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3-Phase Induction Motor Drive with Dead Time Distortion Correction Using MC68HC908MR32
Designer Reference Manual
M68HC08
Microcontrollers
DRM019/D Rev. 03/2003
MOTOROLA.COM/SEMICONDUCTORS
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3-Phase Induction Motor Drive with Dead Time Distortion Correction Reference Design
Designer Reference Manual
Radim Visinka, Ph.D. Motorola Czech Systems Laboratories Roznov Radhostem, Czech Republic
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Revision history
provide most up-to-date information, revision documents World Wide will most current. Your printed copy earlier revision. verify have latest information available, refer following revision history table summarizes changes contained this document. your convenience, page number designators have been linked appropriate location.
Revision history
Date January 2003 Revision Level Initial version Description Page Number(s)
Designer Reference Manual
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Designer Reference Manual 3-ph. ACIM Drive with
List Sections
Section Introduction Section System Description.
Section Hardware Design. Section Software Design Section System Setup Appendix References. Appendix Glossary.
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Designer Reference Manual 3-ph. ACIM Drive with
Table Contents
Section Introduction
Contents Application Functionality Benefits Solution.
Section System Description
Contents System Concept Dead Time Distortion Correction
Section Hardware Design
Contents System Configuration MC68HC908MR32 Control Board 3-Phase BLDC High Voltage Power Stage. Optoisolation Board Motor-Brake Specifications. Hardware Documentation
Section Software Design
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Contents Introduction Data Flow
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Table Contents
Algorithm Dead Time Distortion Correction
Section System Setup
Contents Hardware Setup Warning Jumper Settings Controller Board. Required Software Tools Building Application Executing Application Controlling Application with Master Software
Appendix References Appendix Glossary
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Designer Reference Manual 3-ph. ACIM Drive with
List Figures
Figure Title Page
System Block Diagram Volt Hertz Ramp Dead Time Distortion Topology Current Polarity Sensing Proposed Current Threshold Correction Toggling. Hardware Configuration MC68HC908MR32 Control Board 3-Phase High Voltage Power Stage Data Flow 3-Phase Sine Waves with Amplitude mcgen3PhWaveSine Data Explanation Phase Dead Time Correction State Machine. Setup Application MC68HC908MR32 Jumper Reference. Execute Make Command Control Elements USER LEDs, LEDs, RESET Master Software Control Window
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List Tables
Table Title Page
values loaded into registers PVAL1-6 Prescaler Sensing Current Polarity Magnitude Electrical Characteristics Control Board Electrical Characteristics Power Stage Electrical Characteristics Optoisolation Board. Motor Brake Specifications State Machine Flag Registers dtStateFlagsAB State Machine Flag Registers dtStateFlagsC dtCorrect_s Structure Elements. MC68HC908MR32EVM Jumper Settings Motor Application States Dead Time Distortion Correction
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Designer Reference Manual 3-ph. ACIM Drive with
Section Introduction
Contents
Application Functionality Benefits Solution.
Application Functionality
This Reference Design describes design 3-phase induction motor drive with dead time distortion correction. based Motorola's MC68HC908MR32 microcontroller which dedicated motor control applications. system designed motor drive system medium power three-phase induction motors targeted applications both industrial appliance fields (e.g. washing machines, compressors, conditioning units, pumps simple industrial drives). reference design incorporates both hardware software parts system including hardware schematics with bill material, software listing.
Benefits Solution
design very cost variable speed 3-phase motor control drives become prime focus point appliance designers semiconductor suppliers. Replacing variable speed universal motors maintenance-free, noise asynchronous (induction) motors trend that supposes total system costs being equivalent. Six-transistor inverter most used topology motor drives. dead time must inserted between turning transistor inverter half bridge turning complementary transistor.
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Introduction
dead time causes distortion generated voltage, thus non-sinusoidal phase current. This distortion causes distortion motor performance. especially apparent speeds, when dead time comparable with pulse width. Also, longer dead time, higher influence over motor performance. Dead time distortion corrected properly modulating power stage control signals. advantages dead time distortion correction are: Smoother running motors Less torque ripple Quieter motors More efficient operation (less harmonic losses).
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Designer Reference Manual 3-ph. ACIM Drive with
Section System Description
Contents
System Concept Dead Time Distortion Correction
System Concept
application designed drive 3-phase motor open speed loop mode with dead time distortion correction (see Figure 2-1). desired speed set-up user interface. desired frequency amplitude motor voltage sine wave calculated according desired speed using Volt-per-Hertz table. sine wave generator generates values three phases bridge inverter according selected type dead time distortion correction algorithm. system incorporates following hardware blocks: power supply rectifier, three-phase inverter including optoisolation, feedback sensors: DC-Bus voltage, DC-Bus current, temperature, polarity phase currents, microcontroller MC68HC908MR32.
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System Description
3-phase Power Stage
Line
Voltage Current Temperature Polarity Phase Currents sense
LOAD
MC68HC908MR32
PWM's
Fault Protection Desired Sine Frequency Sine Generation Desired Sine Amplitude Desired Correction PWM's
START STOP DOWN Control
V/Hz Ramp Req. Speed Speed Ramp Desired Speed
Dead Time Correction State Machine
Dead Time Correction Disabled Partial Full
Figure 2-1. System Block Diagram drive designed "Volt-per-Hertz" drive. means that control algorithm keeps constant magnetizing current (flux) motor varying stator voltage with frequency. commonly used Volt-per-Hertz ramp 3-phase induction motor illustrates Figure 2-2.
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System Description System Concept
Phase Voltage 100%
Base Point
Boost Voltage
Boost Frequency
Base Frequency
Frequency (rpm)
Figure 2-2. Volt Hertz Ramp Volt Hertz ramp defined following parameters: Base Point defined Base Frequency (usually 50Hz 60Hz) Boost Defined Boost Voltage Boost Frequency
ramp profile specific motor easily changed accommodate different ones.
dead time distortion correction algorithms provide correction values with respect actual polarity phase currents. current polarity evaluated sensing phase voltage during dead time carried on-chip circuitry 908MR32 microcontroller. types dead time distortion correction algorithms implemented partial, full correction. partial correction algorithm detects just current polarity correction done almost entirely on-chip hardware. other hand, full correction algorithm also detects magnitude phase currents (low/high), implements advanced which improves correction results. user choice selecting either correction algorithms. type dead time distortion correction indicated yellow 908MR32 controller board.
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System Description
frequency changed time during motor operation following values: 4kHz 8kHz 16kHz 32kHz drive incorporates fault protection, case DC-Bus over-current, DC-Bus over-voltage, DC-Bus under-voltage faults, internal fault logic asserted application enters fault state. This state exited only fault disappears acknowledged, toggling START/STOP switch through STOP state. application states displayed green 908MR32 control board. application operate modes: Manual Operating Mode drive controlled START/STOP switch. direction motor rotation FWD/REV switch. motor speed SPEED potentiometer. Master Software (Remote) Operating Mode drive controlled remotely from through serial communications interface (SCI) communication channel device RS-232 physical interface. drive enabled START/STOP switch, which used safely stop application time.
Dead Time Distortion Correction
Six-transistor inverter most used topology motor drives. dead time must inserted between turning transistor inverter half bridge turning complementary transistor. dead time causes distortion generated voltage, thus non-sinusoidal phase current.
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System Description Dead Time Distortion Correction
order achieve sinusoidal phase current, thus limit harmonic losses, noise, torque ripple, dead time distortion correction needs implemented. on-chip Pulse-Width-Modulation (PWM) module, MC68HC908MRxx family Motorola microcontrollers, contains patented hardware block that simplifies task. dead time correction based evaluation phase current polarity respective phase, proper counter-modulation dead-time distortion. basic situation shown Figure 2-3. desired load voltage affected dead time. During dead time, load inductance defines voltage needed keep inductive current flowing through diodes. full positive full negative voltage applied phase, according phase current polarity. positive current (i+), actual voltage pulses shortened dead time, negative phase current voltage pulses lengthened dead time.
Desired load voltage
deadtime
+U/2
transistor
iPWM bottom transistor
Actual load voltage (for
Actual load voltage (for
Dave Wilson
Figure 2-3. Dead Time Distortion
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System Description
achieve distortion correction, different correction factors must added desired value, depending whether bottom transistor controlling output voltage during dead time. When voltage pulse shortened dead time, control signal extended dead time, actual voltage pulse matches desired voltage. Vice versa, when voltage pulse lenghtened dead time, control signal shortened dead time, again actual voltage pulse matches desired voltage. Therefore actual signal equals desired one, generated phase current sinusoidal. dead time distortion correction utilizes phase current sensing. on-chip module MC68HC908MRxx microcontrollers contains block that enables them evaluate polarity size phase current without need expensive current sensor. based sampling evaluation phase voltage level during dead time. zero voltage during dead time reflects positive phase current, full DC-Bus voltage during dead time reflects negative phase current. comparing phase voltage with half DC-Bus voltage enables evaluation current polarity. topology illustrated Figure 2-4. output comparator connected current polarity sensing input MC68HC908MR32 microcontroller. microcontroller contains hardware that samples current sensing inputs during dead time. enables evaluation current polarity also region currents.
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System Description Dead Time Distortion Correction
PWM0
iPWM1
Figure 2-4. Topology Current Polarity Sensing During reload ISR, desired values three phases calculated PWM1 phase PWM2 phase PWM3 phase
values loaded into individual PVAL registers separate phases shown Table 2-1. Since motor control utilizes center-aligned modulation, only half dead time needs added substracted from desired duty cycle achieve distortion correction. Without dead time correction, even PVAL registers loaded with required value, PVAL registers used. When dead time correction used, even PVAL registers loaded with desired plus half dead time (PWMx+DT/2), while PVAL registers loaded with desired minus half dead time (PWMx-DT/2).
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System Description
Table 2-1. values loaded into registers PVAL1-6
Phase PVAL register PVAL1 PVAL2 PVAL3 PVAL4 PVAL5 PVAL6 Required values PVAL without dead time correction PWM1 PWM2 PWM3 Required values PVAL with dead time correction PWM1 DT/2 PWM1 DT/2 PWM2 DT/2 PWM2 DT/2 PWM3 DT/2 PWM3 DT/2 Actual values loaded into PVAL registers PWM1 DEADTM/2/PWM_PRESC PWM1 DEADTM/2/PWM_PRESC PWM2 DEADTM/2/PWM_PRESC PWM2 DEADTM/2/PWM_PRESC PWM3 DEADTM/2/PWM_PRESC PWM3 DEADTM/2/PWM_PRESC
Phase
Phase
Phase
When calculating values loaded into PVAL registers, MRxx's Dead Time register used. dead-time register (DEADTM) holds 8-bit value which specifies number clock cycles used dead-time, when complementary mode selected. Dead-time affected changes prescaler value. other hand, PVAL values affected prescaler counter. Therefore value stored into dead time register needs scalled prescaler (PWM_PRESC Table 2-1). Control Register (PCTL2) contains generator prescaler. buffered read/write bits, PRSC0 PRSC1, select prescaler according Table 2-2.
Table 2-2. Prescaler
Prescaler bits PRSC0 PRSC1 Frequency fOP/2 fOP/4 fOP/8 Prescaler PWM_PRESC
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System Description Dead Time Distortion Correction
on-chip module MC68HC908MRxx microcontrollers enables them perform types dead time distortion correction: Partial correction Full correction
Partial dead time distortion correction based only polarity detection phase current. hardware, sensing current polarity according Figure 2-4, needs implemented. software responsible calculating both compensated values placing them odd/even register pair according Table 2-1. distortion correction fully implemented on-chip module according following scheme: current sensed motor that pair positive (voltage current low), value used pair. Likewise, current sensed motor that pair negative (voltage current high), even value used.
partial correction, on-chip dead time correction block automated mode current sense correction bits ISENS1:ISENS0 Control Register (PCTL1) 10). disadvantage partial correction that some dead time distortion still exist current flattened zero crossings.
Full dead time distortion correction (implemented dtCorrectFull algorithm) improves partial dead time correction sensing only polarity, also magnitude actual phase current. full dead time correction method, threshold, where correction values should toggled zero level, slightly advanced. threshold illustrated Figure 2-5. Toggling correction offset needs occur before current chance
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System Description
flatten current zero-crossing. current sense scheme must sense that current waveform approaching zero-crossing.
Current with Correction Disabled
Falling threshold
High Positive Magnitude Magnitude
Rising threshold
High Negative Magnitude
Dave Wilson
Figure 2-5. Proposed Current Threshold Correction Toggling achieve full distortion correction, again different correction factors must added desired value, depending whether bottom transistor controlling output voltage during dead time. software responsible calculating both compensated values placing them odd/even register pair. Then needs determine which value used, according following scheme: current sensed motor that pair positive high magnitude, negative small magnitude trend approaching zero crossing, value used pair. Likewise, current sensed motor that pair negative, positive small magnitude trend approaching zero crossing, even value used.
MR32 contains hardware circuitry that enables sense current polarity together with magnitude. current polarity magnitude sensed using DT-DT6 FTACK register '908MR32
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System Description Dead Time Distortion Correction
microcontroller. Phase bits used shown Table 2-3. Table 2-3. Sensing Current Polarity Magnitude
Current Condition Phase high magnitude high magnitude Ilow magnitude, either polarity
phase bits used. phase bits used. stated determination correct PVAL used generation done purely software. on-chip dead time correction block manual mode current sense correction bits ISENS1:ISENS0 Control Register (PCTL1)
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Designer Reference Manual 3-ph. ACIM Drive with
Section Hardware Design
Contents
System Configuration MC68HC908MR32 Control Board 3-Phase BLDC High Voltage Power Stage. Optoisolation Board Motor-Brake Specifications. Hardware Documentation
System Configuration
application designed drive 3-phase motor. consists following modules (see Figure 3-1): MC68HC908MR32 Control Board 3-phase AC/BLDC High Voltage Power Stage Optoisolation Board 3-phase Induction Motor
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Hardware Design
White Black
White
Black
+12VDC
Designer Reference Manual
flat ribbon cable
JP1.1 JP1.2
flat ribbon cable
Controller Board
J11.1 J11.2
AC/BLDC High Voltage Power Stage
Optoisolation Board
ECOPT
MC68HC908MR32
240VAC
J13.1 J13.2 J13.3
AM40V
SG40N
Motor-Brake
ECOPTHIVACBLDC
Figure 3-1. Hardware Configuration
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ECMTRHIVAC
Connected
Connected
DRM019
MOTOROLA
Hardware Design MC68HC908MR32 Control Board
MC68HC908MR32 Control Board
Motorola's embedded motion control series MR32 motor control board designed provide control signals 3-phase induction, 3-phase brushless (BLDC), 3-phase switched reluctance (SR) motors. combination with embedded motion control series power stages, optoisolation board, provides software development platform that allows algorithms written tested without need design build hardware. With software supplied CD-ROM, control board supports wide variety algorithms induction, BLDC motors. User control inputs accepted from START/STOP, FWD/REV switches, SPEED potentiometer located control board. Alternately, motor commands entered transmitted over serial cable DB-9 connector. Output connections power stage feedback signals grouped together 40-pin ribbon cable connector. Motor feedback signals connected Hall sensor/encoder connector. Power supplied through 40-pin ribbon cable from optoisolation board low-voltage power stage. control board designed configurations. connected M68EM08MR32 emulator M68CBL08A impedance matched ribbon cable, operate using daughter board. M68EM08MR32 emulator board used either MMDS05/08 MMEVS05/08 emulation system. Figure shows block diagram board's circuitry.
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Hardware Design
TERMINAL
OPTOISOLATED RS-232
FORWARD/REVERSE SWITCH START/STOP SWITCH
SPEED
TACHOMETER INPUT HALL EFFECT INPUTS
EMULATOR/ PROCESSOR CONNECTOR
CONFIG. JUMPERS
RESET SWITCH OPTION SWITCHES
POWER
REGULATED POWER SUPPLY
LEDs OPTO/POWER DRIVER CONNECTOR 40-PIN RIBBON CONNECTOR
OVERCURRENT/ OVERVOLTAGE INPUTS
CURRENT/TEMP SENSE INPUTS OUTPUTS
BACK INPUTS MISC. POWER CONTROL
Figure 3-2. MC68HC908MR32 Control Board electrical characteristics Table apply operation 25°C. Table 3-1. Electrical Characteristics Control Board
Characteristics power supply voltage Quiescent current logic input voltage (MR32) logic input voltage (MR32) Propagation delay (Hall sensor/encoder input) Analog input range RS-232 connection speed sink current Symbol tdly 10.8* 16.5* 9600 Units Baud
When operated powered separately from other Embedded Motion Control tool products
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DRM019 MOTOROLA
Hardware Design 3-Phase BLDC High Voltage Power Stage
3-Phase BLDC High Voltage Power Stage
Motorola's embedded motion control series high-voltage (HV) power stage 180-watt (one-fourth horsepower), 3-phase power stage that will operate input voltages from volts line voltages from volts. combination with embedded motion control series control boards optoisolation board, provides software development platform that allows algorithms written tested without need design build power stage. supports wide variety algorithms both induction brushless (BLDC) motors. Input connections made 40-pin ribbon cable connector J14. Power connections motor made output connector J13. Phase phase phase labeled Ph_A, Ph_B, Ph_C board. Power requirements with single external 140- 230-volt power supply line voltage. Either input supplied through connector J11. Current measuring circuitry 2.93 amps full scale. Both phase currents measured. cycle-by-cycle over-current trip point 2.69 amps. high-voltage power stage both printed circuit board power substrate. printed circuit board contains IGBT gate drive circuits, analog signal conditioning, low-voltage power supplies, power factor control circuitry, some large, passive, power components. power electronics, which need dissipate heat, mounted power substrate. This substrate includes power IGBTs, brake resistors, current sensing resistors, power factor correction MOSFET, temperature sensing diodes. Figure shows block diagram.
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Hardware Design
POWER INPUT
SWITCH MODE POWER SUPPLY
CONTROL BRAKE
SIGNALS TO/FROM CONTROL BOARD
3-PHASE IGBT POWER MODULE GATE DRIVERS PHASE CURRENT PHASE VOLTAGE CURRENT VOLTAGE MONITOR BOARD BLOCK ZERO CROSS BACK-EMF SENSE 3-PHASE MOTOR
Figure 3-3. 3-Phase High Voltage Power Stage electrical characteristics Table apply operation 25°C with 160-Vdc power supply voltage.
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Hardware Design Optoisolation Board
Table 3-2. Electrical Characteristics Power Stage
Characteristics input voltage input voltage Quiescent current logic input voltage logic input voltage Symbol VOut ISense VBus PBK(Pk) Pdiss 8.09 mV/A mV/V Units
Input resistance Analog output range current sense voltage voltage sense voltage Peak output current Brake resistor dissipation (continuous) Brake resistor dissipation Total power dissipation
Optoisolation Board
Motorola's embedded motion control series optoisolation board links signals from controller high-voltage power stage. board isolates controller, peripherals that attached controller, from dangerous voltages that present power stage. optoisolation board's galvanic isolation barrier also isolates control signals from high noise power stage provides noise-robust systems architecture. Signal translation virtually one-for-one. Gate drive signals passed from controller power stage high-speed, high dV/dt, digital optocouplers. Analog feedback signals passed back through HCNR201 high-linearity analog optocouplers. Delay times typically
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Hardware Design
digital signals, analog signals. Grounds separated optocouplers' galvanic isolation barrier. Both input output connections made 40-pin ribbon cable connectors. assignments both connectors same. example, signal PWM_AT appears input connector also output connector. addition usual motor control signals, MC68HC705JJ7CDW serves serial link, which allows controller software identify power board.
Power requirements controller side circuitry with single external 12-Vdc power supply. Power power stage side circuitry supplied from power stage through 40-pin output connector. electrical characteristics Table apply operation 25°C, 12-Vdc power supply voltage.
Table 3-3. Electrical Characteristics Optoisolation Board
Characteristic Power Supply Voltage Quiescent Current Logic Input Voltage Logic Input Voltage Analog Input Range Input Resistance Analog Output Range Digital Delay Time Analog Delay Time Symbol VOut tDDLY tADLY 70(1) 200(2) 0.25 500(3) Units DC/DC converter logic logic Notes
Power supply powers optoisolation board only. Current consumption optoisolation board plus board (powered from this power supply) Maximum current handled DC/DC converters
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DRM019 MOTOROLA
Hardware Design Motor-Brake Specifications
Motor-Brake Specifications
induction motor-brake incorporates 3-phase induction motor attached BLDC motor brake. induction motor four poles. incremental position encoder coupled motor shaft, position Hall sensors mounted between motor brake. They allow sensing position required control algorithm. Detailed motor-brake specifications listed Table 3-4. target application customer specific motor used.
Table 3-4. Motor Brake Specifications
Manufactured Motor Specification: Brno, Czech Republic eMotor Type: Pole-Number: Nominal Speed: Nominal Voltage: Nominal Current: Brake Specification: Brake Type: Nominal Voltage: Nominal Current: Pole-Number: Nominal Speed: Position Encoder Type: Pulses Revolution: AM40V 3-Phase Induction Motor 1300 0.88 SG40N 3-Phase BLDC Motor 1500 Baumer Electric 16.05A 1024-12-5 1024
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Hardware Design Hardware Documentation
system parts supplied documented according following references: MC68HC908MR32 Control Board: supplied ECCTR908MR32 described Motorola Embedded Motion Control MC68HC908MR32 Control Board User's Manual MEMCMR32CBUM/D 3-ph AC/BLDC High Voltage Power Stage supplied with Optoisolation Board ECOPTHIVACBLDC described Motorola Embedded Motion Control 3-Phase BLDC High-Voltage Power Stage User's Manual MEMC3PBLDCPSUM/D Optoisolation Board supplied with 3-ph AC/BLDC High Voltage Power Stage ECOPTHIVACBLDC supplied alone ECOPT optoisolation board described Motorola Embedded Motion Optoisolation Board User's Manual MEMCOBUM/D Motor-Brake AM40V SG40N supplied ECMTRHIVAC Detailed descriptions individual boards found comprehensive User's Manuals belonging each board. manuals available Motorola web. User's Manual incorporates schematic board, description individual function blocks bill materials. individual board ordered from Motorola standard product.
Designer Reference Manual
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Designer Reference Manual 3-ph. ACIM Drive with
Section Software Design
Contents
Introduction Data Flow Algorithm Dead Time Distortion Correction
Introduction
This section describes design software blocks drive. software will described terms Software Data Flow Algorithm Dead Time Distortion Correction
Data Flow
requirements drive dictate that software takes some values from user interface sensors, processes them generates 3-phase signals motor control. control algorithm closed loop drive described Figure 4-1. consists processes described following sub-sections. dead time distortion correction algorithm described separately successive section.
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Software Design
Communication
Switches
converters omega_reqPCM_mech
Process Master Software Control
Process Speed Command dtCorrectOption Process Status Control Current Polarity Sensing
u_dc_bus
omega_reqOMP_mech
Process Dead Time Distortion Correction
Process Acceleration/Deceleration Ramp appFaultStatus omega_reqRMP_mech Process Fault Control pDtCorrectApp
Process V/Hz Ramp
Fault
Fault u_ramp phase_increment
Process Generation
PVAL1,2
PVAL3,4
PVAL5,6
Figure 4-1. Data Flow
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Software Design Data Flow
4.3.1 Speed Command Status Control Manual Operating Mode, required speed speed potentiometer switches (start/stop, forward/reverse). Master Software (Remote) Operating Mode, required speed process, input parameters evaluated speed command calculated accordingly. Also DC-Bus voltage measured. application fault status analyzed state drive set. status LED's controlled according system state.
4.3.2 Acceleration/Deceleration Ramp process calculates speed command based required speed according acceleration deceleration ramp.
4.3.3 V/Hz Ramp This process provides voltage calculation according V/Hz ramp. input this process generated inverter frequency omega_req_RMP_mech. outputs this process output sine wave parameters required generation process: table increment phase_increment that corresponds frequency omega_req_RMP_mech used roll through wave table order generate output inverter frequency, corresponding amplitude generated inverter voltage u_ramp.
4.3.4 Process Generation This process generates system three phase sinewaves shifted 120o each other. function mcgen3PhWaveSine used sine wave calculation. mcgen3PhWaveSine function calculates immediate value three-phase sinusoidal system from given amplitude actual phase pointer:
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Phase sPhaseVoltage.PhaseA
Designer Reference Manual
Software Design
Phase sPhaseVoltage.PhaseB Phase sPhaseVoltage.PhaseC
individual waves shifted 120° each other. shape generated waveforms depends data stored sine table. motor control applications, data usually describes pure sinewave sinewave with addition third harmonic component. Figure shows duty cycles generated mcgen3PhWaveSine function when amplitude 50%.
DutyCycle.PhaseA DutyCycle.PhaseB DutyCycle.PhaseC
Figure 4-2. 3-Phase Sine Waves with Amplitude calculation based wave table stored FLASH memory microcontroller. table describes either pure sinewave sinewave with third harmonic addition. second case often preferred because allows generate first harmonic sine voltage equal input line voltage. format stored wave table data from #0x0000 (for ZERO Voltage) 0x7fff (for 100% Voltage). Thus proper data scaling secured (see Figure 4-3).
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Software Design Data Flow
important note that Modulus loaded corresponding PVAL registers) corresponds ZERO phase voltage. wave table, ZERO phase voltage corresponds number #0x0000. Therefore fetched wave value from table must added Modulation quadrant substracted from Modulation quadrant Thus correct value loaded.
0x7fff 0x7fff
ActualPhase(n) Actual Phase
PhaseIncrement Phase Increment
amplitude 100% Amplitude 100%
ActualPhase(n-1) Actual Phase (n-1)
0x4000 0x4000
(DutyCycle.PhaseA) (DutyCycle.PhaseA)
0x0000 0x0000
0x8000 -180° 0x8000 -180
amplitude Amplitude
0x7fff 0x7fff 180°
Figure 4-3. mcgen3PhWaveSine Data Explanation Phase output parameters process are: value phase PVAL1 register value phase PVAL3 register value phase PVAL5 register
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Software Design
case dead time distortion correction, corrected PVAL values PVAL1-6 calculated used generation according detected phase current polarity. process described following points: Wave pointer phase updated table increment. Based wave pointer, values three phases calculated. values rescaled according modulo (PWM frequency) loaded into PVAL1, registers. Registers PVAL2, loaded automatically because complementary mode selected during module initialisation. case dead time distortion correction, corrected values PVAL1-6 calculated used generation according detected phase current polarity.
process accessed regularly rate given frequency selected interrupt prescaler.
4.3.5 Master Software Control process provides communication with using master software service routines. These routines fully independent motor control tasks. They enable example desired speed, frequency type dead time distortion correction.
4.3.6 Fault Control This process responsible fault handling. software accommodates three fault events: DC-Bus over-current, DC-Bus over-voltage DC-Bus under-voltage. DC-Bus Over-current: case DC-Bus over-current, external hardware provides rising edge DC-Bus over-current fault input microcontroller. This signal disables motor control outputs (PWM1 PWM6) sets application fault status.
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DRM019 MOTOROLA
Software Design Algorithm Dead Time Distortion Correction
DC-Bus Over-voltage: case DC-Bus over-voltage, external hardware provides rising edge DC-Bus over-voltage fault input microcontroller. This signal disables motor montrol outputs (PWM1 PWM6) sets application fault status. DC-Bus Under-voltage: sensed DC-Bus voltage compared with limit within software. case DC-Bus under-voltage, motor control outputs (PWM1 PWM6) disabled application fault status set.
faults occurs, application status changed into Fault Status.
4.3.7 Dead Time Distortion Correction process defines value registers used generation according type dead time distortion correction state immediate phase current polarity. dead time correction required, PVAL1,3,5 used, complementary PVAL values calculated on-chip peripheral automatically. partial dead time correction required, PVAL value selected on-chip peripheral automatically according phase current polarity sensing full dead time correction required, process selects desired PVAL registers according dead time distortion correction state machine.
following section dead time distortion correction algorithm described detail.
Algorithm Dead Time Distortion Correction
algorithm dtCorrectFull calculates IPOL bits defining PVAL registers used MC68HC908MR32 generation full dead time correction. IPOL bits determined according phase
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Designer Reference Manual
Software Design
current polarity detection bits DT1-6, actual sine wave pointer, actual state algorithm state machine. algorithm state machine samples actual state phase current, selects appropriate PVAL registers used generation. state machine, implemented dtCorrectFull algorithm, illustrated Figure 4-4. When algorithm enabled, state machine entered from initial state waiting till high magnitude positive current detected (State confirmed State then algorithm enters state machine (State state machine performed circle 3-4-5-6-3. soon magnitude negative current detected, IPOL changed requesting even-numbered registers used generation, actual value wave pointer recorded (C), State entered. State preserved electrical degrees, until high negative current expected. Then State entered. soon magnitude positive current detected, IPOL changed requesting odd-numbered registers used generation, actual value wave pointer recorded (C), State entered. State preserved electrical degrees, until high positive current expected. Then State entered state machine loop repeated. this way, ensured that required IPOL changes when small amplitude respective current detected hardware. Please note, that wave pointer recorded into algorithm variable PointA, PointB, PointC, moment when respective phase current crosses current threshold.
Designer Reference Manual
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Software Design Algorithm Dead Time Distortion Correction
INITIAL STATE
Algorithm enabled
Initial recognition positive current
High positive current
X0/0
Waits high positive current
X1/1
negative current
Change IPOL (current treshold crossing) Waits high negative current
|-C|>80o
|-C|>80o/1
positive current
0X/0
High negative current
1X/1
STATE TRANSITION KEY: IPOL REGISTERS CONTROL OUTPUT IPOL ODD-NUMBERED REGISTER CONTROLS OUTPUT NUMBERED REGISTERS CONTROL OUTPUT IPOL EVEN-NUMBERED REGISTER CONTROLS OUTPUT EVEN NUMBERED
Figure 4-4. Dead Time Correction State Machine Such state machine independently implemented each phase algorithm contains flag variables, determining actual state state machine individual phases. Flag variable dtStateFlagsAB determines state state machine phases dtStateFlagsC determines state state machine phase meaning individual bits dtStateFlagsAB listed Table 4-1. meaning individual bits dtStateFlagsC listed Table 4-2.
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Software Design
Table 4-1. State Machine Flag Registers dtStateFlagsAB
phase bits bit0 lock bit1 bit2 bit3 bit4 lock bit5 bit6 bit7 State
phase
phase
Table 4-2. State Machine Flag Registers dtStateFlagsC
phase bits bit0 lock bit1 bit2 bit3 bit4 bit5 bit6 bit7 State
phase
reserved
NOTE:
Detailed explanation dead time distortion correction found comprehensive application note Motorola, AN1728 "Making Low-Distortion Motor Waveforms with MC68HC708MP16" David Wilson. Note, that MC68HC708MP16 predecessor MC68HC908MRxx family contains identical on-chip block.
Algorithm Data Structure: Algorithm data structure defined dtCorrect.h header file. Table 4-3.
typedef struct UByte dtBits; UByte ipolBits; type_uBits dtStateFlagsAB; type_uBits dtStateFlagsC; Designer Reference Manual Software Design More Information This Product, www.freescale.com DRM019 MOTOROLA
Software Design Algorithm Dead Time Distortion Correction
SByte pointA; SByte pointB; SByte pointC; SByte pointerA; dtCorrect_s;
Table 4-3. dtCorrect_s Structure Elements
Variable Explanation INPUT: actual status dead time bits DT1-6, format |DT6|DT5| |DT4|DT3|DT2|DT1| fits FTACK `MR32 OUTPUT: ipolBits top/bottom correction bits IPOL1-3, format |IPOL1| |IPOL2|IPOL3| fits PCTL2 `MR32 internal dead-time correction flags phases internal dead-time correction flags phase internal capture pointer phase internal capture pointer phase internal capture pointer phase INPUT: actual pointer generated wave phase
dtBits
ipolBits dtStateFlagsAB dtStateFlagsC pointA pointB pointC pointerA
dead time correction algorithm dtCorrectFull adds correction factor originally calculated sine wave. necessary ensure that calculated duty cycles exceed modulus. dtCorrectInit function must called before starting call dtCorrectFull function, ensure proper functionality.
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Software Design
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DRM019 MOTOROLA
Designer Reference Manual 3-ph. ACIM Drive with
Section System Setup
Contents
Hardware Setup Warning Jumper Settings Controller Board. Required Software Tools Building Application Executing Application Controlling Application with Master Software
Hardware Setup
Figure illustrates hardware setup application. incorporates following modules: MC68HC908MR32 Control Board 3-phase AC/BLDC High Voltage Power Stage Optoisolation Board 3-phase Induction Motor
correct phase order (phase phase phase shown induction motor Phase wire Phase white wire Phase black wire
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Designer Reference Manual
System Setup
view motor looking into shaft end, phase order phase motor shaft should rotate clockwise direction (i.e., positive direction, positive speed).
Figure 5-1. Setup Application
Warning
This application operates environment that includes dangerous voltages rotating machinery. aware, that application power stage optoisolation board electrically isolated from mains voltage they live with risk electric shock when touched.
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DRM019 MOTOROLA
System Setup Jumper Settings Controller Board
isolation transformer should used when operating power line. isolation transformer used, power stage grounds oscilloscope grounds different potentials, unless oscilloscope floating. Note, that probe grounds and, therefore, case floated oscilloscope subjected dangerous voltages. user should aware, that: Before moving scope probes, making connections, etc., generally advisable power down high-voltage supply. avoid inadvertent touching live parts, plastic covers. When high voltage applied, using only hand operating test setup minimizes possibility electrical shock. Operation setups that have grounded tables and/or chairs should avoided. Wearing safety glasses, avoiding ties jewelry, using shields, operation personnel trained high-voltage techniques also advisable. Power transistors, coil, motor reach temperatures enough cause burns. When powering down; storage capacitors, dangerous voltages present until power-on off.
Jumper Settings Controller Board
MC68HC908MR32 control board jumper settings shown Figure Table required execute 3-phase motor control application with dead time distortion correction. detailed description jumper settings, refer MC68HC908MR32 Control Board User's Manual (Motorola document order number MEMCMR32CBUM/D).
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System Setup
Figure 5-2. MC68HC908MR32 Jumper Reference
Table 5-1. MC68HC908MR32EVM Jumper Settings
Jumper Group Comment Tachometer input selected Encoder input selected Back signals selected Power factor correction zero cross signal selected Power factor correction signal selected Power Supply connected jack Connections connection connection connection connection
Required Software Tools
application requires following software development tools:
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System Setup Building Application
Metrowerks1CodeWarrior®2 MC68HC08 microcontrollers version later. master software version 1.2.0.11 later
Building Application
build this application, open 3ph_acim_dt_correct.mcp project file execute Make command; Figure 5-3. This command will build link motor control application along with needed Metrowerks libraries.
Figure 5-3. Execute Make Command
Executing Application
execute motor control application, pull-down menu choose Project/Debug command CodeWarrior® IDE, followed command.
Metrowerks® Metrowerks logo registered trademarks Metrowerks, Inc., wholly owned subsidiary Motorola, Inc. CodeWarrior® registered trademark Metrowerks, Inc., wholly owned subsidiary Motorola, Inc.
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Designer Reference Manual
System Setup
MMDS target selected, CodeWarrior will automatically download MMDS05/08 emulator. application operate modes: Manual Operating Mode drive controlled START/STOP switch (SW3). direction motor rotation FWD/REV switch (SW4). motor speed SPEED potentiometer (P1). Refer Figure this description.
Speed Speed potentiometer Potentiometer
Fault Fault Over-Voltage Over-Voltage
Forward Reverse Forward Reverse Switch switch
Fault Over-Current Over-Current
Start Stop Start Stop Switch switch
Figure 5-4. Control Elements
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DRM019 MOTOROLA
System Setup Executing Application
Figure 5-5. USER LEDs, LEDs, RESET Master Software (Remote) Operating Mode drive controlled remotely from through serial communications interface (SCI) communication channel device RS-232 physical interface. drive enabled START/STOP switch, which used safely stop application time. Setting required speed motor supported control action. application states displayed with on-board LEDs. Refer Figure positions. application runs motor spinning disabled (i.e., system ready), green status will blink. When motor rotation enabled, green status will actual state pulse-width modulator (PWM) outputs indicated with output LEDs, labeled PWM1 PWM6. DC-Bus over-current DC-Bus over-voltage occurs, wrong system board identified, green status will start flash quickly master software will signal identified fault. This state exited only with application reset.
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System Setup
Refer Table description application states their corresponding indications. Table 5-2. Motor Application States
Application State Stopped Running Fault Motor State Stopped Spinning Stopped Green State Blinking frequency Blinking frequency
Once application running: Move START/STOP switch (SW3) from STOP START Select direction rotation FWD/REV switch (SW4) required speed SPEED potentiometer
successful, 3-phase induction motor will spinning.
NOTE:
START/STOP switch START position when application starts, toggle switch between STOP START positions enable motor spinning. This protection feature preventing motor start spinning when application executed from CodeWarrior. should also lighted green indicating application running. application stopped, green will blink 2-Hz frequency. When application started, type dead time distortion correction desired frequency selected using master software control page. phase voltage motor current observed using oscilloscope, efficiency dead time distortion correction evaluated. type dead time distortion correction indicated yellow MR32 controller board. When dead time distortion correction disabled, yellow turned off. When partial correction selected, flashes with frequency. With full correction, turned (refer Table 5-3).
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DRM019 MOTOROLA
System Setup Controlling Application with Master Software
Table 5-3. Dead Time Distortion Correction
Distortion Correction Disabled Partial (h/w) Full (s/w) Blinking frequency Yellow State
Controlling Application with Master Software
Project file master software located Start master software application window choose appropriate master software project. Figure shows master software control window 3ph_acim_dt_correct.pmp. type dead time distortion correction (no/partial/full), frequency (4kHz/8kHz/16kHz/32kHz) selected variables pane, shown Figure 5-6.
NOTE:
desired dead time application configuration file appconfig.h, where on-chip modules 68HC908MR32 microcontroller initialized.
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Designer Reference Manual
System Setup
Select partial full dead time distortion correction
Figure 5-6. Master Software Control Window master software displays following information: required actual speed motor phase voltage amplitude (related given DC-Bus voltage) application mode START/STOP DC-Bus voltage fault status
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DRM019 MOTOROLA
System Setup Controlling Application with Master Software
master software allows user frequency (the frequency changed time during motor operation):
select dead time distortion correction (the selection done time during motor operation): partial full
frequency type dead time distortion correction selected both manual master modes, using master software. possible oscilloscope display phase currents voltages dead time distortion evaluation.
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Designer Reference Manual
System Setup
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DRM019 MOTOROLA
Designer Reference Manual 3-ph. ACIM Drive with
Appendix References
Motorola, Inc. (2001). 68HC908MR32 User's Manual, MC68HC908MR32/D
Motorola, Inc. (2000). Motorola Embedded Motion Control MC68HC908MR32 Control Board User's Manual, MEMCMR32CBUM/D Motorola, Inc. (2000). Motorola Embedded Motion Control 3-Phase BLDC High-Voltage Power Stage User's Manual, MEMC3PBLDCPSUM/D Motorola, Inc. (2000). Motorola Embedded Motion Optoisolation Board User's Manual, MEMCOBUM/D Motorola, Inc. (1997). Making Low-Distortion Motor Waveforms with MC68HC708MP16, AN1728
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Designer Reference Manual
References
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DRM019 MOTOROLA
Designer Reference Manual DRM019
Appendix Glossary
Alternating Current ACIM Induction Motor
Analogue-to-Digital Converter BLDC brushless motor Direct Current "Dead Time (DT)" Dead Time Correction, "Dead Time (DT)" Dead Time (DT) short time that must inserted between turning transistor inverter half bridge turning complementary transistor limited switching speed transistors. duty cycle ratio amount time signal versus time off. Duty cycle usually represented percentage. interrupt temporary break sequential execution program respond signals from peripheral devices executing subroutine. input/output (I/O) Input/output interfaces between computer system external world. reads input sense level external signal writes output change level external signal. logic voltage level approximately equal input power voltage (VDD). logic voltage level approximately equal ground voltage (VSS).
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Glossary
MC68HC08 Motorola family 8-bit MCUs Microcontroller Unit. complete computer system, including CPU, memory, clock oscillator, input/output (I/O) single integrated circuit. MR32 (908MR32, MC68HC908MR32) "MC68HC08" phase-locked loop (PLL) clock generator circuit which voltage controlled oscillator produces oscillation which synchronized reference signal. PVAL value register motor control module MC68HC908MR32 microcontroller. defines duty cycle generated signal. Pulse Width Modulation reset force device known condition. "serial communications interface module (SCI)" serial communications interface module (SCI) module that supports asynchronous communication. serial peripheral interface module (SPI) module that supports synchronous communication. software Instructions data that control operation microcontroller. software interrupt (SWI) instruction that causes interrupt associated vector fetch. "serial peripheral interface module (SPI)" switched reluctance motor timer module used relate events system point time.
Designer Reference Manual
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REACH USA/EUROPE/LOCATIONS LISTED: Motorola Literature Distribution; P.O. 5405, Denver, Colorado 80217 1-303-675-2140 1-800-441-2447 JAPAN: Motorola Japan Ltd.; SPS, Technical Information Center, 3-20-1, Minami-Azabu Minato-ku, Tokyo 106-8573 Japan 81-3-3440-3569 ASIA/PACIFIC:
Motorola Semiconductors H.K. Ltd.; Silicon Harbour Centre, King Street, Industrial Estate, N.T., Hong Kong 852-26668334 TECHNICAL INFORMATION CENTER: 1-800-521-6274 HOME PAGE:
Information this document provided solely enable system software implementers Motorola products. There express implied copyright licenses granted hereunder design fabricate integrated circuits integrated circuits based information this document. Motorola reserves right make changes without further notice products herein. Motorola makes warranty, representation guarantee regarding suitability products particular purpose, does Motorola assume liability arising application product circuit, specifically disclaims liability, including without limitation consequential incidental damages. "Typical" parameters which provided Motorola data sheets and/or specifications vary different applications actual performance vary over time. operating parameters, including "Typicals" must validated each customer application customer's technical experts. Motorola does convey license under patent rights rights others. Motorola products designed, intended, authorized components systems intended surgical implant into body, other applications intended support sustain life, other application which failure Motorola product could create situation where personal injury death occur. Should Buyer purchase Motorola products such unintended unauthorized application, Buyer shall indemnify hold Motorola officers, employees, subsidiaries, affiliates, distributors harmless against claims, costs, damages, expenses, reasonable attorney fees arising directly indirectly, claim personal injury death associated with such unintended unauthorized use, even such claim alleges that Motorola negligent regarding design manufacture part.
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Motorola, Inc. 2003
DRM019/D
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