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Brushless DC

Motor Control
with

Age
nda
Basics of a BLDC Motor
Topology
BLDC Motor with Hall Sensors
BLDC Motor with Hardware
BEMF-Detection
BLDC Motor Sensor less
Control

Switching Pattern for Driving a


BLDC
How to use the CAPCOM6E for
a BLDC
Introduction CAPCOM6E for
BLDC purpose
CAPCOM6E & ADC

Electrical Motor Types


Electric
Electric
Motor
Motortypes
types

AC
AC

Asynchronous
Asynchronous

DC
DC

Synchronous
Synchronous

Induction
Induction
PMSM
PMSM

Synchronous
Synchronous

Switched
SwitchedRel.
Rel.

Stepper
Stepper

BLDC
Basics

Basics of a BLDC Motor


+

N
U
W

U
V

3-Phase Brush-less DC Motor


DC Motor with 3
Brushes
According
to the theory of DC machine, the motor rotational speed can be written as
follows:

N = ( Ud - I R ) / (Ke )
While,
N stands for the motor rotational speed
Ud stands for the DC voltage applied to the motor windings
R is the pure resistance of the winding while I stands for the winding current
Ke is the magnet coefficient while stands for the motor magnetic flux
From the above formula, there are two methods to change the speed of DC motor: One is to change the DC
voltage of the motor windings (Ud), the other one is to change the magnetic flux of the motor (). As the BLDC
motor has permanent magnet rotor, only the first method can be used in practical application. The principal of
generating variable DC voltage is to use PWM for chopping: change the duty cycle of the PWM voltage,
proportionally change the DC voltage.

How an Inverter Turns a BLDC


(1)

How an Inverter Turns a BLDC


(2)

How an Inverter Turns a BLDC


(3)

How an Inverter Turns a BLDC


(4)

How an Inverter Turns a BLDC


(5)

How an Inverter Turns a BLDC


(6)

BLDC with Hall Sensors Switching


Pattern
Typical Switching Pattern for a BLDC

Hall Sequence depends on motor construction


Output pattern levels depends on inverter topology

BLDC with
Hall Sensors

BLDC with Hall Sensors -Topology


Typical Circuit Block Diagram
Hall Sensors detect the position
Over current protection and control via ADC

Block Diagram CAPCOM6E for BLDC


Usage

Usage of CAPCOM6E to Control a BLDC


(1)
BEMF-Detection/Hall
Signals
HW-noise filter on
CCPOSx inputs
(BEMF-signals)

CC60

a c t. s p e e d

CC61

p h a s e d e la y

CC62

tim e o u t

H a r d w a r e N o is e
S u p p r e s s io n

c h 0 g e ts c a p tu re d
v a lu e f o r a c t . s p e e d
c h 1 c o m p a re
f o r p h a s e d e la y

c h 2 c o m p a re
fo r tim e o u t

C a p tu re
E vent
R e s e ts T 1 2

CCPO S0

CCPO S1

CCPO S2

CC6x
CO UT6y

0
1
1

Usage of CAPCOM6E to Control a BLDC


(2)
BEMF-Detection/Hall
Signals
HW-noise filter on
CCPOSx inputs
(BEMF-signals)
automatic reset of
T12 with interrupt
actual speed by
capture ch0

CC60

a c t. s p e e d

CC61

p h a s e d e la y

CC62

tim e o u t

H a r d w a r e N o is e
S u p p r e s s io n

c h 0 g e ts c a p tu re d
v a lu e f o r a c t. s p e e d
c h 1 c o m p a re
f o r p h a s e d e la y

c h 2 c o m p a re
f o r tim e o u t

C a p tu re
E vent
R e s e ts T 1 2

CCPO S0

CCPO S1

CCPO S2

CC6x
C O UT6y

0
1
1

Usage of CAPCOM6E to Control a BLDC


(3)
BEMF-Detection/Hall
Signals
HW-noise filter on
CCPOSx inputs
(BEMF-signals)
automatic reset of
T12 with interrupt
actual speed by
capture ch0
phase delay
function on ch1

CC60

a c t. s p e e d

CC61

p h a s e d e la y

CC62

tim e o u t

H a r d w a r e N o is e
S u p p r e s s io n

c h 0 g e ts c a p tu re d
v a lu e f o r a c t . s p e e d
c h 1 c o m p a re
f o r p h a s e d e la y

c h 2 c o m p a re
fo r tim e o u t

C a p tu re
E vent
R e s e ts T 1 2

CCPO S0

CCPO S1

CCPO S2

CC6x
CO UT6y

0
1
1

Usage of CAPCOM6E to Control a BLDC


(4)
BEMF-Detection/Hall
Signals
HW-noise filter on
CCPOSx inputs
(BEMF-signals)
automatic reset of
T12 with interrupt
actual speed by
capture ch0
phase delay
function on ch1
time out function
on ch2

CC60

a c t. s p e e d

CC61

p h a s e d e la y

CC62

tim e o u t

H a r d w a r e N o is e
S u p p r e s s io n

c h 0 g e ts c a p tu re d
v a lu e f o r a c t . s p e e d
c h 1 c o m p a re
f o r p h a s e d e la y

c h 2 c o m p a re
fo r tim e o u t

C a p tu re
E vent
R e s e ts T 1 2

CCPO S0

CCPO S1

CCPO S2

CC6x
CO UT6y

0
1
1

Usage of CAPCOM6E Hall Sensor


Mode (1)
CCPOSx Inputs
for Hallsensor Interface

MCMOUTSH / MCMOUTSL
SW programmable state
machine

Usage of CAPCOM6E Hall Sensor


Mode (2)
CCPOSx Inputs
edge detection triggers Dead Time Counter

MCMOUTSH / MCMOUTSL
compare CCPOSx level
with programmed value

Usage of CAPCOM6E Hall Sensor


Mode (2)
CCPOSx Inputs

MCMOUTSH / MCMOUTSL
switch to next state on
valid edge by hardware

Usage of CAPCOM6E Hall Sensor


Mode (3)
CCPOSx Inputs
wait on edge

MCMOUTSH / MCMOUTSL
prepare next state by
software

Usage of CAPCOM6E
Modulation Control (some Choices)

Usage of CAPCOM6E
Generate the PWM Pattern for BLDC

Usage of CAPCOM6E
Generate the PWM Pattern for BLDC

Usage of CAPCOM6E
Generate the PWM Pattern for BLDC

Usage of CAPCOM6E
Generate the PWM Pattern for BLDC

Usage of CAPCOM6E
Generate the PWM Pattern for BLDC

Usage of CAPCOM6E
Generate the PWM Pattern for BLDC

Usage of CAPCOM6E
Modulation and Synchronization

Usage of CAPCOM6E
Modulation and Synchronization

Usage of CAPCOM6E
Modulation and Synchronization

Usage of CAPCOM6E
Modulation and Synchronization

Usage of CAPCOM6E to Control a BLDC


(5)

Usage of CAPCOM6E to Control a BLDC


(6)

Usage of CAPCOM6E to Control a BLDC


(7)

Usage of CAPCOM6E to Control a BLDC


(8)

BLDC
Sensor less

BLDC in Theory Back Electro


Magnetic Force
Theory
UP = (R x i) + (L x di/dt) + eP

where

"UP" stands for phase voltage


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

while
i = 0 and di/dt = 0:
UP = eP
by measuring UP
a position detection
is possible

BLDC in Reality (1) BEMF vs.


Current
Real BEMF Voltage and Current:
shape depends on magnets, motor speed, voltage

BLDC in Reality (2a) BEMF vs. Current


Zoom In:

BEMF is only visible at active switching

Phase
Current

BEMF
Voltage

BLDC in Reality (2b) BEMF vs. Current


Current Commutation in a Coil
Freewheeling diode conducts

Phase
Current

BEMF
Voltage

BLDC in Reality (3) All Important


Signals
BEMF
Voltage

Phase
Current

BLDC Sensor less with Hardware BEMFDetection


Typical Circuit Block Diagram

Comparators and RC-Filter detect the BEMF zero crossing


for position detection

BLDC Sensor less Using ADC


Typical Circuit Block Diagram

Use simple resistor divider and ADC for position detection

CAPCOM6E & ADC


Synchronize ADC on T13

T13 period match can trigger the ADC


equidistant sampling of analog signals
exact timing guaranteed by hardware
no timing jitter due to software delays

CAPCOM6E & ADC


Synchronize T13 on T12
T13 performs delay for
stable measurement
T13 period match
triggers ADC

Useful for Current


Measurement

E.g. induction machine

CAPCOM6E & ADC


T13PM triggers ADC

Delay between T13PM


and high voltage
switching event due to
driving circuit

Useful for Voltage or


Current Measurement

E.g. BEMF detection


Sample shortly before
power device is
switched off (BEMF is
noise free)

CAPCOM6E & ADC


T13PM triggers ADC

Delay between T13PM


and high voltage
switching event due to
driving circuit

Useful for Voltage or


Current Measurement

E.g. Current in DC link


path
Sample shortly before
power device is switched
off (current is noise free)

BLDC Sensor less Using ADC


T13 used for

Modulation
ADC trigger

T12 used for

Phase delay

Software (for 60
sector)

With every T13PM


the BEMF voltage is
sampled and
compared to a BEMFwave table
When crossing a limit
the software
generates a CHEevent (1)
Speed reference is
captured and phase
delay for T12ch1 is
calculated
At T12ch1 the pattern
for the next sector is
switched (2)

BLDC Sensor less with Current


Control
T13 used for
Modulation
ADC trigger

T12 used for

Phase delay

Software (for 60
sector)

With every T13PM the


ADC alternatively
samples

BEMF voltage
Phase current

The current set value


can be controlled by
adjusting the PWM
duty cycle

BLDC Sensor less Scope Shots


Port pin toggles when
BEMF is below limit

Phase
Current

BEMF
Voltage

High Voltage 3-Phase Brushless DC / Induction Motor


Reference Design and Development Kit
Application: Line powered Industrial Drives
Power: 750 W
Current: max. 5 A
AC Input Voltage: 110 to 264 VAC

Features:

8-bit MCU: C868 with on-chip 8 kB SRAM, with 8bit ADC and powerful PWM module
CoolSet: TDA61831G instead of a transformer
for 12V supply
6 rugged IGBT DuoPacks
EEPROM: 8 kB to store program + stand alone
boot option
Optically Isolated Serial Interface to PC for SW
development + boot from PC option
Protection: shut down protection for over current
and over temperature
Extension for alternative MCU like XC164 or
TC1775
SW environment: Keil Compiler + Debugger or
Mini Debugger (free software)
Board can be used for current/torque or speed
control
Supports Hall-Effect sensors or sensor-less
control

Low Voltage 3-Phase Brushless DC / Induction Motor


Reference Design and Development Kit

Application: Industrial & Automotive Drives


Power: 1.2 kW
Current: max. 50 A
Voltage: 12 - 24 V DC

Features:
8-bit MCU: C868 with on-chip 8 kB SRAM, with
8-bit ADC and powerful PWM module
3-Phase Bridge Driver: TLE6280G
6 OptiMOS MOSFETs
EEPROM: 8 kB to store program + stand alone
boot option
RS232: Interface to PC for SW development +
boot from PC option
Protection: shut down protection for over
current and over temperature
Extension for alternative MCU like XC164
SW environment: Keil Compiler + Debugger
or Mini Debugger (free software)
Board can be used for current/torque or speed
control
Supports Hall-Effect sensors or sensor-less
control

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