Renesas RL78G14 Installation and operating instructions

APPLICATION NOTE

RESH-OS-MC-20001 Rev.1.00 Page 1 of 26

Nov 03,2011

RL78/G14

Power Tool 120 deg. Reference Development

Introduction

This document will provide an overview of power tool 120 degree reference development. This solution is based on

Renesas Electronics' next-generation MCU (RL78 family), which combines advanced features from both the 78K and

R8C families. Same as mainstream power tool products in market, BLDC control is used in this solution.

Target Device

RL78/G14 Group

Contents

1. Overview ........................................................................................................................................... 2

2. System Diagram................................................................................................................................ 3

3. Configuration of R5F104BE .............................................................................................................. 4

4. Control theory.................................................................................................................................... 9

5. Hardware structure.......................................................................................................................... 13

6. Hardware and test data................................................................................................................... 19

7. Software flowchart........................................................................................................................... 22

APPENDIX .............................................................................................................................................. 25

RESH-OS-MC-20001

Rev.1.00

Nov 03, 2011

RL78/G14 Group Document Name

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Nov 03,2011

1. Overview

1.1 Overview

120 degree control method are widely used in power tool controller, this kind of control mode not only include the

torque variation caused by phase change, but also include the torque variation caused by the step performance caused by

the control theory itself. This project adopts new method to overcome the torque variation on the basis of 120 control

mode.

The RL78 Family is Renesas Electronics' next-generation microcontroller family combining advanced features from

both the 78K and R8C families to deliver low power consumption and high performance. As one member of RL78

family, RL78/G14 achieves reduced system power consumption overall, and supports multifunctional consumer and

industrial applications without requiring additional external components. Since there is built-in three-phase PWM

output timer and two-phase encoder timer: Motor control, it is suitable to be used for Brushless DC motor control.

RL78/G14 is used to develop the 120 degree control method for the power tool controller. The main functions are list

below:

●120 degree sinusoidal wave control;

●Close-loop control of current;

●Three-step speed control;

●Over current protection;

●Thermal protection;

1.2 Electrical Specifications

Size: 50mm(L)*46.8mm(W)

Storage Environment: -20 ~ 85 ℃，40% ~ 95% RH

Operation Environment: 0 ~ 70 ℃，40% ~ 95% RH

Rated Voltage: DC 14V

Rated Current: 3.5A

Rated Power: 50W

Speed: High level: 0～2400 RPM

Middle level: 0～1800 RPM

Low level: 0～1100 RPM

RL78/G14 Group Document Name

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Nov 03,2011

2. System Diagram

Figure 2-1 120 degree control system diagram

VDD=14.4V

BLDC

LM317

RL78/G14

R5F104BE

Driver IC

L6387

Speed set

Direction set

LED lighting

…………

Strength set

LED Indication

RL78/G14 Group Document Name

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Nov 03,2011

3. Configuration of R5F104BE

3.1 Pin of R5F104BE

Figure 3-1 Pin of R5F104BE

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Nov 03,2011

3.2 Structure of R5F104BE

Figure 3-2 Structure of R5F104BE

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Nov 03,2011

3.3 Function list of R5F104xx

Table 3-1 Function List

Item R5F104Ax R5F104Bx R5F104Cx R5F104Ex

Pin Count 30 32 36 40

Flash memory

(KB)

16 to 64 16 to 64 16 to 64 16 to 64

RAM (KB) 2.5 to 5.5 2.5 to 5.5 2.5 to 5.5 2.5 to 5.5

Internal

memory

Data Flash (KB) 4 4 4 4

Memory Space 1MB

High-speed

system clock

X1 (crystal/ceramic) oscillation, external main system clock

input (EXCLK)

1 to 20 MHz: VDD = 2.7 to 5.5 V, 1 to 8 MHz: VDD = 1.8 to

2.7 V, 1 to 4 MHz: VDD = 1.6 to 1.8 V

Main

system

Clock

（Oscillation

frequency

）

Internal high-

speed

oscillation

clock

Internal oscillation

64 MHz/48 MHz/32 MHz/24 MHz/16 MHz/12 MHz/8 MHz/4

MHz/1 MHz (TYP.)

Internal low-speed oscillation

clock

(For WDT)

Internal oscillation (Watchdog timer, Real-time clock,

Interval timer clock)

15 kHz (TYP.): VDD = 1.6 to 5.5 V

General-purpose register 8 bits 32 registers (8 bits 8 registers 4 banks)　　　

0.03125 μs (Internal high-speed oscillation clock: fIH = 32

MHz operation)

0.05 μs (High-speed system clock: fMX = 20 MHz

operation)

Minimum instruction

execution time

30.5 μs (Subsystem clock: fSUB = 32.768 kHz operation)

Instruction set • 8-bit operation, 16-bit operation

• Multiplication (8 bits × 8 bits, 16 bits × 16 bits), Division (16

bits ÷ 16 bits, 32 bits ÷ 32 bits)

• Product-sum operation (16 bits × 16 bits + 32 bits)

• Bit manipulation (Set, reset, test, and Boolean operation),

etc.

I/O port

30-pin

produc

32-pin

produc

36-pin

produc

40-pin

product

Total 26 28 32 36

CMOS I/O 21 22 26 28

CMOS input 3 3 3 5

CMOS output - - - -

N-ch open-drain

I/O

(6 V tolerance

2 3 3 3

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Nov 03,2011

Timer

outputs

• 16-bit timer: 8 channels

• Watchdog timer: 1 channe

• Real-time counter: 1 channel

• Interval timer: 1 channel

A/D converter 8/10-bit resolution 8 channels　

Serial interface [30-pin, 32-pin products]

• CSI: 1 channel/UART: 1 channel/simplified I2C: 1 channel

• CSI: 1 channel/UART (UART supporting LIN-bus): 1

channel/simplified I2C: 1 channel

[36-pin, 40-pin products]

• CSI: 1 channel/UART: 1 channel/simplified I2C: 1 channel

• CSI: 2 channels/UART (UART supporting LIN-bus): 1

channel/simplified I2C: 2 channels

Multiplier/divider • 16 bits × 16 bits = 32 bits (Unsigned or signed)

• 16 bits ÷ 16 bits = 16 bits, 32 bits ÷ 32 bits = 32 bits

(Unsigned)

• 16 bits × 16 bits + 32 bits = 32 bits (Unsigned or signed)

Data transfer controller

(DTC)

29 sources

Internal 24Vector

interrupt

source External 7

Reset • Reset by RESET pin

• Internal reset by watchdog timer

• Internal reset by power-on-reset

• Internal reset by voltage detector

• Internal reset by illegal instruction execution Note

• Internal reset by RAM parity error

• Internal reset by illegal-memory access

Voltage detector When voltage rises: between 1.63 V and 3.98 V (14 stages)

When voltage drops: between 1.67 V and 4.06 V (14 stages)

Power supply voltage VDD = 1.6 to 5.5 V

Operating ambient

temperature

TA = -40 to +85 C　

RL78/G14 Group Document Name

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Nov 03,2011

3.4 Pin function of R5F104BE

Table 3-2 Pin Function Configuration

Pin NO. Pin name Pin Function Note

1 P40/TOOL0 Program interface Input/Ouput

2 RESET Reset Input

3 P137/INTP0 AD analog input over-current

protection

4 P122/X2/EXCLK Not used

5 P121/X1 Not used

6 REGC Group via cap

7 VSS Group

8 VDD Power

9 P60/SCLA0 Direction control Input

10 P61/SDAA0 Strength indication 3 output

11 P62/SSI00 Strength indication 2 output

12 P31/TI03/TO03/INTP4/PCLBUZ0 Strength indication 1 output

13 P70 unused

14 P30/INTP3/SCK00/SCL00/TRJO0 HALL W Input

15 P50/INTP1/SI00/RxD0/TOOLRxD/SDA00/

TRGIOA HALL U Input

16 P51/INTP2/SO00/TxD0/TOOLTxD/TRGIO

B HALL V Input

17 P17/TI02/TO02/TRDIOA0/TRDCLK0 LED Lighting For lighting

18 P16/TI01/TO01/INTP5/TRDIOC0 Tact Switch Input

19 P15/PCLBUZ1/SCK20/SCL20/TRDIOB0 Drive of U High PWM output

20 P14/RxD2/SI20/SDA20/TRDIOD0 Drive of U Low PWM output

21 P13/TxD2/SO20/TRDIOA1 Drive of V High PWM output

22 P12/SO11/TRDIOB1 Drive of W High PWM output

23 P11/SI11/SDA11//TRDIOC1 Drive of V Low PWM output

24 P10/SCK11/SCL11/TRDIOD1 Drive of W Low PWM output

25 P147/ANI18 AD analog input Speed control

26 P23/ANI3 AD analog input Over-current

protection

27 P22/ANI2 AD analog input Thermal protection

28 P21/ANI1/AVREFM Not used

29 P20/ANI0/AVREFP AD power reference

30 P01/ANI16/TO00/RxD1/TRGCLKB/TRJIO

0 Failure indication Output

31 P00/ANI17/TI00/TxD1/TRGCLKA Tact switch

32 P120/ANI19 Battery check

RL78/G14 Group Document Name

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Nov 03,2011

4. Control theory

4.1 Basic control theory of BLDC

The motors used in most power tool are Brushless DC motor, which the rated power is commonly very low. External

rotor structure is usually adopted to drive the power tool directly, but the power is very low because of its low rated

speed. Which cause the motor much bigger than other types of motor which have the same power value.

BLDC motor consists of motor, position sensor and electrical circuit. The stator is often made of several phases (such as

3 phases, four phases and five phases etc.), the rotor is consists of permanent magnet which arranged with different pole

pairs. Figure 4-1 shows a three phases, two poles BLDC motor.

电

源位置

传

感器

电子开关

电机本体

Figure 4-1 Structure of three phases, two poles BLDC motor

Three stator coils are connected with correspondent power devices in electrical circuit, A, B, C phase coils each

connected with power switch V1, V2, V3. Position sensors are used to detect the rotor position.

When one of the stator coils are power on, the current will cause torque by the interaction with magnetic field caused by

the rotor permanent magnetism, and the torque will cause the rotor running, the rotor position will be converted to

electrical signal by position sensors to control the electrical switches, thus make the each coils of stator are switched on

sequentially, the stator phase current will also change sequentially according to the position of rotor. Because of the

power on sequence of electrical switches are synchronous with the rotor angle, thus cause the same effect of mechanical

phase change.

Figure 4-2 shows the theory diagram of the half-bridge control of three phases, two poles BLDC motor. Photo-electric

devices are use as the position sensors. The power logic unit consists of three power MOSFET. The control theory will

be discussed below according to the half-bridge control.

Power

Motor

Hall sensors

Electrical switch

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Nov 03,2011

电

源

123

Figure 4-2 Three phase brushless motor

The discrepancy of space position of three photo-electrical devices VP1、VP2 and VP3 are 120 degree each. Via the

function of photo-electrical, the rotor position can be achieved.

a) b) c) d)

Figure 4-3 Commutation sequence and the rotation of magnetic field

The rotor position of figure 4-2 is same as that of figure 4-3a). at this position, the power MOSFET V1 is switched on

and the current flows into coil A-A’, the torque caused by the interaction between the coil current and rotor magnetic

will make the rotor rotate as the direction shown in figure 4-3b). when the rotor locate at the position as in figure 4-

3b), the power MOSFET V1 will be switched off and V2 will be switched on, the current will be changed form coil

A-A’ to B-B’, and the rotor will continue to rotate as the direction shown in figure 4-3b). When the rotor reaches the

position shown as in figure 4-3c), the power MOSFET V2 will be switched off and V3 will be switched on，the

current will be flowed through C-C’，thus the rotor will continue rotate to the position shown in figure 4-3a).

With the change of position sensor signal, the stator coil will be switched on and off sequentially, then the phase

current will be changed sequentially. During the phase change period, the rotating magnetic field generated by the

coils of the stator is not continuous. This kind of rotating magnetic field has three state in 360 degree range, each

state lasts 120 degree. The relationship between each coil and rotor magnetic field are showed in figure 4-3. Figure 4-

3a）is the first state, Fa is the magnetic force generated by coil A-A’, then the interaction between the coil current

and rotor magnetic field will make the rotor rotate clockwise. After 120 degree，the rotor will be in the second state,

the coil A-A’ will be switched off and coil B-B’ will be switched on，the magnetic field generated by stator coil

rotate 120 degree range shown as in figure 4-3b）, and the motor rotor continue to rotate clockwise. After another

Power

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