Microcontroller AP90001 Hardware Description Low Voltage Inverter Application Note V1.0 2009-01-29 M ic ro c on tro ll er s Edition 2009-01-29 Published by Infineon Technologies AG 81726 Munich, Germany © 2009 Infineon Technologies AG All Rights Reserved. Legal Disclaimer The information given in this document shall in no event be regarded as a guarantee of conditions or characteristics. With respect to any examples or hints given herein, any typical values stated herein and/or any information regarding the application of the device, Infineon Technologies hereby disclaims any and all warranties and liabilities of any kind, including without limitation, warranties of non-infringement of intellectual property rights of any third party. Information For further information on technology, delivery terms and conditions and prices, please contact the nearest Infineon Technologies Office (www.infineon.com). Warnings Due to technical requirements, components may contain dangerous substances. For information on the types in question, please contact the nearest Infineon Technologies Office. Infineon Technologies components may be used in life-support devices or systems only with the express written approval of Infineon Technologies, if a failure of such components can reasonably be expected to cause the failure of that life-support device or system or to affect the safety or effectiveness of that device or system. Life support devices or systems are intended to be implanted in the human body or to support and/or maintain and sustain and/or protect human life. If they fail, it is reasonable to assume that the health of the user or other persons may be endangered. AP90001 Low Voltage Inverter Low Voltage Inverter Revision History: V1.0, 2009-01-29 Previous Version(s): none Page Subjects (major changes since last revision) We Listen to Your Comments Is there any information in this document that you feel is wrong, unclear or missing? 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Please send your proposal (including a reference to this document) to: [email protected] Application Note V1.0, 2009-01-29 AP90001 Low Voltage Inverter Table of Contents Table of Contents 1 1.1 1.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Key Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 2.1 2.2 2.3 2.4 2.5 2.6 Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MOSFET Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DC-Link Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 PCB Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3 3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 PMSM Motor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application Note 1 14 14 14 15 15 15 16 V1.0, 2009-01-29 AP90001 Low Voltage Inverter Overview 1 Overview The Low Voltage Inverter is designed to provide a robust power inverter including feedback signals for 24 V and 48 V motors. The Inverter offers a seamless fit to the DriveCards offered by Infineon. A PMSM motor board is available in addition to the low voltage inverter, and is also described in this application note. Figure 1 1.1 Low Voltage Inverter with PMSM Motor Key Features Low Voltage Inverter • • • • • • 3 phase full bridge inverter with n-channel MOSFETs Integrated driver with bootstrap technology On Board power supply – Switch mode power supply (15 V) for MOSFET driver – low drop voltage regulator (5 V) for MCU Voltage range: 23 V .. 56 V Maximum DClink current: 7.5 A Seamless connection of Infineon Technologies DriveCards, dedicated for motor control 19.6 mΩ, 100 V 6ED003L06-F ICE3B0565JG TLE4264-2 Microcontroller boards Pluggable PMSM Motor Board • • • • Easy to use with 24 VDC plug-in power supply Additional filter capacitor (100 µF, 50 V) on board Motor connections fed via jumpers for easy current measurement Small PMSM motor on board (24 V, 15 W) (Maxon EC flat 32) Application Note 2 V1.0, 2009-01-29 AP90001 Low Voltage Inverter Overview 1.2 Block Diagram Figure 2 shows the block diagram of the Inverter and motor board. The design targets robustness, compatibility to standard Inverter designs and flexibility. The Inverter’s power devices are MOSFETs with an RDS(ON) of less than 20 mΩ, the driver is based on SOI technology with a voltage rating up to 600 V, and the motor is placed on a separate board which can be unplugged. The Inverter board contains a Switch Mode Power Supply (SMPS) providing 15 V for the gate driver. A low drop voltage regulator generates the 5 V supply for the microcontroller board, which can be plugged onto the system. The DClink current can be measured via a 20 mΩ shunt and an operational amplifier adjusted to a gain of 34. For sensorless block commutation algorithms, the output voltages can be measured via voltage dividers by the microcontroller. The pluggable motor board contains, next to the motor, an EC flat motor from Maxon Motors, a filter capacitor. This motor board is intended to provide an easy start with motor control algorithms provided as software packages by Infineon Technologies. As soon as the first step is taken, the motor board can be unplugged and a custom motor can be connected directly to the low voltage Inverter. Note: Remember to connect a filter capacitor at the supply voltage with a power rating that fits to that motor. VDClink SMPS 15V 5V + - V CC MOSFET driver LDO 100µF / 50V HINx U V W LINx 3-phase motor 5V EN U_H / U_L V _H / V _L W_H / W_L FO GND ITRIP E nable 20mΩ Gain: 34 I D C li n k Opamp GND V_U/ V _V/ V _W Back-EMF feedback signals BlockDiagram.emf Figure 2 Block Diagram of Low Voltage Inverter Application Note 3 V1.0, 2009-01-29 AP90001 Low Voltage Inverter Hardware Description 2 Hardware Description 2.1 Connectors The power supply for the Low Voltage Inverter is connected to X1. The SMPS is designed to start operation at supply voltages greater than 23 V. For correct operation with high peak currents, it is recommended to add a filter capacitor externally unless the motor board is connected. The motor board itself is equipped with a filter capacitor. The 3 phase motor is connected at X2. See Figure 3 for details: Figure 3 Power Supply Connector X1, Motor Connector X2 and Drive Card Connector X3 The standard 32-pin connector (DIN 41612, Q/2) provides all connectivity to a microcontroller. The lowside (_L) and highside (_H) switches of the three power stages U, V and W are to be connected to the PWM signals of the MCU. A low signal at the CTRAP pin switches all power stages in passive state and acts as an emergency shut-down for the Inverter. A 5 V power supply is provided at pins A1-B1 of connector X3 of the Inverter board in order to supply the MCU and peripheral components. Table 1 lists the signals available at the DriveCard connector X3 and the appropriate signals of the available DriveCards. The DriveCards listed below can be used together with the Low Voltage Inverter: Order Code MCU Algorithm Example KIT_XC886_DC_V1 XC886CM sensorless FOC for PMSM Motor KIT_XC878_DC_V1 XC878CM sensorless FOC for PMSM Motor + digital PFC Application Note 4 V1.0, 2009-01-29 AP90001 Low Voltage Inverter Hardware Description Order Code MCU Algorithm Example KIT_XC164CM_DC_V1 XC164CM Encoder based FOC for PMSM Motor KIT_XE164_DC_V1 XE164F Two sensorless, encoder based or resolver based FOC algorithms + digital PFC Table 1 XE164 Signal Connections to Drive Cards XC164 XC878 XC886 X3 1) 1) XC886 XC878 XC164 XE164 VDD 5 V VCC VCC VCC VCC GND GND GND GND GND A16 B16 P0.6 P1H.5 P5.3& P5.4 - - A15 B15 - - P5.2 P9.1 P0.5 ADC1ch5 AN14 - - - A14 B14 - - P5.5 AN6 ADC1ch6 ADC0ch5 AN15 - - - A13 B13 V_DC AN1 AN1 AN4 ADC1ch15 ADC1ch0 AN10 - - - A12 B12 V_U AN7 AN7 AN0 ADC0ch0 ADC1ch2 AN11 - - - A11 B11 V_V AN6 AN6 AN1 ADC0ch3 ADC01- AN12 ch11 AN2 AN2 - A10 B10 V_W AN5 AN5 AN2 ADC01 -ch9 ADC01- AN13 ch10 AN3 AN3 IDCLINK A9 B9 IDCLINK A AN4 AN4 AN3 ADC01 -ch8 P1.7 - P4.0 - - A8 B8 CC60 P3.0 P3.0 P1L.0 P10.0 P1.5 - P4.1 - - A7 B7 COUT60 P3.1 P3.1 P1L.1 P10.3 P1.6 - P4.4 - - A6 B6 CC61 P3.2 P3.2 P1L.2 P10.1 P1.4 - P4.5 - - A5 B5 COUT61 P3.3 P3.3 P1L.3 P10.4 P1.2 - P4.6 - - A4 B4 CC62 P3.4 P3.4 P1L.4 P10.2 P1.1 - P4.7 - - A3 B3 COUT62 P3.5 P3.5 P1L.5 P10.5 P1.0 - P4.3 - - A2 B2 CTRAP P3.6 P3.6 P1L.7 P10.6 P0.1 - P5.1 - - A1 B1 ENABLE P4.0 P5.0 P1H.3 P0.0 1) A: Lower and inner row, B: Upper and outer row Application Note 5 V1.0, 2009-01-29 AP90001 Low Voltage Inverter Hardware Description 2.2 MOSFET Driver The gate driver (6ED003L06F) is a full bridge driver to control power devices like MOStransistors or IGBTs in 3-phase systems with a maximum blocking voltage of +600V. Based on the use of SOI-technology, there is an excellent ruggedness on transient voltages. No parasitic thyristor structures are present in the device. Hence, no parasitic latch up can occur at all temperature and voltage conditions. This full-bridge driver provides signal interlocking of every phase to prevent cross- conduction. Figure 4 shows the schematics of the gate driver including the bootstrap circuitry. Figure 5 shows the schematics of the MOSFET power stages. The gates of the MOSFETs are connected via resistors to the driver. By changing these resistors, the switching behavior (especially slew rate) of the MOSFETs can be adjusted to the application’s needs. Of course, the MOSFETs can be changed if required. Please refer to: www.infineon.com/MOSFETS. There are resistive voltage dividers at the outputs of the full bride. They are intended to be used for back EMF measurement at block commutating algorithms. Figure 4 Gate Driver Application Note 6 V1.0, 2009-01-29 AP90001 Low Voltage Inverter Hardware Description Figure 5 Power MOSFETs and Back EMF Resistors The shunt resistor RS1 is used by the gate driver both to detect heavy over load and for DC-link current measurement. 2.3 DC-Link Current Measurement A differential amplifier is provided in order to measure the DC-Link current via a single shunt in the common lowside path of the MOSFETs. The bandwidth of this amplifier is chosen to enable the phase current reconstruction from the common DC-Link current. The amplifier is adjusted to a gain of 34. The current measurement ratio UIDClink / IDC_Link = 0.68 V/A. As a result, the maximum current which can be measured by a 5 V A/D converter is 7.35 A. A mounting option R40 is available in order to adjust an additional offset voltage to the measurement. In case negative voltages have to be measured as well, it is recommended to mount the resistors R9, R39 and R40 with 16 kΩ. As a result, the offset voltage is 2.5 V and the gain is 17. The measurement range is then extended to +/7.35 A. Please refer to Figure 6 for details of the DC-Link current measurement circuitry. Application Note 7 V1.0, 2009-01-29 AP90001 Low Voltage Inverter Hardware Description Figure 6 DC-Link Current Measurement Note: Although the system is adjusted to 7.35 A, it can be easily enhanced to motors with lower impedance by replacing the MOSFETS, the shunt resistor and/or the gain of the operational amplifier. Application Note 8 V1.0, 2009-01-29 AP90001 Low Voltage Inverter Hardware Description 2.4 Power Supply There are three power domains at the Low Voltage Inverter. First the main power supply that is used for the power Inverter. The main power supply voltage (DC-link) is fed to a switch mode power supply circuit (SMPS) which will provide a 15 V power supply for the gate driver, the second power domain VCC. Please see Figure 7 for details. Figure 7 Switch Mode Power Supply (SMPS) The CoolSET™-F3 (ICE3B0565JG) meets the requirements for Off-Line Battery Adapters and low cost SMPS for the lower power range. The switching frequency is fixed to 67 kHz with frequency jittering for low EMI. The CoolSET F3 family provides the highest output power with the lowest losses available in the industry. The CoolSET-F3 is designed for voltages up to 600 V, but can be used for low voltage applications as well. This wide operating range is limited for the lowest voltages, which could cause the startup circuit to fail. It is recommended not to use the board below 23 V. The output voltage of the SMPS is taken by a Low Drop Voltage regulator (LDO) which provides a 5 V power supply. This third power supply domain VDD is used by the operational amplifier and the MCU which is connected at the DriveCard connector X3. Figure 8 Low Drop Voltage Regulator (LDO) An LED is mounted to the board signaling the availability of the 5 V supply voltage. Application Note 9 V1.0, 2009-01-29 AP90001 Low Voltage Inverter Hardware Description 2.5 PCB Layout Figure 9 PCB Layout Top Layer Figure 10 PCB Layout Bottom Layer Application Note 10 V1.0, 2009-01-29 AP90001 Low Voltage Inverter Hardware Description Figure 11 2.6 PCB Layout Component Placement Bill of Materials Component C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 Application Note Value 10u/25V 100pF 22n 1u/25V 1u/25V 1u/25V 1u/25V 220n/63V 10u/25V 470n 100n 100n 470n 220u/25V 100n 10u/10V 33pF 100n/100V Package/Size C1210 C0603 C0603 C0805 C0805 C0805 C0805 C_CASE_RADIAL and SMD C1210 C0805 C0603 C0603 C0805 CASEG C0603 C1206 C0603 C0805 11 V1.0, 2009-01-29 AP90001 Low Voltage Inverter Hardware Description Component C19 C20 C21 D1 D2 D3 D4 D5 D6 D7 0R0 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 R24 R25 R26 R27 Application Note Value n.m. 100n/100V 100n/100V US1D fast recovery US1D fast recovery US1D fast recovery 1N4148 13V zener diode US1D fast recovery US1D fast recovery 0R 10K 10K 100K 3R3 3R3 3R3 1k 1k 33k 1k 1k n.m. 13R n.m. 13R n.m. 13R n.m. n.m. 13R 13R n.m. n.m. 13R 56k 56k 56k Package/Size C0603 C0805 C0805 DO214AC DO214AC DO214AC R0603 SOD110-R DO214AC DO214AC R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 12 V1.0, 2009-01-29 AP90001 Low Voltage Inverter Hardware Description Component R29 R30 R31 R32 R33 R34 R35 R36 R37 R38 R39 R40 R41 RS1 L1 X1 X2 X3 FET1 FET2 FET3 FET4 FET5 FET6 IC1 IC2 IC3 IC4 Q1 ENABLE VDD Application Note Value 5k1 5k1 0R 180R 10R 2R2 1k5 1k5 5k1 56k 33k n.m. 3k6 0R02 1mH GMSTBA2MSTBA GMSTBA3MSTBA FAB32Q2 BSC196N10NS BSC196N10NS BSC196N10NS BSC196N10NS BSC196N10NS BSC196N10NS 6ED003L06-F-GATEDRIVER ICE3B0565 TLE4264-2G LMV721M5 BCR108W LED 0603 red LED 0603 red 13 Package/Size R0603 R0603 R0805 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R0603 R1206 and metal strip SMD10X10 PHOENIX PHOENIX female, 32pins type Q/2 SuperSO08, TDSON SuperSO08, TDSON SuperSO08, TDSON SuperSO08, TDSON SuperSO08, TDSON SuperSO08, TDSON P-DSO-28 P-DSO16 SOT223 SOT23-5 SOT323 CHIPLED_0603 CHIPLED_0603 V1.0, 2009-01-29 AP90001 Low Voltage Inverter PMSM Motor Board 3 PMSM Motor Board The Pluggable Permanent Magnet Synchronous motor board is intended to be used as a reference motor together with software packages for motor control. 3.1 Schematics The schematics in Figure 12 contains the connectors to the Inverter board X1 and X2, the power supply connector X3 and the motor connector X4. The jumper JP1 can be used for current measurement as well as a connector for your custom motor. Figure 12 3.2 Schematics of PMSM Motor Board Board Layout top layer Figure 13 bottom layer Layout of PMSM Motor Board Application Note 14 V1.0, 2009-01-29 AP90001 Low Voltage Inverter PMSM Motor Board 3.3 Motor In this section, the technical data (revision April 2006) of the motor can be found. Please refer directly to Maxon Motor internet page http://www.maxonmotor.com for the latest information about this ECflat motor. 3.3.1 Figure 14 3.3.2 Figure 15 Motor Data Motor Data Operating Range Operating Range Application Note 15 V1.0, 2009-01-29 AP90001 Low Voltage Inverter PMSM Motor Board 3.3.3 Figure 16 Geometry Geometry Application Note 16 V1.0, 2009-01-29 w w w . i n f i n e o n . c o m Published by Infineon Technologies AG AP90001