View detail for AVR927: Using ATmega88 and ATA6832 for BLDC motor control in high temperature environment

APPLICATION NOTE
Fully Integrated BLDC Motor Control from the Signal
Generation to the Full BLDC Motor Control Chain
ATA6832-DK
Description
The purpose of this document is to explain the theory and application of Atmel®’s integrated
BLDC driver solution. The worldwide demand for BLDC systems is increasing rapidly. To
fulfill this need, Atmel provides a BLDC system with integrated output stages up to 1A. The
system is suitable for “under the hood” applications with ambient temperatures up to
150°C. Various built-in protection features make it ideal for a variety of automotive applications containing small motors.
Figure 1.
Fully Integrated BLDC Motor Control
4987C-AUTO-02/15
1.
Fully Integrated BLDC System
Figure 1-1. Fully Integrated BLDC Motor Control Application
Battery
+
ATA6624
Protection
VCC
Regulator
LIN
U
VCC
Charge Pump
16 Bit SPI, PWM
TRX
BLDC
Motor
V
Watchdog
Diagnosis
LIN
W
ATA6832
Tx
Rx
Commutation
Speed Control
ATmega88
SPI, PWM
HALL
The system consists of three integrated circuits: Microcontroller ATmega88, Triple Half Bridge Driver ATA6832 and LIN
System Basis Chip ATA6624 (Figure 1-1). The driver IC integrates three half bridges to run a BLDC motor directly.
The output drivers are fully protected. Open load, overtemperature, overload, and undervoltage will be reported to the
microcontroller by SPI (Serial Peripheral Interface). The outputs will also be switched with the SPI interface. The direct PWM
input is independent of the SPI and can be flexibly linked to the 6 output stages. This ensures an intelligent cruise control for
various movement profiles adapted to the load.
The loop between motor movement and microcontroller is assured by hall sensors. The commutation is done by the
microcontroller ATmega88. Furthermore, ATmega88’s flash memory and computing capacity allow operation of LIN protocol
2.0.
The BLDC system is connected with the LIN transceiver ATA6624 to the automotive environment. Furthermore, this device
generates the digital supply voltage.
No additional protection circuitry, e.g. current sensing is required due the enhanced in-circuit protection features for overload
and overtemperature.
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ATA6832-DK [APPLICATION NOTE]
4987C–AUTO–02/15
2.
Theory of BLDC Operation
Brushless DC motors are used in a growing number of applications as they offer several advantages, including reduced
noise, long lifetime (no brush erosion), reduced noise, good weight/size to power ratio, and hazardous operation
environment usability (with flammable products).
These types of motor have a little rotor inertia compared with other motor types. Coils are attached to the stator, and
commutation is controlled by electronics using position sensors feedback or back electromotive force measurements.
A BLDC motor stator basically includes three coils, which can be replicated to reduce torque ripple. In the same way, a rotor
basically includes permanent magnets, composed of one to multiple pair of poles; this also affects step size (see Figure 2-1).
Position can be estimated using three hall sensors, each spread at 120° around the stator.
Figure 2-1. Three-coil BLDC Motor, 1 and 2 Pair Poles
A
A
N
N
S
C
S
S
N
B
B
C
BLDC motor operation can be simplified by considering only three coils and one pair pole. The commutation of the phase
depends on the position, in our case, the hall sensors value. When motor coils are supplied, a magnetic field is created and
the rotor moves. The most elementary commutation driving method is an on-off scheme: a coil is either conducting or not.
Only two coils are supplied at the same time; the third is floating. This is referred to as trapezoidal commutation or block
commutation.
Figure 2-2. Power Stage
HS1
HS2
HS3
A
B
C
LS1
LS2
LS3
ATA6832-DK [APPLICATION NOTE]
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3
Figure 2-3. Commutation Steps for CW Operation
010
011
001
A
A
A
110
B
C
100
B
C
B
C
101
Step 1
Step 2
Step 3
A
A
A
B
C
Step 4
B
C
B
C
Step 5
Step 6
Reading the hall sensors value indicates commutation to be performed. For multiple pole motors, electrical rotation
corresponds to mechanical rotation with the pair pole number factor.
Table 2-1.
Switches Commutation for CW and CCW Rotation
Hall Sensors Value
(CBA)
Switches Commutation for CW Rotation
Switches Commutation for CCW Rotation
Coils
Switches
Coils
Switches
101
A-B
HS1 - LS2
B-A
HS2 - LS1
001
A-C
HS1 - LS3
C-A
HS3 - LS1
011
B-C
HS2 - LS3
C-B
HS3 - LS2
010
B-A
HS2 - LS1
A-B
HS1 - LS2
110
C-A
HS3 - LS1
A-C
HS1 - LS3
100
C-B
HS3 - LS2
B-C
HS2 - LS3
Commutations are updated at each step to create a rotating magnetic field as shown in Figure 2-3.
This method takes full advantage of the ATA6832 as commutations can be transmitted at each step, while PWM allows
magnetic field magnitude tuning to act independently on motor torque and speed.
4
ATA6832-DK [APPLICATION NOTE]
4987C–AUTO–02/15
3.
Driver ATA6832
The ATA6832 offers a variety of diagnostic and protection features including supervised low battery voltage, overload, open
load, and temperature monitoring.
3.1
Maximum Speed
The commutation is done by microcontroller. The hall sensors are the input channel, which provide the motor position
feedback. The SPI interface, which is the interface to the integrated triple half-bridge driver, is the output channel. The time
schedule for commutation is shown in Figure 5-1 on page 9.
The data transfer rate of the SPI is restricted; 2 MHz is the maximum transfer rate to the ATA6832. 16bit plus communication
control allows a maximum theoretical SPI rate of up to 100kHz – one command every 10µs.
The maximum output switch speed of the ATA6832 is up to 25kHz. Changing the output state is possible every 40µs.
A BLDC motor with a 3-pole stator and one double pole enables, with a defined control, the maximum speed. A rotor with
two double poles enables half the speed. A single double-pole motor in one rotation passes through 6 different switching
states of the three output half bridges (refer to Table 2-1 on page 4). Each switching state is controlled by one SPI command;
therefore, six SPI commands are required for one turn.
An output switch rate of 40µs and 6 times each turn results in a minimum of 240µs for one rotation.
3.2
Open BLDC Load Detection
To detect the open load, there are integrated current sources on each output stage. Turning off open-load detection bit (OLD
set to low), the current sources are switched on. The low side test current is guaranteed by design to be higher than high
side test current. Therefore, if no load is connected to an output, all the three low-side switches will report open load by
turning their output register bit on.
If one output is switched to high and the BLDC motor is connected correctly, both neighboring outputs will show high-side
open load. In the event of open load on one string, this output will signal low-side open load.
Under normal operation, the open load current sources should be switched off by setting OLD bit to high.
Otherwise, this circuitry will produce power dissipation.
3.3
Switching PWM
To control the outputs with PWM, there is one PWM input pin available for all six outputs. The outputs to operate with PWM
can be selected by activating the corresponding bit of the six input data registers PLx/PHx. If PWM operation mode is
activated for an output by these input bits, its input data register switch HSx/LSx is “and-connected” with the input pin PWM.
The selected outputs follow the PWM input signal.
For cruise control, e.g., to start or stop a BLDC motor, PWM is necessary. To control the speed, only one dedicated PWM for
all three BLDC motor strings is required. Controlling the current through the strings, it is sufficient to switch only one output of
a half bridge, either high side or low side. This circumstance enables running of the BLDC driver with only one PWM
frequency. Only one microcontroller timer is necessary.
The high-side switches of the ATA6831 and ATA6832 are faster than the low-side switches. PWM frequency up to 25kHz is
possible using the high-side switches.
3.4
Cooling Area Design
The drivers IC ATA6831/ATA6832 are housed in a special QFN package. QFN package is particularly suitable for power
package because of the exposed die pad. To make use of this advantage, it has to be assured the head slug is completely
soldered to the PCB.
To reduce thermal resistance, vias are required down to the soldering layer. A sufficing ground plane has to be placed on the
soldering layer to eliminate the thermal energy.
A via diameter of 0.3mm to 0.4mm and a spacing of 1mm to 1.5mm has proven to be most suitable. Some care should be
taken of the copper area's planarity, in particular, any solder bumps arising at the thermal vias should be avoided.
To minimize package size down to 4mm  4mm, pins are only on three sides of the package.
ATA6832-DK [APPLICATION NOTE]
4987C–AUTO–02/15
5
4.
The Application Board
The application board is run capable when connected to 12V at connector LIN (see Figure 4-1 on page 7). The board can be
connected to the automotive environment over a LIN bus by a LIN clamp; however, there is no LIN protocol implemented in
the microcontroller. The ATA6625 on this application board is used to generate a 5V digital supply.
A switch (DIR) for run/stop, clockwise, counterclockwise, and a potentiometer (SPEED) for variable speed (PWM) input are
available on the board for stand-alone prototyping.
The feedback loop from BLDC motor to microcontroller ATmega88 is done by hall sensors. The three hall inputs can be
linked to the connector HALL as well as the 5V supply for the hall sensors
4.1
On-board Features
The application board provides the following features:
● ATmega88 QFN32
●
ATA6832 QFN
●
ATA6625 SO8
●
Integrated triple half bridges to drive BLDC motor and check its operations
●
1 x LIN interface 1.3 and 2.0 compliant
●
5V power supply regulator
●
Up to 125°C (Using an ATA6624 with an external transistor would allow up to 150°C operation)
●
On-Off-On switch
●
Potentiometer
●
System clock
●
Connectors
●
●
●
●
Note:
6
MCU
●
Stand-alone commands interface: Run/stop, clockwise, and counterclockwise.
Stand-alone speed variation command (PWM ratio)
Internal RC oscillator
●
Power supply (battery voltage) and LIN
●
BLDC Motor connector (3 phase)
●
Hall sensor inputs and supply (3 filtered inputs and 5V regulated supply voltage)
●
ISP/debugWire connector, for on-chip in-situ Programming (ISP) and for on-chip debugging using JTAG ICE
supported by AVR Studio® interface(1)
Dimensions: 45 mm  45 mm
1.
The ATmega88 is supported by AVR Studio, version 4.12 or higher. For up-to-date information on this and
other AVR® tool products, please consult our web site. The newest version of AVR Studio, AVR tools and this
user guide can be found in the AVR section of the Atmel web site, http://www.atmel.com
ATA6832-DK [APPLICATION NOTE]
4987C–AUTO–02/15
Figure 4-1. Application Board Top View and Connector Usage
Vbat
LIN
PGND
Phase U
Phase V
Speed
Phase W
5V
Hall A
CCW
Hall B
Stop
CW
JP1
Hall C
GND
MISO
SCK
NRES
1
3
5
VCC 5V
2
4
6
MOSI
GND
ISP MK2 Header
4.2
High Ambient Temperature
The BLDC system is designed for high temperature environments. The MCU ATmega88 and the driver ATA6832 are
qualified up to an ambient temperature of 150°C. The ATA6832 has enhanced temperature management; each of its output
stages contains a thermal sensor. In addition to the thermal shutdown function, a thermal prewarning function is available. If
the temperature exceeds the prewarning threshold, the microcontroller can react by reducing output power.
The SBC (system basis chip) ATA6625 is only qualified for junction temperatures up to 150°C. The power dissipation of its
voltage regulator only allows for ambient temperature up to 125°C. ATA6624, a member of the same SBC family, allows
operation with a discrete transistor for line regulation. Transistors are available for junction temperatures higher than 150°C.
If such a line regulation transistor dissipates the heat, ATA6624’s temperature rise is only 3°C. Its possible ambient
temperature is 147°C. Using a high temperature voltage regulator instead of Atmel’s SBC enables a full 150°C temperature
range.
All discrete components used are enabled for temperatures up to 150°C.
Mounted connectors, a switch, and a potentiometer on the board, enable prototyping; however, these components are not
high temperature qualified. The board can be integrated in hot temperature environment by wires.
ATA6832-DK [APPLICATION NOTE]
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7
5.
Software Description
All code is implemented in C language, except SPI interrupt subroutine, which is implemented in assembly. Source code can
be compiled using IAR® EWAVR 4.20A as well as AVR-GCC (WinAVR-20060421 with AVR Studio).
HTML documentation is included in the package. Use the High_temp_BLDC.html file in the root directory to start viewing the
documentation.
Software behavior can be dispatched in three main working modes:
● Motor stopped
●
●
5.1
●
In this mode, no hall sensors interrupts occurs. To maintain ATA6832 diagnostics, SPI communication is
constantly performed by main loop.
●
Command switch enables starting of the motor. A first frame has to be sent to the power driver to start the
motor. This frame shall contain commutations to be applied according to motor position (hall sensors inputs)
and to desired direction.
●
While stopped, ATA6832 is switched into standby mode to decrease current consumption to lower than 20µA.
Motor running
●
Once the motor is started, SPI communications (commutations), are only handled by hall sensors ISR, each
time an interrupt occurs.
●
Command switch can be used to break the commutations evolution, and thus stop the motor.
Degraded mode: two possibilities
●
Motor has been stopped because of an overload, an over temperature, etc. Software waits for the user to clear
the fault (operate switch to stop position).
●
Motor is still running (software behavior is similar to the motor running mode). User is informed that a fault has
been detected (over temperature, one or more switches are secured, etc.). Software can reduce output power
and waits for a user order to clear the fault (operate switch to stop position).
Resources
Table 5-1.
Code, Data, and CPU Resources (Without Compiler Optimizations)
Compiler/Resources
Code Size (Flash)
Data Size (Ram)
IAR EWAVR 4.20A
1 304bytes
367bytes
AVR-GCC
1 826bytes
48bytes
The following MCU peripherals are used:
● SPI
●
Timer 1
●
ADC channel 0
●
Pin change interrupts
●
I/O
●
Optional (not managed by this stand-alone software)
●
●
●
●
●
8
Commutation data and status data transfer to/from ATA6832 power driver
●
PWM generation through Output Compare 1A (OC1A pin)
Speed potentiometer value acquisition (Acts on PWM ratio)
Hall sensor edges detection are used to detect motor position evolution
LED, Switch operations
UART and Input Capture for LIN implementation
ATA6832-DK [APPLICATION NOTE]
4987C–AUTO–02/15
CPU Load
See §Schedule
Schedule
Figure 5-1. Software Schedule
Hall Sensor ISR
Next Commutation
SPI
1st Commutation Data Tx
Main Loop (Background)
Motor Stopped
Motor Startup
Motor Running
Motor Start Order
CPU load while motor is running
● Using IAR EWAVR 4.20A
The main loop is continually executed in background. It could be scheduled. Main loop measured time cycle is 21µs.
For each output commutation, one hall interrupt and two SPI interrupts occur. This makes for one commutation:
CPU time = Hall ISR time + Both SPI ISR time = 8.4µs + 4.8µs = 13.2µs/commutation.
●
Using AVR-GCC
The main loop is continually executed in background. It could be scheduled. The main loop measured time cycle is 30µs.
For each output commutation, one hall interrupt and two SPI interrupts occur. This makes for one commutation:
CPU time = Hall ISR time + Both SPI ISR time = 16µs + 4.8µs = 20.8µs / commutation.
The main loop is not taken into account for CPU load computation below, as it is not scheduled and executed in background.
Assuming we have 6 interrupts for a complete motor rotation and a 4-pair pole motor, we can determine the following CPU
load versus rotation speed.
Figure 5-2. CPU Load versus Speed for an 8 Pole Motor
8
7
6
% CPL
5.2
5
CPU Avr GCC
4
CPU IAR
3
2
1
0
0
2000
4000
6000
8000
10000
12000
RPM (Rotation Per Minute)
ATA6832-DK [APPLICATION NOTE]
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9
5.3
Diagrams
Figure 5-3. Flowchart for Hall Sensors ISR
Pin Change Interrupt
(Hall Sensor ISR)
Read Hall Sensor Signals from Port C
Y
Stop?
N
Select Next Commutation
State from CW Sequence
Y
Clockwise
Rotation?
N
Select Next Commutation
State from CCW Sequence
Transmit Commutation Data on SPI
Figure 5-4. Flowchart for SPI Transfer Completed ISR
SPI Transmit
Completed ISR
Read Rx Buffer
Store to ATA6832 Status
Release Slave Select Pin
Report Transmit Completed
10
ATA6832-DK [APPLICATION NOTE]
4987C–AUTO–02/15
Y
Both Command
Bytes (16 bits) Sent?
N
Read Rx Buffer
Store to ATA6832 Status
Write Tx Buffer
Report One Byte Transferred
Figure 5-5. Main Loop Flowchart
Main Loop
(Background)
Initialize I/O, SPI, ADC, Hall Sensors ISR, Timer1-PWM, ATA6832
Refresh ATA6832 Status Buffer
Set PWM Ratio According to ADC
Manage Motor
Status
Stopped?
Start?
Y
Send Commutation Command
According to Position and Direction
N
Send SPI to ATA6832 Continuously
Started CW?
Stop?
Started CCW?
Stop?
Over Temperature?
Overload ?
Under Voltage ?
Y
Motor Status Stopped
Y
Motor Status Stopped
Y
Toggle LED
N
Over Temperature ?
Set LED
Y
Limit Output Power
Reset ATA6832
Y
Stop?
ATA6832-DK [APPLICATION NOTE]
4987C–AUTO–02/15
11
5.4
Modules
void SPI_MasterInit(void)
Initializes SPI used to access ATA6832, configures I/O, 2MHz frequency, data sample at clock falling edge,
LSB first.
SPI_status_t SPI_transmit_16(unsigned int data_16)
Sends 16 bit data on SPI (using interrupts), depending on returned SPI status. Returns SPI_Initiate_tx status if
successful.
SPI_status_t SPI_get_Rx_data(unsigned int *data_16_ptr)
Puts the SPI received data into pointed buffer when data has been received. In that case it returns
SPI_Completed status and changes SPI status to ready.
void ADC_Init(void)
Sets up ADC to acquire desired speed from potentiometer.
unsigned int get_speed()
Returns last acquired desired speed from potentiometer. Checks ADC end conversion flag to start new conversions and update latest desired speed.
void Hall_sensors_ISR_init(void)
Sets up pin change interrupts on hall sensor inputs.
Motor_ctrl_t BLDC_start(unsigned char direction)
Sends first commutation order to start motor according to desired direction and to hall sensors inputs. Returns
started status when SPI frame has been emitted.
void Timer1_start(void)
Configures timer 1 for PWM on Output compare 1 A.
void manage_time_base(void)
Manages a general purpose time base (for LED toggling, etc.).
TIMER1_SET_OC1A_PWM(val)
Changes PWM ratio (macro).
12
ATA6832-DK [APPLICATION NOTE]
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1
ATA6832-DK [APPLICATION NOTE]
4987C–AUTO–02/15
AGND
2
4
6
1
3
5
GND
MOSI
VCC
5V
SWITCH_CW
SWITCH_CCW
ISP MK2 Header
NRES
SCK
MISO
JP1
DIR
220pF
C11
PGND
GND
Speed Set
0Ω
R3
0Ω
R2
PGND
LIN
ON/OFF/ON Switch
Right Angle
GND
GND
100kΩ
VCC
5V
GND
PGND
LIN
3
GND GND
100nF
C9
VCC
5V
8
7
6
5
4
3
SWITCH_CW 2
SWITCH_CCW 1
PGND
10μF
50V
10μF
50V
GND
4.7μF
10V
C3
R1
10kΩ
VCC
5V
LIN_RXD
LIN_TXD
NRES
6
PWM
330Ω
R4
LED CMS Green
D2
PB7(TOSC2/XTAL2/PCINT7)
PB6(TOSC1/XTAL1/PCINT6)
VCC
GND
VCC
GND
PB5(SCK/PCINT5)
AVCC
ADC6
AREF
GND
ADC7
PC0(ADC0/PCINT8)
3
SPI_SS
PD4(T0/XCK/PCINT20)
7
PWM
CS
DO
CLK
DI
VCC
5V
17 SCK
18
19
20
21
22
VBat
3 Half
Bridge
AGND
1
2
13
12
16
1nF
C12
Hall_C
Hall_B
Hall_A
VCC
5V
HallC
HallB
HallA
1nF
C14
R7
4.7kΩ
GND
1nF
C13
R6
4.7kΩ
VCC
5V
GND
100nF
C7
PH_C
PH_B
PH_A
PGND
C2
100nF
50V
VBat
15
R5
4.7kΩ
OUT3S
OUT3
OUT2S
OUT2
OUT1S
OUT1
U2
ATA6832
AGND AGND
100 nF
C10
PGND
C8
100nF
VCC
5V
23 Speed Set
24
5
SCK
4
MISO
MOSI
GND
PC1(ADC1/PCINT9)
5
6
7
C1
100nF
VCC
5V
PD3(INT1/OC2B/PCINT19)
100nF
50V
RXD
LIN
C4
TXD
NRES
GND
LIN_EN
C6
4
3
2
C5
VBat
VCC
5V
GND
LIN
LIN_EN
8
9
PD5(T1/OC0B/PCINT21)
10
PD6(AIN0/OC0A/PCINT22)
11
2
LIN Transceiver
VREG
VS
VCC5
12
LIN_RXD
1
LIN_EN
13
PWM
D1
30BQ040
VCC
5V
LIN_TXD
32
ATA6625
LIN_RXD
31
PD2(INT0/PCINT18)
NRES
PD1(TXD/PCINT17)
30
PC6(RESET/PCINT14)
14
SPI_SS
9
VCC
U1
PB1(OC1A/PCINT1)
15
MOSI
VBat
PB2(OC1B/SS/PCINT2)
29
PD0(RXD/PCINT16)
PD7(AIN1/PCINT23)
HALL_C
PB3(MOSI/OC2A1/PCINT3)
28
PB0(ICP1/CLKO/PCINT0)
HALL_B
27
PC5(ADC5/SCL/PCINT13)
HALL_A
PC3(ADC3/PCINT11)
26
PC4(ADC4/SDA/PCINT12)
25
PC2(ADC2/PCINT10)
PB4(MISO/PCINT4)
16
MISO
17
PGND1
14
GND
8
10
VS1
PGND2
11
VS2
PGND3
18
MOT
100Ω
R10
100Ω
R9
100Ω
R8
1
2
1
2
1
2
1
2
HallC
HallB
HallA
B4
HALL
B2
6.
Application Board Full Description
Figure 6-1. BLDC Application Board Schematic
13
Figure 6-2. BLDC Application Board Top View and Component Placement
Figure 6-3. BLDC Application Board Bottom View
14
ATA6832-DK [APPLICATION NOTE]
4987C–AUTO–02/15
Table 6-1.
BLDC Application Board Connectors
Connector
LIN
MOT
B2
HALL
B4
Clamp
Function
Direction
1
Power ground
Input
2
LIN input
Input
3
Power 12V
Input
1
Motor phase A
Output
2
Motor phase B
Output
1
Motor phase C
Output
2
Power 5V
Output
1
Hall A
Input
2
Hall B
Input
1
Hall C
Input
2
Power GND
Output
ATA6832-DK [APPLICATION NOTE]
4987C–AUTO–02/15
15
7.
Revision History
Please note that the following page numbers referred to in this section refer to the specific revision mentioned, not to this
document.
16
Revision No.
History
4987C-AUTO-02/15
Put document in the latest template
ATA6832-DK [APPLICATION NOTE]
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XXXXXX
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consent. Safety-Critical Applications include, without limitation, life support devices and systems, equipment or systems for the operation of nuclear facilities and weapons systems.
Atmel products are not designed nor intended for use in military or aerospace applications or environments unless specifically designated by Atmel as military-grade. Atmel products are
not designed nor intended for use in automotive applications unless specifically designated by Atmel as automotive-grade.