shown in the figure
H1,H2, H3 and L1, L2,L3 make 3 phase voltage source inverter connected across the
power supply indicated by VDC+ and VDC-. Stator windings A, B and C are
connected in star to the inverter.
In coming slide we will see how these stator windings are energized in synchronous
with the Hall sensor inputs.
Switching Sequence
(1) (2) (3) (4) (5) (6) (1) (2) (3) (4) (5) (6)
Phase A
Phase B
Phase C
H3
L2
H1
L2
H1
L3
H2
L3
H2
L1
H3
L1
H3
L2
H1
L2
H1
L3
H2
L3
H2
L1
101 001 011 010 110 100 101 001 011 010 110
Step
Hall sensor
Hall A
Hall B
Hall C
Hall
A
Hall
B
Hall
C
Phase
A
Phase
B
Phase
C
1 0 1 NC Vdc- Vdc+
1 0 0 Vdc+ Vdc- NC
1 1 0 Vdc+ NC Vdc-
0 1 0 NC Vdc+ Vdc-
0 1 1 Vdc- Vdc+ NC
0 0 1 Vdc- NC Vdc+
High switch
Low switch
Sequence table example
With 3 Hall sensors on the motor, every 60 degrees of electrical cycle, a Hall sensor
makes transition either from low to high or from high to low. With this every
electrical cycle has 6 steps to complete one full cycle. The energizing sequence will
have 6 combinations of turning ON and Off of the 6 switches that we saw in the
previous slide. A typical switching sequence is shown on the table here.
The Hall sensor inputs are at 120 degrees phase shift to each other. Every sequence
has two windings connected across the power supply and third winding left open.
Considering the first step where the Hall sensor input is 101, Phase C is connected
to positive DC bus and phase B is connected to negative DC bus and phase A is left
open. In order to achieve this switch H3 and L2 should be closed and all other
switches should be open. This will turn the rotor by 60 degree electrical in the given
direction. This will make the Hall sensor to make another transition triggering the
next point on the sequence table and so on.
The electrical cycle and shaft rotation have a definite relation. The electrical cycle
repeats with every rotor pole pairs. So to complete one rotation on the shaft, these 6
steps should be repeated as many times as rotor pole pairs.
If the sequence is followed with rated motor voltage across the motor windings,
motor will run at rated speed. Speed can be controlled using PWMs, by PWMing
each switch according to the speed required.
The phase current waveform looks trapezoidal in shape with each phase current
having 120 degrees phase shift to each other.
Control using Hall Sensors
/MCLR
1 28
2
3
4
5
6
7
8
9
11
12
13
14
10
27
26
25
24
23
22
21
20
18
17
15
19
16
AN0
AN1/IC1
AN2/IC2
AN3/IC3
AN4
AVdd
AVss
OSC1
OSC2
RC0
/FLTA/CCP2
/FLTB/CCP1
RC3/INT0
PWM2
PWM1
PWM0
Vdd
Vss
RC7/RX/DT
RC6/TX/CK
RC5/INT2
RC4/INT1
PWM3
PWM5
RB6/PGC
RB7/PGD
PWM4
R-Low
R-High
Y-Low
Y-High
B-High
B-Low
Motor current
Potentiometer
+
Motor current
Reference
-
Hall sensors
P
I
C
1
8
F
2
4
3
1
BLDC
Motor
3 phase
Inverter
bridge
AC in
+ - DC bus
Hall
sensors
Motor
current
This slide shows the hardware interface used for controlling a BLDC motor. Hall
sensors are used for commutation. Hall sensors can be connected to either Interrupt on
change pins that are on port C or they can be connected to Input capture pins on
Motion feedback module.
The input capture module has a mode in which the module generates an interrupt on
transition on each pin, making it ideal for Hall sensor interface. Optionally, Timer5 can
be captured on each transition. This Timer5 value can be used for determining the
speed at which motor is running. This gives a low resolution speed measurement.
For the applications where high resolution of speed measurement is required,
quadrature encoder is used. The QE gives speed, position and direction of rotation.
OVDCOND v/s PWM output
(1) (2) (3) (4) (5) (6) Step
101 001 011 010 110 100
Hall sensor
PWM5 - H3
PWM4 - L3
PWM3 - H2
PWM2 - L2
PWM1 - H1
PWM0 - L1
00100100 00000110 00010010 00011000 00001001 00100001
OVDCOND
Now let us see how to control the speed using PCPWM module. PCPWM module
has a feature of over riding the PWM outputs based on the value in OVDCOND
register. When the corresponding value in OVDCOND is set to 1, the PWM output
becomes active and vise versa. With this we can efficiently allow the required PWM
to appear on the pin, when required as per the sequence, and inhibit when not
required.
Speed variation is achieved by varying the duty cycle of each PWM. To increase the
speed, the active part on duty cycle needs to be increased and to reduce the speed,
the active time is reduced. By doing this the average voltage supplied across the
motor winding varies, thus controlling the motor speed.
This slide shows the relationship between the OVDCOND register and the PWM
output. PWM0 to PWM5 control on and off of 6 switches. The PWMs are passed
and inhibited according to the sequence discussed earlier.
Control Flow Chart
Initialization
Load new step sequence
to the OVDCOND
register from Table
Hall sensor
change?
Yes
No
Key scan/
Other application?
Change
Speed?
Calculate new PWM
duty cycle
Yes
No
Hall
A
Hall
B
Hall
C
Phase
A
Phase
B
Phase
C
1 0 1 NC Vdc- Vdc+
1 0 0 Vdc+ Vdc- NC
1 1 0 Vdc+ NC Vdc-
0 1 0 NC Vdc+ Vdc-
0 1 1 Vdc- Vdc+ NC
0 0 1 Vdc- NC Vdc+
This shows a simplified control flow chart for BLDC motor control. The sequence
table dictates the PWM channels that should be in active or inactive states, based on
the Hall sensor states. On every transition on Hall sensor input, new step from the
sequence is loaded to the OVDCOND register.
Any change in the speed command is read either using a potentiometer connected to
one of the AD channel or a digital value from another controller calculate a new
PWM duty cycle and load to the appropriate registers.
Control using Quadrature Encoder
1
4
0 2
3
4
5
6
7
9
12
15
16
17
18
14
39
38
37
36
35
34
33
32
30
29
26
31
28
INDX
Vss
OSC1
FLTA/CCP2
INT0/RC3
PWM2
PWM1
PWM0
Vdd
Vss
RD7
RD6
RD5
RD4
PWM3
PWM5
PWM4
RB6/PGC
RB7/PGD
8
10
13
Vdd
OSC2
19
20
RD0
RD1
11
27
RC7/RX/DT
25
RC6/TX/CK
24
RC5/INT2
23
RC4/INT1
22
RD3
21
RD2
/MCLR
AN0
QEA
QEB
AN4
AN5
AN6
AN7
AN8
RC0
FLTB/CCP1
BLDC
Motor
3 phase
Inverter
bridge
R-Low
R-High
Y-Low
Y-High
B-High
B-Low
AC in
+ - DC bus
Hall
sensors
INT0
QE
QE interface
Motor current
Potentiometer
Temp. sensor
+
Motor current
Reference
-
Power factor
correction
P
I
C
1
8
F
4
4
3
1
Motor
current
With QE for speed, position and direction feedback and Hall sensors for commutation
can be interfaced as shown here.
Hall sensors connected to INT pins, and QE connected to motion feedback module.
Sensorless control
1
4
0 2
3
4
5
6
7
9
12
15
16
17
18
14
39
38
37
36
35
34
33
32
30
29
26
31
28
IC1
Vss
OSC1
FLTA/CCP2
INT0/RC3
PWM2
PWM1
PWM0
Vdd
Vss
RD7
RD6
RD5
RD4
PWM3
PWM5
PWM4
RB6/PGC
RB7/PGD
8
10
13
Vdd
OSC2
19
20
RD0
RD1
11
27
RC7/RX/DT
25
RC6/TX/CK
24
RC5/INT2
23
RC4/INT1
22
RD3
21
RD2
/MCLR
AN0
IC2
IC3
AN4
AN5
AN6
AN7
AN8
RC0
FLTB/CCP1
3 phase
Inverter
bridge
R-Low
R-High
Y-Low
Y-High
B-High
B-Low
AC in
+ - DC bus
Back EMF ZC detect
Motor current
Potentiometer
Temp. sensor
+
Motor current
Reference
-
+
-
Back EMF ZC detect
BLDC
Motor
Power factor
correction
P
I
C
1
8
F
4
4
3
1
Motor
current
Sensorless control of BLDC motor gives many advantages, most importantly lowered
system cost. Every phase develops a voltage called Back EMF, that opposes the power
applied to the phase. During the non energized phase of the sequence, this back EMF
crosses from positive voltage to negative voltage. From the the zero cross over point,
rotor position can be determined, and used for commutation. This method eliminates
the requirement of sensors for commutation.
However, this may require additional hardware on the drive side and additional
firmware overhead on the microcontroller.
Sensorless control schemes
1) Compare with DC bus/2 2) Compare with virtual neutral
3) Using ADC Channels
A
C
B
DC+
DC-
DC/2
+
_
Back EMF
To IC2
BZ_B
+
_ To IC1
BZ_A
+
_ To IC3
BZ_C A
C
B
DC+
DC-
Virtual
Neutral
+
_
Back EMF
+
_ To IC1
BZ_A
+
_ To IC3
BZ_C
To IC2
BZ_B
A
C B
AN0
AN1
AN2
Back EMF
We will see three different methods of determining the Back EMF zero cross point.
1) Comparing WRT center point of DC bus: Every sequence has two windings
connected across power supply and third winding left open. The BEMF generated in
the non energized winding is compared with respect to the half of DC bus. This gives a
fairly good result, when the motor terminal voltage is approximately equal to the DC
bus voltage. If the DC bus voltage is disproportionately high, the cross over point may
drift away, making it difficult to determine a workable commutation sequence at all
speeds.
2) Comparing with a virtual neutral: A virtual neutral point can be generated using
resistor ladders as shown and the BEMF in the non-energized winding can be
compared with this neutral point. This makes it comparatively easy to determine the
zero cross point at all measurable speeds.
3) Using High speed ADCs: The BEMF signals are attenuated and read directly using
an on chip ADC on a PIC18Fxx31 can give a great flexibility in determining the zero
cross over point.
However, at low speeds, the BEMF developed is very low in amplitude, which makes
it difficult to determine a zero cross over point.
Summary
G Overview of motor control solutions from Microchip
G PIC18Fxx31 peripherals for motor control
G BLDC motor control using PIC18Fxx31
G Open loop control
G Closed loop control using Hall sensors
G Closed loop control using Quadrature encoder
G Sensorless control
Resources
G Application notes:
G AN885 : Brushless DC motor fundamentals
G AN899 : Brushless DC motor control using PIC18Fxx31
G AN857 : Brushless motor control made easy
G Demo and development board
G PICDEM
TM
MC
G Completely isolated, debug tools can be connected
when the board is live
G Low cost design
G Web design center: www.microchip.com/motor
These are additional resources for more information on Microchips Motor Control
solutions.

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