AN2154 Freescale Semiconductor, Inc. Low-Cost, 3-Phase, Moto

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AN2154 Freescale Semiconductor, Inc. Low-Cost, 3-Phase, Moto

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AN2154
Freescale Semiconductor, Inc.
Low-Cost, 3-Phase, Motor Control System with Power Factor Correction Based MC68HC908MR32
Petr Stekl Zdenek Kubiczek Motorola Czech System Application Laboratory Roznov Radhostem, Czech Republic
Introduction
This application note describes design 3-phase, induction motor drive with digital power factor correction (PFC) single lowcost microcontroller, MC68HC908MR32 (MR32). Most usual variable speed induction motor drive designs contain full-bridge rectifier large dc-bus capacitor input. Such circuit draws peak current from wall socket, which provokes high content harmonics. low-power factor (PF), described present circuit, reduces necessary power from mains increases efficiency mains supply network. international standard IEC1000-3-2 defines limits harmonic content input current mains supplied equipment. meet norms, design requires power factor correction input. present design allows simultaneous driving power factor correction algorithm induction motor. This way, significant cost reductions design achieved. Moreover, wide range input voltages from volts volts regulation dc-bus voltage achieved. Another benefit design possibility easy modification system software updates.
Motorola, Inc., 2001
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Freescale Semiconductor, Inc. Application Note System Concept
design based conjunction induction motor control system with digital power factor correction application. Detailed ideas induction control design described application note, Low-Cost, 3-Phase, Motor Control System Based MC68HC, Motorola order number AN1664/D.
Freescale Semiconductor, Inc.
This application note presents only basic facts concerning particular designs focused primarily conjunction both algorithms. system driven Motorola 8-bit microcontroller (MCU) MC68HC908MR32. This simultaneously performs control motor control. block diagram whole motor control system seen Figure
BULK CAPACITOR
230-V MAINS
BOOST
INVERTERS
MOTOR
MICROCONTROLLER
Figure Block Diagram Motor Control System with drives boost and, through inverters, also drives motor. microcontroller built-in interfacing peripherals. Through input interfaces (like analog-to-digital converters port pins), collects signals from sensors converts these analog values into digital forms that further processed control program. result program, control parameters converted through output interfaces (like channels, digital-to-analog converters, port pins) into control signals, which drive induction motor.
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Application Note System Hardware
present design help user start development system according particular requirements. save much engineering time speed time market.
System Hardware
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System Specifications
system hardware consists following equipment: MR32 control board Optoisolation board 3-phase, high-voltage BLDC (brushless power stage board induction motor with speed sensor 15-V power supply 110-V/60-Hz 230-V/50-Hz power supply/wall socket
printed circuit boards (PCB) user's manuals available from Motorola. Table System Specifications
Nominal input voltage Input voltage frequency Maximum input current Maximum electrical output power Maximum dc-bus voltage Output phase voltage Output voltage frequency 90-265 50/60 0-230 0-100
MR32 Control Board
more detailed description MR32 control board, refer Motorola Embedded Motion Control MC68HC908MR32 Control Board User's Manual, Motorola document order number MEMCMR32CBUM/D, that comes with board (kit number ECCTR908MR32).
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Freescale Semiconductor, Inc. Application Note
control board designed used hardware software design single, 3-phase, permanent magnet, brush, brushless motor drive applications. does contain MC68HC908MR32 microcontroller. control board designed directly connected MR32 board, which part MMDS/MMEVS emulation system, connected impedance matched ribbon cable. daughter board designed house MR32 microcontroller will plug into control board place emulator cable. With daughter board plugged into control board, standalone operation system possible. features control board include: motor control (pulse-width modulation) outputs with (light-emitting diode) indicators Speed control potentiometer Optoisolated half-duplex RS232 interface START/STOP FORWARD/REVERSE switches Hall effect inputs (for brushless motor control) Back (electromotive force) inputs (for brushless motor control) Configuration jumpers 2-position (dual in-line package) switches user option control Emulator/daughter board connectors Processor reset switch system fault inputs Nine analog inputs Three software controlled LEDs On-board regulated power supply Motor (input/output) interface ribbon cable connector
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Application Note System Hardware
MR32 Control Board Jumper Settings
3-phase induction drive control system with requires following jumper settings MR32 control board: closed Speed sensor (tacho) closed zero crossing signal closed signal open
software independent switch settings.
Freescale Semiconductor, Inc.
Optoisolation Board
function optoisolation board provide galvanic isolation barrier between control board's input/outputs (I/O), both analog digital parts, high-voltage system power board's I/Os. These isolated signals, from optoisolation board, connected 40-pin ribbon cables. assignment both connectors same. signal flow through optoisolation board, both directions, one-to-one relation source. more detailed description optoisolation board, refer Motorola Embedded Motion Control Optoisolation Board User's Manual, Motorola document order number MEMCOBUM/D. power requirement control board's circuitry satisfied with single external 15-volt power supply. connected optoisolation board either connector JP1, labeled "Ext. Power DC," power jack Either one, both, used. This power supply control board through 40-pin ribbon cable connector. excitation power stage side circuitry supplied power stage through 40-pin output connector located optoisolation board. addition usual motor control signals, MC68HC705JJ7 microcontroller serves serial link. allows controller board's software identify configuration optoisolation board power stage board. passes configuration information control board processing checking system configuration.
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Freescale Semiconductor, Inc. Application Note
Power Stage more detailed description 3-phase, BLDC, high-voltage power stage board setup, refer Motorola Embedded Motion Control 3-Phase BLDC High-Voltage Power Stage User's Manual, Motorola document order number MEMC3PBLDCPSUM/D. power stage provides high-power drive circuitry various types motors. suitable driving induction, permanent magnet, brush brushless motors. power stage consists printed circuit boards. boards power module containing power IGBTs (isolating gate bipolar transistor), brake IGBT, power factor corrector field effect resistor (FET), temperature sensing diodes. second board contains IGBT drive circuits, analog signal conditioning, low-voltage power supplies, power factor control circuitry, MC68HC705JJ7 microcontroller, used board configuration identification. features power stage include: 1-phase bridge rectifier Power factor switch diode Power factor correction coil dc-bus brake IGBT brake current limiting resistors 3-phase bridge inverter (six IGBTs) Individual phase dc-bus current sensing shunt resistors with Kelvin connections Power stage temperature sensing diodes IGBT gate drivers Current temperature signal conditioning 3-phase back-EMF voltage sensing (zero crossing) detection circuitry Board identification processor (MC68HC705JJ7) Low-voltage on-board power supplies Cooling fans
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Application Note Software
Power Stage Jumper Settings
operate properly, 3-phase induction drive control system with requires JP201 jumper position.
Software
system software includes three algorithms: 3-phase V/Hz induction motor control algorithm Digital power factor correction algorithm PC-Master communication routines
Freescale Semiconductor, Inc.
system software executed MMDS05/08 emulator system programmed MC68HC908MR32, resident daughter board, plugged into control board. algorithms judged independent their software design basic features described separately. Basic features V/Hz control software include: Controlled acceleration deceleration Speed range 2400 4-pole motor drive clockwise counterclockwise. Speed sensed tachometer/generator. frequency kHz. Operation PC-Master manual operating mode Overvoltage overcurrent protection
Basic features PC-Master communication software include: Ability read/write variable Ability read variable Execution PC-Master commands
Basic features power factor correction software include:
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Automatic input voltage detection V/60 V/50 dc-bus voltage regulation Overvoltage overcurrent protection
Freescale Semiconductor, Inc. Application Note Software Design
this section, design particular applications described first, separately, then overall functionality described.
Initilization
main routine provides initialization microcontroller: Clears Initializes clock Initializes module: Center-aligned complementary mode, positive polarity (MOR register) enable (MOR register) modulus defines frequency (PMOD register) 2-µs dead time (DEADregister) interrupt reload every fourth cycle (PCTL2 register) FAULT2 (overcurrent fault) manual mode, interrupt enabled (FCR register) Sets ports Initializes timer input capture (IC), output compare (OC), software timer reference Initializes timer generation Initializes (analog-to-digital) converter Detects connected boards Detects input line voltage limits Detects input line frequency Calibrates feedback offset FB_offset error occurs, fault turned failure register set, software waits reset. Enables interrupts
Freescale Semiconductor, Inc.
When MR32 reset, software configures various system I/O, FORWARD/REVERSE switch, START/STOP switch. dc-bus voltages checked speed potentiometer's value
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Application Note Software Design
input. yellow control board illuminated when system ready. Afterward, identification connected boards (for example, optoisolation power boards) checked. default operation mode manual. PC-Master operation mode PC-Master command. algorithm initialized. When passed, fault flag (Failure) tested system fault. Anytime fault detected system, control board turned status LEDs described later this application note.
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Power Factor Correction
algorithm drives analog part PFC. MR32 features assigned algorithm follows: Timer input capture (TCH0A pin) detection Timer channels (TCH0B pin) Buffered signal generation Analog-to-digital converter, channel (ATD2 pin) dc-bus voltage sensing Input/output port (PTA0 pin) inhibit signal
control algorithm performs these tasks: Converts sensed output voltage into digital value Calculates software regulator feedback loop Programs channel create pattern input current Synchronizes (using mains zero crossing detector) operation mains frequency
interrupt handlers used operation are: input capture interrupt handler channel timer performs synchronization PFC. output compare interrupt handler generates waveform input current. interrupt handler performs control output voltage.
flow diagram control software depicted Figure
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Freescale Semiconductor, Inc. Application Note
START
INITIALIZE
WAIT MAINS ZERO CROSSING
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TIMER
WAIT OUTPUT COMPARE
SELECT MILESTONE POINTER
MILESTONE
MILESTONE
MILESTONE
MILESTONE
MILESTONE
ACTIVATE INHIBIT
DEACTIVATE INHIBIT
PROGRAM
PROGRAM
MEASURE VOut
RESET POINTER
REGULATOR
PROGRAM INCREMENT POINTER
Figure Control Software Flow Diagram
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Application Note Software Design
desired shape input current non-sine wave with stairs. number size stairs optimized fulfill these requirements: Least complex avoid overloading microcontroller Harmonic currents content complies with standard IEC1000-3-2.
waveform input current consists current levels five time intervals half-period time range. generated current waveform shown Figure
Freescale Semiconductor, Inc.
INPUT CURRENT 0.00
0.01 TIME
0.02
Figure Input Current 1-kW Output Power Input Capture Interrupt Handler TIMA, Channel After initialization, software waits mains zero-crossing (ZC) signal which used synchronization algorithm with line voltage. PFCzc() function called service interrupt. output compare channel programmed first input current waveform milestone. programmed value corresponds 848-µs time interval. Output compare interrupts channel enabled. input capture detection signal) disabled better noise immunity. disable flag PFC_status status word (for example, overvoltage detected), output disabled next half period. serviced here well.
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Freescale Semiconductor, Inc. Application Note
Output Compare Interrupt Handler TIMA, Channel PFCwave() function called service interrupt. main task this function define input current waveform milestones (time intervals) hence form input current waveform. variable Point used determine next step. During each step, next output compare channel programmed proper input current level programming duty cycle timer duty cycle. When step (Point=2) reached, conversion channel started. senses dc-bus voltage conversion complete interrupt enabled. When last step (Point=5) reached, output compare TIMA channel disabled input capture channel enabled synchronization). position milestones inductor current seen from Figure
4398 4398
Freescale Semiconductor, Inc.
START SIGNAL FROM
Figure Milestones Induction Current Conversion Complete Interrupt Handler, Channel PFCcntrl() function called service interrupt. sensed dc-bus voltage stored into variable Out_volt_new. interrupts disabled conversion channel started required speed sensing. During initialization, algorithm jumps feedback loop offset calibration routine. When offset found, CALIB_OFFSET flag PFC_status status word cleared LOAD_ON_FLG flag Mcs_status status word set. Once CALIB_OFFSET flag cleared, calibration routine skipped next algorithm execution. sensed voltage into regulator. nominal dc-bus output voltage Vdc. required output voltage determined Out_Volt_Max variable. output
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Application Note Software Design
voltage regulator amplitude input inductor current. calculated input current limited maximum input value zeroed negative. value variable Curr_level1 variable derived, representing higher level input current, value variable Curr_level2 variable calculated lower level input current. PC-Master Communication PC-Master Communication program resident MR32 that communicates (serial communications interface) with PC-Master software parse commands, return status information process control information from MR32 features assigned algorithm follows. PC-Master Communication software intended used developing motor control software. When using PC-Master software, required actions motor control software manipulated operator. PC-Master software executes that connected isolated RS232 serial port control board. PC-Master software user interface displays various sets views (tabs) programmed HTML code with embedded objects scripts. They used control board's application, present block diagram, show graphically status variables, many other features that extended user. small program resident MR32 that communicates with PC-Master software parse commands, return status information process control information from actions controlled PC-Master are: Start/Stop control Motor speed setpoint Reset drive system Motor rotation direction control clockwise/counter clockwise (CW/CCW)
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Freescale Semiconductor, Inc. Application Note
following default variables read PC-Master software displayed user: Required speed Actual motor speed dc-bus voltage Power module temperature Display system status error flags
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PC-Master commands described Table Table PC-Master Commands
Command manual mode PC-master mode Command Code Demo Suitcase Action Setting manual mode Setting PC-master mode
status error flags read PC-Master periods. flags used determine status operation software PC-Master application.
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Application Note Software Design
Descriptions control, status, failure flags found Table Table PC-Master Status Error Flags
Register Description Stop motor Start motor Forward direction Reward direction Reserved Clear clear error START/STOP switch stop flag START/STOP switch start flag Motor stopped Motor running Reserved 230-V line detected 120-V line detected Reserved Overcurrent failure Overheating failure Overvoltage failure Reserved
Motor_Ctrl
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Motor_Status Failure
Drive Operating Modes
motor drive able operate following operating modes (OM). MANUAL/PC-Master option PC-Master command when START/STOP switch STOP position. (The motor stops green off.) confirmed hardware after START/STOP switch been START position. MANUAL Operating Mode
Default mode after reset. MANUAL required action switches mounted control board (START/STOP, FORWARD/REVERSE) potentiometer (Speed). status drive displayed LEDs.
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Freescale Semiconductor, Inc. Application Note
PC-Master Operating Mode Required software actions motor drive controlled PC-Master commands running connected control board. motor stopped case emergency setting START/STOP switch STOP position. actions, controlled PC-Master control page, are: Start/stop motor Control speed Reset drive Drive direction variables read PC-Master control page default will Required speed Actual motor speed dc-bus voltage Power module temperature Read status error flags software other variable read/written. LEDs Status software uses active-high indicators connected pins configured outputs according following description: Motor running (green) PTC6 status Run; otherwise, off. Status (yellow) PTC5 status Stand_By Fault. turned off. status Stop. turned Fault (red) PTC4 status Stand_By, Run, Stop. turned off. status Initialization Error. turned status Fault (overvoltage, overcurrent). flashing with frequency
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Otherwise, turned off.
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Application Note Software Design
Brief V/Hz Algorithm Description
Freescale Semiconductor, Inc.
motor control software monitors state sensors they periodically scanned software timer loop. speed motor calculated utilizing input capture interrupt. green control board will illuminate whenever motor running. According operational mode, setup, state control signals (START/STOP switch, FORWARD/REVERSE switch, speed potentiometer), speed command calculated using acceleration/deceleration ramp. comparison between actual speed command tachometer speed generates speed error. speed error passed speed controller generating corrected motor frequency. corresponding voltage calculated using V/Hz ramp. generation process calculates system 3-phase voltages representing required amplitude frequency, including dead times. 3-phase motor control signals then output power stage. dc-bus voltage dc-bus current measured during control process. They used overvoltage overcurrent protection drive. overvoltage protection performed software while overcurrent fault signal utilizes fault input microcontroller. mentioned faults occur, motor control outputs disabled drive protection system fault state displayed. These faults, depending operating mode system, output LEDs controller and/or terminal that connected control board. control algorithm close loop drive described Figure consists processes that described briefly subsections that follow. details, refer application note, 3-Phase Induction Motor Control System Based MC68HC908MR32, Motorola document order number AN1857/D. found Motorola's pages.
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Freescale Semiconductor, Inc. Application Note
SWITCHES START/STOP FORWARD/REVERSE OPERATION MODE JUMPER
CONVERTERS
PROCESS SPEED COMMAND PROCESS CONTROL
TACHO
Out_volt_new
V_command PROCESS SPEED SENSOR
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PROCESS ACCELERATION/DECELERATION RAMP V_tacho GF_FLAG V_com_actual PROCESS CONTROLLER
PROCESS FAULT CONTROL
V_out
FAULT
PCTL1
PROCESS V/Hz RAMP
Amplitude
Table_inc
PROCESS GENERATION
PVAL1
PVAL3
PVAL5
Figure Data Flow Diagram
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Application Note Software Design
measured dc-bus voltage represented variable Out_volt_new. input value from speed potentiometer labeled Pot_voltage. input parameters process evaluated speed command V_command calculated accordingly. general fault GF_FLAG analyzed state drive set. drive state diagram shown Figure state LEDs controlled according system status. calculated speed command V_command 2-byte variable where first byte integer second byte remainder (for instance, 0x0100). upper byte represents integer portion lower byte represents fractional portion value. This format kept throughout program speed variables. system software calculates speed based requested speed, according acceleration deceleration ramp.
Freescale Semiconductor, Inc.
RESET
STAND-BY STATE V_command<>0 START/STOP DISABLED
GENERAL FAULT RECOVERY
STATE
V_command START/STOP
FAULT RECOVERY STATE DISABLED GENERAL FAULT
ENABLED
START/STOP FAULT STATE
V_command<>0 V_command V_out STOP STATE DISABLED
DISABLED
OVERVOLTAGE
OVERCURRENT
Figure Drive State Diagram
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Freescale Semiconductor, Inc. Application Note
Drive Deceleration During deceleration motor work generator. generator state, dc-bus capacitor charged voltage could easily exceed maximal voltage. Therefore, dc-bus voltage measured compared with limit. case deceleration overvoltage, deceleration interrupted motor runs with constant speed discharge capacitor down acceptable value. Deceleration then continue. During deceleration, depending input line voltage, dc-bus voltage, controlled PFC, maintained below volts. speed sensing process utilizes MR32's input capture interrupt function. input capture interrupt reads time between rising edges speed sensor's output calculates actual motor speed, V_tacho. software filter speed measurement incorporated process better noise immunity. this case, actual motor speed calculated average value several measurements. general principle behind control loop shown Figure speed closed-loop control characterized measurement actual motor speed. This information compared with reference setting point error signal generated. magnitude polarity error signal corresponds difference between actual required speed. Based speed error, controller generates corrected motor frequency error compensation reaches required motor speed. This process takes these input parameters: actual speed command V_com_actual actual motor speed measured tachogenerator V_tacho. Then calculates speed error performs speed control algorithm. output controller frequency fundamental sine wave that generated inverter, V_out.
REFERENCE SPEED (V_com_actual) ACTUAL MOTOR SPEED (V_tacho) SPEED ERROR CORRECTED SPEED (V_out) CONTROLLED SYSTEM
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Speed Control Loop
CONTROLLER
Figure Closed Loop Control
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Application Note Software Design
Volt-per-Hertz Ramp Implementation
drive designed constant Volt-per-Hertz drive. This means that control algorithm keeps magnetizing current (flux) motor constant varying stator voltage with frequency. ratio voltage divided frequency constant during linear portion profile. commonly used volt-per-Hertz ramp profile 3-phase induction motor illustrated Figure
PHASE VOLTAGE
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100%
BASE POINT
BOOST VOLTAGE
BOOST FREQUENCY
BASE FREQUENCY
FREQUENCY (rpm)
Figure Volt-per-Hertz Ramp volt-per-Hertz ramp defined with these parameters: Base point Defined base frequency (usually Boost Defined boost voltage boost frequency
ramp profile fits specific motor easily changed accommodate different ones. software function RAMP.C provides voltage calculation according V/Hz ramp. input this software function generated inverter frequency, V_out. output function amplitude generated voltage, Amplitude.
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Freescale Semiconductor, Inc. Application Note
Generation Parameters, required generation process, output this software function: Table increment, Table_inc, that corresponds frequency V_out, used roll through wave table generation output inverter frequency. Amplitude generated inverter voltage
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process sine wave generation provides 3-phase sine waves, each shifted degrees relative each other. sine waves pure sine waves they have third harmonic component. calculation based wave table stored MCU's ROM. table describes either pure sine wave sine wave with additional third harmonic. second case often preferred because allows generation first harmonic sine voltage equal input line voltage. Because quarter wave symmetry, only first quadrant wave period stored table. wave values other quadrants calculated from first one. data format stored wave table from 0x00 (for voltage) modulus/2 (for percent voltage). Thus, proper data scaling secured. detailed process description PWM, refer application note, AN1857, 3-Phase, Induction Motor Control System Based MC68HC908MR32, that found Motorola pages. input parameters process are: table increment Table_inc updates wave pointer. Amplitude generated inverter voltage
output parameters process are: value phase PVAL1 register value phase PVAL3 register value phase PVAL5 register
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Application Note Software Design
process setting these registers' values accessed regularly rate given frequency selected interrupt prescaler (register named PCTL2). This process repeated often enough, compared wave frequency, generate correct wave shape. Therefore, 16-kHz frequency, called every fourth pulse. Thus registers updated 4-kHz rate (for example, every µs).
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General Application Overview
processes described previously implemented single state machine illustrated Figure Figure Figure general state diagram incorporates main routine, entered from reset, eight interrupt states. main routine includes initialization microcontroller software timer control algorithm timebase. interrupt states provide calculation actual speed motor, overcurrent fault handler, generation process, zero crossing interrupt PFC, output compare generate input current waveform, interrupt control output voltage, read, transmit routines. software timer routine provides timing sequence required subroutines. software timer performed instead output compare interrupt handler. main program several timedemanding interrupt routines, more interrupt requirements cause software fault. software timer routine timed outputs: READ_CONST routine that scans inputs, calculates speed command, handles fault routines, driver. PI_CONST routine that provides overvoltage protection during deceleration, speed ramp (acceleration/deceleration), controller, V/Hz ramp, provides parameters generation.
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Freescale Semiconductor, Inc. Application Note
interrupt handlers have following functions: input capture (IC) interrupt handler reads time between subsequent edges (basic part process speed sensor). fault interrupt handler takes care overcurrent fault interrupt (overcurrent part process fault control). interrupt handler generates system 3-phase voltages motor (process generation). input capture interrupt handler channel timer makes synchronization PFC. output compare (OC) interrupt handler generates waveform input current. interrupt handler performs control output voltage. read interrupt handler services receive interrupts PC-Master communication routines. transmit interrupt handler services transmit interrupts PC-Master communication routines.
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Application Note Software Design
INPUT CAPTURE INTERRUPT SPEED
RESET
INPUT CAPTURE INTERRUPT
INPUT CAPTURE INTERRUPT HANDLER DONE FAULT INTERRUPT FAULT INTERRUPT HANDLER INITIALIZE SOFTWARE DONE TIMEOUT READ_CONST SOFTWARE TIMER
INPUT CAPTURE INTERRUPT HANDLER DONE OUTPUT COMPARE INTERRUPT OUTPUT COMPARE INTERRUPT HANDLER DONE DONE
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DONE TIMEOUT
INTERRUPT DONE INTERRUPT HANDLER PI_CONST DONE
TIMEOUT
INTERRUPT INTERRUPT HANDLER DONE
TRANSMITTER INTERRUPT
RECEIVER INTERRUPT RECEIVER INTERRUPT HANDLER DONE
TRANSMITTER INTERRUPT HANDLER DONE
Figure State Diagram General Overview READ_CONST accessed from main software timer READ_CONST rates. following sequence performed. Figure inputs scanned (speed pot, START/STOP switch, FORWARD/REVERSE switch, temperature, dc-bus current). dc-bus voltage measured interrupt routine. speed command calculated according operational mode. dc-bus voltage compared with overvoltage limit overcurrent flag checked case fault condition, fault recovery routine entered until recovery time expires, drive remains disabled.
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Freescale Semiconductor, Inc. Application Note
Finally, driver controls individual LEDs according status drive. hardware enabled/disabled according drive status. PC-Master commands serviced.
READ_CONST TIMEOUT
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SCAN INPUTS DONE
OPERATING MODE DISTRIBUTION
MANUAL OPERATING MODE DONE FAULT DETECTION DONE
PC-MASTER OPERATING MODE DONE
ENABLE FAULT RECOVERY DONE FAULT RECOVERY DONE
DRIVER DONE
RETURN SCHEDULER
Figure State Diagram READ_CONST Timeout
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Application Note Software Design
PI_CONST accessed from main software timer PI_CONST rates. rates define time constant controller. following sequence performed (see Figure 11): During deceleration, dc-bus voltage checked and, case overvoltage, deceleration interrupted until capacitor discharged. When deceleration overvoltage measured, acceleration/deceleration speed profile calculated. actual motor speed calculated. based time measurement between subsequent rising edges input capture. speed controller performed corrected motor frequency calculated.
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corresponding voltage amplitude calculated according Voltper-Hertz profile. Thus, both parameters generation available (Table_inc, Amplitude).
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Freescale Semiconductor, Inc. Application Note
PI_CONST TIMEOUT
DECELERATION OVERVOLTAGE PROTECTION OVERVOLTAGE OVERVOLTAGE
ACCELERATION/DECELERATION RAMP CONTROL DONE
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TACHO SPEED CALCULATION
DONE
SPEED CONTROLLER
DONE
V/Hz RAMP
DONE
RETURN SCHEDULER
Figure State Diagram PI_CONST Timeout Fault Handling important note that, event system fault, software services event timely manner. accommodates fault inputs, overcurrent overvoltage. Overcurrent: external hardware provides rising edge fault input microcontroller's FAULT2 input through fault generation circuit. This signal disables motor control PWM's outputs (PWM1-PWM6) sets general fault flag, GF_FLAG. Also OVER_CURRENT flag Failure register, used PC-Master control interface.
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Application Note Software Design
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Overvoltage: sensed dc-bus voltage compared with limit within software. case overvoltage, motor control outputs disabled software, which sets bits MCU's control register (PCTL1) sets general fault flag, GF_FLAG. Also, OVER_VOLTAGE flag Failure register, used PC-Master control interface. overvoltage fault only motor braking generator mode). motor mode (the motor supplies power load), overvoltage occurs, disabled; overvoltage failure detected motor blocked. important note that output voltage operates very close volts, which overvoltage limit. regulation overshoot would cause overvoltage failure when running. Therefore, overvoltage blocked when running.
these faults occur, fault will flash. system remains disabled until fault cleared switching START/STOP switch STOP then START position cleared PCMaster setting ERROR_CLEAR_PMFLG control register Motor_Ctrl. soon START/STOP switch START, motor restarts.
Software Files
software consists following parts: Code_ISR.C Contains interrupt reset vector addresses system's MR32 software DigitPFC.C Contains software used drive power factor correction hardware resident power board. software sets duty cycle timer channel that pulse-width modulates power board's input hardware kHz. FAULT.C Contains fault interrupt service routine MAIN.C This entry point following reset after initial startup code. contains initialization software state code, main state machine with software timer state code.
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Freescale Semiconductor, Inc. Application Note
MR_IDENT.C Contains code that communicates with MC68HC705JJ7 microcontrollers, resident optoisolation power boards. resulting information from this routine used configuration checking input system time parameters. PCMASTER.C Contains PC-Master communication routines PI.C Contains PI_CONST timeout code (deceleration overvoltage protection state, tacho speed calculation state, speed controller state, calls acceleration/deceleration ramp state V/Hz ramp state appropriately)
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PWMCALC.C Contains code service interrupts which ultimately generate sine outputs power stage RAM.C Contains global variable definitions MR32 system software RAMP.C Contains code acceleration deceleration ramp state, V/Hz ramp state SPEED.C Contains READ_CONST code (scan inputs state; operational mode distribution state; speed calculation, manual operational mode state, speed calculation; PC-Master operation mode state; fault detection state; enable state; fault recovery state; driver state; enable/disable logic) TACHO.C Contains timer channel interrupt code that calculates time between tachometer interrupts 3RDHQUAD.H Header file that contains 256-word 1-quadrant sine table with third harmonic injection CODE_FUN.H Header file containing prototypes external functions V/Hz control CONST.H Header file that contains global system constants definitions system's MR32 software MR_IDENT.H Contains board type identification constants MR24IO.H Provides MR24/MR32 registers PCMASTER.H Contains PC-Master communication constant variables declarations
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Application Note Conclusion
RAM.H Header file that contains global variable declarations MR32 system software MR24_VHz_PFC.PRM Parameter file containing interrupt reset vector addresses system's MR32 software
References
information regarding PC-Master software, application note software, microcontroller documentation, refer www.motorola.com/mcu, Motorola's site microcontrollers.
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Conclusion
this application note, design 3-phase, speed-controlled, induction motor software described with special attention power factor correction optional PC-Master communication. hardware part this system purchased from Motorola. toolset enables MR32 evaluated system without necessity building prototype hardware. design, described this application note, illustrates efficiency simplicity using MC68HC908MR32 microcontroller processing heart robust motor control system low-cost industrial consumer motor control applications. addition, Motorola application notes Low-Cost 3-Phase Motor Control System Based MC68HC908MR24, document order number AN1664/D, 3-Phase Induction Motor Control System Based MC68HC908MR32, document order number AN1857/D, give reader full view presented application software hardware, which found Motorola pages.
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Freescale Semiconductor, Inc. Application Note
Freescale Semiconductor, Inc.
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. Motorola registered trademarks Motorola, Inc. Motorola, Inc. Equal Opportunity/Affirmative Action Employer.
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:
Motorola, Inc., 2001
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AN2154 Freescale Semiconductor, Inc. Low-Cost, 3-Phase, Moto

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