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three-phase micro power stage reference manual devices supported: mcf5235 mcf5234 mcf5233 mcf5232 memc3pmbldcrm rev. 0.1 11/2004
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three-phase micro power stage reference manual, rev. 0.1 freescale semiconductor iii contents paragraph number title page number chapter 1 introduction and setup 1.1 about this manual ........................................................................................................... ....1 1.2 warnings .................................................................................................................... ..........3 1.3 setup guid e................................................................................................................. .........3 chapter 2 operational description 2.1 electrical char acteristics .................................................................................................. ...2 2.2 pittman motor characteristics .............................................................................................2 chapter 3 pin descriptions 3.1 signal descri ptions ......................................................................................................... .....2 3.1.1 evm motor board power c onnectors j2 and j3 ............................................................3 3.1.2 the 3-ph. micro power stage 40-pin ribbon j1 connector ...........................................3 3.1.3 the 3-ph. micro power stage j4 connector....................................................................4 3.1.4 motor power connector...................................................................................................5 3.1.5 motor hall sensor connector ..........................................................................................5 chapter 4 schematics and parts list 4.1 schematics .................................................................................................................. .........1 4.2 parts list .................................................................................................................. ............7 chapter 5 design considerations 5.1 3-phase driver .............................................................................................................. .......1 5.2 bus voltage and curr ent feedback .....................................................................................2 5.3 back emf si gnals ............................................................................................................ ...3
three-phase micro power stage reference manual, rev. 0.1 iv freescale semiconductor contents paragraph number title page number
three-phase micro power stage reference manual, rev. 0.1 freescale semiconductor v figures figure number title page number 1-1 system confi gurations....................................................................................................... ....... 1-2 1-2 3-ph. micro powe r stage ..................................................................................................... ..... 1-2 1-3 3-ph. micro power stage setu p ............................................................................................... .1-4 1-1 40-pin input c onnector j1 ................................................................................................... ..... 1-2 1-1 3-ph. micro power stage power connection............................................................................ 1-1 1-2 3-ph. micro power stage 3.3v analog voltage ge neration .................................................... 1-2 1-3 uni-3 conne ctor ............................................................................................................. ......... 1-2 1-4 motor conne ctor............................................................................................................. .......... 1-3 1-5 phase predrivers............................................................................................................ ............ 1-4 1-6 power m odules ............................................................................................................... .......... 1-5 1-7 bus current feedback........................................................................................................ ....... 1-5 1-8 back emf si gnals ............................................................................................................ ........ 1-6 1-9 dc bus voltage sensing ...................................................................................................... ..... 1-6 1-10 brushless dc motor connecti ons ? schematic view.............................................................. 1-7 1-1 phase a output .............................................................................................................. ........... 1-1 1-2 bus feedback ................................................................................................................ ............ 1-3 1-3 phase c back em f feedback................................................................................................... 1-3
three-phase micro power stage reference manual, rev. 0.1 vi freescale semiconductor figures figure number title page number
tables table number title page number three-phase micro power stage reference manual, rev. 0.1 freescale semiconductor vii 1-1 electrical char acteristics .................................................................................................. ........ 1-2 1-2 pittman motor ch aracteristi cs ............................................................................................... ... 1-2 1-1 the j1 connector si gnal descriptions...................................................................................... 1- 3 1-2 the j4 connector si gnal descriptions...................................................................................... 1- 5 1-3 motor hall sens or connector ................................................................................................. .. 1-5 1-1 parts li st .................................................................................................................. ................. 1-7
tables table number title page number three-phase micro power stage reference manual, rev. 0.1 viii freescale semiconductor
three-phase micro power stage reference manual, rev. 2 freescale semiconductor 1-1 chapter 1 introduction and setup motorola?s three-phase micro power stage is a 12-volt, 3-amp power stage that is an integral part of motorola?s embedded motion cont rol series of development tools. it is supplied in a kit, along with a small brushless dc motor with hall sensors and a 40-pin ribbon cable. in combination with one of the embedded motion control series control or evaluation boards, it provides a re ady-made software development platform for small brushless dc mo tors among others. the enclosed mo tor is capable of being controlled with hall sensors or with sensorle ss techniques. an illustration of the systems? configurations is shown in figure 1-1 . figure 1-2 is an illustration of the board. 1.1 about this manual key items can be found in the following locations in this manual: ? setup instructions are found in section 1.4, ?setup guide .? ? schematics are found in section 4.1, ?schematics .? ? pin assignments are shown in figure 3-1 , and a pin-by-pin descri ption is contained in section 3.1, ?signal descriptions .? ? for those interested in the reference design asp ects of the board?s circui try, a description is provided in chapter 5, ?design considerations .? figure 1-1. system configurations controller board 3-ph. micro power stage motor workstation mmds08 controller board 3-ph. micro power stage motor workstation b) m523xevb, mpc555, 56800/e hybrid controller, a) mc68hc08 microcontroller optional feedback optional feedback s12exx microcontroller
three-phase micro power stage reference manual, rev. 2 1-2 freescale semiconductor figure 1-2. three-phase micro power stage 1.2 terms and acronyms bemf back electro-motive force (emf) bldc brushless dc hall sensor sensor whose output changes based on changes in ma gnetic flux. used to measure motor position. pwm pulse width modulation uni-3 user-to-network interface 1.3 warnings the three-phase micro power stage includes power components that can reach temperatures hot enough to cause burns. to facilitate safe operation, 12-volt input pow er should come from a dc laboratory power supply that is current limited to no more than 4 amps. the user should be aware of the following: ? before moving scope probes, maki ng connections, etc., it is genera lly advisable to power down the 12 vdc supply. ? operation in lab setups that have grounded tables and/or chairs should be avoided. ? wearing safety glasses, avoiding ties and jewelr y, using shields, and operation by personnel trained in power electronics lab tec hniques are also advisable. 1.4 setup guide setup and connections for the th ree-phase micro power stage are straightforward. the three-phase micro power stage connects to a motorola embedded motion control series control board via a 40-pin ribbon cable. the motor?s power leads plug into output connector j4, and its hall sensors plug into the control board?s hall sensor/encoder input connector. figure 1-3 depicts a completed setup.
setup guide three-phase micro power stage reference manual, rev. 2 freescale semiconductor 1-3 follow these steps to set up the board: 1. plug one end of the 40-pin ribbon cable that is supplied with motorola embedded motion control series control boards into input c onnector j1, located at the edge of the board. the other end of this cable goes to the control boa rd?s 40-pin output connector. 2. plug the free end of the cable connected to i nput connector j1 into the control board?s 40-pin connector. 3. connect a 12 vdc power supply to the power jack j2 labeled ?power?. then either connect outgoing cable from the three-phase micro power stage labeled ?+12vdc? to the controller board jack or use separete pow er supply to power the contro ller board. those connectors are located in a corner of the three-phase micro power stage. 4. if protection features are desi red, set the control board?s over current detection comparator to 2.25 v. this value limits dc bus current to 3 amps. 5. apply power to the three-phas e micro power stage. the green power-on led is lit when power is present. note that the three-phase micro po wer stage doesn?t power the control board, so the control board must be powered by means of this board outgoing +12 vdc cabl e and/or an external 12 vdc power supply to r un a complete system. figure 1-3. three-phase micro power stage setup motor 3-ph. micro 12-volt motor supply control board 40-pin ribbon cable j1 power stage j4
three-phase micro power stage reference manual, rev. 2 1-4 freescale semiconductor this page intentionally left blank
three-phase micro power stage reference manual, rev. 2 freescale semiconductor 2-1 chapter 2 operational description motorola?s embedded motion control series three- phase micro power stage is a 12-volt, 3-amp, surface-mount power stage th at is shipped with a pi ttman (size 23) brushles s dc (bldc) motor. in combination with one of the embedded motion contro l series control boards, it provides a software development platform that allows al gorithms to be written and tested without the need to design and build a power stage. it supports algorithms that use hall se nsors and back emf (electro motive force) signals for sensorless control. the three-phase micro power stage does not have any overcurrent protection that is independent of the control board, so some care in its setup and use is required if a lower impedance motor is used. with the motor that is supplied in the kit, the power output stage will withstand a full -stall condition without the need for overcurrent protection. curr ent measuring circuitry is set up for 8.25 amps full scale. in a 25 c ambient operation at up to 3a con tinuous rms output current is with in the board?s thermal limits. input connections are made via 40- pin ribbon cable connector j1. pin a ssignments for the input connector are shown in figure 3-1 . power connections to the motor are ma de on output connector j4. phase a, b, and c are labeled on the board. powe r requirements are met with a singl e external 12 v, 4 a power supply. two connectors, labeled j2 and j3, are provided for the 12 vdc power supply. while the former is used for 12 vdc input, the latter is used fo r 12 vdc output for powering the contro ller board. both are located in a corner of the board. a summary of the information needed to use the three-phase micro power stage follows. for design information, see chapter 4, ?schematics and parts list .? 2.1 electrical characteristics the electrical characteristics in table 2-1 apply to operation at 25 c and a 12-vdc power supply voltage. table 2-1. electrical characteristics characteristic symbol min typ max units power supply voltage vdc 10 12 16 v quiescent current i cc ?18?ma min logic 1 input voltage v ih 2.4 ? ? v max logic 0 input voltage v il ??0.8v input resistance r in ?10?k ? analog output range v out 0?3.3v bus current sense voltage i sense ?200?mv/a bus voltage sense voltage v bus ?202?mv/v power mosfet on resistance (top switch) r ds(on) ?6070m ? power mosfet on resi stance (bottom switch) r ds(on) ?170200m ? continous output current i d ?? 3 a pulsed output current i dm ??15 a
three-phase micro power stage reference manual, rev. 2 2-2 freescale semiconductor 2.2 pittman motor characteristics the motor characteristics in table 2-2 apply to operation at 25 c. total power dissipation p diss ?? 2 w deadtime t off 400 ? ? ns table 2-2. pittman (size 23) bldc motor characteristics characteristic symbol min typ max units reference windind voltage v t ??9.6v speed @ v t ? ? 12000 rpm torque constant k t ?0.007?nm/a ? 1.082 ? oz-in/a voltage constant k e ? 0.8 ? v/krpm terminal resistance r t 0.13 ? 0.18 w winding inductance l ? 2.9 ? mh continuous current i cs ??9.96a no load current @ v t i ps ?1.20? a number of poles j m ?8?? temperature rating ?10 ? 80 c 14 ? 176 f table 2-1. electrical characteristics (continued) characteristic symbol min typ max units
three-phase micro power stage reference manual, rev. 2 freescale semiconductor 3-1 chapter 3 pin descriptions inputs and outputs are locat ed on four connectors: ? four connectors that are located on the three- phase micro power stage board (uni-3, motor power, power input, power output). ? two connectors are associated with the motor (power, hall sensors). pin descriptions for each of these co nnectors and the test points are identi fied in the following information. pin assignments for the uni-3 connectors are shown in figure 3-1 . signal descriptions are provided in table 3-1 through table 3-3 .
three-phase micro power stage reference manual, rev. 2 3-2 freescale semiconductor figure 3-1. 40-pin input connector j1 3.1 signal descriptions pin descriptions are identi fied in this subsection. 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 bemf_sense_c bemf_sense_b bemf_sense_a shielding shielding i_sense_dcb v_sense_dcb gnda gnda gnd gnd pwm_cb shielding pwm_ct shielding pwm_bb shielding pwm_bt shielding pwm_ab shielding pwm_at schematic view j1 con/40 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 shielding shielding shielding shielding shielding gnd gnda i_sense_dcb shielding bemf_sense_a bemf_sense_c pwm_at pwm_ab pwm_bt pwm_bb pwm_ct pwm_cb gnd gnda v_sense_dcb shielding bemf_sense_b physical view
signal descriptions three-phase micro power stage reference manual, rev. 2 freescale semiconductor 3-3 3.1.1 evm motor board power connectors j2 and j3 two connectors, labeled j2 and j3, are provided for the 12-volt power suppl y. while the former is used for power supply input, the latter is used for power s upply output for the controll er board powering. j2 and j3 are located in a corner of the board. the j2 connector is a 2.1-mm power jack fo r plug-in type 12 v power supply connections. the j3 co nnector is used as 12 v output which wi ll power the contro ller board. power is supplied to the j2 one. the power supply should be able to deliver at least 3 amps. 3.1.2 the three-phase micro power st age 40-pin ribbon j1 connector signal inputs are grouped together on a 40-pin ribbon cable conn ector j1, located at th e edge of the board. pin assignments are shown in figure 3-1 . pin descriptions are listed in table 3-1 . table 3-1. the j1 connector signal descriptions (sheet 1 of 2) pin no. signal name description 1 pwm_at the gate drive signal for the top half-bridge of phase a. a logic high at input connector j1 turns on the phase a top switch. 2 shielding connected to a shield wire in the ribbon cable, and ground on the board. 3 pwm_ab the gate drive signal for the bottom half-bri dge of phase a. a logic high at input connector j1 turns on the phase a bottom switch. 4 shielding connected to a shield wire in the ribbon cable, and ground on the board. 5 pwm_bt the gate drive signal for the top half-bridg e of phase b. a logic high at input connector j1 turns on the phase b top switch. 6 shielding connected to a shield wire in the ribbon cable, and ground on the board. 7 pwm_bb the gate drive signal for the bottom half-br idge of phase b. a logic high at input connector j1 turns on the phase b bottom switch. 8 shielding connected to a shield wire in the ribbon cable, and ground on the board. 9 pwm_ct the gate drive signal for the top half-bridge of phase c. a logic high at input connector j1 turns on the phase c top switch. 10 shielding connected to a shield wire in the ribbon cable, and ground on the board. 11 pwm_cb the gate drive signal for the bottom half-bri dge of phase c. a logic high at input connector j1 turns on the phase c bottom switch. 12 gnd digital power supply ground 13 gnd digital power supply ground, redundant connection 14 ? no connection 15 ? no connection 16 ? no connection 17 gnda analog power supply ground 18 gnda analog power supply ground, redundant connection 19 ? no connection 20 ? no connection
three-phase micro power stage reference manual, rev. 2 3-4 freescale semiconductor 3.1.3 the three phase micro power stage j4 connector power outputs to the motor are located on connector j 4, labeled ?motor.? pin as signments are described in table 3-2 . 21 v_sense_dcb analog sense signal that measures dc bus voltage. it is scaled at 0.206 v per volt of dc bus voltage. 22 i_sense_dcb analog sense signal that measures dc bu s current. it is scaled at 0.412 v per amp of dc bus current. 23 ? no connection 24 ? no connection 25 ? no connection 26 ? no connection 27 ? no connection 28 shielding connected to a shield wire in the ribbon cable, and ground on the board. 29 ? no connection 30 ? no connection 31 ? no connection 32 ? no connection 33 ? no connection 34 ? no connection 35 ? no connection 36 ? no connection 37 shielding connected to a shield wire in the ribbon cable, and ground on the board. 38 bemf_sense_a analog sense signal that measures phase a back emf. it is scaled at 0.206 v per volt of dc bus voltage. 39 bemf_sense_b analog sense signal that measures phase b back emf. it is scaled at 0.206 v per volt of dc bus voltage. 40 bemf_sense_c analog sense signal that measures phase c back emf. it is scaled at 0.206 v per volt of dc bus voltage. table 3-1. the j1 connector signal descriptions (sheet 2 of 2) pin no. signal name description
signal descriptions three-phase micro power stage reference manual, rev. 2 freescale semiconductor 3-5 3.1.4 motor power connector motor power connections are grouped into a connector that plugs into the three phase micro power stage?s motor connector, j4. pin assignments are iden tical to the three phase micro power stage j4 output connector. 3.1.5 motor hall sensor connector hall sensor connections are made wi th a connector that plugs into the control board?s hall sensor/encoder connector. pin assignments are described in table 3-3 . table 3-2. the j4 connector signal descriptions pin no. signal name description 1 phase_a supplies power to motor phase a. the motor wire color is brown. 2 phase_b supplies power to motor phase b. the motor wire color is red. 3 phase_c supplies power to motor phase c. the motor wire color is orange. table 3-3. motor hall sensor connector pin no. signal name description 1 +5v supplies power from the control board to the hall sensors. the wire color is violet. 2 gnd the hall sensor ground. the wire color is black. 3 hall a open collector output from hall sensor a. the wire color is gray. 4 hall b open collector output from hall sensor b. the wire color is blue. 5 hall c open collector output from hall sensor c. the wire color is white.
three-phase micro power stage reference manual, rev. 2 3-6 freescale semiconductor this page intentionally left blank
three-phase micro power stage reference manual, rev. 2 freescale semiconductor 4-1 chapter 4 schematics and parts list a set of schematics for the three-ph ase micro power stage appears in figure 4-1 through figure 4-10 . power connectors are shown in figure 4-1 . figure 4-2 represents 3.3 v generation for analog sensing. figure 4-3 shows uni-3 connector and figure 4-4 shows three-phase motor connector. the phase pre-drivers are shown in figure 4-5 , power modules appears in figure 4-6 . bus current feedback is shown in figure 4-7 . back emf signals appear in figure 4-8 . the brushless dc motor is shown in figure 4-10 . unless otherwise specified, resistor values are in ohms, resistors are specified as 1/8 watt 5%, and interrupted lines coded with the same letters are elect rically connected. 4.1 schematics the schematics for the evaluation motor board appear below and on the following pages. figure 4-1. three-phase micro power stage power connection figure 4-2. three-phase micro power stage 3.3 v analog voltage generation +12v d7 power +12v gnd dcb_pos +v 1 -v 2 -v 3 j2 power in +12v +12v green led gnd r34 2.4k dcb_neg 1 2 j3 power out +12v gnd +12v d8 mbra340t3 +12v d7 power +12v gnd dcb_pos +v 1 -v 2 -v 3 j2 power in +12v +12v green led gnd r34 2.4k dcb_neg 1 2 j3 power out +12v gnd +12v d8 mbra340t3 -v -v +v -v +v
three-phase micro power stage reference manual, rev. 2 4-2 freescale semiconductor figure 4-3. uni-3 connector figure 4-4. three-phase motor connector bemf_sense_a bemf_sense_b bemf_sense_c sheilding pwm_at gnda 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 j1 con/40 +12v sheilding zero_cross_c v_sense_dcb_3.3 zero_cross_b i_sense_dcb zero_cross_a gnda i_sense_a bemf_sense_c i_sense_b bemf_sense_b i_sense_c bemf_sense_a temp_sense serial_con brake_control sheilding pwm_cb sheilding sheilding pwm_ct sheilding pwm_bb sheilding pwm_bt pwm_ab pwm_cb pwm_ct pwm_bb pwm_bt pwm_ab pwm_at i_sense_dcb v_sense_dcb gnd phase_a 1 2 3 j4 3-ph. motor phase_b phase_c
schematics three-phase micro power stage reference manual, rev. 2 freescale semiconductor 4-3 figure 4-5. phase predrivers r29 10k dcb_pos dcb_neg gate_at r32 10k gate_ab phase a predriver + c13 10uf/16v c14 100nf/25v r33 10k dcb_pos dcb_neg gate_bt r35 10k gate_bb phase b predriver + c15 10uf/16v c16 100nf/25v 2 3 5 6 7 4 outb inb gnd ina outa vdd u6 max628csa r36 10k dcb_pos dcb_neg gate_ct r37 10k gate_cb phase c predriver + c17 10uf/16v c18 100nf/25v 2 3 5 6 7 4 outb inb gnd ina outa vdd u7 max628csa pwm_at 2 3 5 6 7 4 outb inb gnd ina outa vdd u4 max628csa pwm_ab pwm_bt pwm_bb pwm_ct pwm_cb
figure 4-6. power modules figure 4-7. bus current feedback 1 2 r13 0.051-1% dcb_pos dcb_neg phase_a phase_b phase_c 1 2 7 8 q1-1 mmdf2c03hd/so-8 3 4 5 6 q1-2 mmdf2c03hd/so-8 1 2 7 8 q2-1 mmdf2c03hd/so-8 3 4 5 6 q2-2 mmdf2c03hd/so-8 i_sense_dcb2 r2 100 r1 330 d1 mbrm140t3 gate_at r8 100 r7 330 d4 mbrm140t3 gate_ab i_sense_dcb1 r4 100 1 2 7 8 q3-1 mmdf2c03hd/so-8 r3 330 3 4 5 6 q3-2 mmdf2c03hd/so-8 d2 mbrm140t3 gate_bt r10 100 r9 330 d5 mbrm140t3 gate_bb r5 100 r6 330 d3 mbrm140t3 gate_ct r12 100 r11 330 d6 mbrm140t3 gate_cb + c1 330uf/35v + c3 330uf/35v + c2 330uf/35v c4 100nf/25v driver for phase a driver for phase b driver for phase c r16 20k-1% r18 20k-1% delta = +/-330 mv @ +/- imax 1.65v +/- 1.65v @ +/- imax 5 6 7 + - u1b mc33502/so-8 gnda 1.65v ref r25 33k-1% gnda r20 390 r21 100k-1% 8 5 4 u2 lm285m/so-8 c8 100nf/6.3v gnda +3.3v_a gnda 3 2 1 8 4 + - u1a mc33502/so-8 c6 100nf/6.3v gnda +3.3v_a r19 100k-1% r14 100k-1% i_sense_dcb vref = 1.24 (1 + r25 / r21) i_sense_dcb1 i_sense_dcb2
schematics three-phase micro power stage reference manual, rev. 2 freescale semiconductor 4-5 figure 4-8. back emf signals figure 4-9. dc bus voltage sensing bemf_sense_a bemf_sense_b bemf_sense_c phase_a phase_b phase_c r23 13k-1% r27 3.3k-1% dcb_neg bemf sensing phase b 3.30v @ 16.3v max. 16.3v r24 13k-1% r28 3.3k-1% dcb_neg bemf sensing phase c 3.30v @ 16.3v max. 16.3v r22 13k-1% r26 3.3k-1% dcb_neg 3.30v @ 16.3v max. 16.3v bemf sensing phase a v_sense_dcb r15 13k-1% r17 3.3k-1% dcb_pos dcb_neg 3.30v @ 16.3v
three-phase micro power stage reference manual, rev. 2 4-6 freescale semiconductor figure 4-10. brushless dc moto r connections ? schematic view 4.2 parts list the three-phase micro power stage?s parts cont ent is described in the following parts list. table 4-1. parts list qty. reference part value des cription mfg. mfg. part no. 3 c1, c2, c3 330 f/35 v electrolytic capacitor 10mm, 330 f/35 v multicomp 921-373 5 c4, c9, c14, c16, c18 100 nf /25 v ceramic capacitor, 0805, 100 nf avx 08055g104zat1a 3 c6, c8, c11 100 nf/6.3 v ceramic capacitor, 0805, 100 nf avx 08055g104zat1a 5 c10, c12, c13, c15, c17 10 f/16 v smd aluminiun electrolytic capacitor, 4 mm, 10 f/16 v panasonic eevfc1c100r 6 d1, d2, d3, d4, d5, d6 mbrm140t3 shottky rectifiers 40 v, 1a on semiconductor mbrm140t3 1 d7 led green led_qt_plcc2_ca ezk ka3528lsgt motorola embedded motion control series j2 phase_c phase_b phase_a brushless + 12 vdc evaluation module 40-pin ribbon cable 1 2 3 4 5 motor motorola embedded motion control series 3-ph. micro power stage 3 2 1 j4 hall/encoder connector brown red orange + ? j1 hall c (white) hall b (blue) hall a (gray) gnd (black) +5v (violet) + 12 vdc + ? j3 + 12 vdc + ?
parts list three-phase micro power stage reference manual, rev. 2 freescale semiconductor 4-7 1 d8 mbra340t3 voltage antireverse avoid on semiconductor mbra340t3 1 j1 con/40 header 40 pins breakaway connector fischer elektronik aslg40g 1 j2 power jack power jack type connector 2.5 mm cui stack pj-002a 1 j3 header with lock 2 way header with lock molex 22-29-2021 1 j4 header with lock 3 way header with lock molex 39-26-3030 (mating with molex 26-11-2033) 3 q1, q2, q3 mmdf2c03hd p+n mosfet transistor, 30 v, 6 a on semiconductor mmdf2c03hd 6 r1, r3, r6, r7, r9, r11 330 resistor 330 ? , 5%, 0805 multicomp mc 0.1w 0805 5% 330r 6 r2, r4, r5, r8, r10, r12 100 resistor 100 ? , 5%, 0805 multicomp mc 0.1w 0805 5% 100r 1 r13 0.040-1% shunt resistor vishay lvr-3 0.040 1% 3 r14, r19, r21 100k-1% resistor 100 k ? , 1%, 0805 multicomp mc 0.1w 0805 1% 100k 4 r15, r22, r23, r24 13k-1% resistor 13 k ? , 1%, 0805 multicomp mc 0.1w 0805 1% 13k 2 r16, r18 20k-1% resistor 20 k ? , 1%, 0805 multicomp mc 0.1w 0805 1% 20k 4 r17, r26, r27, r28 3.3k-1% resistor 3.3 k ? , 1%, 0805 multicomp mc 0.1w 0805 1% 3k3 1 r20 390 resistor 390 ? , 5%, 0805 multicomp mc 0.1w 0805 5% 390r 1 r25 33k-1% resistor 33 k ? , 1%, 0805 multicomp mc 0.1w 0805 1% 33k 6 r29, r32, r33, r35, r36, r37 10k resistor 10 k ? , 5%, 0805 multicomp mc 0.1w 0805 5% 10k 1 r30 390-1% resistor 10 k ? , 1%, 0805 multicomp mc 0.1w 0805 1% 390r 1 r31 240-1% resistor 240 ? , 1%, 0805 multicomp mc 0.1w 0805 1% 240r 1 r34 2.4k-1% resistor 2.4 k ? , 1%, 0805 multicomp mc 0.1w 0805 5% 2k4 1 u1 mc33502/so-8 operational amplifier on semiconductor mc33502/so-8 1 u2 lm285m/so-8 adujstable voltage reference national semiconductor lm285m 3 u4, u6, u7 max628csa mosfet pre-driver maxim max4428csa 1 u5 lm317ld linear voltage regulator on semiconductor lm317ld table 4-1. parts list (continued) qty. reference part value des cription mfg. mfg. part no.
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three-phase micro power stage reference manual, rev. 2 freescale semiconductor 5-1 chapter 5 design considerations from a systems point of view, the three-phase micro power stag e kit fits into an architecture that is designed for code development. in a ddition to the hardware that is needed to run a motor, a variety of feedback signals that facilitate cont rol algorithm devel opment are provided. the three-phase micro power stage? s power output stage is a compleme ntary mos field effect transistor (mosfet) 3-phase bridge that is capable of supplying and sensing 4 amps of continuous current. feedback signals include bus voltage , bus current, and back emf (elect romotive force). descriptions of each of these blocks are contained in section 5.1, ?3-phase driver ,? section 5.2, ?bus voltage and current feedback ,? and section 5.3, ?back emf signals .? 5.1 3-phase driver the output stage is configured as a 3-phase driver with complementar y mosfet output tran sistors. it is simplified considerably by dual integrated gate driv ers that each have one inve rting and one non-inverting driver. a simplified schematic that shows one phase is illustrated in figure 5-1 . figure 5-1. phase a output at the input, weak pulldown resistor s, r38 and r39, set a logic low in the absence of a signal. open input pulldown is important, since it is desirable to keep th e power transistor s off in case of either a broken connection or absence of power on the control boa rd. gate drive is suppl ied by a maxim max628csa, which has a minimum logic 1 input voltage of 2.4 volts and maximum l ogic 0 input voltage of 0.8 volts. the three-phase micro power stag e will, therefore, accept inputs for either 3.3 or 5 volt logic. under-voltage lockout is not include d in the gate drive. if this fe ature is desired, the control board?s under-voltage detection comparator can be set for 1.24 volts. one of the more important design deci sions in a motor drive is selectio n of gate drive impedance for the output transistors. in figure 5-1 , resistors r1, r2, and di ode d1 determine gate drive impedance for the lower half-bridge transistor. a si milar network is used on the upper half-bridge. these networks set turn-on gate drive impedance at approximately 430 ? and turn-off gate drive impedance at approximately 100 ? . these values produce transition times of approximately 60 ns. transition times of this length represent a carefully weighed compromise betw een power dissipation and noise generation. generally speaki ng, transition times longer than 250 ns tend to get power hungry at pwm_at 2 3 5 6 7 4 outb inb gnd ina outa vdd u8 max628csa pwm_ab dcb_pos dcb_neg phase_a 1 2 7 8 q1-1 mmdf2c03hd/so-8 3 4 5 6 q1-2 mmdf2c03hd/so-8 r2 100 r1 330 d1 mbrm140t3 r8 100 r7 330 d4 mbrm140t3 r38 10k r39 10k
three-phase micro power stage reference manual, rev. 2 5-2 freescale semiconductor non-audible pwm rates; and transition times under 50 ns create di / dt ?s so large that proper operation is difficult to achieve. the three-phas e micro power stage is designed with switching times at the lower end of this range to mini mize power dissipation. 5.2 bus voltage and current feedback feedback signals proportional to bus voltage and bus current are provided by the circuitry shown in figure 5-2 . bus voltage is scaled down by a voltage divi der consisting of r15 and r17. the values are chosen such that a 16-volt maximum bus voltage corresponds to a 3.3 volt maximum analog-to-digital (a/d) input. bus current is sampled by resistor r13 in figure 4-6 and amplified by the circuit in figure 5-2 . this circuit provides a voltage output suitable for sampling with a/d inputs. an mc33502 is used for the differential ampl ifier. the gain is given by: a = r14 / r16 the output voltage is shif ted up by 1.65 v, to accommoda te both positive and nega tive current swings. a 209 mv voltage drop across the shunt resistor corresponds to a measured current range of 8.25 amps. note that the three-phase micro power stage measur es, but does not limit, cu rrent. current limiting is performed on the control board, wh ere a 2.25 volt setting for the ove rcurrent detect ion comparator produces a 3.0 amp current limit. figure 5-2. bus feedback 5.3 back emf signals back emf and zero crossing signals are included to support sensorle ss algorithms for brushless dc motors. referring to figure 5-3 , which shows circuitry for phase c, the raw phase voltage is scaled down by a voltage divider consisting of r24 and r28. one output from this divider produces back emf sense voltage bemf_sense_c. resistor values are chosen such that a 16 volt maximu m phase voltage corresponds to a 3.3 volt maximum a/d input. r16 12.7k-1% r18 12.7k-1% r25 33.2k-1% gnda r20 390 r21 100k-1% 8 5 4 u2 lm285m/so-8 c8 100nf/6.3v gnda +3.3v_a 3 2 1 + - u1a mc33502/so-8 r19 100k-1% r14 100k-1% i_sense_dcb v_sense_dcb i_sense_dcb1 i_sense_dcb2 r15 12.7k-1% r17 3.3k-1% dcb_pos dcb_neg
back emf signals three-phase micro power stage reference manual, rev. 2 freescale semiconductor 5-3 figure 5-3. phase c back emf feedback bemf_sense_c phase_c r24 12.7k-1% r28 3.3k-1% dcb_neg
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