Sensored BLDC Sinusoidal Drive Controller For Refrigerator Fans

TI Designs
Sensored BLDC Sinusoidal Drive Controller for

Refrigerator Fans
Design Overview Design Features

The DRV10970 is an integrated, three-phase BLDC • Output Stage of DRV10970 Consists of Three Half
motor driver for home appliances, fans, and other Bridges With Rdson of 450 mΩ (With Each Half
general-purpose motor control applications. The Bridge Capable of Delivering 1-A RMS and 1.5-A
embedded intelligence, small form factor, and simple Peak Current)
pin-out structure reduce the design complexity, board • Cost-Effective Single-Side Board Design
space, and overall system cost. The integrated
protections improve the system robustness and – Small Form Factor Board With Hall Sensors
reliability. The design is targeted for fans in – Speed Control Through External PWM Control
refrigerators. • 180° Sine Wave Commutation Algorithm Helps for
High Efficiency, Superior Acoustic Performance,
Design Resources
and Low Torque Ripple
TIDA-00919 Tool Folder Containing Design Files • Automatic Drive Angle Adjustment Enables
Optimized Efficiency
DRV10970 Product Folder
DRV5013 Product Folder • Supports Single Hall- and Three Hall-Based
Applications
• Features Such as PWM Speed Input, Direction
ASK Our E2E Experts
Reversal, FG Output, and Motor Lock Indicator
Featured Applications
• Cooling Fans
• Small Appliances
• General-Purpose BLDC Motor Drivers
TIDUBH6 – March 2016 Sensored BLDC Sinusoidal Drive Controller for Refrigerator Fans 1
Submit Documentation Feedback
Copyright © 2016, Texas Instruments Incorporated
Key System Specifications www.ti.com
An IMPORTANT NOTICE at the end of this TI reference design addresses authorized use, intellectual property matters and other
important disclaimers and information.
1 Key System Specifications

A refrigerator is a very common household appliance which consists of a main compressor motor and a
motor for a circulation fan. The circulation fan serves as a blower that rotates cold airflow throughout the
unit to keep it cold. The fan for a refrigerator is typically a sensored brushless DC (BLDC) motor, which
requires an electronic controller. The TIDA-00919 reference design is a ready platform for driving such a
fan motor.
This reference design is a cost-effective, small-form-factor, three-phase sinusoidal motor drive for
sensored BLDC fan motors specified up to a maximum current of 1 A RMS at 18 V maximum. Unlike most
sensored drivers, the DRV10970 drives a motor with a 180° sinusoidal commutation, which results in low
torque ripple, better acoustics, and a high drive efficiency. The speed input command can be utilized in the
form of a pulse width modulation (PWM) input and a direction control by controlling a pin high or low.
Table 1 lists the key system specifications for the design.
Table 1. Key System Specifications

PARAMETER SPECIFICATION
DC input voltage 12 V
Rated power capacity 15 W
Speed input PWM
Operating ambient temperature –20°C to 50°C
Inverter efficiency ≥ 97% at rated load
Protections Overcurrent, overtemperature, and short circuit
The drive board has been designed for a small form factor in consideration of the small factors of the
appliance fans. Because the motor driver has sensors, the printed-circuit board (PCB) is typically housed
inside the motor, which explains the requirement for placing Hall sensors on the board. The low-cost
requirement also confines the design to a single-side board.
2 Sensored BLDC Sinusoidal Drive Controller for Refrigerator Fans TIDUBH6 – March 2016
www.ti.com System Description
2 System Description
The use of permanent-magnet brushless DC motors continue to gain prominence in the field because of
their high efficiency, low maintenance, high reliability, low rotor inertia, and low noise as compared to the
brushed motor counterpart. A brushless permanent-magnet motor has a wound stator, which is a
permanent magnet rotor assembly. These types of motors generally use internal or external devices to
sense rotor position. The sensing devices provide logic signals for electronically switching the stator
windings in the proper sequence to maintain rotation of the magnet assembly.
The DRV10970 is an electronic drive which is used to sinusoidally control the drive of a sensored BLDC
motor. The system operates at 12-V power and provides the motor terminal outputs. The design
implements Hall sensors because the electronic components are placed inside the motor for most
sensored BLDC motors. The system also accepts user inputs such as direction and speed also in addition
to providing some feedback, such as lock detection and speed feedback.
3 System Design Theory

The DRV10970 device controls three-phase BLDC motors using a speed command (PWM), direction (FR)
interface, and Hall signals from the motor. The device is capable of driving up to 1-A RMS and 1.5-A peak
current.
When the DRV10970 device powers up, it starts to drive the motor in trapezoidal communication mode
based on Hall sensor information. If all three Hall sensors have been connected, the commutation logic
relies on all three Hall sensors. If a U-phase Hall sensor is the only sensor connected (VHP is floating),
then the DRV10970 device starts to drive the motor in a single Hall sensor mode.
After six electrical cycles, the device switches to sinusoidal drive mode if the CMTMOD pin is not floating.
If the motor has a 0° placement for the Hall sensor (set on the CMTMOD pin accordingly), the DRV10970
device automatically adjusts the driving angle based on the feedback from the motor. The DRV10970
device optimizes the efficiency regardless of the motor parameters and the load conditions.
This automatic function that drives the angle adjustment can be disabled by the DAA pin. A fixed driving
angle is available for the user to optimize the motor drive efficiency if this automatic function has been
disabled.
The PWM input duty cycle commands the steady-state motor speed, which converts to an average output
voltage of VM multiplied by the duty cycle. A floating PWM pin functions as the full-speed command. The
FR input can be used to control the direction of motor rotations. The user can adjust the rotational
direction while the motor is spinning. The device has a time delay (TLOCK_EX) before reversing direction.
The FG output is aligned with a U-phase Hall sensor signal, which indicates the motor speed. If the motor
has been locked by an external force for TLOCK_EN, then the RD output is asserted to indicate the motor lock
condition and DRV10970 retries after the TLOCK_EX period, which is determined by the capacitor on the
RETRY pin.
When the motor is not spinning (either in lock condition or PWM = 0), the state of the phases are selected
by the BRKMOD pin. The phases can be maintained floating (coasting condition) or pulled down to GND
(braking condition).
The DRV10970 device enters sleep mode when the PWM has been driven low for TSLEEP time and internal
circuits including regulators are turned off and the power consumption is less than 35 µA.
Overcurrent, current limit, thermal shutdown, and undervoltage protection circuits prevent system
components from being damaged during extreme conditions.
System Design Theory www.ti.com
3.1 Single-Side Design

The design targets the use of a single-side board because of the extremely cost-sensitive application.
With the constraint of a single-side board, the GND connection is routed to multiple places throughout the
board. To avoid the noise associated with ground loop on current sense and VINT, a provision has been
established to connect an optional resistor R13 of 0 Ω, which acts as a jumper if required.
3.2 Hall Sensor Connections

Hall sensors and their connections are very important parameters to consider while driving a sensored
BLDC motor. The DRV10970 device has been designed to work with Hall sensor elements as well as the
latched output types of Hall sensors. Apart from working with these sensor types, the DRV10970 also
works with different Hall sensor placements and with single hall mode and three-hall mode as well.
The TIDA-00919 design has three DRV5013 Hall sensors (U2, U3, and U4), which are of the single-
ended, latch output type. The supply to the Hall sensors travels through VINT from the DRV10970 device,
which is 5 V. Three Hall sensors are placed at 120° mechanical apart in the slot made for the rotor (see
Figure 1). Because the device has been designed to operate as differential input Hall sensor outputs, the
design requires the creation of a reference point when being supplied with single-ended Hall sensor
outputs. This reference is created as VINT / 2 by a simple resistor divider formed by R3 and R5. This
reference connects to all the negative terminals of the Hall sensor connections as Figure 2 shows.
C3
DNP U_HP U_HN
0.1µF
C4
DNP V_HP V_HN
VINT 0.1µF
C5
DNP W_HP W_HN
0.1µF
R6 R7 R8
10k 10k 10k
U2
1 VCC OUT 3 U_HP
GND 2
DRV5013ADQLPGM
U3
1 3 V_HP
VCC OUT
2
GND
DRV5013ADQLPGM
U4
1 3 W_HP
VCC OUT
2
GND
DRV5013ADQLPGM
GND
Figure 1. TIDA-00919 Board Image Figure 2. Hall Sensor Connections
www.ti.com System Design Theory
The three capacitors C3, C4, and C5 filter the noise on the Hall sensor outputs. The Hall sensors are
typically located inside the motor; for this reason, the user can connect the Hall sensor outputs across
these capacitors if it is not feasible to mount the complete board inside the PCB. Take the appropriate
level of care with the reference in this configuration. If using the board directly inside the motor and the
Hall sensors require mounting on the component side (the design is on the top side), the user must modify
the Hall sensor pinout.
3.3 Hardware Settings

The DRV10970 is capable of driving a BLDC motor in sinusoidal or trapezoidal way. The user can set
other features by hardware, such as adaptive angle adjustment and brake mode adjustment. Configure
the required settings by making the appropriate placements of R9 to R12, as Table 2 details and Figure 3
shows.
Table 2. Drive Settings

FUNCTION SETTINGS RESISTOR
Place R11 Sine drive with 30° Hall placement
Commutation mode
Remove R11 Trapezoidal drive
Brake mode Place R9 Coasting mode
Place R12 10° drive angle adjustment
Adaptive angle adjust
Remove R12 Auto-drive angle adjustment
Direction control Remove R10 Direction reversal
VINT VINT VINT DAA
R9 R10 R11 R12

10k 10k 10k 10k
BRKMOD FR CMTMOD
Figure 3. Hardware Settings
The current sense resistor helps to set the current limit during operation. The current sense resistor is
calculated by Equation 1 (refer to the datasheet for more details).
ILIMIT =
(VILIM _ THR ´ ACL )
RCS
where
• VILIM_THR = 1.2 V (typical)
• ACL = 25000 A/A (typical) (1)
During a fault condition, the device stops the drive and attempts to drive the motor again after a certain
time. The capacitor CRETRY determines this retry time, which is controlled by the charging and discharging
of the cap with VRETRY_H (1.2 V) and VRETRY_L (0.6 V) and source and sink current at 10 uA typical
(see Equation 2 and Figure 4).
TLOCK _ EX = 15.36 ´ 106 ´ CRETRY
where
• TLOCK_EX is in seconds (2)
System Design Theory www.ti.com
FR 23 FR
RETRY 22 RETRY
C7 PWM 19 PWM
0.1µF
CS 17 CS
R4 CPP 9 CPP
24.0k
C8
GND 0.1µF CPN 10 CPN
GND DRV10970PWP
Figure 4. Current Sense and Retry Circuit
With the constraint of a single-side board, the GND connection is routed to multiple places throughout the
board. To avoid the ground loop on current sense and VINT, utilize the optional resistor provision on the
board. If the GND noise is too much to handle for the current sense and VINT circuit, R13 can be added
on the board.
3.4 Control
The design has a provision for controlling user inputs through connections (Figure 5).
• PWM: A PWM input (frequency range of 15 kHz to 100 kHz) is used to control the speed of the motor
during runtime.
• FG: The FG signal provides the electrical speed of the motor by toggling an open-drain output, which
has already been pulled high to VINT on the board.
FG PWM PWM
FG
Figure 5. Control Inputs
www.ti.com Block Diagram
4 Block Diagram
Figure 6. TIDA-00919 Block Diagram
4.1 Highlighted Products

The design contains a three-phase, sensored, sinusoidal BLDC driver (DRV10970) and three Hall sensors
(DRV5013).
4.1.1 DRV10970
The DRV10970 is an integrated, three-phase BLDC motor driver for home appliances, cooling fans, and
other the general-purpose motor control applications. The embedded intelligence, small form factor, and
simple pinout structure reduce the design complexity, board space, and system cost. The integrated
protections improve the system robustness and reliability.
The output stage of the DRV10970 device consists of three half bridges. Each half bridge is capable of
driving up to 1-A RMS and 1.5-A peak output current. When the device enters sleep mode, it consumes a
typical 35-μA of current.
The advanced 180° sine-wave commutation algorithm is embedded into the device that achieves high
efficiency, low torque ripple, and superior acoustic performance. The automatic driving angle adjustment
function achieves the most optimized efficiency regardless of the motor parameters and load conditions.
The DRV10970 has been designed for Hall sensor-based applications. The differential Hall signal inputs
are detected by the integrated comparators. The device supports single Hall-based applications and three
Halls-based applications. The single Hall sensor mode reduces the system cost by eliminating two Hall
sensors.
The device implements a standard control interface which includes PWM input (speed command), FG
output (speed feedback), FR input (forward and reverse direction control), and RD output (motor lock
indicator).
Block Diagram www.ti.com
The DRV10970 supports both 30° and 0° Hall sensors (with respect to the corresponding phase back-
electromotive force [BEMF]). The device implements a trapezoidal drive mode to address the higher
power requirement.
The DRV10970 device determines the motor lock condition based on the absence of hall input switching.
The device re-attempts to spin the motor after an adjustable auto-retry time, which can be configured by a
capacitor connected to the RETRY pin.
The device incorporates multiple protection features such as overcurrent, undervoltage, overtemperature,
and locked rotor conditions to improve the system robustness.
The DRV10970 is packaged in a thermally enhanced 24-pin TSSOP package (eco-friendly: RoHS and no
Sb/Br).
4.1.2 DRV5013
The DRV5013 device is a chopper-stabilized Hall effect sensor that offers a magnetic sensing solution
with superior sensitivity stability over temperature and integrated protection features.
The magnetic field is indicated through a digital bipolar latch output. The integrated circuit (IC) has an
open-drain output stage with a 30-mA current sink capability. A wide operating voltage range from 2.5 V to
38 V with reverse polarity protection up to –22 V makes the device suitable for a wide range of industrial
applications.
Internal protection functions have been provided for reverse supply conditions, load dump, and output
short circuit or overcurrent.
Device features
• Digital bipolar-latch Hall sensor
• Superior temperature stability
– BOP ±10% overtemperature
• High sensitivity options (BOP and BRP)
– +2.7 / –2.7 mT (AD)
– +6 / –6 mT (AG)
– +12 / –12 mT (BC)
• Supports a wide voltage range
– 2.5 to 38 V
– No external regulator required
• Wide operating temperature range
– TA = –40 to 125°C (Q)
• Open-drain output (30-mA sink)
• Fast 35-µs power-on time
• Small package and footprint
– Surface mount 3-pin SOT-23 (DBZ)
• 2.92 mm × 2.37 mm
– Throughhole 3-pin TO-92 (LPG)
• 4.00 mm × 3.15 mm
• Protection features
– Reverse supply protection (up to –22 V)
– Supports up to 40-V load dump
– Output short-circuit protection
– Output current limitation
www.ti.com Getting Started
5 Getting Started
The hardware is capable of exploring all the available features of the DRV10970 device.
5.1 Hardware Settings

Before connecting the motor to the board, the user must be aware of the Hall placement if the Hall signals
are being externally provided to the board. Configure the following required hardware settings before
getting started with the hardware (see Table 2 as well).
• CS: Check whether the onboard resistor is correct as per the expected motor current. Change this
resistor if required.
• BRKMOD: Check R9 to confirm if either must be present for the appropriate brake mode.
• CMTMOD: Check R11 for the appropriate commutation mode. A provision has been provided to either
pull the pin high or keep it floating.
• DAA: The DAA settings can be changed while in three-Hall sensor mode by using R12.
• Hall sensor: Depending on the type of Hall sensors and placement in the motor, connect the Hall
sensors (if they are being provided externally). Take note of the Hall sensor pinout, as this
configuration depends on the way that the PCB has been used inside the motor.
5.2 Start
After having correctly implemented the hardware settings, connect the power supply to the board and
motor connected to U/V/W terminals on the board.
Switch on the power supply and apply the PWM input to the PWM jumper for speed control. The FG
output shows the speed as an electrical frequency.
5.3 Runtime
Change the speed command through the PWM input and observe the speed feedback on the FG pin.
Test Setup www.ti.com
6 Test Setup
The board was tested with a Hurst motor number DMB0224C10002. The board was supplied by an
Agilent E3634A power supply at 12 V. The following waveforms have been captured using the Tektronix
DPS4034 oscilloscope. The power supply setting was kept at 12 V with a current limit of 3 A. Figure 7
shows an image of the test setup.
Figure 7. Test Setup
7 Test Data
7.1 DRV10970 Driving With Three-Hall Mode
Figure 8. DRV10970 Driving Motor With Three-Hall Mode
www.ti.com Test Data
7.2 DRV10970 Driving With Trapezoidal Mode
Figure 9. DRV10970 Driving With Trapezoidal Mode
7.3 DRV10970 Ph-Ph Short and Recovery
Figure 10. DRV10970 Ph-Ph Short and Recovery
Test Data www.ti.com
7.4 Thermal Image at 18-V, 1-A Load
Figure 11. Thermal Image at 18-V, 1-A Load
www.ti.com Design Files
8 Design Files
8.1 Schematics
To download the schematics, see the design files at TIDA-00919.
8.2 Bill of Materials

To download the bill of materials (BOM), see the design files at TIDA-00919.
8.3 Layer Plots

To download the layer plots, see the design files at TIDA-00919.
8.4 Altium Project

To download the Altium project files, see the design files at TIDA-00919.
8.5 Gerber Files

To download the Gerber files, see the design files at TIDA-00919.
8.6 Assembly Drawings

To download the assembly drawings, see the design files at TIDA-00919.
9 References
1. Texas Instruments, DRV10970 3-Phase Brushless DC Motor Driver, DRV10970 Datasheet (SLVSCU7)
10 Terminology
BEMF— Back-electromotive force
BLDC— Brushless DC motor
ESD— Electrostatic discharge
FET— Field-effect transistor
MOSFET— Metal-oxide-semiconductor field-effect transistor
PWM— Pulse width modulation
RMS— Root mean square
RPM— Rotations per minute
11 About the Author

JASRAJ DALVI is an applications engineer at Texas Instruments, where he is responsible for developing
reference design solutions and control algorithms for motor control applications. He completed his
Bachelors of Engineering degree in Electrical Engineering from University of Pune, India and his Post
Graduate Diploma in Marketing Management at S.I.B.M. in Pune, India.
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TI Designs

Sensored BLDC Sinusoidal Drive Controller for

Design Overview Design Features

1 Key System Specifications

Table 1. Key System Specifications

3 System Design Theory

3.1 Single-Side Design

3.2 Hall Sensor Connections

1 VCC OUT 3 U_HP

Figure 1. TIDA-00919 Board Image Figure 2. Hall Sensor Connections

3.3 Hardware Settings

Table 2. Drive Settings

VINT VINT VINT DAA

R9 R10 R11 R12

Figure 3. Hardware Settings

Figure 4. Current Sense and Retry Circuit

Figure 5. Control Inputs

Figure 6. TIDA-00919 Block Diagram

4.1 Highlighted Products

5.1 Hardware Settings

Figure 7. Test Setup

7.1 DRV10970 Driving With Three-Hall Mode

Figure 8. DRV10970 Driving Motor With Three-Hall Mode

7.2 DRV10970 Driving With Trapezoidal Mode

Figure 9. DRV10970 Driving With Trapezoidal Mode

7.3 DRV10970 Ph-Ph Short and Recovery

Figure 10. DRV10970 Ph-Ph Short and Recovery

7.4 Thermal Image at 18-V, 1-A Load

Figure 11. Thermal Image at 18-V, 1-A Load

8.2 Bill of Materials

8.3 Layer Plots

8.4 Altium Project

8.5 Gerber Files

8.6 Assembly Drawings

11 About the Author

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