Freescale Semiconductor, Inc. Rev. 0, 09/2003 Freescale Semiconductor, Inc... Applications Enabled by HighPerformance Hybrid Controllers White Paper Motorola 56F8300 Hybrid Controller Family MOTOROLA.COM/SEMICONDUCTORS © Motorola, Inc., 2003 For More Information On This Product, Go to: www.freescale.com Freescale Semiconductor, Inc... Freescale Semiconductor, Inc. For More Information On This Product, Go to: www.freescale.com Freescale Semiconductor, Inc. Applications Enabled by High-Performance Hybrid Controllers Freescale Semiconductor, Inc... Introduction 1.1 Overview This paper will first review the features and benefits of performance-leading 56F8300 hybrid controllers, then investigate some applications now enabled by these revolutionary hybrid controllers. Motorola’s hybrid and microcontrollers have a long and distinguished history in industrial and control applications. The new 56F8300 Series is the latest addition to the widely adopted 56F800 portfolio of high-performance, Flash-based hybrid controllers. The 56F8300 devices combine the capabilities of a microcontroller with the signal processing performance of a Digital Signal Processor (DSP), and the raw protocol and control processing power of a 32-bit RISC. Some of the features and benefits of the 56F8300 solutions that this paper will explore are: • Exceptional integration of powerful internal peripherals--significantly lowers system costs • High-performance, reliable internal Flash memory--offers flexibility in development, production and inventory with the reliability and performance traditionally associated with read-only memory • High 60MHz/60 MIPS performance--enables a broad range of applications at a lower cost • Hybrid MCU/DSP core architecture--speeds development and lowers component count • Integrated safety features for high reliability--creates safer, lower-risk, more reliable end products • Extended temperature operation--allows innovative end products that can be used in the harshest environments • Powerful, award-winning CodeWarriorTM Integrated Development Environment--lowers software development costs and frees your software developers © Motorola, Inc., 2003 1. Introduction ....................................1 1.1 Overview .........................................1 2. Applications Enabled by the 56F8300 Hybrid Controller ......8 Bill Hutchings 1. Contents 2.1 Network-enabled, High-performance UPS ...................8 2.2 High-Performance Switched-Mode Power Supply.................................11 2.3 Digital By-wire and Power-Assist Systems..........................................13 2.4 Intelligent Sensor Applications .....18 3. Conclusions ..................................20 For More Information On This Product, Go to: www.freescale.com Freescale Semiconductor, Inc. Introduction • Innovative Processor ExpertTM rapid application development tool--dramatically speeds software development and the developer’s learning curve These elements mean that the 56F8300 Series of components is ideally suited for a broad range of industrial applications. The 56F8300 Series is a part of the greater Motorola Embedded Flash portfolio, as shown in Figure 1-1. M•CORE™ PowerPC ISA* 32-Bit RISC 33MHz 128K Flash 32-Bit PowerPC™ RISC 40-56 MHz 448K - 1MB Flash MMC2107 MMC2113 MMC2114 MPC555 MPC566 MPC565 MPC564 MPC563 32-bit Freescale Semiconductor, Inc... 56800/E Hybrid Controllers 16-Bit/32-Bit, 60 MHz, 48KB-280KB Flash 56F8322 56F8323 56F8345 56F8345 56F8356 56F8357 16-bit 16-Bit, 30-40 MHz, 24KB-144KB Flash 56F801 56F802 56F803 56F805 56F807 56F826 56F827 68HC08 HC(S)12 16-Bit, 5-25 MHz, 32K to 512K Flash HC812A4 HC12BC32 912DG128/A 9S12A128 9S12DG256 9S12DP256 9S12H128 9S12DJ64 HC912B32 HC12BE32 912DT128A 9S12A256 9S12DJ128 9S12DT128 9S12A64 9S12DP512 HC912BC32 912D60A HC12D60 9S12DB128 9S12DJ256 9S12DT256 9S12D64 8-Bit 8 MHz 1.5K up to 60K Flash 8-bit HC908KX2 HC908RK2 HC908JL3 HC908JK3 HC908JK1 HC908QT1 HC908QY2 HC908JB8 HC908GR8 HC908GR4 HC908RF2 HC908KX8 HC908QT2 HC908QY4 HC908AB32 HC908MR32 HC908MR16 HC908GP32 HC908SR12 HC908QT4 HC908GZ16 HC908AZ60A HC908AS60A HC908LD64 HC908LD60 HC908BD48 HC908QY1 HC908EY16 Italic: Introduction 2003 *Instruction Set Architecture Figure 1-1. Motorola’s Controller Continuum Figure 1-2 illustrates the broad portfolio of 56800/E components; all are code compatible. The 56F800 Series is based on the original 56800 core and offer the best of both MCU and DSP functionality. The 56F8300 Series is based around the enhanced version of the 56800 core, the 56800E, and offers improved DSP and MCU performance, as well as improved 32-bit capability. The 56850 Series is RAM-based and targeted for high performance voice, multimedia, telecom, and hybrid networking applications. 2 Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com Motorola Freescale Semiconductor, Inc. Introduction Features 56858 56857 56855 56854 56853 56852 56850 Series Telecom/voice processors, RAM-based, 120 MMACS, 81–144 pins Freescale Semiconductor, Inc... 56F8300 Series Automotive, industrial, Flash-based, 60 MMACS, 16-512KB PFlash, 48–160 pins Production 56F8357 56F8356 56F8346 56F8345 56F8323 56F8322 56F82x Family General Purpose, Flashbased, 40 MMACS, 100–128 pins 56F80x Family Industrial controllers, Flash-based, 40 MMACS, 32–160 pins 0.18µ, 56800E 120 MMACS 56F827 56F826 0.25µ, 56800E 60 MMACS 56F807 56F805 56F803 56F801 0.25µ, 56800 30/40 MMACS 56F802 56F801A 56F802A 2000 2001 2002 2003 2004 2005 Figure 1-2. Motorola Hybrid Controller Portfolio The 56F8300 devices are the highest-performance Flash-based hybrid controllers in the portfolio. The components in the 56F8300 Series have a broad range of package, memory, and peripheral configurations. Table 1 and Figure 1-3 show the details of the 56F8300 portfolio. MOTOROLA Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com 3 Freescale Semiconductor, Inc. Introduction Table 1: 56F8300 Portfolio Details 56F8322 56F8323 56F8345 56F8346 56F8356 56F8357 Performance 60MHz 60MHz 60MHz 60MHz 60MHz 60MHz Temperature Range -40°C to +105°C or -40°C to +125°C -40°C to +105°C or -40°C to +125°C -40°C to +105°C or -40°C to +125°C -40°C to +105°C or -40°C to +125°C -40°C to +105°C or -40°C to +125°C -40°C to +105°C or -40°C to +125°C 2.6V / 3.3V 2.6V / 3.3V 2.6V / 3.3V 2.6V / 3.3V 2.6V / 3.3V 2.6V / 3.3V Program Flash 32KB 32KB 128KB 128KB 256KB 256KB Program RAM 4KB 4KB 4KB 4KB 4KB 4KB Data Flash 8KB 8KB 8KB 8KB 8KB 8KB Data RAM 8KB 8KB 8KB 8KB 16KB 16KB BootFlash 8KB 8KB 8KB 8KB 16KB 16KB Flash Security Yes Yes Yes Yes Yes Yes External Memory Interface No No No Yes Yes Yes Regulator (On-Chip / Off-Chip) On-Chip On-Chip / Off-Chip On-Chip / Off-Chip On-Chip / Off-Chip On-Chip / Off-Chip On-Chip / Off-Chip On-Chip Relaxation Oscillator Yes Yes No No No No Quad Timer 2 2 4 4 4 4 Quadrature Decoder 1 x 4 channel 1 x 4 channel 2 x 4 channel 2 x 4 channel 2 x 4 channel 2 x 4 channel PWM 1 x 6 channel 1 x 6 channel 2 x 6 channel 2 x 6 channel 2 x 6 channel 2 x 6 channel PWM Fault Input 1 3 4+4 3+4 3+4 4+4 PWM Chip Select Pins 0 3 3+ 3 3+ 3 3+ 3 3+ 3 12-bit ADC 2 x 3 channel 2 x 4 channel 4 x 4 channel 4 x 4 channel 4 x 4 channel 4 x 4 channel Yes Yes Yes Yes Yes Yes FlexCAN 1 1 1 1 1 1 SCI (UART) 2 2 2 2 2 2 SPI (Synchronous) 2 2 2 2 2 2 GPIO (Maximum) 21 27 49 62 49 76 JTAG/EOnCE Yes Yes Yes Yes Yes Yes 48 LQFP 64 LQFP 128 LQFP 144 LQFP 144 LQFP 160 LQFP Freescale Semiconductor, Inc... Voltage (Core / I/O) Temperature Sensor Package 4 Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com Motorola Freescale Semiconductor, Inc. Introduction Freescale Semiconductor, Inc... Program Flash JTAG/EOnCE JTAG/EOnCE Voltage Regulators Interrupt Controller Power Supervisor COP Serial Interfaces Program RAM Boot Flash External Memory Interface Data Flash Data RAM 56800E Core Quad Timer Modules FlexCAN GPIOs System Clock Relaxation Generator Oscillator (OSC & PLL) PWM Modules with Fault Inputs Quadrature Decoders ADC Module Temp Sensor Package: From 48 up to 160 pin LQFP Figure 1-3. 56F8300 Block Diagram The 56F8300 Series offers an excellent complement of peripherals and a broad range of memory and packages. Some of the 56F8300 Series’ benefits include: • High performance 56800E hybrid core • — Superior 16-bit, fixed-point signal processing performance provided by the bus architecture and the hybrid controller core — Excellent control and protocol processing capability and code density — Superior 32-bit performance provided by the internal 32-bit-wide buses and registers Performance-leading Flash memory — — — — • Unbeatable, field-proven reliability in the harshest environments Features that enable emulation of EEPROM Flexible, full in-circuit Flash programmability Performance-enhancing interfacing and bus structure, enabling the greatest signal processing capability from Flash in the controller continuum portfolio — Flash block protection features for IP protection Flexible External Memory Interface (EMI) — Some 56F8300 devices include a flexible External Memory Interface that enables glueless connection with programmable chip selects and separate wait state generation, allowing the most cost-effective and lowest possible chip count when interfacing to external memory or peripherals — The EMI interface can be configured as GPIO MOTOROLA Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com 5 Freescale Semiconductor, Inc. Freescale Semiconductor, Inc... Introduction • Voltage regulator and power supervisor • — The chips come equipped with an on-board voltage regulator and power supervisor. When supplied with a 3.3V voltage, the chip creates all required internal voltages — Includes features such as Power-On Reset (POR) and low-voltage detection, eliminating external components and saving system costs On-chip Relaxation Oscillator • — Some 56F8300 devices are equipped with a precision on-chip, factory-trimmed oscillator (0.25% of 8MHz), enabling the elimination of an external crystal and providing system cost savings On-Chip Clock Synthesis (OCCS) • — 56F8300 hybrid controllers are equipped with on-chip crystal and ceramic resonator oscillator drive circuitry, enabling the direct connection of an external crystal or ceramic resonator — The OCCS capability includes a flexible, programmable Phase Locked Loop (PLL), enabling selection of an exact operating frequency — The OCCS also includes unique loss-of-lock detection, allowing the detection of a cut crystal and the proper safety-critical shut down Quad Timer — 56F8300 devices are equipped with powerful timer modules. Each timer module has four independent 16-bit timers that can be: — Cascaded — Used for input capture — Used to generate output waveforms — Used to trigger the ADC — Used to generate auxiliary PWM waveforms — Used as a Digital-to-Analog Converter (DAC) when utilized in conjunction with an external low-pass filter • Quadrature Decoder — Full-featured, four-input decoder with: — 32 bit directional position tracking — Programmable digital filtered inputs — Integral watchdog timer to flag a non-rotating shaft condition — Ability to calculate velocity measurement • 3-Phase PWM module — The high-performance 15-bit PWMs can be used in edge-aligned and center-aligned modes, as well as in complementary and independent modes and have programable dead-time generation — These PWM modules have a sophisticated set of programmable fault lines that do not require a system clock for proper operation — These and other features make these PWM modules industry leaders in safety, reliability, and performance 6 Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com Motorola Freescale Semiconductor, Inc. Introduction • Analog-to-Digital Converter (ADC) Module — Each high-performance 12-bit ADC has two sample and hold circuits, enabling simultaneous or sequential conversion at a rate of up to 1.2µs per conversion — ADCs can be used in single-ended or differential modes and have a sophisticated set of unique features, including: — Self-calibration — H/low and zero crossing detection Freescale Semiconductor, Inc... — Power-saving modes • — ADCs can be triggered through variety of methods, including PWM synchronization — ADC inputs have on-chip current protection circuitry, enabling their use in the harshest of industrial applications Temperature Sensor • — Enables the measurement of the device’s operating temperature, which can be important in safety-critical or harsh temperature environments — Highly accurate sensor which can measure 1°C increments — Each component is factory-calibrated for reliable operation — The temperature sensing function can be configured to provide an interrupt when a certain threshold is reached, detecting overheating with zero overhead FlexCAN — This powerful second-generation Controller Area Network (CAN) module is fully compliant with version 2.0 A/B — Features include: — Time stamps based on a 16-bit, free-running timer — Programmable wake-up functionality with integrated low-pass filter — 16 Transmit (TX) / Receive (RX) buffers — This peripheral enables the reliable and flexible networking of processors and intelligent devices at speeds up to 1Mbps • Serial Communication Interface (SCI) • — This module operates as a full duplex Universal Asynchronous Receiver Transmitter (UART) — Fully interrupt driven and programmable, providing a multitude of operating modes and baud rates Serial Peripheral Interface (SPI) • — This synchronous serial interface is double-buffered — Operates in wide variety of modes, rates, and bit lengths, enabling the glueless connection to external peripherals and other processors at rates up to 30Mbps General Purpose Input/Output (GPIO) — All digital pins for the on-board peripherals can also be individually assigned to be GPIO and individually assigned a direction — In addition to I/O capability, the GPIO can also generate interrupts — Each GPIO has programmable pull-ups — The GPIO also has a push-pull mode to efficiently implement a keypad interface MOTOROLA Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com 7 Freescale Semiconductor, Inc. Applications Enabled by the 56F8300 Hybrid Controller • Computer Operating Properly (COP) • — Assists software recovery from runaway code — The COP is a free-running down counter which, once enabled, is designed to generate a reset when reaching zero — Software must periodically service the COP to clear the counter and prevent a reset — The COP enhances end system reliability and safety JTAG/EOnCETM Freescale Semiconductor, Inc... — This enhanced on-board emulation module enables true full-rate emulation without the need for expensive hardware emulators — To perform powerful, non-intrusive, real-time debugging, simply attach to the processor with the industry-standard JTAG interface The 56F8300’s truly impressive set of features demonstrates why Motorola is the world leader in embedded processors. These components are applicable to a broad range of industrial and automotive applications, such as: 2. • Compressors • Smart appliances • Home security • Instrumentation • Data acquisition • Factory automation • Metering • Industrial networking • Lifts / elevators / cranes • HVAC blowers & fans • Uninterruptible Power Supplies (UPS) • Switching power supplies • Hydraulics replacement Applications Enabled by the 56F8300 Hybrid Controller The 56F8300 Series is a very capable product line with excellent performance and a very high level of peripheral and memory integration. In addition, the 56F8300 devices are very affordable. The power and affordability offered by the 56F8300 Series enable new applications as well as new features to existing products. This white paper details a few of these applications. 2.1 Network-enabled, High-performance UPS Uninterruptible Power Supplies (UPS) have been widely used for office equipment, computers, communication systems, medical/life support and many other systems. The goal of UPS is to provide clean and continuous power to a load, regardless of power grid conditions. Customers are demanding new levels of reliability, performance, and connectivity in these UPS products. Among the new requirements are a target expectation for UPS reliability of 99.999% power availability, performance demands of zero switch over time, and complex network connectivity and control methods, such as simple network management protocol (SNMP). Market pressures are driving UPS prices down at the same time these more-difficult requirements must be met. To satisfy these new and complex demands, 8 Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com Motorola Freescale Semiconductor, Inc. Applications Enabled by the 56F8300 Hybrid Controller new UPS topologies and solutions are required. Among the various UPS topologies, on-line triple-conversion UPS provides both clean and uninterruptible power to the load and satisfies the reliability and performance requirements. Since an on-line UPS always stays in active mode, the output voltage can remain stable, regardless of input voltage sag or power failure. It can provide stable, glitch-free AC power with fixed frequency and no switching time. Another benefit of on-line triple-conversion UPS is that battery life can be significantly extended compared to other on-line UPS topologies. To improve availability and avoid a single point failure, the new requirements for UPS are scalable architectures, the ability to hot-swap UPS modules and batteries, high power densities and networking capability. Freescale Semiconductor, Inc... The 56F8300 hybrid controller family is an excellent choice as the processing and control engine required for this advanced UPS architecture. A 56F8300 hybrid controller uniquely offers the features needed to support the required functions cost effectively. These features include: • 56F8300 MCU features supporting the network stacks and control processing • 56F8300 DSP features supporting the signal processing required for UPS algorithms • Advanced PWM and ADC peripherals supporting AC-to-DC conversion, DC-to-AC conversion, and battery charge without the need for external components • Superior on-chip Flash supporting SoC design that can be used reliably in the harshest environments An on-line triple-conversion UPS block diagram is shown in Figure 1-4. During normal operation, the AC input voltage is rectified by an AC/DC converter which not only rectifies the input voltage but also regulates the input power factor. The output of the AC/DC converter is a DCBus voltage that is used as the source for both the battery charger and DC/AC inverter. The battery charger is a boost/buck DC/DC converter. When the system is charging the batteries, the DC/DC converter works in buck mode, which steps the high DCBus voltage down to the batteries acceptable voltage level and charges the batteries. When the battery pack is fully charged, the converter switches to standby mode. If an input power failure occurs, the DC/DC converter works in boost mode, which supplies power to the DCBus from the batteries. The DC/AC inverter is used to convert the DC voltage to approximated sinusoidal output voltage pulses. The pulse string is input to an LC filter, which generates a true sinusoidal output voltage that is supplied to the load. The frequency of the sinusoidal output voltage is selectable by the user and can either be synchronized to the input voltage frequency or to any other desired independent stable frequency. When any failures or faults are generated or maintenance is needed in the UPS system, the bypass switch will be engaged, which turns the UPS system off and connects the load directly to the input power source. MOTOROLA Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com 9 Freescale Semiconductor, Inc. Applications Enabled by the 56F8300 Hybrid Controller Bypass Switch (Option) AC Input Rectifier + Power Factor Correction DC to AC Inverter LC Filter DC DC 2 2 2 2 Over Voltage & Over Current Battery Over Current Freescale Semiconductor, Inc... ADC PWM Fault ADC PWM Fault 0 1 Input 0,1 Input 2,3 ADC Input ADC PWM Fault Input 4,5 2,3 Current Feedback Voltage Feedback ADC Input ADC Input 56F8300 External Memory Interface CS8900 Ethernet LAN Controller LCD Controller SCI CAN SPI RS232 Physical Drive CAN Physical Drive 802.15 Controller RS232 CAB bus GPIOs Wireless Motorola Device Figure 1-4. Network-enabled UPS Hardware Diagram Figure 1-5 shows the implementation of the functional blocks in a triple-conversion on-line UPS system. The power stages interface to the 56F8300 via gate drivers. All necessary control functions are implemented within the 56F8300, such as: 10 • Power on/off control • DCBus voltage regulation • Input power factor correction • Battery management • AC output voltage regulation • Frequency synchronization of input and output • Power source monitoring • System self-diagnostics and self-protection • Emergency event processing • Real-time multi-tasking system operation • Communication protocols Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com Motorola Freescale Semiconductor, Inc. Freescale Semiconductor, Inc... Applications Enabled by the 56F8300 Hybrid Controller Figure 1-5. UPS Functional Block Diagram The 56F8300-controlled UPS will minimize the number of system components, maximize the system reliability and enable the easy addition of advanced functions, without increasing cost. The key advantages of a hybrid-controlled UPS are: • Bi-directional AC-DC conversion • High-input power factor and lower power pollution to the power grid • Extended battery life • Power source and load conditioning can be monitored in real time • Network communication • Lower maintenance cost The 56F8300 is an excellent and very cost-effective choice for use in high-performance UPS systems. 2.2 High-Performance Switched-Mode Power Supply The main purpose of a power supply is to provide clean and stable power to a load, regardless of power grid conditions. The Switched-Mode Power Supplies (SMPS) has been widely used in office equipment, computers, communication systems and other applications because of its high efficiency and high energy density. MOTOROLA Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com 11 Freescale Semiconductor, Inc. Applications Enabled by the 56F8300 Hybrid Controller Presently, the vast majority of SMPS are performed in an analog fashion. But analog implementations have some significant disadvantages that can be rectified by implementing the SMPS using modern digital mechanisms. Until recently, this has not been cost effective, due to performance and cost of the processors required to do the job. The 56F800 and 56F8300 Series of hybrid controllers have the required performance, peripherals, and price targets to enable SMPS to make the conversion from analog-to-digital implementations. L2 V+ D1 L1 D2 C2 T1 T2 D3 T4 T3 D4 Freescale Semiconductor, Inc... C1 AC110V Or AC220V Q1 C3 GND2 GND2 Shunt D5 L3 GND1 If Vsynch AN0 PWM AN1 V- Vf If AN2 PWM1 Current Regulator Voltage Regulator 56F801 Vf AN0 AN1 Vref Current Regulator Vref SCI SCI Voltage Regulator 56F8323 SCI Figure 1-6. Example Digital SMPS A block diagram for a 56F800/56F8300-based switched-mode power supply is shown in Figure 1-6. The system in this example is a 100-Watt switched-mode power supply controlled by a 56F801 on the primary side and a 56F8323 on the secondary side. Optional components could include user interfaces, such as an LCD or LED display. During normal operation, an AC/DC rectifier controlled by a 56F801 will correct the input power factor while simultaneously rectifying the AC input voltage. The output of the AC/DC rectifier is a DC voltage that will feed the DC/DC converter, which is controlled by a 56F8323. The DC/DC converter has a full bridge topology, used to convert the DCBus voltage to a precise and constant DC output voltage. For the Power Factor Correction (PFC) converter, the 56F801 samples the input AC voltage, input AC current, and DC output voltage. The output DC voltage is regulated by the 56F801, while maintaining the same phase for both the AC input current and voltage. The PWM module on the 56F801 produces the PWM pulse for the PFC main power component. The DC/DC converter controlled by the 56F8323 is operating on a phase-shifted soft-switching mode, so that switching losses and noise can be kept to a minimum. Control functions implemented within the secondary hybrid controller are: 12 • Power on/off control • DCBus voltage regulation • Output DC voltage regulation Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com Motorola Freescale Semiconductor, Inc. Applications Enabled by the 56F8300 Hybrid Controller • DC/DC full-bridge phase-shifted control strategy • Power system monitoring and communication protocols (optional) • Fault and mode management Control functions implemented within the primary hybrid controller are: • Input power factor correction • Automatic detection of input voltage frequency Freescale Semiconductor, Inc... The digital 56F8300 Switched-Mode Power Supply minimizes the number of system components, maximizes the system reliability, and makes it possible to easily add advanced functions without increasing cost. The key advantages of this digitally controlled SMPS are: • Power applications become more flexible and universal • High input power factor lowers power pollution to the power grid • Intelligent mode management and fault supervision • Operating status can be monitored and controlled in real time • Lower system and maintenance cost The 56F8300 and 56F800 performance, integrated peripherals, and low cost make the digital SMPS possible and practical. 2.3 Digital By-wire and Power-Assist Systems With the introduction of the 56F8300, a new set of control applications is now possible that will revolutionize the way vehicles and heavy equipment are designed, maintained, and used. Currently, a large number of hydraulic control systems in vehicles and heavy equipment are used to transform human inputs from foot pedals, steering wheels, and hand levers to power-assisted mechanical control action on brake pads, engines, wheels, pulleys, and other mechanical elements. Today, through the use of the 56F8300 advanced hybrid controllers, these hydraulic control systems can be replaced with digital electro-mechanical systems. The general benefits are many and significant and include: • Lower system costs • Lower maintenance costs • Higher reliability • Lighter and smaller systems • More intelligent systems, allowing control algorithms only available using digital methods • Easier modification and lower development costs • Better engine performance • Environmentally friendly These benefits are achieved by replacing traditional mechanical hydraulic components and subsystems with electrical components and subsystems. The electrical components are less expensive, lighter, more reliable, and more maintenance-free than the hydraulic mechanical components and subsystems they replace. The digital by-wire systems enable much greater flexibility and intelligence because they are driven by microprocessors, such as the 56F8300 hybrid controllers, that are programmed via software. The most basic nature of the system’s operation is software-controlled, making it very easy to update for new functionality and customize for any given end product. This ease of update and customization is simply not possible in physical hydraulic systems. The improved engine performance is achieved because the electro-mechanical systems do not siphon as much of the engine power as the hydraulic systems do to perform the same task. This greater efficiency enables the engine to operate MOTOROLA Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com 13 Freescale Semiconductor, Inc. Applications Enabled by the 56F8300 Hybrid Controller with better fuel performance or to transfer more power to the main engine task and less to the control systems. Since hydraulic fluid is not required, this environmentally hazardous material can be eliminated from the system. The 56F8300 Series is uniquely well-suited for use in digital electro-mechanical systems. These components have all the elements critical to implementing these electro-mechanical systems in a cost-effective way, including the required integrated high-performance peripherals such as PWM, encoders, CAN, ADC, and internal Flash memory. The 56F8300 hybrid controllers also have the signal processing power required by advanced motion algorithms, the MCU capability for the control code, and the raw processing power required by these sophisticated systems. Freescale Semiconductor, Inc... Most importantly, the 56F8300 processors meet the requirements of safety-critical applications. Many of the hydraulic systems that are to be replaced are used in end systems in which their improper operation could cause physical harm to humans. These types of systems, termed safety-critical, must operate properly at all times. A 56F8300 device has many features that make it easier and less expensive to implement safety-critical applications. These include extensive fault analysis and factory testing of the internal structure of the components to ensure that every component delivered to a customer will operate to the data sheet’s specifications. Also, the features of the 56F8300 devices, such as the internal temperature sensor, fault inputs, and internal self-checking circuitry, ensure that the components are operating correctly. The 56F8300 controllers are designed and tested to enable their use in the harshest operational environments. Motorola, the leading supplier of embedded processors to the automotive industry, has been in the business for many years and, as such, is uniquely qualified to develop and supply processors for safety-critical applications in harsh environments. The following sections contain specific examples where hydraulic systems are replaced with digital electro-mechanical ones. 14 Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com Motorola Freescale Semiconductor, Inc. Applications Enabled by the 56F8300 Hybrid Controller Resolver Encoder Figure 1-7 shows a block diagram of digital electric power-assisted steering system. This system replaces a hydraulic-based power steering system for automobiles and steered industrial heavy equipment. In the example shown, the electro-mechanical system performs a power assist similar to the one performed by a hydraulic system. A mechanical connection exists between the steering wheel and the tires, with the digital electric system amplifying the force supplied by the human driver. A by-wire steering system would entirely remove the physical mechanical connection between the steering wheel and the tires, with total control provided by the 3-phase electric motor. The steering wheel generates the torque command, and the electric motor provides the steering assistance to overcome the load. The 56F8300’s internal PWM directly drives the 3-phase power stage that powers and controls the motor. The internal ADC inputs the feedback signals from the motor, such as the current sense and resolver. The quad timer also gets feedback on the motor shaft position from the encoder. The internal CAN peripheral is used to connect into the vehicle’s real-time control network. The internal temperature sensor constantly checks to ensure the proper operating temperature is not exceeded. 3-Phase Low Voltage Power Stage U_Dc bus Gearbox Position Steering Wheel Torque Load Measurement Cosine Sine Resolver HW Isc Isb Current Meas. Position 6 CAN Isa DC Bus Voltage PWM Control Network Torque Sensor Steering Load PMSM Motor 12 Vdc Freescale Semiconductor, Inc... 2.3.1 Electric Power-Assisted Steering Reference ADC 56F8300 Hybrid Controller Quad Timer Temp Sense Figure 1-7. Digital Electric Power-Assisted Steering MOTOROLA Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com 15 Freescale Semiconductor, Inc. Applications Enabled by the 56F8300 Hybrid Controller Figure 1-8 shows an example of the software block diagram for the steering system. This application exhibits the suitability and advantages of the 56F8300 family for torque control applications using a 3-phase PMSM motor with an encoder and resolver position sensor. The application utilizes a vector control approach of the 3-phase Permanent Magnet Synchronous Motor (PMSM). Us_q Is_d Angle Tracking Observer Us_alpha DC-bus ripple com pensation Us_beta sin cos theta_ atual _el Is_beta Forward Park Transform ation alpha,beta->d,q Current Sensing Processing Is_alpha Forward Clark Transform ation a,b,c ->alpha,beta Is_b_comp Is_c_comp Torque_ load _ meas Is_q Us_beta_comp Inverse Park Transform ation d,q->alpha,beta Current d PI Controller Reference Generation & Quad Tim er Us_alpha_comp Is_a_comp Torque_ Req Is_q_ Req Us_d Sine Sector PW M M odulation Current q PI Controller Is_a Is_b Is_c Sine Dutycycle a Dutycycle b Dutycycle c Torque Controller Driver U_dcb Driver Cosine Isc Driver Application Control Q UAD Tim er Driver Cosine GPIO Driver Ref ADC PW M CAN Freescale Semiconductor, Inc... Isb PW M Isa U_Dc bus Control Netw ork Software switch M otorola 56F8300 Figure 1-8. Software Block Diagram Digital electric power-assisted steering has significant advantages over traditional hydraulic systems, including: • Improved fuel economy • Faster development and tuning • Simpler and less-expensive system • Improved reliability Eliminating the hydraulic system load from the engine improves fuel economy. The hydraulic system is inherently less efficient than the electric one. In addition, the hydraulic system represents a more constant load on the engine, while the electric system mainly loads the engine during wheel movement. Once the wheel remains in the same position, such as when driving straight ahead, the load on the engine is minimized. The digital electric system is faster to develop and tune to a specific model type because many of the operating characteristics of the system are defined by the software operating on the 56F8300 device and software is much easier to modify than physical hydraulic systems. The digital electric system doesn’t require the various pumps, reservoir, piping, and other components that the hydraulic system requires, making the electric system less expensive and simpler to install and store. The digital electric system uses a higher percentage of solid state components that are much more reliable and maintenance-free than mechanical systems. 16 Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com Motorola Freescale Semiconductor, Inc. Applications Enabled by the 56F8300 Hybrid Controller The system as shown is a direct replacement for the hydraulic system. The opportunity exists to include new features, such as avoidance system features, that can be added easily with little to no cost. This is possible because the 56F8300 core of the system is a software-programmable processor. New features and performance can be added simply by changing the software loaded into the 56F8300. The system in this example is applicable directly to all types of automobiles. The automotive industry is aggressively developing and fielding EPAS systems and the 56F8300 device is the premier solution for the hybrid processing required in these systems. The EPAS system is generally applicable to a large number of applications in industrial heavy equipment, where power-assisted steering is used. Freescale Semiconductor, Inc... 2.3.2 Digital Electro-Mechanical Brake (EMB) System This is sometimes referred to as “brake by wire”. This type of system replaces a traditional power-assisted braking system controlled by hydraulics. Figure 1-9 shows an EMB system applied to a four-wheeled vehicle. The system is comprised of a brake pedal unit that senses the brake pedal’s movement and position. It commands the four EMB units that are attached to each of the wheels. The EMB unit controls a motor that applies the force to the braking pads. The braking commands and status are communicated via a CAN bus. B ra k e P e d a l Pedal S e n so r F a u lt In d ic a to r CAN P e d al Sensor C AN 56F8300 S te e rin g A n g le S en s o r F a u lt In d ic a to r S w itc h SBC F a u lts P ow er S ta g e W heel Speed D rive r 5 6F 8 30 0 S w itc h SBC F a u lts P e d al B rak e E C U W h ee l B rak e E C U Pow er P ow er E M B U n it Figure 1-9. EMB System The system shown is representative of an ordinary passenger vehicle, but can also be applied to any vehicle or industrial system that uses brakes. Figure 1-10 shows the EMB unit as it is interfaced to the physical brake pad and rotor. MOTOROLA Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com 17 Freescale Semiconductor, Inc. Encoder PMSM Motor Hall Effect Brake Gearbo x Applications Enabled by the 56F8300 Hybrid Controller 56F8300 56F8300 Freescale Semiconductor, Inc... 3-ph. 3-ph. Motor Motor Board Board (EMB (EMB Control) Control) Figure 1-10. EMB Unit detail The digital EMB system has many advantages when compared to a traditional hydraulic system. These include: • Simpler, smaller, less-expensive system • Improved braking performance in key areas such as distance and stability • Intelligent system, enabling advanced traction control • More reliable • New networked braking features possible • Easier support for driver/operator customization There are a number of benefits to the EMB system as a simple replacement of the hydraulic system. A number of intelligent features are possible, since the system is processor driven. Examples are traction control and stability improvements, as each brake is controlled individually but coordinated by a central unit. In addition, since the system is networked with other components, it is now possible to receive information from many different sources and take braking action. These could be inputs from sensors attached to the vehicle which provide avoidance collision or intelligent cruise control. In addition, information could come in from sources entirely external to the vehicle, such as traffic control systems. Since the EMB is inherently an intelligent system, these features can be added without increasing the cost of the braking system itself. 2.4 Intelligent Sensor Applications Combining today’s low-cost, high-performance sensor technology with the processing capability of the 56F8300 makes traditionally high-cost intelligent sensor systems much more affordable. With the greatly reduced cost and increased performance these systems can be applied to many new markets. One such system is the Inertial Sensor, which can be used to determine the angular and linear motion of an object. Traditionally, the inertial sensors have been used for active stabilization and navigation applications. But in the past, the intelligent inertial sensor systems were quite expensive because of the cost of mechanical accelerometers and gyros, and the cost of the high-performance processors required in the system. This made their use practical only for expensive and complex systems, such as military submarines and commercial aircraft. Now, with the introduction of low-cost MEMs sensor technology and the low-cost 56F8300 hybrid processors, much more economical inertial sensors can now be produced. 18 Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com Motorola Freescale Semiconductor, Inc. Applications Enabled by the 56F8300 Hybrid Controller Figure 1-11 shows the degrees of freedom of a moving object that the inertial system can detect. This is an example of an inertial sensor with six degrees of freedom and a measurement of linear and angular motion on each of the three dimensional axis. Depending on the type of end system, not all variables are required. z y X axis (Roll) Y axis (Pitch) x Figure 1-11. Inertial Sensor Variables Inertial sensors find application in a broad range of end systems, such as: • Automotive active stabilization and navigation • Heavy equipment active stabilization and navigation • Industrial applications such as robotics, container handling, lift systems, machine tools • Biometric systems • Active stabilization of camera and antennas • Unmanned vehicles GPIO GPIO ADC SCI MM1250D Acceleration Sensor GPIO GPIO ADC SPI Angular Rate/Velocity Sensor ADC System Communication CAN MM1250D Acceleration Sensor Freescale Semiconductor, Inc... Z axis (Yaw) 56F8300 Figure 1-12. Intelligent Inertial Sensor with Three Variables MOTOROLA Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com 19 Freescale Semiconductor, Inc. Conclusions Figure 1-12 shows an implementation of a three-variable inertial sensor. In this example, the sensor can only detect motion in two axes and rotation on a single axis. More sensors must be added to perform all six possible variables. A three-variable inertial sensor such as this could be set up for x and y axis motion detection and z axis rotation (yaw) and could be used in a vehicle for steering/traction assistance by detecting the direction of actual vehicle movement in comparison to the desired movement. The important factors in relation to the vehicle are x and y movement and the yaw. The z axis motion is not pertinent, nor are the pitch and roll. Motorola’s low G accelerometers have been used because they are well-suited for this type of application. Freescale Semiconductor, Inc... The cost of this inertial sensor is reduced by using the 56F8300 hybrid controller that has both the performance and integrated peripherals required by the system, and by using low-cost, high-performance MEM sensors. The unit is maintenance free and, since it is solid state, very reliable. The much-reduced price point for the end unit makes it practical for use in automotive and industrial applications. 3. Conclusions With the introduction of the 56F8300 Series, Motorola has provided a new level of performance and integration to Flash-based products. The 56F8300 Series provides our current 8/16-bit MCU and 56F800 customers with an excellent path to increased performance and features. The enhanced performance, memory, and features of the 56F8300 Series enable a developer to expand his horizons with new product possibilities. This white paper has shown only a few of the applications made possible and practical using the new performance-leading and affordable 56F8300 hybrid controllers from Motorola. 20 Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com Motorola Freescale Semiconductor, Inc. Freescale Semiconductor, Inc... Conclusions MOTOROLA Motorola 56F8300 Hybrid Controller Family For More Information On This Product, Go to: www.freescale.com 21 Freescale Semiconductor, Inc. HOW TO REACH US: USA/EUROPE/LOCATIONS NOT LISTED: Motorola Literature Distribution; P.O. Box 5405, Denver, Colorado 80217 1-303-675-2140 or 1-800-441-2447 JAPAN: Motorola Japan Ltd.; SPS, Technical Information Center, 3-20-1, Minami-Azabu Minato-ku, Tokyo 106-8573 Japan 81-3-3440-3569 Freescale Semiconductor, Inc... ASIA/PACIFIC: Information in this document is provided solely to enable system and software Motorola Semiconductors H.K. Ltd.; Silicon Harbour Centre, 2 Dai King Street, Tai Po Industrial Estate, Tai Po, N.T., Hong Kong 852-26668334 TECHNICAL INFORMATION CENTER: implementers to use Motorola products. There are no express or implied copyright licenses granted hereunder to design or fabricate any integrated circuits or integrated circuits based on the information in this document. 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