BLDC Motor Control Board for Industrial and Appliance Applications Designer Reference Manual

152 Pages·2003·2.12 MB·English

by  Freescale Semiconductor, Inc.

Freescale Semiconductor, Inc.
BLDC Motor
Control Board
for Industrial
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MOTOROLA.COM/SEMICONDUCTORS

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For More Information On This Product,
Go to: www.freescale.com
Freescale Semiconductor, Inc.
BLDC Motor Control Board
for Industrial and Appliance
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. Applications Reference Design
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t By: Jorge Zambada
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Applications Engineer — Mexico Applications Lab
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Diego Garay
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Applications Engineer — Mexico Applications Lab
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Maurizio Acosta
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Email: [email protected]
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Applications Engineer — Mexico Applications Lab

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Motorola and the Stylized M Logo are registered trademarks of Motorola, Inc.
DigitalDNA is a trademark of Motorola, Inc.
This product incorporates SuperFlash® technology licensed from SST. ©Motorola, Inc., 2003
BLDC Motor Control Board for Industrial and Appliance Applications DRM007
MOTOROLA 3
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Go to: www.freescale.com
Freescale Semiconductor, Inc.
Revision History
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://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.
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Date Description
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o February, 2003 N/A Initial release N/A
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DRM007 BLDC Motor Control Board for Industrial and Appliance Applications
4 MOTOROLA
For More Information On This Product,
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Freescale Semiconductor, Inc.
Designer Reference Manual — BLDC Motor Control Board
List of Sections
Section 1. Introduction and Setup. . . . . . . . . . . . . . . . . .15
Section 2. Operational Description . . . . . . . . . . . . . . . . .37
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Section 3. Schematics and Bill of Materials. . . . . . . . . .43
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n Section 6. Practical Results. . . . . . . . . . . . . . . . . . . . . . .97

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i Section 7. Source Code . . . . . . . . . . . . . . . . . . . . . . . . .103
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BLDC Motor Control Board for Industrial and Appliance Applications DRM007
MOTOROLA List of Sections 5
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List of Sections
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DRM007 BLDC Motor Control Board for Industrial and Appliance Applications
6 List of Sections MOTOROLA
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Freescale Semiconductor, Inc.
Designer Reference Manual — BLDC Motor Control Board
Table of Contents
Section 1. Introduction and Setup
1.1 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
. 1.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
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1.3 MC68HC908MR8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
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I 1.4 MC68HC908MR8 Pulse-Width Modulator . . . . . . . . . . . . . . . .21

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r 1.4.1 Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
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1.4.2 PWM Output Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
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c 1.4.3 PWM Counter Timebase . . . . . . . . . . . . . . . . . . . . . . . . . . .24
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1.4.4 PWM Load Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
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n 1.4.5 Direct Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

o 1.4.6 Deadtime Insertion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

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i 1.5 Brief Overview to Brushless DC Motors. . . . . . . . . . . . . . . . . .25
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e 1.6 Washing Machine Application’s Overview . . . . . . . . . . . . . . . .28

S 1.6.1 Movement Patterns of the Washer. . . . . . . . . . . . . . . . . . . .28

e 1.6.2 Agitator Hits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

al 1.6.3 Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

c 1.6.4 User’s Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

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1.6.5 Control Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
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e 1.6.6 Target Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

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F 1.7 System Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
1.8 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
1.9 Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
1.9.1 Programming Mode Setup . . . . . . . . . . . . . . . . . . . . . . . . . .33
1.9.2 Running Mode Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
BLDC Motor Control Board for Industrial and Appliance Applications DRM007
MOTOROLA Table of Contents 7
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Table of Contents
Section 2. Operational Description
2.1 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.3 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2.4 User Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
2.5 Connectors Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . .41
2.5.1 J1 — AC Jack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
2.5.2 J2 — 3-Phase Motor Connector. . . . . . . . . . . . . . . . . . . . . .41
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. 2.5.3 J3 — Single Phase Motor 1 Connector . . . . . . . . . . . . . . . .41
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2.5.4 J4 — Temperature Sensor Connector . . . . . . . . . . . . . . . . .41
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2.5.5 J5 — RS-232 Interface Connector. . . . . . . . . . . . . . . . . . . .42
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2.5.8 J8 — Motor Hall Effect Sensor Connector . . . . . . . . . . . . . .42
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Section 3. Schematics and Bill of Materials
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3.1 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
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e 3.3 Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

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c 4.1 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

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4.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
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4.4 RS-232 interface and MON08 Hardware Interface. . . . . . . . . .58
4.5 Clock Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
4.6 Hall-Effect Sensors Interface . . . . . . . . . . . . . . . . . . . . . . . . . .60
4.7 LCD Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
4.8 Reset Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
4.9 3-Phase H-Bridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
4.10 Current Feedback and Cycle-by-Cycle Limiting. . . . . . . . . . . .64
DRM007 BLDC Motor Control Board for Industrial and Appliance Applications
8 Table of Contents MOTOROLA
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Table of Contents
4.11 Voltage Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
4.12 Current and Voltage Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . .68
4.13 Heat Sink Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Section 5. Software Design Considerations
5.1 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
5.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
5.3 Controller Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
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n 5.4.1 Motor Stalled Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . .79
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5.5 Commutation Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
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5.6 Data Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
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Period Measuring, and Speed Calculation . . . . . . . . . . .84
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5.6.2 Process Speed Controller . . . . . . . . . . . . . . . . . . . . . . . . . .84
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o 5.6.3 Process MOSFET Gating Selection. . . . . . . . . . . . . . . . . . .84

c 5.6.4 Process Washing Machine. . . . . . . . . . . . . . . . . . . . . . . . . .86

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5.7 Application State Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

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S 5.8 Drive State Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

e 5.9 Description of Routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

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a 5.9.1 Main(void). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

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5.9.1.1 Stop Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
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e 5.9.1.2 Waiting for Command . . . . . . . . . . . . . . . . . . . . . . . . . . .89

e 5.9.1.3 Displaying Actual and Reference Speed . . . . . . . . . . . . .89

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F 5.9.1.4 Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
5.9.1.5 Spin CW and Spin CCW . . . . . . . . . . . . . . . . . . . . . . . . .90
5.9.1.6 Fixed Reference Speed. . . . . . . . . . . . . . . . . . . . . . . . . .90
5.9.2 InitPLL(void). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
5.9.3 InitPWMMC(void). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
5.9.4 InitTimerA(void) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
5.9.5 InitTimerB(void) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
5.9.6 Byte ResolveButtons(void). . . . . . . . . . . . . . . . . . . . . . . . . .91
5.9.7 InitMotor(Byte Commanded_Operation) . . . . . . . . . . . . . . .91
5.9.8 TimerAOverflow_ISR(void). . . . . . . . . . . . . . . . . . . . . . . . . .91
BLDC Motor Control Board for Industrial and Appliance Applications DRM007
MOTOROLA Table of Contents 9
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Table of Contents
5.9.9 Signed Word 16 PIController(void). . . . . . . . . . . . . . . . . . . .92
5.9.10 MotorStalledProtection(void) . . . . . . . . . . . . . . . . . . . . . . . .92
5.9.11 HALLA_ISR(void) and HALLB_ISR(void). . . . . . . . . . . . . . .92
5.9.12 HALLC_ISR(void). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
5.9.13 Fault1_ISR(void) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
5.9.14 NextSequence(void). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
5.9.15 InitLCD(void) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
5.9.16 CtrlLCD(Byte ctrl). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
5.9.17 Ctrl8LCD(Byte ctrl). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
5.9.18 MovCursorLCD(Byte places, Byte dir) . . . . . . . . . . . . . . . . .93
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5.9.20 StringLCD(Byte *msgLCD). . . . . . . . . . . . . . . . . . . . . . . . . .94
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5.9.21 WaitMs(Byte milis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
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5.10 MCU Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
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Section 7. Source Code
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e 7.2 Include Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

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7.2.1 MR8IO.H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

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7.2.2 START08.H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
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a 7.2.3 MAIN.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

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7.2.4 TIMER.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
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e 7.2.5 LCD.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

e 7.2.6 TABLES.H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
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7.3 Source Code Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
7.3.1 START08.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
7.3.2 MAIN.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
7.3.3 TIMER.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
7.3.4 LCD.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
DRM007 BLDC Motor Control Board for Industrial and Appliance Applications
10 Table of Contents MOTOROLA
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