Motorola M68HC08 User manual

MOTOROLA.COM/SEMICONDUCTORS

M68HC08

Microcontrollers

DRM028/D

Rev. 0, 03/2003

Sensorless BLDC

Motor Control

Using the

MC68HC908MR32

Manual

Designer Reference

Freescale Semiconductor, I

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Freescale Semiconductor, I

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DRM028 — Rev 0 Designer Reference Manual

MOTOROLA 3

Sensorless BLDC Motor

Control Using the

MC68HC908MR32

Designer Reference Manual — Rev 0

by: Libor Prokop

Motorola Czech System Laboratories

Roznov pod Radhostem, Czech Republic

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Revision history

Designer Reference Manual DRM028 — Rev 0

4MOTOROLA

To provide the most up-to-date information, the revision of our

documents on the World Wide Web will be the most current. Your printed

copy may be an earlier revision. To verify you have the latest information

available, refer to:

http://www.motorola.com/semiconductors

The following revision history table summarizes changes contained in

this document. For your convenience, the page number designators

have been linked to the appropriate location.

Revision history

Date Revision

Level Description Page

Number(s)

February,

2003 1 Initial release N/A

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DRM028 — Rev 0 Designer Reference Manual

MOTOROLA 5

Designer Reference Manual — Sensorless BLDC Motor Control

List of Sections

Section 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Section 2. System Description. . . . . . . . . . . . . . . . . . . . . 15

Section 3. BLDC Motor Control . . . . . . . . . . . . . . . . . . . . 23

Section 4. Hardware Design. . . . . . . . . . . . . . . . . . . . . . . 57

Section 5. Software Design . . . . . . . . . . . . . . . . . . . . . . . 75

Section 6. User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Appendix A. References. . . . . . . . . . . . . . . . . . . . . . . . . 161

Appendix B. Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . .163

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List of Sections

Designer Reference Manual DRM028 — Rev 0

6MOTOROLA

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DRM028 — Rev 0 Designer Reference Manual

MOTOROLA 7

Designer Reference Manual — Sensorless BLDC Motor Control

Table of Contents

Section 1. Introduction

1.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

1.2 Application Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

1.3 Benefits of the Solution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Section 2. System Description

2.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.2 System Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.3 System Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Section 3. BLDC Motor Control

3.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

3.2 Brushless DC Motor Control Theory. . . . . . . . . . . . . . . . . . . . .23

3.3 Used Control Technique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

3.4 Application Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Section 4. Hardware Design

4.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

4.2 System Configuration and Documentation . . . . . . . . . . . . . . . .57

4.3 All HW Sets Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

4.4 High-Voltage Hardware Set Components. . . . . . . . . . . . . . . . . 66

4.5 Low-Voltage Evaluation Motor Hardware Set Components . . .70

4.6 Low-Voltage Hardware Set Components . . . . . . . . . . . . . . . . .72

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Table of Contents

Designer Reference Manual DRM028 — Rev 0

8MOTOROLA

Section 5. Software Design

5.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

5.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

5.3 Data Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

5.4 Main Software Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

5.5 State Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

5.6 Implementation Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Section 6. User Guide

6.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

6.2 Application Suitability Guide . . . . . . . . . . . . . . . . . . . . . . . . . .109

6.3 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

6.4 Application Hardware and Software Configuration . . . . . . . . .113

6.5 Tuning for Customer Motor. . . . . . . . . . . . . . . . . . . . . . . . . . .126

Appendix A. References

Appendix B. Glossary

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DRM028 — Rev 0 Designer Reference Manual

MOTOROLA 9

Designer Reference Manual — Sensorless BLDC Motor Control

List of Figures

Figure Title Page

2-1 System Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

3-1 BLDC Motor Cross Section. . . . . . . . . . . . . . . . . . . . . . . . . . . .24

3-2 3-Phase Voltage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

3-3 BLDC Motor Back EMF and Magnetic Flux . . . . . . . . . . . . . . .26

3-4 Classical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

3-5 Power Stage — Motor Topology. . . . . . . . . . . . . . . . . . . . . . . .28

3-6 Phase Voltage Waveform. . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

3-7 Mutual Inductance Effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

3-8 Detail of Mutual Inductance Effect . . . . . . . . . . . . . . . . . . . . . .33

3-9 Mutual Capacitance Model . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

3-10 Distributed Back-EMF by Unbalanced

Capacity Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

3-11 Balanced Capacity Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . .36

3-12 Back-EMF Sensing Circuit Diagram . . . . . . . . . . . . . . . . . . . . .37

3-13 The Zero Crossing Detection . . . . . . . . . . . . . . . . . . . . . . . . . .38

3-14 Commutation Control Stages . . . . . . . . . . . . . . . . . . . . . . . . . .39

3-15 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

3-16 BLDC Commutation with Back-EMF

Zero Crossing Sensing Flowchart. . . . . . . . . . . . . . . . . . . . . . .42

3-17 BLDC Commutation Time with Zero Crossing Sensing . . . . . .43

3-18 Vectors of Magnetic Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

3-19 Back-EMF at Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

3-20 Calculation of the Commutation Times During the Starting

(Back-EMF Acquisition) State. . . . . . . . . . . . . . . . . . . . . . . . . .49

4-1 High-Voltage Hardware System Configuration . . . . . . . . . . . . .59

4-2 Low-Voltage Evaluation Motor Hardware

System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

4-3 Low-Voltage Hardware System Configuration . . . . . . . . . . . . .63

4-4 MC68HC908MR32 Control Board . . . . . . . . . . . . . . . . . . . . . .65

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List of Figures

Designer Reference Manual DRM028 — Rev 0

10 MOTOROLA

4-5 3-Phase AC High Voltage Power Stage . . . . . . . . . . . . . . . . . .67

4-6 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

5-1 Main Data Flow — Part1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

5-2 Main Data Flow — Part 2: Alignment, Starting,

Running Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

5-3 Closed Loop Control System . . . . . . . . . . . . . . . . . . . . . . . . . .81

5-4 Main Software Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

5-5 Main Software Flowchart — Main Software Loop. . . . . . . . . . .86

5-6 Software Flowchart — Interrupts . . . . . . . . . . . . . . . . . . . . . . .89

5-7 Application State Transitions . . . . . . . . . . . . . . . . . . . . . . . . . .90

5-8 Stand-by State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

5-9 Align State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

5-10 Back-EMF Acquisition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

5-11 Running State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

5-12 STOP State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

5-13 Fault State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

6-1 High-Voltage Hardware System Configuration . . . . . . . . . . . .114

6-2 Low-Voltage Evaluation Motor Hardware

System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

6-3 Low-Voltage Hardware System Configuration . . . . . . . . . . . .116

6-4 Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

6-5 Execute Make Command . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

6-6 PC Master Software Control Window . . . . . . . . . . . . . . . . . . .124

6-7 Follow-up for Software Customizing to Customer Motor . . . .128

6-8 Follow-up for Advanced Software Customizing . . . . . . . . . . .129

6-9 Follow-up for Software Customizing Trouble Shouting. . . . . .129

6-10 PC Master Software Parameters Tuning Control Window . . .130

6-11 PC Master Software Parameters Tuning Control Window . . .131

6-12 PC Master Software Current Parameters Tuning Window . . .141

6-13 PC Master Software Start Parameters Tuning Window . . . . .149

6-14 PC Master Software Speed Parameters Tuning Window. . . .154

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