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Brushless DC

Motor Control
with
C868
and
Drives & Control
June 2003
A. Jansen
CAPCOM6
1
Agenda

 Basics of a BLDC Motor


 Topology
 BLDC Motor with Hall Sensors
 BLDC Motor with Hardware
BEMF-Detection
 BLDC Motor Sensor less Control
 Switching Pattern for Driving a
BLDC
 How to use the CAPCOM6E for a
BLDC
 Introduction CAPCOM6E for
BLDC purpose
 CAPCOM6E & ADC

Drives & Control


June 2003
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Electrical Motor Types

Electric
Electric
Motor
Motortypes
types

AC
AC DC
DC

Asynchronous
Asynchronous Synchronous
Synchronous

Induction
Induction

PMSM
PMSM Synchronous
Synchronous Switched
SwitchedRel.
Rel. Stepper
Stepper

Drives & Control


June 2003
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BLDC
Basics

Drives & Control


June 2003
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4
Basics of a BLDC Motor

+ N

U
U
W
V

V
W
-
S

 DC Motor with 3 Brushes  3-Phase Brush-less DC Motor


According to the theory of DC machine, the motor rotational speed can be written as
follows:
N = ( Ud -  I  R ) / (Ke  )
While,
“N” stands for the motor rotational speed
“Ud” stands for the DC voltage applied to the motor windings
“R” is the pure resistance of the winding while “I” stands for the winding current
Drives & Control “Ke” is the magnet coefficient while “” stands for the motor magnetic flux
June 2003 From the above formula, there are two methods to change the speed of DC motor: One is to change the DC
A. Jansen voltage of the motor windings (Ud), the other one is to change the magnetic flux of the motor (). As the BLDC
motor has permanent magnet rotor, only the first method can be used in practical application. The principal of
5 generating variable DC voltage is to use PWM for chopping: change the duty cycle of the PWM voltage,
proportionally change the DC voltage.
How an Inverter Turns a BLDC (1)

1 1
A
C+
C’ B’
N
0
B-
S
B C

A’

Drives & Control


June 2003
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How an Inverter Turns a BLDC (2)

1 1
A
C+
C’ B’
N
0
B-
S
B C

A’

Drives & Control


June 2003
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How an Inverter Turns a BLDC (3)

1>>0 1
A
C+
C’ B’

N
0

S
B-
B C

A’

Drives & Control


June 2003
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How an Inverter Turns a BLDC (4)

0 1
A
C+
C’ B’

N
S
A-
B C

A’

Drives & Control


June 2003
A. Jansen
9
How an Inverter Turns a BLDC (5)

0 1>>0
A
B+
C’ B’

S
0

N
A-
B C

A’

Drives & Control


June 2003
A. Jansen
10
How an Inverter Turns a BLDC (6)

0 1>>0
A
B+
C’ B’
S
0
N
A-
B C

A’

Drives & Control


June 2003
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11
BLDC with Hall Sensors – Switching Pattern

 Typical Switching Pattern for a BLDC


 Hall Sequence depends on motor construction
 Output pattern levels depends on inverter topology

Drives & Control


June 2003
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BLDC with
Hall Sensors

Drives & Control


June 2003
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13
BLDC with Hall Sensors -- Topology

 Typical Circuit Block Diagram


 Hall Sensors detect the position
 Over current protection and control via ADC
V+
C868
CC60
Motor

HV Driver
COUT60
CC61
COUT61
CC62
COUT62
CCPOS0

CCPOS1

CCPOS2

Hall Sensor
CTRAP

+
-

Drives & Control


June 2003
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14
Block Diagram CAPCOM6E for BLDC Usage

capture
channel 0
compare trap
T12 channel 1
control
channel 2 compare multi-channel control

compare noise
T13 channel 3 filter
2 2 2 3 1

capture/compare input / output control

CCPOS0
CCPOS1
CCPOS2
COUT62
COUT60

COUT61

CTRAP
CC60

CC61

port control CC62


Drives & Control
June 2003
A. Jansen
15
Usage of CAPCOM6E to Control a BLDC (1)

 BEMF-Detection/Hall CC60 a c t. s p e e d c h 0 g e ts c a p tu re d
Signals v a lu e f o r a c t . s p e e d
 HW-noise filter on CC61 p h a s e d e la y
c h 1 c o m p a re
CCPOSx inputs CC62 tim e o u t f o r p h a s e d e la y
(BEMF-signals)
H a r d w a r e N o is e
S u p p r e s s io n C a p tu re c h 2 c o m p a re
E vent f o r t im e o u t
R e s e ts T 1 2

CCPO S0 1 1 1 0 0 0

CCPO S1 0 0 1 1 1 1

CCPO S2 1 0 0 0 1 1

CC6x

Drives & Control CO UT6y


June 2003
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Usage of CAPCOM6E to Control a BLDC (2)

 BEMF-Detection/Hall CC60 a c t. s p e e d c h 0 g e ts c a p tu re d
Signals v a lu e f o r a c t. s p e e d
 HW-noise filter on CC61 p h a s e d e la y
c h 1 c o m p a re
CCPOSx inputs CC62 tim e o u t f o r p h a s e d e la y
(BEMF-signals)
 automatic reset of H a r d w a r e N o is e
T12 with interrupt S u p p r e s s io n C a p tu re c h 2 c o m p a re
 actual speed by E vent f o r tim e o u t
capture ch0 R e s e ts T 1 2

CCPO S0 1 1 1 0 0 0

CCPO S1 0 0 1 1 1 1

CCPO S2 1 0 0 0 1 1

CC6x

Drives & Control C O U T6y


June 2003
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Usage of CAPCOM6E to Control a BLDC (3)

 BEMF-Detection/Hall CC60 a c t. s p e e d c h 0 g e ts c a p tu re d
Signals v a lu e f o r a c t . s p e e d
 HW-noise filter on CC61 p h a s e d e la y
c h 1 c o m p a re
CCPOSx inputs CC62 tim e o u t f o r p h a s e d e la y
(BEMF-signals)
 automatic reset of H a r d w a r e N o is e
T12 with interrupt S u p p r e s s io n C a p tu re c h 2 c o m p a re
 actual speed by E vent f o r t im e o u t
capture ch0 R e s e ts T 1 2
 phase delay
function on ch1
CCPO S0 1 1 1 0 0 0

CCPO S1 0 0 1 1 1 1

CCPO S2 1 0 0 0 1 1

CC6x

Drives & Control CO UT6y


June 2003
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Usage of CAPCOM6E to Control a BLDC (4)

 BEMF-Detection/Hall CC60 a c t. s p e e d c h 0 g e ts c a p tu re d
Signals v a lu e f o r a c t . s p e e d
 HW-noise filter on CC61 p h a s e d e la y
c h 1 c o m p a re
CCPOSx inputs CC62 tim e o u t f o r p h a s e d e la y
(BEMF-signals)
 automatic reset of H a r d w a r e N o is e
T12 with interrupt S u p p r e s s io n C a p tu re c h 2 c o m p a re
 actual speed by E vent f o r t im e o u t
capture ch0 R e s e ts T 1 2
 phase delay
function on ch1
 time out function CCPO S0 1 1 1 0 0 0
on ch2 CCPO S1 0 0 1 1 1 1

CCPO S2 1 0 0 0 1 1

CC6x

Drives & Control CO UT6y


June 2003
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Usage of CAPCOM6E – Hall Sensor Mode (1)

 CCPOSx Inputs  MCMOUTSH / MCMOUTSL


 for Hallsensor Interface  SW programmable state machine

Hall n+1 n+2


H2 1 1 0

H1 1 0 0

H0 0 0 0
Hall n n+1

start ? ?
Dead Time Counter
after edge detection

Drives & Control


June 2003
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Usage of CAPCOM6E – Hall Sensor Mode (2)

 CCPOSx Inputs  MCMOUTSH / MCMOUTSL


 edge detection triggers Dead Time Counter  compare CCPOSx level with programmed
value

Hall n+1 n+2


H2 1 1 0

H1 1 0 0

H0 0 0 0
Hall n n+1

compare
valid level ? ?
after noise Correct
DTC count down expected
Hall Event

Drives & Control


June 2003
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Usage of CAPCOM6E – Hall Sensor Mode (2)

 CCPOSx Inputs  MCMOUTSH / MCMOUTSL


 switch to next state on valid edge by hardware

Hall n+1 n+2


H2 1 1 0

H1 1 0 0

H0 0 0 0
Hall n+1 n+2

? !
noise Correct
expected
Hall Event
set
Drives & Control
CHE-flag
June 2003
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22
Usage of CAPCOM6E – Hall Sensor Mode (3)

 CCPOSx Inputs  MCMOUTSH / MCMOUTSL


 wait on edge  prepare next state by software

prepare next state


Hall n+2 n+3
H2 1 1 0

H1 1 0 0

H0 0 0 0
Hall n+1 n+2
wait on
edge
? ?

Drives & Control


June 2003
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Usage of CAPCOM6E –
Modulation Control (some Choices)
1 T12.COUT0 1 T12.COUT0

1 MODT13out A- 1 MODT13out A-
1 MCMOUTH.1 1 MCMOUTH.1

1 CTRAP# 0 CTRAP#

1 T12.COUT0 1 T12.COUT0

MODT13out A- MODT13out A-
1 MCMOUTH.1 0 MCMOUTH.1

1 CTRAP# 1 CTRAP#

T12.COUT0

MODT13out A-
1 MCMOUTH.1
Drives & Control
1 CTRAP#
June 2003
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Usage of CAPCOM6E –
Generate the PWM Pattern for BLDC
H2
H1
1 T12.COUT2 H0
MODT13out C-
0>0>0>1>1>0>0 MCMOUTH.5

1 CTRAP#

1 T12.CC2

1 MODT13out C+
1>1>0>0>0>0>1 MCMOUTH.4

1 CTRAP#

1 T12.COUT1

MODT13out B-
1>0>0>0>0>1>1 MCMOUTH.3

1 CTRAP#

1 T12.CC1

1 MODT13out B+
0>0>1>1>0>0>0 MCMOUTH.2

1 CTRAP#

1 T12.COUT0

MODT13out A-
0>1>1>0>0>0>0 MCMOUTH.1

Drives & Control 1 CTRAP#

June 2003 1 T12.CC0

A. Jansen 1 MODT13out A+
25 0>0>0>0>1>1>0 MCMOUTH.0

1 CTRAP#
Usage of CAPCOM6E –
Generate the PWM Pattern for BLDC
H2
H1
1 T12.COUT2 H0
MODT13out C-
0>0>0>1>1>0>0 MCMOUTH.5

1 CTRAP#

1 T12.CC2

1 MODT13out C+
1>1>0>0>0>0>1 MCMOUTH.4

1 CTRAP#

1 T12.COUT1

MODT13out B-
1>0>0>0>0>1>1 MCMOUTH.3

1 CTRAP#

1 T12.CC1

1 MODT13out B+
0>0>1>1>0>0>0 MCMOUTH.2

1 CTRAP#

1 T12.COUT0

MODT13out A-
0>1>1>0>0>0>0 MCMOUTH.1

Drives & Control 1 CTRAP#

June 2003
1 T12.CC0

A. Jansen 1 MODT13out A+
26 0>0>0>0>1>1>0 MCMOUTH.0

1 CTRAP#
Usage of CAPCOM6E –
Generate the PWM Pattern for BLDC
H2
H1
1 T12.COUT2 H0
MODT13out C-
0>0>0>1>1>0>0 MCMOUTH.5

1 CTRAP#

1 T12.CC2

1 MODT13out C+
1>1>0>0>0>0>1 MCMOUTH.4

1 CTRAP#

1 T12.COUT1

MODT13out B-
1>0>0>0>0>1>1 MCMOUTH.3

1 CTRAP#

1 T12.CC1

1 MODT13out B+
0>0>1>1>0>0>0 MCMOUTH.2

1 CTRAP#

1 T12.COUT0

MODT13out A-
0>1>1>0>0>0>0 MCMOUTH.1

Drives & Control 1 CTRAP#

June 2003 1 T12.CC0

A. Jansen 1 MODT13out A+
27 0>0>0>0>1>1>0 MCMOUTH.0

1 CTRAP#
Usage of CAPCOM6E –
Generate the PWM Pattern for BLDC
H2
H1
1 T12.COUT2 H0
MODT13out C-
0>0>0>1>1>0>0 MCMOUTH.5

1 CTRAP#

1 T12.CC2

1 MODT13out C+
1>1>0>0>0>0>1 MCMOUTH.4

1 CTRAP#

1 T12.COUT1

MODT13out B-
1>0>0>0>0>1>1 MCMOUTH.3

1 CTRAP#

1 T12.CC1

1 MODT13out B+
0>0>1>1>0>0>0 MCMOUTH.2

1 CTRAP#

1 T12.COUT0

MODT13out A-
0>1>1>0>0>0>0 MCMOUTH.1

Drives & Control 1 CTRAP#

June 2003 1 T12.CC0

A. Jansen 1 MODT13out A+
28 0>0>0>0>1>1>0 MCMOUTH.0

1 CTRAP#
Usage of CAPCOM6E –
Generate the PWM Pattern for BLDC
H2
H1
1 T12.COUT2 H0
MODT13out C-
0>0>0>1>1>0>0 MCMOUTH.5

1 CTRAP#

1 T12.CC2

1 MODT13out C+
1>1>0>0>0>0>1 MCMOUTH.4

1 CTRAP#

1 T12.COUT1

MODT13out B-
1>0>0>0>0>1>1 MCMOUTH.3

1 CTRAP#

1 T12.CC1

1 MODT13out B+
0>0>1>1>0>0>0 MCMOUTH.2

1 CTRAP#

1 T12.COUT0

MODT13out A-
0>1>1>0>0>0>0 MCMOUTH.1

Drives & Control 1 CTRAP#

June 2003 1 T12.CC0

A. Jansen 1 MODT13out A+
29 0>0>0>0>1>1>0 MCMOUTH.0

1 CTRAP#
Usage of CAPCOM6E –
Generate the PWM Pattern for BLDC
H2
H1
1 T12.COUT2 H0
MODT13out C-
0>0>0>1>1>0>0 MCMOUTH.5

1 CTRAP#

1 T12.CC2

1>1>0>0>0>0>1
1 MODT13out C+
MCMOUTH.4

1 CTRAP#

1 T12.COUT1

MODT13out B-
1>0>0>0>0>1>1 MCMOUTH.3

1 CTRAP#

1 T12.CC1

1 MODT13out B+
0>0>1>1>0>0>0 MCMOUTH.2

1 CTRAP#

1 T12.COUT0

MODT13out A-
0>1>1>0>0>0>0 MCMOUTH.1

Drives & Control 1 CTRAP#

June 2003
1 T12.CC0

A. Jansen 1 MODT13out A+
30 0>0>0>0>1>1>0 MCMOUTH.0

1 CTRAP#
Usage of CAPCOM6E –
Modulation and Synchronization

Correct
Hall Event
write by software
T13pm
6
T12pm Reset

T12om MCMPS MCMOUTSL


Flag
T12c1cm
SW-Trigger
no action
T12zm
T13zm MCMP MCMOUTL
direct
6

Drives & Control to modulation


June 2003 selection
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31
Usage of CAPCOM6E –
Modulation and Synchronization

Correct
Hall Event
write by software
T13pm
6
T12pm Reset

T12om MCMPS MCMOUTSL


Flag
T12c1cm
SW-Trigger
no action
T12zm
T13zm MCMP MCMOUTL
direct
6

Drives & Control to modulation


June 2003 selection
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32
Usage of CAPCOM6E –
Modulation and Synchronization

Correct
Hall Event
write by software
T13pm
6
T12pm Reset

T12om MCMPS MCMOUTSL


Flag
T12c1cm
SW-Trigger
no action
T12zm
T13zm MCMP MCMOUTL
direct
6

Drives & Control to modulation


June 2003 selection
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33
Usage of CAPCOM6E –
Modulation and Synchronization

Correct
Hall Event
write by software
T13pm
6
T12pm Reset

T12om MCMPS MCMOUTSL


Flag
T12c1cm
SW-Trigger
no action
T12zm
T13zm MCMP MCMOUTL
direct
6

Drives & Control to modulation


June 2003 selection
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34
Usage of CAPCOM6E to Control a BLDC (5)

1 1
A
MCMOUTSL MCMOUTSH
C+
0 1 0 0 1 0 1 0 0 0 0 0 C’ B’
N
0
0 1 1 0 0 0 1 1 0 1 0 0 B-
S
B C
MCMOUTL MCMOUTH

A’

Drives & Control


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35
Usage of CAPCOM6E to Control a BLDC (6)

1>>0 1
A
MCMOUTSL MCMOUTSH
C+
0 1 0 0 1 0 1 0 0 0 0 0 C’ B’

N
0

S
0 1 1 0 0 0 1 0 0 0 0 0 B-
B C
MCMOUTL MCMOUTH

A’

Drives & Control


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36
Usage of CAPCOM6E to Control a BLDC (7)

0 1
A
MCMOUTSL MCMOUTSH
C+
0 1 0 0 1 0 0 0 0 0 0 1 C’ B’

N
S
0 1 0 0 1 0 1 0 0 0 0 0 A-
B C
MCMOUTL MCMOUTH

A’

Drives & Control


June 2003
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37
Usage of CAPCOM6E to Control a BLDC (8)

0 1>>0
A
MCMOUTSL MCMOUTSH
B+
0 1 1 0 0 0 0 0 0 0 0 1 C’ B’

S
0

N
0 1 0 0 1 0 0 0 0 0 0 1 A-
B C
MCMOUTL MCMOUTH

A’

Drives & Control


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BLDC
Sensor less

Drives & Control


June 2003
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39
BLDC in Theory – Back Electro Magnetic Force

 Theory
 UP = (R x i) + (L x di/dt) + eP

 where
"UP" stands for phase voltage
"R" stands for winding resistance
"i" stands for actual phase current
"L" stands for phase inductance
"di/dt" stands for changment of phase current over time
"eP" stands for electromagnetic voltage caused by magnet

via
 while ia
i = 0 and di/dt = 0:
UP = e P
30° 120°
 by measuring UP
a position detection vib
is possible ib
Drives & Control
June 2003
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40
BLDC in Reality (1) – BEMF vs. Current

 Real BEMF Voltage and Current:


 shape depends on magnets, motor speed, voltage

ia

via

Drives & Control


June 2003
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41
BLDC in Reality (2a) – BEMF vs. Current

 Zoom In:
 BEMF is only visible at active switching

Phase
Current

BEMF
Voltage
Drives & Control
June 2003
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42
BLDC in Reality (2b) – BEMF vs. Current
V+
 Current Commutation in a Coil
 Freewheeling diode conducts
Motor

Current
Flow

Phase
Current GND
V+

BEMF Motor

Voltage
Current Flow
Freewheeling
Drives & Control Diode
June 2003
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GND
43
BLDC in Reality (3) – All Important Signals

BEMF Phase
Voltage Current

Drives & Control


June 2003
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44
BLDC Sensor less with Hardware BEMF-Detection

 Typical Circuit Block Diagram


 Comparators and RC-Filter detect the BEMF zero crossing
for position detection
V+
C868
CC60 Motor

HV Driver
COUT60
CC61
COUT61
CC62
COUT62
RC
CCPOS0

CCPOS1

CCPOS2

CTRAP

Filter

+
-
-
+
- virtual
Drives & Control +
Star
June 2003 -
A. Jansen +
45
BLDC Sensor less Using ADC

 Typical Circuit Block Diagram


 Use simple resistor divider and ADC for position detection
V+
C868
CC60
Motor

HV Driver
COUT60
CC61
COUT61
CC62
COUT62
CTRAP
AN0

AN1

AN2

BEMF
+ Detection
-

Drives & Control


June 2003
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46
CAPCOM6E & ADC

 Synchronize ADC on T13


 T13 period match can trigger the ADC
 equidistant sampling of analog signals
 exact timing guaranteed by hardware
 no timing jitter due to software delays

f(n+2)
analog
signal
f(n-1)
f(n) f(n+1)

T13

start sampling
by hardware

Drives & Control conversion


ADC
June 2003 channel 0
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47
CAPCOM6E & ADC

 Synchronize T13 on T12


 T13 performs delay for
stable measurement
 T13 period match
triggers ADC Compare value

 Useful for Current T12 synchronize


Measurement T13 on T12cm
 E.g. induction machine T13

CC6x

Phase
Current x

Start ADC when


Drives & Control
signal is stable after a
June 2003
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programmable delay
48
CAPCOM6E & ADC

 T13PM triggers ADC Modulation for


 Delay between T13PM Block-Commutation
and high voltage T13
switching event due to
driving circuit
 Useful for Voltage or
Current Measurement
 E.g. BEMF detection CC6x IGBT’s gate signal
 Sample shortly before
power device is switched
off (BEMF is noise free) IGBT
drain Delay due to
IGBT driving circuit
volt.

Voltage signal at
BEMF currentless phase
signal for position detection

Drives & Control


June 2003
A. Jansen Start ADC sampling
49
CAPCOM6E & ADC

 T13PM triggers ADC Modulation for


 Delay between T13PM and Block-Commutation
high voltage switching T13
event due to driving circuit
 Useful for Voltage or
Current Measurement
 E.g. Current in DC link
CC6x IGBT’s gate signal
path
 Sample shortly before
power device is switched
off (current is noise free)
IGBT
Delay due to
drain IGBT driving circuit
volt.

DC Link
Drives & Control Current
June 2003
A. Jansen Start ADC sampling
50
BLDC Sensor less Using ADC
 T13 used for CompareValue
 Modulation T12_ch1
T12
 ADC trigger
1 2
 T12 used for
 Phase delay T13
 Software (for 60°
BEMF
sector) Voltage
 With every T13PM Phase Analog
C
the BEMF voltage is CompareValue
sampled and
compared to a BEMF- Current
wave table Phase C
 When crossing a limit
the software
generates a CHE-
event (1) Current
 Speed reference is Phase A

captured and phase


Measure
delay for T12ch1 is Measure Measure
Voltage
Drives & Control BEMF-Voltage DC-Link Current
calculated (Phase C) (Phase A)
(Phase
June 2003 B)
 At T12ch1 the pattern
A. Jansen
for the next sector is
51
switched (2)
BLDC Sensor less with Current Control
 T13 used for CompareValue
 Modulation T12_ch1

 ADC trigger T12

 T12 used for 1 2

 Phase delay
T13
 Software (for 60°
sector) BEMF
Voltage
 With every T13PM the Phase
ADC alternatively C Analog
CompareValue
samples
 BEMF voltage
 Phase current Current
Phase C
 The current set value Control
can be controlled by Current Value
adjusting the PWM
duty cycle Current
Phase A

Measure
Measure Measure Measure
Measure BEMF
Drives & Control DC-Link DC-Link BEMF
DC-Link Current Voltage
Current Current Voltage
June 2003 (Phase A) (Phase
(Phase C) (Phase A) (Phase C)
B)
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52
BLDC Sensor less Scope Shots

Phase Port pin toggles when


Current BEMF is below limit

Drives & Control


June 2003 BEMF
A. Jansen
53 Voltage
High Voltage 3-Phase Brushless DC / Induction Motor
Reference Design and Development Kit
 Application: Line powered Industrial Drives
 Power: 750 W
 Current: max. 5 A
 AC Input Voltage: 110 to 264 VAC
 Features:
 8-bit MCU: C868 with on-chip 8 kB SRAM, with 8-
bit ADC and powerful PWM module
 CoolSet: TDA61831G instead of a transformer
for 12V supply
 6 rugged IGBT DuoPacks
 EEPROM: 8 kB to store program + stand alone
boot option
 Optically Isolated Serial Interface to PC for SW
development + boot from PC option
 Protection: shut down protection for over current
and over temperature
 Extension for alternative MCU like XC164 or
TC1775
 SW environment: Keil Compiler + Debugger or
Mini Debugger (free software)
 Board can be used for current/torque or speed
control
 Supports Hall-Effect sensors or sensor-less
Drives & Control control
June 2003
A. Jansen
54
Low Voltage 3-Phase Brushless DC / Induction Motor
Reference Design and Development Kit

 Application: Industrial & Automotive Drives


 Power: 1.2 kW
 Current: max. 50 A
 Voltage: 12 - 24 V DC
 Features:
 8-bit MCU: C868 with on-chip 8 kB SRAM, with 8-
bit ADC and powerful PWM module
 3-Phase Bridge Driver: TLE6280G
 6 OptiMOS MOSFETs
 EEPROM: 8 kB to store program + stand alone
boot option
 RS232: Interface to PC for SW development +
boot from PC option
 Protection: shut down protection for over current
and over temperature
 Extension for alternative MCU like XC164
 SW environment: Keil Compiler + Debugger or
Mini Debugger (free software)
 Board can be used for current/torque or speed
control
 Supports Hall-Effect sensors or sensor-less
control
Drives & Control
June 2003
A. Jansen
55

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