ETC DRM019

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3-Phase AC Induction
Motor Drive with
Dead Time Distortion
Correction Using the
MC68HC908MR32
Designer Reference
Manual
M68HC08
Microcontrollers
DRM019/D
Rev. 0, 03/2003
MOTOROLA.COM/SEMICONDUCTORS
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3-Phase AC Induction Motor
Drive with Dead Time
Distortion Correction
Reference Design
Designer Reference Manual — Rev 0
by:
Radim Visinka, Ph.D.
Motorola Czech Systems Laboratories
Roznov pod Radhostem, Czech Republic
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Designer Reference Manual
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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://www.motorola.com/semiconductors
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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.
Revision history
Date
Revision
Level
January
2003
1
Description
Initial version
Designer Reference Manual
Page
Number(s)
N/A
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Designer Reference Manual — 3-ph. ACIM Drive with DTC
List of Sections
Section 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Section 2. System Description. . . . . . . . . . . . . . . . . . . . . 15
Section 3. Hardware Design. . . . . . . . . . . . . . . . . . . . . . . 27
Section 4. Software Design . . . . . . . . . . . . . . . . . . . . . . . 37
Section 5. System Setup . . . . . . . . . . . . . . . . . . . . . . . . . 49
Appendix A. References. . . . . . . . . . . . . . . . . . . . . . . . . . 61
Appendix B. Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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List of Sections
Designer Reference Manual
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Designer Reference Manual — 3-ph. ACIM Drive with DTC
Table of Contents
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Section 1. Introduction
1.1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.2
Application Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3
Benefits of the Solution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section 2. System Description
2.1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.2
System Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3
Dead Time Distortion Correction . . . . . . . . . . . . . . . . . . . . . . . 18
Section 3. Hardware Design
3.1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.2
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3
MC68HC908MR32 Control Board . . . . . . . . . . . . . . . . . . . . . . 29
3.4
3-Phase AC BLDC High Voltage Power Stage. . . . . . . . . . . . . 31
3.5
Optoisolation Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.6
Motor-Brake Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .35
3.7
Hardware Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Section 4. Software Design
4.1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
4.2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3
Data Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Table of Contents
4.4
Algorithm of Dead Time Distortion Correction . . . . . . . . . . . . . 43
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Section 5. System Setup
5.1
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.2
Hardware Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.4
Jumper Settings of Controller Board. . . . . . . . . . . . . . . . . . . . .51
5.5
Required Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.6
Building the Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.7
Executing the Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.8
Controlling the Application with PC Master Software . . . . . . . . 57
Appendix A. References
Appendix B. Glossary
Designer Reference Manual
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Designer Reference Manual — 3-ph. ACIM Drive with DTC
List of Figures
Figure
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2-1
2-2
2-3
2-4
2-5
3-1
3-2
3-3
4-1
4-2
4-3
4-4
5-1
5-2
5-3
5-4
5-5
5-6
Title
Page
System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Volt per Hertz Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Dead Time Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Topology of Current Polarity Sensing . . . . . . . . . . . . . . . . . . . . 21
Proposed Current Threshold for Correction Toggling. . . . . . . . 24
Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
MC68HC908MR32 Control Board . . . . . . . . . . . . . . . . . . . . . . 30
3-Phase AC High Voltage Power Stage . . . . . . . . . . . . . . . . . . 32
Data Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3-Phase Sine Waves with Amplitude of 50% . . . . . . . . . . . . . . 40
mcgen3PhWaveSine Data Explanation - Phase A . . . . . . . . . . 41
Dead Time Correction State Machine. . . . . . . . . . . . . . . . . . . . 45
Setup of the Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
MC68HC908MR32 Jumper Reference. . . . . . . . . . . . . . . . . . . 52
Execute Make Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Control Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
USER LEDs, PWM LEDs, and RESET . . . . . . . . . . . . . . . . . . 55
PC Master Software Control Window . . . . . . . . . . . . . . . . . . . . 58
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List of Figures
Designer Reference Manual
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Designer Reference Manual — 3-ph. ACIM Drive with DTC
List of Tables
Table
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2-1
2-2
2-3
3-1
3-2
3-3
3-4
4-1
4-2
4-3
5-1
5-2
5-3
Title
Page
PWM values loaded into registers PVAL1-6 . . . . . . . . . . . . . . 22
PWM Prescaler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sensing of the Current Polarity and Magnitude for Ph. 1 . . . . 25
Electrical Characteristics of Control Board . . . . . . . . . . . . . . . 30
Electrical Characteristics of Power Stage . . . . . . . . . . . . . . . . 33
Electrical Characteristics of Optoisolation Board. . . . . . . . . . . 34
Motor - Brake Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 35
State Machine Flag Registers dtStateFlagsAB . . . . . . . . . . . . 46
State Machine Flag Registers dtStateFlagsC . . . . . . . . . . . . . 46
dtCorrect_s Structure Elements. . . . . . . . . . . . . . . . . . . . . . . . 47
MC68HC908MR32EVM Jumper Settings . . . . . . . . . . . . . . . . 52
Motor Application States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Dead Time Distortion Correction . . . . . . . . . . . . . . . . . . . . . . . 57
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List of Tables
Designer Reference Manual
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Designer Reference Manual — 3-ph. ACIM Drive with DTC
Section 1. Introduction
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1.1 Contents
1.2
Application Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3
Benefits of the Solution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Application Functionality
This Reference Design describes the design of a 3-phase AC induction
motor drive with dead time distortion correction. It is based on Motorola’s
MC68HC908MR32 microcontroller which is dedicated for motor control
applications. The system is designed as a motor drive system for
medium power three-phase AC induction motors and is targeted for
applications in both industrial and appliance fields (e.g. washing
machines, compressors, air conditioning units, pumps or simple
industrial drives). The reference design incorporates both hardware and
software parts of the system including hardware schematics with a bill of
material, and a software listing.
1.3 Benefits of the Solution
The design of very low cost variable speed 3-phase motor AC control
drives has become a prime focus point for the appliance designers and
semiconductor suppliers. Replacing variable speed universal motors by
maintenance-free, low noise asynchronous (induction) motors is a trend
that supposes total system costs being equivalent.
Six-transistor inverter is the most used topology for AC motor drives. The
dead time must be inserted between the turning off of one transistor in
the inverter half bridge and turning on of the complementary transistor.
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Introduction
The dead time causes distortion to the generated voltage, and thus a
non-sinusoidal phase current.
This distortion causes distortion of the motor performance. It is
especially apparent in low speeds, when the dead time is comparable
with the PWM pulse width. Also, the longer the dead time, the higher the
influence it has over the motor performance.
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Dead time distortion can be corrected by properly modulating the power
stage control signals. The advantages of dead time distortion correction
are:
•
Smoother running motors
•
Less torque ripple
•
Quieter motors
•
More efficient operation (less harmonic losses).
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Introduction
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Designer Reference Manual — 3-ph. ACIM Drive with DTC
Section 2. System Description
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2.1 Contents
2.2
System Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3
Dead Time Distortion Correction . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 System Concept
The application is designed to drive a 3-phase AC motor in an open
speed loop mode with dead time distortion correction (see Figure 2-1).
The desired speed is set-up in the user interface. The desired frequency
and amplitude of the motor voltage sine wave is calculated according to
the desired speed using Volt-per-Hertz table. The sine wave generator
generates the PWM values for all three phases of the AC bridge inverter
according to the selected type of dead time distortion correction
algorithm.
The system incorporates the following hardware blocks:
•
power supply rectifier,
•
three-phase inverter including optoisolation,
•
feedback sensors: DC-Bus voltage, DC-Bus current, temperature,
polarity of phase currents,
•
microcontroller MC68HC908MR32.
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System Description
3-phase AC Power Stage
Line AC
AC
ACM
DC
DC Bus Voltage
DC Bus Current
Temperature
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MC68HC908MR32
PWM’s
V/Hz
Ramp
Req.
Speed
DOWN
Speed
Ramp
LOAD
I sense
Fault Protection
START
STOP
Polarity of
Phase
Currents
Desired Sine
Frequency
Dead
Time
Correction
State
Machine
Sine PWM
Generation
Desired
Speed
Desired Sine
Amplitude
Dead Time
Correction
- Disabled
- Partial
- Full
Desired
Correction
of PWM’s
UP
PC Control
SCI
Figure 2-1. System Block Diagram
The drive is designed as a “Volt-per-Hertz“ drive. It means that the
control algorithm keeps constant magnetizing current (flux) of the motor
by varying the stator voltage with frequency. The commonly used
Volt-per-Hertz ramp of a 3-phase AC induction motor illustrates
Figure 2-2.
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System Description
System Concept
Phase
Voltage
Base
Point
100%
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Boost
Voltage
Boost
Frequency
Base
Frequency
Frequency (rpm)
Figure 2-2. Volt per Hertz Ramp
The Volt per Hertz ramp is defined by following parameters:
•
Base Point - defined by Base Frequency (usually 50Hz or 60Hz)
•
Boost - Defined by Boost Voltage and Boost Frequency
The ramp profile is set to the specific motor and can be easily changed
to accommodate different ones.
The dead time distortion correction algorithms provide a correction of the
PWM values with respect to the actual polarity of the phase currents.
The current polarity is evaluated by sensing the phase voltage during the
dead time and is carried out by the on-chip circuitry of the 908MR32
microcontroller. Two types of dead time distortion correction algorithms
are implemented - partial, and full correction. The partial correction
algorithm detects just the current polarity and the correction is done
almost entirely by the on-chip PWM hardware. On the other hand, the full
correction algorithm also detects the magnitude of the phase currents
(low/high), and implements advanced s/w which improves the correction
results. The user has the choice of selecting either of the correction
algorithms. The type of dead time distortion correction is indicated by a
yellow LED on 908MR32 controller board.
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System Description
The PWM frequency can be changed at any time during the motor
operation to one of the following values:
– 4kHz
– 8kHz
– 16kHz
– 32kHz
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The drive incorporates fault protection, so in the case of DC-Bus
over-current, DC-Bus over-voltage, or DC-Bus under-voltage faults,
internal fault logic is asserted and the application enters a fault state.
This state can be exited only if the fault disappears and it is
acknowledged, by toggling the START/STOP switch through the STOP
state. The application states are displayed by green LED on 908MR32
control board.
The application can operate in two modes:
1. Manual Operating Mode
The drive is controlled by the START/STOP switch. The direction
of the motor rotation is set by the FWD/REV switch. The motor
speed is set by the SPEED potentiometer.
2. PC Master Software (Remote) Operating Mode
The drive is controlled remotely from a PC through the serial
communications interface (SCI) communication channel of the
MCU device via an RS-232 physical interface. The drive is
enabled by the START/STOP switch, which can be used to safely
stop the application at any time.
2.3 Dead Time Distortion Correction
Six-transistor inverter is the most used topology for AC motor drives. The
dead time must be inserted between the turning off of one transistor in
the inverter half bridge and turning on of the complementary transistor.
The dead time causes distortion to the generated voltage, and thus a
non-sinusoidal phase current.
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System Description
Dead Time Distortion Correction
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In order to achieve a sinusoidal phase current, and thus limit the
harmonic losses, noise, and torque ripple, the dead time distortion
correction needs to be implemented. The on-chip
Pulse-Width-Modulation (PWM) module, of the MC68HC908MRxx
family of Motorola microcontrollers, contains the patented hardware
block that simplifies the task.
The dead time correction is based on the evaluation of the phase current
polarity of the respective phase, and proper counter-modulation of the
dead-time distortion. The basic situation is shown in Figure 2-3. The
desired load voltage is affected by the dead time. During dead time, load
inductance defines the voltage needed to keep inductive current flowing
through diodes. So full positive or full negative voltage is applied to the
phase, according to the phase current polarity. For positive current (i+),
the actual voltage pulses are shortened by dead time, for negative phase
current the voltage pulses are lengthened by dead time.
TON
Desired load voltage
+U/2
deadtime
PWM to top transistor
i+
iPWM to bottom transistor
TON - 2×deadtime
Actual load voltage (for i+)
- U/2
TON + 2×deadtime
Actual load voltage (for i-)
Dave Wilson
Figure 2-3. Dead Time Distortion
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System Description
To achieve distortion correction, one of two different correction factors
must be added to the desired PWM value, depending on whether the top
or bottom transistor is controlling the output voltage during the dead
time.
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When the voltage pulse is shortened due to dead time, the control PWM
signal is extended by dead time, so the actual voltage pulse matches the
desired voltage. Vice versa, when the voltage pulse is lenghtened due to
dead time, the control PWM signal is shortened by dead time, so again
the actual voltage pulse matches the desired voltage. Therefore the
actual signal equals the desired one, and the generated phase current
is sinusoidal.
The dead time distortion correction utilizes phase current sensing. The
on-chip PWM module of MC68HC908MRxx microcontrollers contains
the block that enables them to evaluate the polarity and the size of the
phase current without the need of an expensive current sensor. It is
based on the sampling and evaluation of the phase voltage level during
the dead time. The zero voltage during dead time reflects a positive
phase current, the full DC-Bus voltage during dead time reflects a
negative phase current. So comparing the phase voltage with the half
DC-Bus voltage enables an evaluation of the current polarity. The
topology is illustrated in Figure 2-4. The output of the comparator is
connected to the current polarity sensing input of the MC68HC908MR32
microcontroller. The microcontroller contains the hardware that samples
the current sensing inputs during dead time. It enables evaluation of the
current polarity and also the region of low currents.
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System Description
Dead Time Distortion Correction
+U
+U
÷2
+
-
i+
PWM0
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ISx
iPWM1
Figure 2-4. Topology of Current Polarity Sensing
During PWM reload ISR, the desired PWM values for all three phases
are calculated as:
•
PWM1 for phase 1
•
PWM2 for phase 2
•
PWM3 for phase 3
The values loaded into the individual PVAL registers of the separate
phases are shown in Table 2-1. Since AC motor control utilizes
center-aligned PWM modulation, only half of the dead time needs to be
added to / substracted from the desired PWM duty cycle to achieve the
distortion correction. Without dead time correction, the even PVAL
registers are loaded with the required PWM value, but the odd PVAL
registers are not used. When dead time correction is used, the even
PVAL registers are loaded with the desired PWM plus half of the dead
time (PWMx+DT/2), while the odd PVAL registers are loaded with the
desired PWM minus half of the dead time (PWMx-DT/2).
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System Description
Table 2-1. PWM values loaded into registers PVAL1-6
Phase
Phase
1
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Phase
2
Phase
3
Required values in
PVAL without dead
time correction
PVAL
register
Required values in
PVAL with dead time
correction
PVAL1
PWM1
PWM1 + DT/2
PVAL2
-
PWM1 - DT/2
PVAL3
PWM2
PWM2 + DT/2
PVAL4
-
PWM2 - DT/2
PVAL5
PWM3
PWM3 + DT/2
PVAL6
-
PWM3 - DT/2
Actual values loaded into
PVAL registers
PWM1 +
DEADTM/2/PWM_PRESC
PWM1 DEADTM/2/PWM_PRESC
PWM2 +
DEADTM/2/PWM_PRESC
PWM2 DEADTM/2/PWM_PRESC
PWM3 +
DEADTM/2/PWM_PRESC
PWM3 DEADTM/2/PWM_PRESC
When calculating the values to be loaded into the PVAL registers, the
MRxx’s Dead Time register can be used.
The dead-time register (DEADTM) holds an 8-bit value which specifies
the number of CPU clock cycles to be used for the dead-time, when
complementary PWM mode is selected. Dead-time is not affected by
changes to the prescaler value. On the other hand, the PVAL values are
affected by the prescaler of the PWM counter.
Therefore the value stored into the dead time register needs to be
scalled by the PWM prescaler (PWM_PRESC in Table 2-1). The PWM
Control Register 2 (PCTL2) contains the PWM generator prescaler. The
buffered read/write bits, PRSC0 and PRSC1, select the PWM prescaler
according to Table 2-2.
Table 2-2. PWM Prescaler
Prescaler bits PRSC0
and PRSC1
00
PWM Frequency
Prescaler PWM_PRESC
fOP
1
01
fOP/2
2
10
fOP/4
4
11
fOP/8
8
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System Description
Dead Time Distortion Correction
The on-chip PWM module of MC68HC908MRxx microcontrollers
enables them to perform two types of dead time distortion correction:
•
Partial correction
•
Full correction
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Partial dead time distortion correction is based only on polarity
detection of phase current. The hardware, sensing the current polarity
according to Figure 2-4, needs to be implemented. The software is
responsible for calculating both compensated PWM values and placing
them in an odd/even PWM register pair according to Table 2-1. The
distortion correction is fully implemented by the on-chip PWM module
according to the following scheme:
•
If the current sensed at the motor for that PWM pair is positive
(voltage on current pin ISx is low), the odd PWM value is used
for the PWM pair.
•
Likewise, if the current sensed at the motor for that PWM pair is
negative (voltage on current pin ISx is high), the even PWM
value is used.
For partial correction, the on-chip dead time correction block is set in the
automated mode - current sense correction bits ISENS1:ISENS0 of
PWM Control Register 0 (PCTL1) are set to 10).
The disadvantage of the partial correction is that some dead time
distortion still exist - the current is flattened out at the zero crossings.
Full dead time distortion correction (implemented in dtCorrectFull
algorithm) improves the partial dead time correction by sensing not only
the polarity, but also the magnitude of the actual phase current.
In the full dead time correction method, the threshold, where the
correction values should be toggled is not in the zero level, but slightly
advanced. The threshold is illustrated in Figure 2-5. Toggling of the
correction offset needs to occur before the current has a chance to
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flatten out at a current zero-crossing. So, the current sense scheme
must sense that the current waveform is approaching the zero-crossing.
Current with Correction Disabled
High Positive
Magnitude
Freescale Semiconductor, Inc...
Falling threshold
Low Magnitude
High Negative
Magnitude
Rising threshold
Dave Wilson
Figure 2-5. Proposed Current Threshold for Correction Toggling
To achieve the full distortion correction, again one of two different
correction factors must be added to the desired PWM value, depending
on whether the top or bottom transistor is controlling the output voltage
during the dead time. The software is responsible for calculating both
compensated PWM values and placing them in an odd/even PWM
register pair. Then the s/w needs to determine which PWM value is to be
used, according to the following scheme:
•
If the current sensed at the motor for that PWM pair is positive
and of high magnitude, or negative and of small magnitude in
a trend approaching zero crossing, the odd PWM value is
used for the PWM pair.
•
Likewise, if the current sensed at the motor for that PWM pair is
negative, or positive and of small magnitude in a trend
approaching zero crossing, the even PWM value is used.
The MR32 contains a hardware circuitry that enables it to sense the
current polarity together with the magnitude. The current polarity and
magnitude is sensed using the DT-DT6 of FTACK register in ’908MR32
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System Description
Dead Time Distortion Correction
microcontroller. For Phase 1, the bits DT1 and DT2 are used as shown
in Table 2-3.
Table 2-3. Sensing of the Current Polarity and Magnitude for Ph. 1
DT1
0
1
0
DT2
0
1
1
Current Condition of Phase 1
high magnitude I+
high magnitude Ilow magnitude, either polarity
Freescale Semiconductor, Inc...
For phase 2, bits DT3 and DT4 are used. For phase 3, bits DT5 and DT6
are used.
As was stated the determination of the correct PVAL used for the PWM
generation is done purely by software. The on-chip dead time correction
block is set in the manual mode - current sense correction bits
ISENS1:ISENS0 of PWM Control Register 0 (PCTL1) are set to 00 or 01.
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System Description
Designer Reference Manual
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Freescale Semiconductor, Inc.
Designer Reference Manual — 3-ph. ACIM Drive with DTC
Section 3. Hardware Design
Freescale Semiconductor, Inc...
3.1 Contents
3.2
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3
MC68HC908MR32 Control Board . . . . . . . . . . . . . . . . . . . . . . 29
3.4
3-Phase AC BLDC High Voltage Power Stage. . . . . . . . . . . . . 31
3.5
Optoisolation Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.6
Motor-Brake Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .35
3.7
Hardware Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2 System Configuration
The application is designed to drive the 3-phase AC motor. It consists of
the following modules (see Figure 3-1):
•
MC68HC908MR32 Control Board
•
3-phase AC/BLDC High Voltage Power Stage
•
Optoisolation Board
•
3-phase AC Induction Motor
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100 - 240VAC
49 - 61 Hz
PE
N
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AM40V
Not Connected
MB1
SG40N
Not Connected
J5
J14
U3
ECOPT
Optoisolation
Board
JP1.1 JP1.2
ECMTRHIVAC
ECOPTHIVACBLDC
J1
40w flat ribbon
cable
GND
Motor-Brake
3ph AC/BLDC
High Voltage
Power Stage
J13.1 J13.2 J13.3
J11.1
J11.2
White
L
Red
U2
Black
28
Red
White
Black
+12VDC
J2
J1
40w flat ribbon
cable
Freescale Semiconductor, Inc...
MC68HC908MR32
Controller Board
U1
Freescale Semiconductor, Inc.
Hardware Design
Figure 3-1. Hardware Configuration
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Hardware Design
MC68HC908MR32 Control Board
3.3 MC68HC908MR32 Control Board
Freescale Semiconductor, Inc...
Motorola’s embedded motion control series MR32 motor control board is
designed to provide control signals for 3-phase AC induction, 3-phase
brushless DC (BLDC), and 3-phase switched reluctance (SR) motors. In
combination with one of the embedded motion control series power
stages, and an optoisolation board, it provides a software development
platform that allows algorithms to be written and tested without the need
to design and build hardware. With software supplied on the CD-ROM,
the control board supports a wide variety of algorithms for AC induction,
SR, and BLDC motors. User control inputs are accepted from
START/STOP, FWD/REV switches, and a SPEED potentiometer
located on the control board. Alternately, motor commands can be
entered via a PC and transmitted over a serial cable to DB-9 connector.
Output connections and power stage feedback signals are grouped
together on 40-pin ribbon cable connector. Motor feedback signals can
be connected to Hall sensor/encoder connector. Power is supplied
through the 40-pin ribbon cable from the optoisolation board or
low-voltage power stage.
The control board is designed to run in two configurations. It can be
connected to an M68EM08MR32 emulator via an M68CBL08A
impedance matched ribbon cable, or it can operate using the daughter
board. The M68EM08MR32 emulator board may be used in either an
MMDS05/08 or MMEVS05/08 emulation system.
Figure 3-2 shows a block diagram of the board’s circuitry.
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SPEED
POT
HALL EFFECT
INPUTS (3)
Freescale Semiconductor, Inc...
EMULATOR/
PROCESSOR
CONNECTOR
dc POWER
12 Vdc
TACHOMETER
INPUT
START/STOP
SWITCH
REGULATED
POWER SUPPLY
RESET
SWITCH
CONFIG.
JUMPERS
TERMINAL
I/F
FORWARD/REVERSE
SWITCH
OPTOISOLATED
RS-232 I/F
(2) OPTION
SWITCHES
PWM LEDs (6)
OPTO/POWER DRIVER I/O CONNECTOR
OVERCURRENT/
OVERVOLTAGE
INPUTS
BACK EMF
INPUTS
CURRENT/TEMP
SENSE INPUTS
40-PIN RIBBON
CONNECTOR
MISC. POWER AND
CONTROL I/O
PWM (6)
OUTPUTS
Figure 3-2. MC68HC908MR32 Control Board
The electrical characteristics in Table 3-1 apply to operation at 25°C.
Table 3-1. Electrical Characteristics of Control Board
Characteristics
Symbol
Min
Typ
Max
Units
DC power supply voltage
Vdc
10.8*
12*
16.5*
V
Quiescent current
ICC
—
80
—
mA
Min logic 1 input voltage
(MR32)
VIH
2.0
—
—
V
Max logic 0 input voltage
(MR32)
VIL
—
—
0.8
V
Propagation delay
(Hall sensor/encoder input)
tdly
—
—
500
ns
Analog input range
VIn
0
—
5.0
V
—
—
9600
Baud
—
—
20
mA
RS-232 connection speed
PWM sink current
IPK
* When operated and powered separately from other Embedded Motion Control tool set products
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Hardware Design
3-Phase AC BLDC High Voltage Power Stage
3.4 3-Phase AC BLDC High Voltage Power Stage
Freescale Semiconductor, Inc...
Motorola’s embedded motion control series high-voltage (HV) AC power
stage is a 180-watt (one-fourth horsepower), 3-phase power stage that
will operate off of DC input voltages from 140 to 230 volts and AC line
voltages from 100 to 240 volts. In combination with one of the embedded
motion control series control boards and an optoisolation board, it
provides a software development platform that allows algorithms to be
written and tested without the need to design and build a power stage. It
supports a wide variety of algorithms for both AC induction and
brushless DC (BLDC) motors.
Input connections are made via 40-pin ribbon cable connector J14.
Power connections to the motor are made on output connector J13.
Phase A, phase B, and phase C are labeled Ph_A, Ph_B, and Ph_C on
the board. Power requirements are met with a single external 140- to
230-volt DC power supply or an AC line voltage. Either input is supplied
through connector J11. Current measuring circuitry is set up for 2.93
amps full scale. Both bus and phase leg currents are measured. A
cycle-by-cycle over-current trip point is set at 2.69 amps.
The high-voltage AC power stage has both a printed circuit board and a
power substrate. The printed circuit board contains IGBT gate drive
circuits, analog signal conditioning, low-voltage power supplies, power
factor control circuitry, and some of the large, passive, power
components. All of the power electronics, which need to dissipate heat,
are mounted on the power substrate. This substrate includes the power
IGBTs, brake resistors, current sensing resistors, a power factor
correction MOSFET, and temperature sensing diodes. Figure 3-3
shows a block diagram.
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HV POWER
INPUT
SWITCH MODE
POWER SUPPLY
3-PHASE IGBT
POWER MODULE
SIGNALS
TO/FROM
CONTROL
BOARD
Freescale Semiconductor, Inc...
PFC CONTROL
dc BUS BRAKE
3-PHASE AC
TO
MOTOR
GATE
DRIVERS
PHASE CURRENT
PHASE VOLTAGE
BUS CURRENT
BUS VOLTAGE
MONITOR
BOARD
ID BLOCK
ZERO CROSS
BACK-EMF SENSE
Figure 3-3. 3-Phase AC High Voltage Power Stage
The electrical characteristics in Table 3-2 apply to operation at 25°C with
a 160-Vdc power supply voltage.
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Hardware Design
Optoisolation Board
Table 3-2. Electrical Characteristics of Power Stage
Freescale Semiconductor, Inc...
Characteristics
Symbol
Min
Typ
Max
Units
DC input voltage
Vdc
140
160
230
V
AC input voltage
Vac
100
208
240
V
Quiescent current
ICC
—
70
—
mA
Min logic 1 input voltage
VIH
2.0
—
—
V
Max logic 0 input voltage
VIL
—
—
0.8
V
Input resistance
RIn
—
10 kΩ
—
Analog output range
VOut
0
—
3.3
V
Bus current sense voltage
ISense
—
563
—
mV/A
Bus voltage sense voltage
VBus
—
8.09
—
mV/V
Peak output current
IPK
—
—
2.8
A
Brake resistor dissipation
(continuous)
PBK
—
—
50
W
Brake resistor dissipation
(15 sec pk)
PBK(Pk)
—
—
100
W
Pdiss
—
—
85
W
Total power dissipation
3.5 Optoisolation Board
Motorola’s embedded motion control series optoisolation board links
signals from a controller to a high-voltage power stage. The board
isolates the controller, and peripherals that may be attached to the
controller, from dangerous voltages that are present on the power stage.
The optoisolation board’s galvanic isolation barrier also isolates control
signals from high noise in the power stage and provides a noise-robust
systems architecture.
Signal translation is virtually one-for-one. Gate drive signals are passed
from controller to power stage via high-speed, high dV/dt, digital
optocouplers. Analog feedback signals are passed back through
HCNR201 high-linearity analog optocouplers. Delay times are typically
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250 ns for digital signals, and 2 µs for analog signals. Grounds are
separated by the optocouplers’ galvanic isolation barrier.
Freescale Semiconductor, Inc...
Both input and output connections are made via 40-pin ribbon cable
connectors. The pin assignments for both connectors are the same. For
example, signal PWM_AT appears on pin 1 of the input connector and
also on pin 1 of the output connector. In addition to the usual motor
control signals, an MC68HC705JJ7CDW serves as a serial link, which
allows controller software to identify the power board.
Power requirements for controller side circuitry are met with a single
external 12-Vdc power supply. Power for power stage side circuitry is
supplied from the power stage through the 40-pin output connector.
The electrical characteristics in Table 3-3 apply to operation at 25°C,
and a 12-Vdc power supply voltage.
Table 3-3. Electrical Characteristics of Optoisolation Board
Characteristic
Symbol
Min
Typ
Max
Units
Notes
Power Supply Voltage
Vdc
10
12
30
V
Quiescent Current
ICC
70(1)
200(2)
500(3)
mA
DC/DC converter
Min Logic 1 Input Voltage
VIH
2.0
—
—
V
HCT logic
Max Logic 0 Input Voltage
VIL
—
—
0.8
V
HCT logic
Analog Input Range
VIn
0
—
3.3
V
Input Resistance
RIn
—
10
—
kΩ
Analog Output Range
VOut
0
—
3.3
V
Digital Delay Time
tDDLY
—
0.25
—
µs
Analog Delay Time
tADLY
—
2
—
µs
1. Power supply powers optoisolation board only.
2. Current consumption of optoisolation board plus DSP EVM board (powered from this power supply)
3. Maximum current handled by DC/DC converters
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Motor-Brake Specifications
3.6 Motor-Brake Specifications
Freescale Semiconductor, Inc...
The AC induction motor-brake set incorporates a 3-phase AC induction
motor and attached BLDC motor brake. The AC induction motor has four
poles. The incremental position encoder is coupled to the motor shaft,
and position Hall sensors are mounted between motor and brake. They
allow sensing of the position if required by the control algorithm. Detailed
motor-brake specifications are listed in Table 3-4. In a target application
a customer specific motor is used.
Table 3-4. Motor - Brake Specifications
Set Manufactured
EM Brno, Czech Republic
Motor Specification:
Brake Specification:
Position Encoder
eMotor Type:
AM40V
3-Phase AC Induction Motor
Pole-Number:
4
Nominal Speed:
1300 rpm
Nominal Voltage:
3 x 200 V
Nominal Current:
0.88 A
Brake Type:
SG40N
3-Phase BLDC Motor
Nominal Voltage:
3 x 27 V
Nominal Current:
2.6 A
Pole-Number:
6
Nominal Speed:
1500 rpm
Type:
Baumer Electric
BHK 16.05A 1024-12-5
Pulses per Revolution:
1024
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3.7 Hardware Documentation
All the system parts are supplied and documented according to the
following references:
•
U1 - MC68HC908MR32 Control Board:
– supplied as: ECCTR908MR32
Freescale Semiconductor, Inc...
– described in: Motorola Embedded Motion Control
MC68HC908MR32 Control Board User’s Manual
MEMCMR32CBUM/D
•
U2 - 3-ph AC/BLDC High Voltage Power Stage
– supplied in kit with Optoisolation Board as:
ECOPTHIVACBLDC
– described in: Motorola Embedded Motion Control 3-Phase AC
BLDC High-Voltage Power Stage User’s Manual
MEMC3PBLDCPSUM/D
•
U3 - Optoisolation Board
– supplied with 3-ph AC/BLDC High Voltage Power Stage as:
ECOPTHIVACBLDC
– or supplied alone as: ECOPT - optoisolation board
– described in: Motorola Embedded Motion Optoisolation Board
User’s Manual MEMCOBUM/D
•
MB1 Motor-Brake AM40V + SG40N
– supplied as: ECMTRHIVAC
Detailed descriptions of individual boards can be found in
comprehensive User’s Manuals belonging to each board. The manuals
are available on the Motorola web. The User’s Manual incorporates the
schematic of the board, description of individual function blocks and a bill
of materials. An individual board can be ordered from Motorola as a
standard product.
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Designer Reference Manual — 3-ph. ACIM Drive with DTC
Section 4. Software Design
Freescale Semiconductor, Inc...
4.1 Contents
4.2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3
Data Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.4
Algorithm of Dead Time Distortion Correction . . . . . . . . . . . . . 43
4.2 Introduction
This section describes the design of the software blocks of the drive. The
software will be described in terms of •
Software Data Flow
•
Algorithm Dead Time Distortion Correction
4.3 Data Flow
The requirements of the drive dictate that software takes some values
from the user interface and sensors, processes them and generates
3-phase PWM signals for motor control.
The control algorithm of closed loop AC drive is described in Figure 4-1.
It consists of processes described in the following sub-sections. The
dead time distortion correction algorithm is described separately in the
successive section.
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SCI Communication
Switches
Process PC Master
Software Control
A/D converters
omega_reqPCM_mech
Freescale Semiconductor, Inc...
Process
Speed Command
dtCorrectOption
Process
Status Control
u_dc_bus
Current Polarity
Sensing
Process
Dead Time
Distortion Correction
omega_reqOMP_mech
Process
Acceleration/Deceleration Ramp
appFaultStatus
pDtCorrectApp
omega_reqRMP_mech
Process
Fault Control
OV Fault
Process
V/Hz Ramp
OC Fault
u_ramp
phase_increment
Process
PWM Generation
PVAL1,2
PVAL3,4
PVAL5,6
Figure 4-1. Data Flow
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Software Design
Data Flow
4.3.1 Speed Command & Status Control
Freescale Semiconductor, Inc...
In the Manual Operating Mode, the required speed is set by speed
potentiometer and switches (start/stop, forward/reverse). In the PC
Master Software (Remote) Operating Mode, the required speed is set by
PC. In the process, the input parameters are evaluated and the speed
command is calculated accordingly. Also the DC-Bus voltage is
measured. The application fault status is analyzed and the state of the
drive is set. The status LED’s are controlled according to the system
state.
4.3.2 Acceleration/Deceleration Ramp
The process calculates the new speed command based on the required
speed according to the acceleration / deceleration ramp.
4.3.3 V/Hz Ramp
This process provides voltage calculation according to V/Hz ramp. The
input of this process is the generated inverter frequency
omega_req_RMP_mech. The outputs of this process are the output sine
wave parameters required by PWM generation process: the table
increment phase_increment that corresponds to the frequency
omega_req_RMP_mech and is used to roll through the wave table in
order to generate the output inverter frequency, and the corresponding
amplitude of the generated inverter voltage u_ramp.
4.3.4 Process PWM Generation
This process generates a system of three phase sinewaves shifted 120o
each other. The function mcgen3PhWaveSine is used for the sine wave
calculation.
The mcgen3PhWaveSine function calculates an immediate value of the
three-phase sinusoidal system from given amplitude and actual phase
pointer:
•
Phase A — sPhaseVoltage.PhaseA
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•
Phase B — sPhaseVoltage.PhaseB
•
Phase C — sPhaseVoltage.PhaseC
The individual waves are shifted 120° each other. The shape of the
generated waveforms depends on the data stored in the sine table. In
motor control applications, data usually describes a pure sinewave or a
sinewave with addition of the third harmonic component.
Freescale Semiconductor, Inc...
Figure 4-2 shows the duty cycles generated by the
mcgen3PhWaveSine function when amplitude is 50%.
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
DutyCycle.PhaseA
0.1
DutyCycle.PhaseB
DutyCycle.PhaseC
0.0
Figure 4-2. 3-Phase Sine Waves with Amplitude of 50%
The calculation is based on the wave table stored in FLASH memory of
the microcontroller. The table describes either a pure sinewave or a
sinewave with the third harmonic addition. The second case is often
preferred because it allows one to generate the first harmonic sine
voltage equal to the input AC line voltage. The format of the stored wave
table data is from #0x0000 (for ZERO Voltage) up to 0x7fff (for the 100%
Voltage). Thus the proper data scaling is secured (see Figure 4-3).
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Data Flow
0x7fff
0x7fff
PhaseIncrement
Phase Increment
ActualPhase(n-1)
Actual Phase (n–1)
amplitude
Amplitude
ActualPhase(n)
Actual Phase (n)
amplitude = 100%
Amplitude = 100%
Freescale Semiconductor, Inc...
It is important to note that 50% PWM (or 50% of PWM Modulus loaded
to the corresponding PVAL registers) corresponds to the ZERO phase
voltage. But in the wave table, the ZERO phase voltage corresponds to
the number #0x0000. Therefore the fetched wave value from the table
must be added to the 50% PWM Modulation for quadrant 1 and 2 or
substracted from the 50% PWM Modulation for quadrant 3 and 4. Thus
the correct PWM value is loaded.
0x4000
0x4000
(DutyCycle.PhaseA)
(DutyCycle.PhaseA)
0x0000
0x0000
0x8000 = =
–180°
0x8000
-180 o
0 0
0x7fff == 180°
0x7fff
180 o
Figure 4-3. mcgen3PhWaveSine Data Explanation - Phase A
The output parameters of the process are:
•
PWM value for phase A: PVAL1 register
•
PWM value for phase B: PVAL3 register
•
PWM value for phase C: PVAL5 register
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In case of dead time distortion correction, the corrected PVAL values
PVAL1-6 are calculated and used for the PWM generation according to
the detected phase current polarity.
Freescale Semiconductor, Inc...
The process can be described by following points:
•
Wave pointer for phase A is updated by the table increment.
•
Based on the wave pointer, the PWM values for all three phases
are calculated.
•
PWM values are rescaled according to the PWM modulo (PWM
frequency) and loaded into PVAL1, 3, 5 registers. Registers
PVAL2, 4, 6 are loaded automatically because of complementary
PWM mode selected during the PWM module initialisation.
•
In case of dead time distortion correction, the corrected values
PVAL1-6 are calculated and used for PWM generation according
to the detected phase current polarity.
The process is accessed regularly in the rate given by the set PWM
frequency and the selected PWM interrupt prescaler.
4.3.5 PC Master Software Control
The process provides SCI communication with PC using PC master
software service routines. These routines are fully independent on the
motor control tasks. They enable for example to set the desired speed,
the PWM frequency and the type of dead time distortion correction.
4.3.6 Fault Control
This process is responsible for fault handling. The software
accommodates three fault events: DC-Bus over-current, DC-Bus
over-voltage and DC-Bus under-voltage.
DC-Bus Over-current: In case of DC-Bus over-current, the external
hardware provides a rising edge on the DC-Bus over-current fault input
of the microcontroller. This signal disables all motor control PWM
outputs (PWM1 - PWM6) and sets the application fault status.
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Algorithm of Dead Time Distortion Correction
DC-Bus Over-voltage: In case of DC-Bus over-voltage, the external
hardware provides a rising edge on the DC-Bus over-voltage fault input
of the microcontroller. This signal disables all motor montrol PWM
outputs (PWM1 - PWM6) and sets the application fault status.
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DC-Bus Under-voltage: The sensed DC-Bus voltage is compared with
the limit within the software. In case of DC-Bus under-voltage, all motor
control PWM outputs (PWM1 - PWM6) are disabled and the application
fault status is set.
If any of the faults occurs, the application status is changed into the Fault
Status.
4.3.7 Dead Time Distortion Correction
The process defines the value registers to be used for PWM generation
according to the type of dead time distortion correction and the state of
the immediate phase current polarity.
•
If no dead time correction is required, the PVAL1,3,5 are used, the
complementary PVAL values are calculated by on-chip PWM
peripheral automatically.
•
If partial dead time correction is required, the PVAL value is
selected by on-chip PWM peripheral automatically according to
the phase current polarity sensing
•
If full dead time correction is required, the process selects the
desired PVAL registers according to the dead time distortion
correction state machine.
In the following section the dead time distortion correction algorithm is
described in detail.
4.4 Algorithm of Dead Time Distortion Correction
The algorithm dtCorrectFull calculates the IPOL bits defining the PVAL
registers to be used for MC68HC908MR32 PWM generation for full dead
time correction. The IPOL bits are determined according to the phase
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current polarity detection bits DT1-6, actual sine wave pointer, and the
actual state of the algorithm state machine.
The algorithm state machine samples the actual state of the phase
current, and selects appropriate PVAL registers to be used for PWM
generation. The state machine, implemented in the dtCorrectFull
algorithm, is illustrated in Figure 4-4.
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When the algorithm is enabled, the state machine is entered from initial
state 0. It is waiting till the high magnitude of positive current is detected
(State 1, confirmed by State 2), then the algorithm enters the state
machine (State 3). The state machine is performed in circle 3-4-5-6-3.
As soon as the low magnitude of negative current is detected, the IPOL
is changed to 1, requesting the even-numbered PWM registers to be
used for PWM generation, the actual value of the wave pointer is
recorded (θC), and State 4 is entered. State 4 is preserved for 80
electrical degrees, until a high negative current can be expected. Then
State 5 is entered. As soon as the low magnitude of positive current is
detected, the IPOL is changed to 0, requesting the odd-numbered PWM
registers to be used for PWM generation, the actual value of the wave
pointer is recorded (θC), and State 6 is entered. State 6 is preserved for
80 electrical degrees, until a high positive current can be expected. Then
State 3 is entered and the state machine loop is repeated. In this way, it
is ensured that the required IPOL changes when a small amplitude of
respective current is detected by the hardware. Please note, that the
wave pointer is recorded into the algorithm variable PointA, PointB, or
PointC, in the moment when the respective phase current crosses the
low current threshold.
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Algorithm of Dead Time Distortion Correction
INITIAL
STATE
Algorithm
enabled
0
1
00
Initial recognition of
positive current
00
00
2
Freescale Semiconductor, Inc...
00
High positive
current
X0/0
3
4
Change IPOL
(current treshold
crossing)
Waits for high
positive current
|θ−θC|>80o / 0
6
Low positive
current
Low negative
current
X1/1
0X/0
Waits for high
negative current
|θ−θC|>80o/1
5
High negative
current
1X/1
STATE TRANSITION KEY: DT1 DT2 / IPOL
REGISTERSCONTROLS
CONTROL OUTPUT
THE OUTPUT
IPOL = 0: ODD-NUMBERED
ODD NUMBERED PWM REGISTER
REGISTERSCONTROLS
CONTROL OUTPUT
THE OUTPUT
IPOL = 1: EVEN-NUMBERED
EVEN NUMBERED PWM REGISTER
Figure 4-4. Dead Time Correction State Machine
Such a state machine is independently implemented for each phase (A,
B, C). The algorithm contains 2 flag variables, determining actual state
of the state machine for individual phases. Flag variable dtStateFlagsAB
determines state of the state machine for phases A & B, dtStateFlagsC
determines state of the state machine for phase C.
The meaning of individual bits of dtStateFlagsAB is listed in Table 4-1.
The meaning of individual bits of dtStateFlagsC is listed in Table 4-2.
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Table 4-1. State Machine Flag Registers dtStateFlagsAB
phase
phase A
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phase B
State
bits
bit0 - lock
bit1
bit2
bit3
bit4 - lock
bit5
bit6
bit7
1
0
0
2
0
1
0
0
0
1
3
4
5
6
1
1
1
1
0
0
1
1
0
1
0
1
1
1
1
1
0
0
1
0
0
1
1
1
Table 4-2. State Machine Flag Registers dtStateFlagsC
phase
phase C
reserved
NOTE:
State
bits
bit0 - lock
bit1
bit2
bit3
bit4
bit5
bit6
bit7
1
0
0
x
x
x
x
2
0
1
x
x
x
x
3
4
5
6
1
1
1
1
0
0
x
x
x
x
1
0
x
x
x
x
0
1
x
x
x
x
1
1
x
x
x
x
Detailed explanation of the dead time distortion correction can be found
in a comprehensive application note of Motorola, AN1728 “Making
Low-Distortion Motor Waveforms with the MC68HC708MP16“ by David
Wilson. Note, that MC68HC708MP16 is the predecessor of
MC68HC908MRxx family and contains identical on-chip PWM block.
Algorithm Data Structure:
Algorithm data structure is defined in dtCorrect.h header file.
See Table 4-3.
typedef struct {
UByte dtBits;
UByte ipolBits;
type_uBits dtStateFlagsAB;
type_uBits dtStateFlagsC;
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Algorithm of Dead Time Distortion Correction
SByte pointA;
SByte pointB;
SByte pointC;
SByte pointerA;
} dtCorrect_s;
Table 4-3. dtCorrect_s Structure Elements
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Variable
Explanation
dtBits
INPUT: actual status of the dead time bits DT1-6,
format | x | x |DT6|DT5| |DT4|DT3|DT2|DT1| fits to FTACK of
‘MR32
ipolBits
OUTPUT: ipolBits - new top/bottom correction bits IPOL1-3,
format | x | x | x |IPOL1| |IPOL2|IPOL3| x | x | fits to PCTL2 of
‘MR32
dtStateFlagsAB
internal dead-time correction flags for phases AB
dtStateFlagsC
internal dead-time correction flags for phase C
pointA
internal capture of the pointer for phase A
pointB
internal capture of the pointer for phase B
pointC
internal capture of the pointer for phase C
pointerA
INPUT: actual pointer of the generated wave phase A
The dead time correction algorithm dtCorrectFull adds the correction
factor to originally calculated sine wave. It is necessary to ensure that the
calculated PWM duty cycles do not exceed the PWM modulus.
The dtCorrectInit function must be called before starting any call to the
dtCorrectFull function, to ensure proper functionality.
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Designer Reference Manual — 3-ph. ACIM Drive with DTC
Section 5. System Setup
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5.1 Contents
5.2
Hardware Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.4
Jumper Settings of Controller Board. . . . . . . . . . . . . . . . . . . . .51
5.5
Required Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.6
Building the Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.7
Executing the Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.8
Controlling the Application with PC Master Software . . . . . . . . 57
5.2 Hardware Setup
Figure 5-1 illustrates the hardware setup of the application. It
incorporates the following modules:
•
MC68HC908MR32 Control Board
•
3-phase AC/BLDC High Voltage Power Stage
•
Optoisolation Board
•
3-phase AC Induction Motor
The correct phase order (phase A, phase B, phase C) for the shown AC
induction motor is:
•
Phase A — red wire
•
Phase B — white wire
•
Phase C — black wire
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If you view the motor looking into the shaft end, and the phase order is
phase A, B, C, the motor shaft should rotate in a clockwise direction (i.e.,
positive direction, positive speed).
Figure 5-1. Setup of the Application
5.3 Warning
This application operates in an environment that includes dangerous
voltages and rotating machinery.
Be aware, that the application power stage and optoisolation board are
not electrically isolated from the mains voltage - they are live with risk of
electric shock when touched.
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Jumper Settings of Controller Board
An isolation transformer should be used when operating off an AC power
line. If an isolation transformer is not used, power stage grounds and
oscilloscope grounds are at different potentials, unless the oscilloscope
is floating. Note, that probe grounds and, therefore, the case of a floated
oscilloscope are subjected to dangerous voltages.
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The user should be aware, that:
•
Before moving scope probes, making connections, etc., it is
generally advisable to power down the high-voltage supply.
•
To avoid inadvertent touching live parts, use plastic covers.
•
When high voltage is applied, using only one hand for operating
the test setup minimizes the possibility of electrical shock.
•
Operation in lab setups that have grounded tables and/or chairs
should be avoided.
•
Wearing safety glasses, avoiding ties and jewelry, using shields,
and operation by a personnel trained in high-voltage lab
techniques is also advisable.
•
Power transistors, the PFC coil, and the motor can reach
temperatures hot enough to cause burns.
•
When powering down; due to storage in the bus capacitors,
dangerous voltages are present until the power-on LED is off.
5.4 Jumper Settings of Controller Board
The MC68HC908MR32 control board jumper settings shown in
Figure 5-2 and Table 5-1 are required to execute the 3-phase AC motor
control application with dead time distortion correction. For a detailed
description of the jumper settings, refer to the MC68HC908MR32
Control Board User’s Manual (Motorola document order number
MEMCMR32CBUM/D).
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System Setup
JP5
JP4
JP3
JP2
JP1
Figure 5-2. MC68HC908MR32 Jumper Reference
Table 5-1. MC68HC908MR32EVM Jumper Settings
Jumper Group
Comment
Connections
JP1
Tachometer input selected
No connection
JP2
Encoder input selected
JP3
Back EMF signals selected
No connection
JP4
Power factor correction — zero cross
signal selected
No connection
JP5
Power factor correction — PWM signal selected
No connection
JP7
Power Supply connected to jack J3
1–2
1–2
5.5 Required Software Tools
The application requires the following software development tools:
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Building the Application
•
Metrowerks1CodeWarrior®2 for MC68HC08 microcontrollers
version 1.2 or later.
•
PC master software version 1.2.0.11 or later
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5.6 Building the Application
To build this application, open the 3ph_acim_dt_correct.mcp project
file and execute the Make command; see Figure 5-3. This command will
build and link the motor control application along with all needed
Metrowerks libraries.
Figure 5-3. Execute Make Command
5.7 Executing the Application
To execute the motor control application, in the pull-down menu choose
the Project/Debug command in the CodeWarrior® IDE, followed by the
Run command.
1. Metrowerks® and the Metrowerks logo are registered trademarks of Metrowerks, Inc., a wholly
owned subsidiary of Motorola, Inc.
2. CodeWarrior® is a registered trademark of Metrowerks, Inc., a wholly owned subsidiary of
Motorola, Inc.
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If the MMDS target is selected, CodeWarrior will automatically download
to the MMDS05/08 emulator.
The application can operate in two modes:
1. Manual Operating Mode
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The drive is controlled by the START/STOP switch (SW3). The
direction of the motor rotation is set by the FWD/REV switch
(SW4). The motor speed is set by the SPEED potentiometer (P1).
Refer to Figure 5-4 for this description.
Speed
Speed
potentiometer
Potentiometer
Fault
Fault POT
POT
Over-Voltage
Over-Voltage
Fault POT
POT
Over-Current
Over-Current
Forward
Reverse
Forward // Reverse
Switch
SW4
switch SW4
Start
Stop
Start / Stop
Switch
SW3
switch SW3
Figure 5-4. Control Elements
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System Setup
Executing the Application
Figure 5-5. USER LEDs, PWM LEDs, and RESET
2. PC Master Software (Remote) Operating Mode
The drive is controlled remotely from a PC through the serial
communications interface (SCI) communication channel of the
MCU device via an RS-232 physical interface. The drive is
enabled by the START/STOP switch, which can be used to safely
stop the application at any time.
Setting the required speed of the motor is the supported control
action.
The application states are displayed with on-board LEDs. Refer to
Figure 5-5 for the LED positions. If the application runs and motor
spinning is disabled (i.e., the system is ready), the green status LED will
blink. When motor rotation is enabled, the green status LED will be on,
and the actual state of the pulse-width modulator (PWM) outputs are
indicated with PWM output LEDs, labeled PWM1 - PWM6. If DC-Bus
over-current / DC-Bus over-voltage occurs, or if the wrong system board
is identified, the green status LED will start to flash quickly and the PC
master software will signal the identified fault. This state can be exited
only with the application reset.
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Refer to Table 5-2 for a description of the application states and their
corresponding LED indications.
Table 5-2. Motor Application States
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Application State
Motor State
Green LED State
Stopped
Stopped
Blinking at a frequency of 2Hz
Running
Spinning
On
Fault
Stopped
Blinking at a frequency of 8Hz
Once the application is running:
•
Move the START/STOP switch (SW3) from STOP to START
•
Select the direction of rotation by the FWD/REV switch (SW4)
•
Set the required speed by the SPEED potentiometer
If successful, the 3-phase AC induction motor will be spinning.
NOTE:
If the START/STOP switch is set to the START position when the
application starts, toggle the switch between the STOP and START
positions to enable motor spinning. This is a protection feature
preventing the motor to start spinning when the application is executed
from CodeWarrior.
You should also see a lighted green LED indicating the application is
running. If the application is stopped, the green LED will blink at a 2-Hz
frequency.
When the application is started, the type of dead time distortion
correction and desired PWM frequency can be selected using the PC
master software control page. The phase voltage and motor current can
be observed using the oscilloscope, and the efficiency of dead time
distortion correction can be evaluated.
The type of dead time distortion correction is indicated by a yellow LED
on MR32 controller board. When the dead time distortion correction is
disabled, the yellow LED is turned off. When partial correction is
selected, the LED flashes with 2Hz frequency. With full correction, the
LED is turned on (refer to Table 5-3).
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System Setup
Controlling the Application with PC Master Software
Table 5-3. Dead Time Distortion Correction
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Distortion Correction
Yellow LED State
Disabled
Off
Partial (h/w)
Blinking at a frequency of 2Hz
Full (s/w)
On
5.8 Controlling the Application with PC Master Software
Project file for the PC master software is located in:
..\pcmaster\3ph_acim_dt_correct.pmp
Start the PC master software application window and choose the
appropriate PC master software project. Figure 5-6 shows the PC
master software control window for 3ph_acim_dt_correct.pmp. The
type of dead time distortion correction (no/partial/full), and the PWM
frequency (4kHz/8kHz/16kHz/32kHz) can be selected in the variables
pane, as shown in Figure 5-6.
NOTE:
The desired dead time can be set in application configuration file
appconfig.h, where all on-chip modules of the 68HC908MR32
microcontroller are initialized.
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System Setup
Select no / partial / full dead
time distortion correction
Figure 5-6. PC Master Software Control Window
The PC master software displays the following information:
•
required and actual speed of the motor
•
phase voltage amplitude (related to given DC-Bus voltage)
•
application mode — START/STOP
•
DC-Bus voltage
•
fault status
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System Setup
Controlling the Application with PC Master Software
The PC master software allows the user to
•
set the PWM frequency (the frequency can be changed at any
time during the motor operation):
– 4 kHz
– 8 kHz
– 16 kHz
– 32 kHz
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•
select dead time distortion correction (the selection can be done
at any time during the motor operation):
– no
– partial
– full
The PWM frequency and type of dead time distortion correction can be
selected in both the manual and the PC master modes, using the PC
master software. It is possible to use the oscilloscope to display the
phase currents and voltages for dead time distortion evaluation.
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System Setup
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Designer Reference Manual — 3-ph. ACIM Drive with DTC
Appendix A. References
1. Motorola, Inc. (2001). 68HC908MR32 User’s Manual,
MC68HC908MR32/D
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2. Motorola, Inc. (2000). Motorola Embedded Motion Control
MC68HC908MR32 Control Board User’s Manual,
MEMCMR32CBUM/D
3. Motorola, Inc. (2000). Motorola Embedded Motion Control
3-Phase AC BLDC High-Voltage Power Stage User’s Manual,
MEMC3PBLDCPSUM/D
4. Motorola, Inc. (2000). Motorola Embedded Motion Optoisolation
Board User’s Manual, MEMCOBUM/D
5. Motorola, Inc. (1997). Making Low-Distortion Motor Waveforms
with the MC68HC708MP16, AN1728
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References
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Designer Reference Manual — DRM019
Appendix B. Glossary
AC — Alternating Current
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ACIM — AC Induction Motor
ADC — Analogue-to-Digital Converter
BLDC — brushless DC motor
DC — Direct Current
DT — see “Dead Time (DT)”
DTC — Dead Time Correction, see “Dead Time (DT)”
Dead Time (DT) — short time that must be inserted between the turning
off of one transistor in the inverter half bridge and turning on of the
complementary transistor due to the limited switching speed of the
transistors.
duty cycle — A ratio of the amount of time the signal is on versus the
time it is off. Duty cycle is usually represented by a percentage.
interrupt — A temporary break in the sequential execution of a program
to respond to signals from peripheral devices by executing a subroutine.
input/output (I/O) — Input/output interfaces between a computer
system and the external world. A CPU reads an input to sense the level
of an external signal and writes to an output to change the level on an
external signal.
logic 1 — A voltage level approximately equal to the input power voltage
(VDD).
logic 0 — A voltage level approximately equal to the ground voltage
(VSS).
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Glossary
MC68HC08 — A Motorola family of 8-bit MCUs
MCU — Microcontroller Unit. A complete computer system, including a
CPU, memory, a clock oscillator, and input/output (I/O) on a single
integrated circuit.
MR32 (908MR32, MC68HC908MR32) — See "MC68HC08"
Freescale Semiconductor, Inc...
phase-locked loop (PLL) — A clock generator circuit in which a voltage
controlled oscillator produces an oscillation which is synchronized to a
reference signal.
PVAL — PWM value register of motor control PWM module of
MC68HC908MR32 microcontroller. It defines the duty cycle of
generated PWM signal.
PWM — Pulse Width Modulation
reset — To force a device to the known condition.
SCI — See "serial communications interface module (SCI)"
serial communications interface module (SCI) — A module that
supports asynchronous communication.
serial peripheral interface module (SPI) — A module that supports
synchronous communication.
software — Instructions and data that control the operation of a
microcontroller.
software interrupt (SWI) — An instruction that causes an interrupt and
its associated vector fetch.
SPI — See "serial peripheral interface module (SPI)"
SR — switched reluctance motor
timer — A module used to relate events in a system to a point in time.
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must be validated for each customer application by customer’s technical experts.
Motorola does not convey any license under its patent rights nor the rights of
others. Motorola products are not designed, intended, or authorized for use as
components in systems intended for surgical implant into the body, or other
applications intended to support or sustain life, or for any other application in which
the failure of the Motorola product could create a situation where personal injury or
death may occur. Should Buyer purchase or use Motorola products for any such
unintended or unauthorized application, Buyer shall indemnify and hold Motorola
and its officers, employees, subsidiaries, affiliates, and distributors harmless
against all claims, costs, damages, and expenses, and reasonable attorney fees
arising out of, directly or indirectly, any claim of personal injury or death associated
with such unintended or unauthorized use, even if such claim alleges that Motorola
was negligent regarding the design or manufacture of the part.
Motorola and the Stylized M Logo are registered in the U.S. Patent and Trademark
Office. digital dna is a trademark of Motorola, Inc. All other product or service
names are the property of their respective owners. Motorola, Inc. is an Equal
Opportunity/Affirmative Action Employer.
© Motorola, Inc. 2003
DRM019/D
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