Smart-Power H-Bridges

Control the Speed and

Torque of DC Brush Motors
Power Products
Data Device Corporation
Designing motion control systems
can be done quickly and easily with DDC's
PWR-82340 and PWR-82341 Smart-
Power H-Bridges, which will drive perma-
nent magnet DC brush motors. The same
Smart-Power H-Bridge, due to its univer-
sal design, can be used in either a veloci-
ty loop for speed control, or a current loop
for torque control depending on the user's
configuration. Figures 1 and 2 show block
diagrams of these two types of control
systems.
Speed Control
The PWR-82341 can be used to
develop a 100V, 5A bi-directional DC
motor speed control with just a few exter-
nal components. The velocity loop can be
closed with the help of a Unitrode UC1637
Switched Mode Controller and a tachome-
ter as seen in Figure 3. The UC1637 is a
pulse width modulation device that
includes a sawtooth generator, error
amplifier, current limit, and two PWM com-
parators for dead-band control.
To obtain speed control, the user
applies a command voltage from poten-
tiometer R2 to the noninverting input (pin
15) of the error amplifier. The PWM will
deliver pulse widths from both the A and B
outputs (pins 4 & 7) that will be a function
of the sign and amplitude of the error sig-
nal. (Important Note: you must clamp
these outputs to prevent exceeding the
allowable input voltage range of the PWR-
82341. You can accomplish this with 12V
zeners VR1 & VR2 and resistors R18 &
R19.) Furthermore, the user can change
the triangle wave threshold voltages and
oscillating frequency depending upon the
external resistors R8, R9, R10 and capac-
itor C2 that they select. The user provides
current limiting by connecting a fractional
ohm current sense resistor R22 (selected
to prevent exceeding the current capability
of the PWR-82341) between the V
SS
pins
of the PWR-82341 and the high-voltage
power return. The circuit will monitor the
voltage drop across this resistor and pro-
vide pulse-by-pulse current limiting when
the motor current exceeds the preset trip
SPEED
REGULATOR
PWM
GENERATOR
DIGITAL
CONTROL
AND
PROTECTION
V-
V+
SPEED
COMMAND
+

ENABLE
PULSE
BY
PULSE
ILIMIT
M
PHASE A
GATE
DRIVE
A B
+VBUS
PHASE B
GATE
DRIVE
R
SENSE
T
FIGURE 1. BIDIRECTIONAL SPEED CONTROL
AN/H-4
SMART POWER H-BRIDGES CONTROL THE
SPEED AND TORQUE OF DC BRUSH MOTORS
2
point. By using a tachometer you can pro-
vide a velocity feedback to the inverting
input of the error amplifier (pin 16). This
feedback will vary the pulse widths from
the UC1637 outputs based on the rela-
tionship between the tach signal and the
speed command, to either increase or
decrease the duty cycle of the MOSFETs
in the PWR-82341. Hence, an increase in
speed command will increase the on-time
of a pair of MOSFETs in the PWR-82341,
which will increase the power applied to
the motor; thereby, increasing the speed.
Torque Control
If you require motor torque control
instead of velocity, then the loop must be
closed on current as seen in Figure 4. The
same UC1637 Switched Mode Controller
will be used again. Here the user feeds a
current command into command amplifier
(U5), which sums it with the current feed-
back signal coming from the current sense
amplifier (U3). This time we get current
sensing right at the motor leads by using a
fractional ohm sense resistor R1. We
+V
TH
-V
TH
-B
IN
+E/A
E/A OUT
-E/A
+A
IN
+B
W
C
T
-A
IN
I
S
-V
S
-C/L
+C/L
B
OUT
A
OUT
+V
S
S.D.
UC1637
+CAP
-CAP
V
UA
V
LA
V
UB
V
LB
V
SD
VR1
1N963
12V
R17
2K
VR2
1N963
12V
R18
8.2K
R19
8.2K
34
32
C3
0.01F
8
10
13
15
12
R15
7.5K
R14
2.5K
14 6
R16
2K
16
17
C1
0.22F
R11
4.7M
8 2 10 18 5
R13
25K
C2
0.0022F
R10
7.5K
15
9
3
R9
5K
R8
7.5K
R4
10K
R5
1.2K
R6
10K
R7
10K
R1
5K
R2
5K
R3
5K
SPEED
CONTROL
+28 VDC
15V RTN
R12
47K
V+ V
LPI
C4
0.01F
C6
0.01F
4 6
+15 VDC
V
CC
V
CC
V
OA
V
OB
V
SSA
V
SSB
GND
13
12
7
4
C5
0.001F
R20
1K
R21
1K
R22
0.05
25,26 18,19 5,11,26
30, 31
23, 24
MOTOR
27, 28
21, 22
+
C9
TANT
TACH
28V RTN
ENABLE
PWR-82341
R24
1K
R23
1K
11
C8
0.1F
C7
0.1F
FIGURE 3. USING THE PWR-82341 IN A VELOCITY LOOP
SPEED
REGULATOR
PWM
GENERATOR
DIGITAL
CONTROL
AND
PROTECTION
V-
V+
CURRENT
MONITOR
+

ENABLE
PULSE
BY
PULSE
I LIMIT
M
PHASE A
GATE
DRIVE
A B
+VBUS
PHASE B
GATE
DRIVE
ABSOLUTE
VALUE
ISENSE
Amp
COMMAND
AMPLIFIER
CURRENT
COMMAND
OFFSET
ADJUST
RSENSE
FIGURE 2. TORQUE CONTROL
base component selection in this section
of the circuit on the maximum operation
bus voltage (V
bus
max) seen at the PWR-
82340 and the maximum load current
SMART POWER H-BRIDGES CONTROL THE
SPEED AND TORQUE OF DC BRUSH MOTORS
3
(I
O
max). We assume the COMMAND
input to be always within 10V. The cur-
rent feedback signal at the CURRENT
MONITOR point will be equal in magni-
tude and opposite in polarity to the current
command signal when the circuit is regu-
lating the load current. To achieve this
objective, the current feedback circuit gain
should yield a +10V signal at a load cur-
rent +I
O
max and -10V at a load current of
-I
O
max.
Selection of R
1
The criterion for selection of the
sense resistor is to get 300mV of signal at
the maximum load current. We also base
the power rating of this high-wattage resis-
tor on the maximum load current. (See
Table 1 for examples.)
AOUT
BOUT
+VS
-BIN
+VTH
-VTH
+AIN
-VS
SHDN
CT
+BIN
-AIN
ISET +E/A -C/L
+C/L
-E/A
E/A OUT
U1
UC1637
VUA
VLA
VUB
VLB
GND
VSD
VLPI VLPO VZ VS
U4
PWR-82340
VOB
VCC
VSSB
VCC
VSSA
GND
6
9
1
3
11
5
-15V
+15V
R20
4.99K
R21
20K
R22
4.99K
C12
0.1F
2
14
8
10
C13
680pF
NPO
18
R23
20K
15 13
R25
1K
C7
1000pF
12
16
17
D1
1N4148
R9
1K
R7
49.9K
15
14
13
7
16
17
D4
1N4148
D5
1N4148
R28
4.99k
R29
4.99k
C13
0.01F
12 11
+15V
9 8
VOA
5
2
6
3
4
C15
0.1F
1
C16
0.1F
18
C17
1F
10V
C18
1F
10V
R6
C6
47pF
+15V
C5
0.1F
-
+
-15V
C4
0.1F
4
3
2
7
6
U3
R27
1K
R30
5.6M
R31
50K
+15V
-15V
R8
1K -
+
U2
+15V
C3
0.1F
R5
7
6
2
-15V C2
0.1F
R4
4
3
R1
R2 R3
MOTOR
VBUS
MOTOR
VBUS RTN
C19
1500F
+
M
R19
10K
R16
1K
R17
1K
R18
10K
-
+
U5
R10
100
+15V
C11
0.1F
2 7
C10
0.1F
6
4
-15V
3
R26
4.99K
R11
10K
D2
1N757A
D3
1N757A
R14
1M
R13
22K
C1
0.047 F
R12
10K
COMMAND +
GND
+15V
C8
10F
+15V
-15V
C9
10F
-15V
ENABLE
CURRENT
MONITOR
R15
100
4
7
NOTES:
1. ALL RESISTORS ARE 1%, 1/8W UNLESS OTHERWISE NOTED.
2. ALL CAPACITORS ARE 10%, 50V UNLESS OTHERWISE NOTED.
FIGURE 4. CLOSING A CURRENT LOOP WITH THE PWR-82340 OR PWR-82341
VUA
VLA
VUB
VLB
+CAP
VLPI V+
U4
PWR-82340
VOB
VCC
VSSB
VCC
VSSA
GND
32
8
10
12
15
13
6
+15V
4
VOA
27, 28
21, 22
30, 31
23, 24
25, 26
18, 19
5, 11, 16
VSD
-CAP
34
0.01F 0.01F
Cc
1.0F
+15V
4
Selection of R
2
- R
6
Base the selection of these resistor
values on the gain requirement of the two
amplifier stages (at U2 & U3). If G1 is the
gain of the differential amplifier at U2, and
G2 is the gain of the differential amplifier
at U3, the overall gain G = G1 * G2 =
10V/300mV = 33.3.
The gain G1 depends upon the maxi-
mum bus voltage (V
bus
max is 100V, G1 =
10V/ V
bus
max = 0.1. This will yield G2 =
333. (See Table 2 for examples.)
Layout Considerations &
User Precautions
Whether you use the PWR-
82340/PWR-82341 as a velocity loop or
current loop it is critical to follow the prop-
er decoupling capacitor recommendations
and ground/layout precautions. Improper
ground schemes or poor decoupling could
result in permanent damage to the PWR-
82340/PWR-82341.
This could be caused by exceeding a
3V differential between the V
SS
pins and
GND pins on the hybrid. Even if you only
instantaneously exceed the 3V limit, this
will damage the gate drive circuitry.
Precautions for the PWR-82340 include
two (2) 1.0F caps directly across the
hybrid from GND (pin 18) to V
SS
(pins 1 &
4). You will not require these for PWR-
82341 because of the lower current levels
involved. Ground paths for both PWR-
82340 and PWR-82341 should be as
short as possible and low inductance.
Short heavy gauge wire, ground plane, or
bus bars will make the best ground con-
nections. If you use current sense resis-
tor(s) in the V
SS
legs, make sure they are
noninductive and low enough in resistance
value so that peak currents don't cause a
voltage drop of 3V across the resistor(s).
The resistor(s) should be located within 2"
of the hybrid.
Overstress to the Power MOSFETs/
Diodes could be caused by exceeding the
absolute maximum voltage rating or cur-
rent rating of the hybrid. The PWR-
82340/PWR-82341 does not have internal
overvoltage or overcurrent protection.
Take care to current limit power supplies
and to make sure the bus voltage doesn't
"pump up" when regenerative energy from
the motor transfers back through the
hybrid and into the bus (during braking, for
example). You could use a bus clamp or
load dump circuit to prevent this.
Selecting the H-Bridge
The user will select either the PWR-
82340 or PWR-82341, depending on max-
imum bus voltage and load current
requirements. Both devices can be used
in either velocity loop or current loop con-
figurations and can be operated in either
two- or four-quadrant mode. DDC rates
the high-power PWR-82340 at 200Vdc,
30A continuous capability, while for lower-
power applications you would use the
PWR-82341, rated at 100Vdc, 5A continu-
ous. Beside the ease of use that the
PWR-82340 and PWR-82341 offer, their
modular approach also offers substantial
printed circuit board size and weight
reduction. Military and Aerospace appli-
cations will benefit by the extremely high
reliability, -55C to +125C operation, and
military processing.
REFERENCES:
UNITRODE: UC1637 - Data sheet
Application Note: U-102 - "Switched Mode
Controller for DC Motor Drive."
DDC: PWR-82340, PWR-82341 - Data Sheets
TABLE 1. SELECTION OF R
1
EXAMPLES
I
O
max R
1
WATTS
30A 0.01 10
10A 0.03 5
5A 0.06 2
TABLE 2. SELECTION OF R
2
- R
6
EXAMPLES
V
bus
max G
1
G
2
R
2
, R
3
R
4
, R
5
R
6
150Vdc 0.0667 499 75 4.99k 499k
100Vdc 0.1 333 49.9 4.99k 332k
80Vdc 0.12 275 39.2 4.75k 274k
50Vdc 0.2 167 24.9 4.99k 165k
DATA DEVICE CORPORATION
REGISTERED TO ISO 9001
FILE NO. A5976
R
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U
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