Motorola M68HC08 User manual

MOTOROLA.COM/SEMICONDUCTORS
M68HC08
Microcontrollers
DRM028/D
Rev. 0, 03/2003
Sensorless BLDC
Motor Control
Using the
MC68HC908MR32
Manual
Designer Reference
Freescale Semiconductor, I
Freescale Semiconductor, Inc.
For More Information On This Product,
Go to: www.freescale.com
nc...

Freescale Semiconductor, I
Freescale Semiconductor, Inc.
For More Information On This Product,
Go to: www.freescale.com
nc...

DRM028 — Rev 0 Designer Reference Manual
MOTOROLA 3
Sensorless BLDC Motor
Control Using the
MC68HC908MR32
Designer Reference Manual — Rev 0
by: Libor Prokop
Motorola Czech System Laboratories
Roznov pod Radhostem, Czech Republic
Freescale Semiconductor, I
Freescale Semiconductor, Inc.
For More Information On This Product,
Go to: www.freescale.com
nc...

Revision history
Designer Reference Manual DRM028 — Rev 0
4MOTOROLA
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
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 Description Page Number(s)
February,
2003 1 Initial release N/A
Freescale Semiconductor, I
Freescale Semiconductor, Inc.
For More Information On This Product,
Go to: www.freescale.com
nc...

DRM028 — Rev 0 Designer Reference Manual
MOTOROLA 5
Designer Reference Manual — Sensorless BLDC Motor Control
List of Sections
Section 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section 2. System Description. . . . . . . . . . . . . . . . . . . . . 15
Section 3. BLDC Motor Control . . . . . . . . . . . . . . . . . . . . 23
Section 4. Hardware Design. . . . . . . . . . . . . . . . . . . . . . . 57
Section 5. Software Design . . . . . . . . . . . . . . . . . . . . . . . 75
Section 6. User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Appendix A. References. . . . . . . . . . . . . . . . . . . . . . . . . 161
Appendix B. Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . .163
Freescale Semiconductor, I
Freescale Semiconductor, Inc.
For More Information On This Product,
Go to: www.freescale.com
nc...

List of Sections
Designer Reference Manual DRM028 — Rev 0
6MOTOROLA
Freescale Semiconductor, I
Freescale Semiconductor, Inc.
For More Information On This Product,
Go to: www.freescale.com
nc...

DRM028 — Rev 0 Designer Reference Manual
MOTOROLA 7
Designer Reference Manual — Sensorless BLDC Motor Control
Table of Contents
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 System Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Section 3. BLDC Motor Control
3.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.2 Brushless DC Motor Control Theory. . . . . . . . . . . . . . . . . . . . .23
3.3 Used Control Technique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
3.4 Application Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Section 4. Hardware Design
4.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
4.2 System Configuration and Documentation . . . . . . . . . . . . . . . .57
4.3 All HW Sets Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
4.4 High-Voltage Hardware Set Components. . . . . . . . . . . . . . . . . 66
4.5 Low-Voltage Evaluation Motor Hardware Set Components . . .70
4.6 Low-Voltage Hardware Set Components . . . . . . . . . . . . . . . . .72
Freescale Semiconductor, I
Freescale Semiconductor, Inc.
For More Information On This Product,
Go to: www.freescale.com
nc...

Table of Contents
Designer Reference Manual DRM028 — Rev 0
8MOTOROLA
Section 5. Software Design
5.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
5.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
5.3 Data Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
5.4 Main Software Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
5.5 State Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
5.6 Implementation Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Section 6. User Guide
6.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
6.2 Application Suitability Guide . . . . . . . . . . . . . . . . . . . . . . . . . .109
6.3 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
6.4 Application Hardware and Software Configuration . . . . . . . . .113
6.5 Tuning for Customer Motor. . . . . . . . . . . . . . . . . . . . . . . . . . .126
Appendix A. References
Appendix B. Glossary
Freescale Semiconductor, I
Freescale Semiconductor, Inc.
For More Information On This Product,
Go to: www.freescale.com
nc...

DRM028 — Rev 0 Designer Reference Manual
MOTOROLA 9
Designer Reference Manual — Sensorless BLDC Motor Control
List of Figures
Figure Title Page
2-1 System Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3-1 BLDC Motor Cross Section. . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3-2 3-Phase Voltage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3-3 BLDC Motor Back EMF and Magnetic Flux . . . . . . . . . . . . . . .26
3-4 Classical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3-5 Power Stage — Motor Topology. . . . . . . . . . . . . . . . . . . . . . . .28
3-6 Phase Voltage Waveform. . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3-7 Mutual Inductance Effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3-8 Detail of Mutual Inductance Effect . . . . . . . . . . . . . . . . . . . . . .33
3-9 Mutual Capacitance Model . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
3-10 Distributed Back-EMF by Unbalanced
Capacity Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
3-11 Balanced Capacity Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . .36
3-12 Back-EMF Sensing Circuit Diagram . . . . . . . . . . . . . . . . . . . . .37
3-13 The Zero Crossing Detection . . . . . . . . . . . . . . . . . . . . . . . . . .38
3-14 Commutation Control Stages . . . . . . . . . . . . . . . . . . . . . . . . . .39
3-15 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
3-16 BLDC Commutation with Back-EMF
Zero Crossing Sensing Flowchart. . . . . . . . . . . . . . . . . . . . . . .42
3-17 BLDC Commutation Time with Zero Crossing Sensing . . . . . .43
3-18 Vectors of Magnetic Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
3-19 Back-EMF at Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
3-20 Calculation of the Commutation Times During the Starting
(Back-EMF Acquisition) State. . . . . . . . . . . . . . . . . . . . . . . . . .49
4-1 High-Voltage Hardware System Configuration . . . . . . . . . . . . .59
4-2 Low-Voltage Evaluation Motor Hardware
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
4-3 Low-Voltage Hardware System Configuration . . . . . . . . . . . . .63
4-4 MC68HC908MR32 Control Board . . . . . . . . . . . . . . . . . . . . . .65
Freescale Semiconductor, I
Freescale Semiconductor, Inc.
For More Information On This Product,
Go to: www.freescale.com
nc...

List of Figures
Designer Reference Manual DRM028 — Rev 0
10 MOTOROLA
4-5 3-Phase AC High Voltage Power Stage . . . . . . . . . . . . . . . . . .67
4-6 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
5-1 Main Data Flow — Part1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
5-2 Main Data Flow — Part 2: Alignment, Starting,
Running Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
5-3 Closed Loop Control System . . . . . . . . . . . . . . . . . . . . . . . . . .81
5-4 Main Software Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
5-5 Main Software Flowchart — Main Software Loop. . . . . . . . . . .86
5-6 Software Flowchart — Interrupts . . . . . . . . . . . . . . . . . . . . . . .89
5-7 Application State Transitions . . . . . . . . . . . . . . . . . . . . . . . . . .90
5-8 Stand-by State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
5-9 Align State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
5-10 Back-EMF Acquisition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
5-11 Running State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
5-12 STOP State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
5-13 Fault State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
6-1 High-Voltage Hardware System Configuration . . . . . . . . . . . .114
6-2 Low-Voltage Evaluation Motor Hardware
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
6-3 Low-Voltage Hardware System Configuration . . . . . . . . . . . .116
6-4 Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
6-5 Execute Make Command . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
6-6 PC Master Software Control Window . . . . . . . . . . . . . . . . . . .124
6-7 Follow-up for Software Customizing to Customer Motor . . . .128
6-8 Follow-up for Advanced Software Customizing . . . . . . . . . . .129
6-9 Follow-up for Software Customizing Trouble Shouting. . . . . .129
6-10 PC Master Software Parameters Tuning Control Window . . .130
6-11 PC Master Software Parameters Tuning Control Window . . .131
6-12 PC Master Software Current Parameters Tuning Window . . .141
6-13 PC Master Software Start Parameters Tuning Window . . . . .149
6-14 PC Master Software Speed Parameters Tuning Window. . . .154
Freescale Semiconductor, I
Freescale Semiconductor, Inc.
For More Information On This Product,
Go to: www.freescale.com
nc...