Renesas YROTATE-IT-RX62T User manual

USER MANUAL
UM-YROTATE-IT-RX62T Rev.1.00 Page 1 of 51
Jan 15, 2014
YROTATE-IT-RX62T
Low Cost Motor Control Kit based on RX62T
Introduction
The Renesas Motor Control Kit, YROTATE-IT-RX62T, is based on the RX62T device fro the powerful 32-bit
RX icrocontroller fa ily.
The kit enables engineers to easily test and evaluate the perfor ance of the RX62T in a laboratory
environ ent when driving any 3-phase Per anent Magnet Synchronous Motor (e.g. AC Brushless Motor)
using an advanced sensorless Field Oriented Control algorith . Typical applications for this type of solution
are co pressors, air conditioning, fans, air extractors, pu ps and industrial drives.
The phase current easure ent is done via three shunts which offers a low cost solution, avoiding the
need for an expensive current sensor. A single shunt current reading ethod is also available.
The powerful user-friendly PC Graphical User Interface (GUI) gives real ti e access to key otor
perfor ance para eters and provides a unique otor auto-tuning facility.
The hardware is designed for easy access to key syste test points and for the ability to hook up to an
RX62T debugger. Although the board is nor ally powered directly fro the USB port of a Host PC,
connectors are provided to utilise external power supplies where required.
The YROTATE-IT-RX62T is an ideal tool to check out all the key perfor ance para eters of your selected
otor, before e barking on a final end application syste design.
Target Device: RX62T/63T Microcontroller Series
UM-YROTATE-IT-
RX62T
Rev.1
.00
Jan 15, 2014

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Contents
1. Key features .................................................................................................................................................................. 3
2. Hardware overview ....................................................................................................................................................... 4
3. Power supply selection ................................................................................................................................................. 6
4. Test points for debugging .............................................................................................................................................. 7
5. LEDs function description ............................................................................................................................................. 8
6. Internal power stage brief description ......................................................................................................................... 9
7. Interface with an external power stage ...................................................................................................................... 10
8. Connection with a 1.5KW external power stage ........................................................................................................ 14
9. Control icrocontroller overview ............................................................................................................................... 15
10. Per anent agnets AC Brushless otor odel ...................................................................................................... 17
11. Sensorless Field Oriented Control Algorith ............................................................................................................ 22
12. Flux Feedback Gain ................................................................................................................................................... 23
13. Software description ................................................................................................................................................. 24
14. Application custo ization using “custo ize.h” file ................................................................................................. 28
15. Start-up procedure .................................................................................................................................................... 30
16. Reference syste transfor ations in details ........................................................................................................... 32
17. PWM odulation technique ..................................................................................................................................... 33
18. PC Graphical User Interface ...................................................................................................................................... 34
19. Motor Auto-calibration using the PC GUI ................................................................................................................. 36
20. List of otors tuned auto atically using the PC GUI ............................................................................................... 46
21. List of variables used in the file na e: “ otorcontrol.c” ......................................................................................... 47

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1. Key features

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2. Hardware overview
The Motor Control kit is a single board inverter, based on the new RX series icrocontroller RX62T. The hardware
includes a low-voltage MOSFETs power stage, and a co unication stage.
The ordering part na e of the kit is: YROTATE-IT-RX62T. The latest updates of the kit aterial are available on the
webpage: http://tinyurl.co /YROTATE-IT-RX62T
To obtain the axi u flexibility, the reference board includes:
•A co plete 3-phase inverter on-board with a low voltage otor, so it beco es easy to test the powerful
sensorless algorith on the RX62T
•USB co unication with the PC via a H8S2212 icrocontroller
•Connectors for hall sensors and encoder connections
•Co patibility with the existing Motor Control Reference Platfor s MCRP05/06 power stage available at
Renesas.
To achieve these ai s, an independent co unication stage was i ple ented, based on the Renesas
icrocontroller H8S2212, which perfor s the USB to serial conversion.
The two serial lines RX and TX are fully insulated
COMMUNICATION
STEP
-
DOWN
STEP_UP
EXTERNAL POWER
STAGE INTERFACE
POWER STAGE
CONTROL STAGE
Signals conditioning
HALL, ENCODER
IS
OL
A
TION

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This stage uses the PC USB power lines as power supply.
Further ore, the possibility to supply all the board using the PC USB port was added, realizing a step-up converter to
obtain the inverter V
BUS
necessary for the otor; obviously, if this feature is used, the syste is no ore insulated
fro the PC.
If external power supply is used for the inverter, the logic power supply is obtained through a step-down converter,
in order to reduce heating and power consu ption.
Please refer to the electrical drawings or sche atics to get the hardware i ple entation in ore details.

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3. Power supply selection
As stated before, there are two ways to supply power to the board.
One possibility is to use directly the PC USB supply, and in this case the current you can give to the otor is li ited
by the USB possibilities. A dual power USB cable is reco ended to give enough power to the board.
The second possibility is to use an external voltage DC source to supply the board.
The reco ended voltage values are between 12V
DC
and 24V
DC
. In this case the co unication stage is insulated
fro the inverter.
The selection between the two possibilities is ade through three ju pers in the J2 connector, as described in the
following figure.
The first ju per configuration connects the USB ground to the inverter ground, the USB 5Vdc to the logic +5Vdc and
the output of the step-up converter (around 13Vdc) to the inverter DC link.
The second ju per configuration connects the external power supply ground to the inverter ground, the output of
the step-down converter (+5Vdc) to the logic +5Vdc and the external +Vdc (fro 12 to 24 Vdc) to the inverter DC
link.
9 4
8
7
5
6 3
2
1
PC USB SUPPLY SELECTION
9 4
8
7
5
6 3
2
1
EXTERNAL SUPPLY SELECTION

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4. Test points for debugging
Several specific test points are available on the board to visualize with the oscilloscope the behavior of
so e internal analog signals. it is very useful during the tuning process for adapting the software to a new
otor to use the test points.
There are specific 3 PWM debug test points; TP5, TP6 & TP7 as shown below.

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5. LEDs function description
Three LEDs available on the board are directly connected to the hardware and allows the user to understand the
status of the supply of the board. Please refer to the LED ap for the following indications:
•DL8 is connected to the USB supply, so it indicates that the USB port is supplied (and, by consequence, all the
co unication section).
•DL7 is connected to the step-down converter output, and it is on only if an external power supply is
connected.
•DL9 is connected to the logic supply, so it indicates that the control section is supplied.
The other LEDs in the board are driven via software, in particular:
•DL6 is blinking if there is a co unication between the PC and the board.
•DL1 is blinking if the control section icrocontroller (RX62T) is running nor ally.
•DL4 is quickly blinking if an alar has been detected.
DL8
DL1
DL9
DL7
DL6
DL4

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6. Internal power stage brief description
The power stage is a co plete 3-phase bridge co posed with discrete low voltage power MOSFETs, ounted on the
botto side of the board. The MOSFETs are the Renesas RJK0654DPB n-channel power MOSFETs (please refer to the
data-sheet for the characteristics).
On the upper side of the board is ounted the MOSFETs driving circuit, co posed with discrete ele ents (refer to
the electric drawings).
The current reading shunts are also in the botto side of the board, while the signal conditioning circuit is in the
upper side.
The inverter has the classical sche a with the three shunts on the lower ar s:
CURRENT READING
SHUNTS
3 PHASES BRIDGE

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7. Interface with an external power stage
Since internal power stage allows only the anage ent of s all otors, an interface with an external power stage
was added to the PCB. This was ade easy due to the presence in the icrocontroller of several ti er sections that
ake it possible to anage up to two 3-phase Brushless AC otors at the sa e ti e.
Please find below the sche atics of the connectors present in the board, used for connecting an external power
stage.
+5V
1
3
2
4
VBUS
EXT
CONN. J12
1
3
5
7
9
11
13
15
2
4
6
8
10
12
14
16
JUMPER JP5
CONN. J11
1
3
5
7
9
11
13
15
2
4
6
8
10
12
14
16
MTIOC3D (UP53)
PHASE
U LOWER
PWM DRIVE SIGNAL
MTIOC4C (UP52)
PHASE
V LOWER
PWM DRIVE SIGNAL
MTIOC4D (UP51)
PHASE
W LOWER
PWM DR
IVE SIGNAL
MTIOC3B (UP56)
PHASE
U UPPER
PWM DRIVE SIGNAL
MTIOC4A (UP55)
PHASE
V UPPER
PWM DRIVE SIGNAL
MTIOC4B (UP54)
PHASE
W UPPER
PWM DRIVE SIGNAL
POE0 (UP57)
HARDWARE ALARM SIGNAL
+5V
NM
100R
10N

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The interface between the board and an external power stage is organized as follows:
a) A 16 pins connector (J11) is used for the PWM drive signals; the signals are directly connected to the
icrocontroller output pins, and there is no pull-up or pull-down resistor connected, so the polarization has
to be done in the power stage (note that in case of alar , the icrocontroller output pins can be placed in
high i pedance state, so the external polarization is necessary); these output co ands are logic level
signals, with li ited current output capability, so an external driver is probably required. A further line is
connected to the icrocontroller: it is the external alar signal, connected to the POE input pin; this pin is
not polarized, so if the POE is enabled and the input is left unconnected, undesired alar s can occur. All the
free pins of the connector are connected to the board ground to ini ize the cross talking of the lines if a
flat cable is used.
b) A 26 pins connector (J13) is used to collect so e signals fro the power stage, in particular the current
readings and the DC link voltage reading; those signals are cla ped and weakly filtered, then directly
connected to the A/D converter input pins of the icrocontroller, so the external power stage has to take
care of the gain and the offset of these signals. An input is dedicated also to a ther al sensor, and a pull-up
resistor is present. Three further signals are anaged: they are the co utation signals fro the output
phases, useful if the hardware co pensation of dead-ti es facility of the MTU is used; those signals are
CONN. J13
1
3
5
7
9
11
13
15
2
4
6
8
10
12
14
16
17
19
21
23
25
18
20
22
24
26
AN102 (UP85)
U PHASE CURRENT
SIGNAL
100R
1N
+5V
15K
+5V
1K
100R
1N
+5V
100R
1N
+5V
15K
+5V
1K
15K
+5V
1K
100R
1N
+5V
10K
+5V
AN101 (UP86)
V PHASE CURRENT
SIGNAL
AN103 (UP84
)
VBUS VOLTAGE
SIGNAL
MTIC5U (UP96)
U PHASE COMM. SIGNAL
MTIC5V (UP97)
V PHASE COMM. SIGNAL
MTIC5W (UP98)
W PHASE COMM. SIGNAL
AN100 (UP87)
W PHASE CURRENT
SIGNAL
AN2 (UP75)
THERMAL SENSOR SIGNAL
1K
100N
+5V
10K

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cla ped with a diode directly connected with the icrocontroller power supply, so a suitable series
resistance is needed in the power stage to avoid da ages to the board.
c) A further connector (J12) can be used to supply the board fro the power stage or vice-versa ( aking a
short circuit between the pins 1 and 2 of the ju per JP5); also the board 5V can be ade available to the
power board ( aking a short circuit between the pins 3 and 4 of JP5), but not vice-versa, because they are
directly connected to the step-down switching supply of the board. The ground connection is always on, and
it represents the reference for all the interface signals.
In the next figure a si ple exa ple regarding how the power board has to be arranged is presented: the power
supply co es fro the supply connector, and the supply for power odule is derived fro it. The external supply is
also used to supply the icrocontroller board through the connector J12A (and the ju per JP5 in icrocontroller
board); the 5V supply for current sensors and for the signal polarization is derived fro the icrocontroller board,
through J12A (and JP5). The PWM drive signals are taken fro J11A, while the current sensing signals and the bus
voltage easure ent are brought to J13A (the phase co utation signals and the te perature sensing signal are
not reported for sake of si plicity).
Please refer to the co plete sche atics for further details.

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8. Connection with a 1.5KW external power stage
The interface for an external power supply was designed to be co patible with the power stages of previous
Renesas otor control platfor s MCRP05/06.
So it beco es possible to use the sa e power stage and connect any Motor Control board using RX62T, RL78/G14 or
RX220 icrocontroller fa ilies.
The sche atics of a 1.5KW power stage are included into the docu entation on the CD-ROM delivered with the Kit.
Please find below the details to connect the power stage to the RX62T otor control kit.
The power supply of 24V
DC
is delivered by the 1.5KW power board (on the left hand side). It’s directly connected to
the RX62T control board thanks to the Ju per JP5 (on the right hand side).
The pin 1 and 2 of the ju per JP5 are short-circuited, while the pin 3 and 4 are left open.
In the icrocontroller board, the supply configuration ju per JP2 is configured in order to select the external supply
(not the USB one).
In the power stage board, a DC bus connector allows the user to provide a higher external DC voltage; in such way
high voltage otors can be anaged.
POWER SUPPLY CONNECTOR
DC B
US CONNECTOR
MOTOR CONNECTOR
J12
J13
J11
JP5
JP
2

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9. Control microcontroller overview
The RX62T/63T Group is a set of icrocontrollers featuring the high-speed, high-perfor ance RX CPU as the 100MHz
processor core.
Each basic instruction of the processor is executable in one cycle of the syste clock. Calculation functionality is
enhanced by the inclusion of a single-precision floating-point calculation unit as well as a 32-bit ultiplier and
divider. Additionally, code efficiency is i proved by instructions with lengths that are variable in byte units to cover
an enhanced range of addressing odes.
A ulti-functional ti er pulse unit 3 (for otor control), general PWM ti er, co pare atch ti ers, watchdog
ti er, independent watchdog ti er, serial co unications interfaces, I2C bus interfaces, CAN odule, serial
peripheral interface, LIN odule, 12-bit A/D converters with three-channel si ultaneous sa pling function, and 10-
bit A/D converter are incorporated as peripheral functions which are essential to otor control devices. In addition,
the 12-bit A/D converters include a window co parator and progra able gain a plifier for additional
functionality.
Please find below the su ary of the RX62T features:
RX600 CPU
High-speed: 100MHz clock
High perfor ance: 1.65MIPS/MHz
Low current consu ption: only 50 A @
100MHz
Single-precision floating point unit FPU,
barrel shifter, MAC, RMPA
256kB Flash/16kB RAM to 64kB Flash/8kB
RAM
Zero wait access to Flash e ory
64pin – 112pin package options
Functions
Enhanced PWM resolution with MTU3, enhanced PWM functionality with GPT
12-bit A/D converter (1µs) : 4 channels x 2 unit , 10-bit A/D converter (1µs) : 12 channels x 1 unit
Three S/H circuits for each unit: Three shunts control enable
Double data registers for each unit: 1 shunt control enable
Progra able gain Operational a plifier, Window co parator for Voltage onitoring
CAN option

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Large-capacity flash e ory units capable of high-speed operation are included as on-chip e ory, significantly
reducing the cost of configuring syste s.
The ain application fields of this icrocontroller are: industrial equip ent, household electrical appliances,
achines requiring otor control, and inverter-powered achines.
Please find below the block diagra of the RX62T and the role of each peripherals.
Watchdog timer x 2 ch
(One of two includes the LOCO)
DTC
SCI x 3 ch
SPI x 1ch
I
2
C x 1 ch
I/O ports
16 bit timer x 4 ch (CMT)
10 bit ADC x 12ch
RCAN x 1ch
POR/LVD
OCO (Low speed)
CRC
RX CPU
100MHz
2.7~3.6V (4.0 5.5V)
FPU
Flash
Data Flash 8KB
RAM
Multiplier divider and
multiplier accumulator
Protection
- External input (POE)
-Clock stop detection
-Clock onitoring
3ph. PWM with dead ti e
(Use two 16-bit ti er ch3&4)
1 or 2 Encoder Input
(Use 1or2 16-bit ti er ch1/2)
Hall sensor / BEMF Input
(Use one 16-bit ti er ch0)
Dead ti e co pensation
(Use one 16-bit ti er ch5)
3ph. PWM with dead ti e
(Use two 16-bit ti er ch6&7)
MTU3
12bit AD
4ch
Self diagnostic
POE
1ph, PWM with dead ti e
Inverter control,PFC etc
GPT
1ph, PWM with dead ti e
Inverter control,PFC etc
1ph, PWM with dead ti e
Inverter control,PFC etc
1ph, PWM with dead ti e
Inverter control,PFC etc
12bit AD
4ch
Self diagnostic
6 OpA p
6 co p
IPM
fault
Shunts reading
PMAC
Motor
M
M
Serial co unication
Maxi u current &
V
BUS
anage ent

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10. Permanent magnets AC Brushless motor model
The synchronous per anent agnets otor (e.g. sinusoidal Brushless otor) is widely used in the industry. More
and ore ho e appliance akers are now using such AC Brushless otor, ainly because of the intrinsic otor
efficiency.
The per anent agnet otor is ade with few co ponents:
1. A stator for ed by stacking sheared etal plates where internally the copper wiring is wound, constructing
the stator winding
2. A rotor in which per anent agnets are fixed
3. Two covers with ball bearings that keep together the stator and the rotor; the rotor is free to rotate inside
the stator
The working principle is quite si ple: if we supply the otor with a three-phase syste of sinusoidal voltages, at
constant frequency, in the stator windings flow sinusoidal currents, which create a rotating agnetic field.
The per anent agnets in the rotor tend to stay aligned with the rotating field, so the rotor rotates at synchronous
speed.
The ain challenge in driving this type of otor is to know the rotor position in real-ti e, so ainly i ple entation
are using a position sensor or a speed sensor.
In our i ple entation, the syste is using either one or three shunts to detect the rotor position in real-ti e.
Let’s analyse the otor fro a athe atic point of view.
If we apply three voltages v
a
(t), v
b
(t), v
c
(t) to the stator windings, the relations between phase voltages and currents
are:
+
+
+
v
a
v
b
v
c
i
a
i
c
i
b
“a” winding
How current flows
into “a” winding
“a” winding
agnetic axis
“b” winding
“c” winding
Motor
axis
(shaft)

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dt
d
iRv
dt
d
iRv
dt
d
iRv
c
cSc
b
bSb
a
aSa
λ
λ
λ
+=
+=
+=
- λ
i
is the agnetic flux linkage with the i-th stator winding
- R
S
is the stator phase resistance (the resistance of one of the stator windings)
The agnetic flux linkages λ
i
are co posed by two ite s, one due to the stator currents, one to the per anent
agnets.
The per anent agnet creates a agnetic field that is constant in a plitude and fixed in position in respect to the
rotor. This agnetic field can be represented by vector Λ whose position in respect to the stator is deter ined by
the angle ϑ between the vector direction and the stator reference fra e.
The contribution of the per anent agnets in the flux linkages depends on the relative position of the rotor and the
stator represented by the echanical-electric angle ϑ.
It is, in every axis, the projection of the constant flux vector Λ in the direction of the axis:
)
3
4
cos(
)
3
2
cos(
)cos(
π
ϑλ
π
ϑλ
ϑ
λ
−Λ+=
−Λ+=
Λ
+
=
mcc
mbb
maa
Li
Li
Li
ϑ
Λ
a
a’
b
c
c’
b’
a axis
b axis
c
axis
Real axes (a, b, c) and equivalent ones (α, β); a fixed a plitude vector can be co pletely deter ined by its
position respect the (α, β) syste (angle ϑ)
α
α
’
α
axis
β
’
β
’
β
axis

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Supposing that the rotor is rotating at constant speed ω (that is: ϑ(t) = ωt) the flux linkages derivatives can be
calculated, and we obtain:
)
3
4
sin(
)
3
2
sin(
)sin(
π
ϑω
π
ϑω
ϑω
−Λ−+=
−Λ−+=
Λ−+=
m
b
bSc
m
b
bSb
m
a
aSa
dt
di
LiRv
dt
di
LiRv
dt
di
LiRv
A “three phases syste ” ay be represented by an equivalent “two phases syste ”. So the by using specific
transfor ations, our three equations syste is equivalent to a two equations syste . It is basically a athe atical
representation in a new reference coordinates syste .
In the two phases (α,β) fixed syste the above equations beco e:
dt
d
iRv
dt
d
iRv
S
S
β
ββ
α
αα
λ
λ
+=
+=
For the agnetic field equations, we got:
)sin(
)cos(
ϑλλ
ϑ
λ
λ
ββββ
αααα
mm
mm
LiLi
LiLi Λ+=+=
Λ
+
=
+
=
After perfor ing the derivation:
mm
mm
dt
di
L
dt
di
L
dt
ddt
di
L
dt
di
L
dt
d
α
βββ
β
ααα
ωλϑω
λ
ωλϑω
λ
+=Λ+=
−=Λ−=
)cos(
)sin(
Finally, we obtain for the voltages in (α,β) syste :
mS
mS
dt
di
LiRv
dt
di
LiRv
α
β
ββ
β
α
αα
ωλ
ωλ
++=
−+=
A second reference fra e is used to represent the equations as the fra e is turning at the rotor speed. So the “d”
axis is chosen in the direction of the agnetic vector Λ , and with the “q” axis orthogonal to the “d” axis. The new
reference syste is (d, q).

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The reference fra e transfor ations fro the (α,β) syste to the (d, q) syste depends on the instantaneous
position angle ϑ
ϑϑ
ϑ
So we obtain two inter-dependant equations in the (d, q) syste :
md
q
qSq
q
d
dSd
Li
dt
di
LiRv
Li
dt
di
LiRv
Λ+++=
−+=
ωω
ω
These two equations represent the mathematical motor model.
A control algorith which wants to produce deter ined currents in the (d, q) syste ust i pose voltages given
fro the for ulas above.
This is ensured by closed loop PI control on both axis “d” & “q” (Proportional Integral).
Since there is a utual influence between the two axes, decoupling ter s can be used.
In the block sche e the echanic part is included, where “p” is the nu ber of pole pairs, while “B” represents
friction, “J” the inertia, “τ
load
“ the load torque and “τ” the otor torque.
Λ××= p
2
3
τ
The angular speed ω is represented in the sche e as ω
e
to distinguish the electrical speed fro the echanical one.
Let’s now consider the equations we have seen in (α,β) syste :
1/(R+sL)
1/(R+sL) (3/2)p
Λ
1/(B+sJ)
τ load
p Λ
pL
V d
V q
+
-
+
- -
+
ω mec
I d
I q τ
+
L ω e
Λω e