Solo BETA User manual
SOLO BETA User Manual
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Product Description
Power Range
SOLO is a member of the SOLO motor
controllers family which are capable of driving
and controlling various types of electrical
motors like DC brushed, BLDC, PMSM and AC
Induction motors in a single platform.They are
made to be easy to use with state of art
technologies.
They offer both sensor-based and sensor-less
options for Speed, Torque and Position control
of motors supported plus numerous types of
other options like full digital and analogue
controls plus active safety measures to keep
the applications safe from unforeseen
behaviours.
Supply Voltage Range : 8- 58 VDC
Peak Current: 100A
Continuous Current: 32A
Features
●Easy to use
●Drives and Controls DC, BLDC, PMSM
and ACIM motors
●Closed-loop and Open-loop controls
●Speed, Torque and Position control
●Sensor-based and sensorless control
●Four Quadrant Regenerative
operation
●Automatic parameter Identification
and self-tuning
●Field Oriented Based Controls with
Nested Position-Speed-Torque loops
●Fast and high performance reference
tracking
●Reverse Polarity, Bus over-voltage,
Bus under-voltage , over-current and
over temperature protections
●Active temperature control
●Full Digital and Analogue Control
Modes of Operation
Commands and feedbacks Source
●Analogue or Digital commanding
●Speed Control
●Torque Control
●Position Control
●0-5V Analogue/ PWM inputs for Speed or
Torque control
●Quadrature Encoder input
●Three position Hall sensors input
●UART, USB, CAN bus
Applications
●Industrial Automations
●Robotics and Traction Units
●Drones
SOLO BETA User Manual
Table of Contents
Power Specifications: 5
Control specifications: 5
Thermal Specifications: 6
Mechanical Specifications: 6
Mechanical Dimensions: 7
SOLO’s Interactional Sections: 8
Absolute Maximum Voltage Ratings: 9
Connectors and Sections: 10
Sections Description: 13
Section 1 - Motor Output 13
Section 2 - Supply Input 13
Section 3 - Analogue Inputs and +5V External Supply 13
“GND” PIN: 14
“+5V” PIN: 14
“DIR” PIN: 15
“P/F” PIN: 15
In Open Loop mode of 3 phase motors : 15
In Closed-Loop mode of DC, BLDC and PMSM motors: 15
In Closed-loop mode of AC Induction Motors: 16
“S/T” PIN in Closed_loop Mode: 17
In Torque mode: 17
In Speed mode: 18
“S/T” and “P/F” PINs in Open_loop Mode: 19
In case of using Analogue Voltages on “S/T”: 19
In case of using PWM inputs on “S/T”: 19
Three phase Motors “Power” Notation in Open-loop Mode: 19
Section 4 and 5_ Speed Controller Kp and Ki : 20
Kp Potentiometer : 20
Ki Potentiometer : 20
Section 6 _Piano Switch: 21
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SOLO BETA User Manual
Pin number 5, Defining the Control Mode - Motor Identification: 21
Pin number 4,Defining The Type of the control- Speed or Torque: 22
Pin number 3, Defining the DFU mode for upgrading the firmware: 22
Pin number 1 and 2 ,Defining the Motor type: 23
Section 7 _ Micro USB 2: 24
Section 8 _ Encoder/Hall Connector: 25
Connection of Quadrature Encoders to SOLO: 26
Encoder Connection for BLDC, PMSM and ACIM motors (3-phase Motors): 27
Hall Sensor Connection for BLDC, PMSM and ACIM motors (3-phase Motors): 28
Encoder Connection for Brushed DC motors: 30
Section 9 _ Communication Port: 31
Section 10, 11 _ Status / Error LEDs: 32
Section 12 _ Power Up LED: 32
Minimum Required Wirings in Analogue Control: 33
BLDC, PMSM or ACIM Motors _ Open-loop Mode: 33
BLDC, PMSM Motors _ Closed-loop Mode: 34
AC Induction Motors_ Closed_loop Mode: 35
DC brushed Motors_ Closed-loop Mode: 36
DC brushed Motors_ Open-loop Mode: 37
Standalone Wiring Example (No External Modules): 38
Essential Wiring Example (SOLO + Arduino Uno) 39
Digital Control using USB or UART protocol : 40
UART or USB hardware settings: 40
Packets formation _ Commanding and Feedbacks: 41
WRITE commands table in Digital Control (USB and UART): 43
WRITE commands table in Digital Control - Continue: 44
READ commands table in Digital Control (USB and UART): 45
READ commands table in Digital Control _Continue: 46
Error Reporting and Handling: 49
Error Register Table: 49
Digital Data Types and their conversions: 50
Convert Fixed-point Sfxt(32-17) data into real world floating point data type: 51
Convert float data toFixed-point Sfxt(32-17) data for SOLO to be sent in a data packet: 52
Convert Hex data read from SOLO to signed Int32: 53
Convert signed Int32 to Hex for sending to SOLO: 54
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SOLO BETA User Manual
Digital Control and Data Packeting Examples: 55
Changing the Direction of Rotation: 55
Stop the Motor [Emergency] 55
Set the Motor’s Number of Poles 56
Change or Set/Reset the Device address: 56
Reset the Device Address to ZERO 57
Enable/Disable Monitoring Mode: 58
Set the output switching Frequency (PWM frequency): 59
Reset the Device to Factory Mode: 59
Digital sensorless Torque Control of a BLDC motor. 60
Digital sensorless Speed Control of a Brushless motor. 61
Digital Speed Control of a Brushless motor using Encoders 62
Digital sensorless Speed Control of a DC Brushed motor 64
Digital Speed Control of a DC Brushed motor using Encoder 66
Digital Open-loop Control of a Brushless motor 68
Digital sensorless closed-loop speed Control of an AC Induction Motor 69
Digital Position Control using Quadrature Encoders Examples: 71
Digital Position Control of a Brushless Motor using Encoders: 72
Digital Position Control of a DC Brushed Motor using Encoders: 74
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SOLO BETA User Manual
Power Specifications:
Control specifications:
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Description
Units
Values
DC Supply Voltage Range (continuous)
VDC
8 to 56
DC Bus Overvoltage Limit
VDC
58
DC Bus Undervoltage Limit
VDC
8
Maximum Peak Output Current
A
100
Maximum Continuous Output Current
A
32
Maximum Continuous Output Power
W
800
Internal Bus Capacitance
µF
1920
Switching Frequency
kHz
8 to 80
Description
Units
Values
Analogue Speed or Torque Commands
VDC
0-5V analogue voltages or PWM inputs with
frequency above 5kHz
Digital Direction Control
VDC
0 - 3.3
Modes of Operation
-
Torque - Speed- Position
Motors supported
-
DC - BLDC - PMSM - BLAC - ACIM
Hardware Protections
-
Reverse Polarity, Bus over-voltage Bus
under-voltage, over-current and over
temperature
Current (Torque) Loop sample time
µs
5
Speed controller Loop sample time
ms
1 or 0.5(selectable)
Position controller Loop sample time
ms
1 or 0.5(selectable)
Maximum Encoder Frequency
MHz
18 (Pre-Quad)
SOLO BETA User Manual
Thermal Specifications:
Mechanical Specifications:
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Description
Units
Values
Board Temperature Range
°C
-20 to 85
Heatsink (base) Temperature Range
°C
0 - 85
Cooling system
-
Natural Convention
Description
Units
Values
Size (H x W x D)
mm
33.40 x 87.15 x 67.10
Weight
gr
99
Form Factor
-
Wall Mount
SOLO BETA User Manual
SOLO’s Interactional Sections:
The most important parts of SOLO for users to interact with are as below divided into 12 main
sections, below you can find the description and details for each one of them plus their maximum
electrical ratings. The user needs to make sure they read this part carefully before applying any
connections to SOLO that might damage it if the inputs are not in range.
Figure1 - SOLO’s interactional sections
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SOLO BETA User Manual
Absolute Maximum Voltage Ratings:
- All The sections are referred to Figure1 above
-The +3.3V parts are NOT +5V tolerant, and in case of applying more than 3.3V, the device might
get permanently Damaged.
-The “DIR” input is a 3.3V input, and it’s NOT 5v tolerant, to apply a 5V input you MUST use a
resistor with a value between 1kΩ to 2.2kΩ, as can be seen in “Essential Wiring Example”below
(The exact value of resistance is not important, but it must be in mentioned range).
- The users should refer to “Typical Max” for the maximum voltage allowed on each pin, the “Absolute
Max” is just for very short times considering the effect of spikes and fast harmonics.
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Section
PIN/Connector name
Input / Output
Units
Min
Typical
Max
Absolute
Max
2
Supply Input
Input
VDC
+8
+56
+58
3
S/T (speed/torque)
Input
VDC
0
+5.0
+5.5
3
P/F (current limit/power/flux)
Input
VDC
0
+5.0
+5.5
3
DIR (Direction control)
Input
VDC
0
+3.3
+3.6
3
+5V (External supply)
Output
VDC
+4.95
+5.0
+5.2
8
CHA(Encoder)/HALL_A
Input
VDC
0
+5.0
+5.5
8
CHB(Encoder)/HALL_B
Input
VDC
0
+5.0
+5.5
8
Index(Encoder)/ HALL_C
Input
VDC
0
+5.0
+5.5
8
Strobe(Encoder)
Input
VDC
0
+5.0
+5.5
9
UART_RX
Input
VDC
0
+3.3
+3.6
9
UART_TX
Output
VDC
0
+3.3
+3.6
9
CAN_RX
Input
VDC
0
+3.3
+3.6
9
CAN_TX
Output
VDC
0
+3.3
+3.6
9
+3.3V(External supply)
Output
VDC
+3.25
+3.3
+3.38
SOLO BETA User Manual
Connectors and Sections:
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Section 1 - Motor Output
PIN
Name
Descriptions / Notes
I/O
1
A
Motor Output 1
-
2
B
Motor Output 2
-
3
C
Motor Output 3
-
Section 2 - Supply Input
PIN
Name
Descriptions / Notes
I/O
1
++
Positive Voltage Input
-
2
- -
Negative Voltage Input ( Ground )
-
Section 3 - Analogue Inputs and +5V External Supply
PIN
Name
Descriptions / Notes
I/O
1
GND
Analog Ground of SOLO
-
2
DIR
Direction of rotation of the motor control
I
3
P/F
Current Limit, Power or Flux reference
I
4
S/T
Speed or Torque reference
I
5
+5V
Supply output for external modules ( fused at 1A)
O
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Section 4 and 5 - Speed Controller Gains
section
Name
Descriptions / Notes
I/O
4
Kp
Proportional Gain of speed controller
-
5
Ki
Integral Gain of speed controller
-
Section 6 - Piano Switch Settings
PIN
Name
Descriptions / Notes
I/O
1
Motor Select-1
Selects the Type of the Motor
-
2
Motor Select-2
Selects the Type of the Motor
-
3
DFU Mode
Puts the device into Firmware Upgrade Mode
-
4
Speed / Torque
Speed or Torque control
-
5
Open / Closed loop
Open-loop or Closed-loop selection, Motor Identification
-
Section 7 - USB Connection
PIN
Name
Descriptions / Notes
I/O
-
USB
Virtual COM port or Device Firmware upgrader
-
Section 8 - Encode/Hall connector
PIN
Name
Descriptions / Notes
I/O
1
+5V/500mA
Encoder +5V external supply
O
2
Encoder CHA/HALL_A
Channel A of the Encoder or Hall position sensors
I
3
Encoder CHB/HALL_B
Channel B of the Encoder or Hall position sensors
I
4
Encoder Index/ HALL_C
Index Input of the Encoder (not mandatory) or Channel C of Hall
position Sensors
I
5
Encoder Strobe
Encoder Strobe (not needed)
I
6
GND
SOLO’s Ground
-
SOLO BETA User Manual
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Section 9 - Communication Port
PIN
Name
Descriptions / Notes
I/O
1
+3.3V / 100mA
+3.3V external supply
O
2
+5V/500mA
+5V external supply
O
3
GND
SOLO’s Ground
-
4
GND
SOLO’s Ground
-
5
+5V/500mA
+5V external supply
O
7
S/T
Speed or Torque reference (alternative to section3 pin 4 )
I
9
P/F
Current Limit, Power or Flux reference (alternative to section3 pin 3 )
I
11
DIR
Direction of rotation of the motor control (alternative to section3 pin 2 )
I
13
CAN_RX
CAN protocol receiver input
I
15
CAN_TX
CAN protocol transmitter output
O
17
UART_TX
UART protocol transmitter output
O
19
UART_RX
UART protocol transmitter input
I
20
GND
SOLO’s Ground
-
Section 10 and 11 - Functionality LEDs
section
Name
Descriptions / Notes
I/O
10
E2
Normal Activity LED
-
11
E1
Error Indicator LED
-
SOLO BETA User Manual
Sections Description:
Section 1 - Motor Output
This connector of SOLO should be connected to the Motors wires. You can find out more about
how to connect them by looking at the “Minimum Required Wirings” part, but in general for 3
phase motors the A,B,C pins should get connected to the 3 phase wires of the motor and for DC
brushed motors only B and C pins are required to be connected to the motor.
Section 2 - Supply Input
This is the Power Supply input of SOLO and you can power it up with any input voltages from 8 to
56 volts in continuous mode, depending on the voltage rating of the Motor Connected at the
output. The max rating for supply input is 58V in transient mode, meaning that SOLO will go into
over-voltage protection mode in case the supply or BUS voltage rises above almost 58 volts.
Section 3 - Analogue Inputs and +5V External Supply
This is the Analogue commanding port of SOLO, through these inputs/outputs, you can control the
Speed or Torque of your motors by sending analogic commands using PWM pulses with any
frequency above 5kHz or sending direct analogue voltages rated from 0V to 5V, you can also use
them to limit the current fed into your Motor in a completely Analogue Mode ( see the Minimum
Required Wirings Section)
This part is composed out of 5 pins:
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SOLO BETA User Manual
Figure 2 - Analogue Inputs and +5V External Supply
“GND” PIN:
This is the Ground or in another word the 0V reference of SOLO, so if you want to send an
analogue commands to SOLO, you need to make sure the Ground of the commanding unit (
Arduino, Raspberry Pi , … ) is shared and connected with SOLO at this point.
“+5V” PIN:
This is a 5V/1A output to supply external peripherals or controllers, remember that this output is
fused, and if you drain more than 1A, the fuse will be blown ( internally ) and this output will
become dysfunctional for safety reasons.
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SOLO BETA User Manual
“DIR” PIN:
This is the Direction control pin which is a digital pin, accepting voltage levels of 0V or 3.3V, so by
giving each of these values, the connected Motor to SOLO, will either rotate in C.W. direction or
C.C.W. direction.
Remember that DIR pin is NOT 5V tolerant and if you like to connect it to a 5V source, you must
use a resistor of a value between 1kΩ to 2.2kΩ (the exact value is not important, it just must be in
this range)
“P/F” PIN:
This is a pin with three main different functionalities depending on the control Mode and the type
of the motor you select as below:
In Open Loop mode of 3 phase motors :
It will act as increasing or decreasing the injected power into the Motor, so by applying 0V of
analogue voltage or 0% duty cycle of PWM, there will be no power injected inside the Motor, and
at 5V or 100% duty cycle of PWM, it will apply the maximum deliverable power into the Motor.
In Closed-Loop mode of DC, BLDC and PMSM motors:
It will act as the current Limit, so if the voltage applied to this pin is 5V, it will stop the current
floating to the motor ( current Limit at zero), and if this pin is left open it will allow up to 32A
floating into your Motor, so any value between these will define the value of current limit. You can
calculate the current limit value based on following formulas:
In case of using PWM:
The current Limit value = ((100 - duty cycle precentage of PWM at P/F input)/100) * 32.0
In case of using Analogue Voltages:
The current Limit value = ((5.0 - the voltage at P/F input)/5.0) * 32.0
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SOLO BETA User Manual
In Closed-loop mode of AC Induction Motors:
it will act as the reference for magnetizing current reference known as “Id” which is in charge of
generation of stator flux. The maximum amount of current that can be injected into the motor
using this pin is 10Amps. So in order to calculate the amount of magnetizing current you can use
the following formulas:
In case of using PWM:
The Magnetizing current value = ((100 - duty cycle of PWM at P/F input)/100) * 10.0
In case of using Analogue Voltages:
The Magnetizing current value = ((5.0 - the voltage at P/F input)/5.0) * 10.0
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SOLO BETA User Manual
“S/T” PIN in Closed_loop Mode:
This is the input for controlling Speed or Torque of the Motor connected to SOLO, you can select
this mode using the Piano switch mentioned in section 6, the analog voltage or the duty cycle of
PWM pulse applied in either of the conditions will be treated as a desired reference of the user
based on following explanations:
In Torque mode:
if you apply an analog 5V or in case of using PWM inputs, a 100% duty cycle to this pin, without
having a current limit, SOLO will try to inject 32A of current inside your motor , given this, the
amount of Torque for motors generally can be calculated:
Applied Motor Torque = Current acting in torque generation * Motor Torque Constant
The “Current acting in torque generation” for DC motors is shown with “IM” and the same for 3
phase motors (BLDC , PMSM or ACIM) is shown by “Iq” or namely the “Quadrature current”.
So the amount of active current in torque generation injected to your motor based on the amount
of voltage or duty cycle you apply to S/T pin can be calculated as:
In case of using PWM:
The torque generation Current = ((100 - duty cycle of PWM at S/T input)/100) * 32.0
In case of using Analogue Voltages:
The torque generation Current = ((5.0 - the voltage at S/T input)/5.0) * 32.0
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SOLO BETA User Manual
In Speed mode:
if you apply an analog 0V or in case of using PWM inputs, a 0% duty cycle to this pin , it will keep
your motor’s speed at 0 RPM, and at the same time by applying 100% duty cycle or 5V analogue
input, SOLO will force your motor to go to the maximum speed based on the Motors type as
below, of course your motor should be able to reach to that speed, otherwise it will stay at its
nominal speed even if you keep increasing the duty cycle. (look at the piano switch settings down
below)
For instance, if we take Normal Brushless motors as an example, and in case of applying analogue
voltages, the speed of the motor can be found based on the following formula:
The Normal BLDC motor speed [RPM] = ((5.0 - the voltage at S/T input)/5.0) * 8000
- To have accurate 3 phase motors speed measurements by SOLO, if needed, you need to
set the number of Poles of you motor at their exact value using one of the methods in
“Digital Commanding and Control” section, since the default value for number of poles in
SOLO is set at 8. If you don’t change this value SOLO will still function but you might need
to tune this value if you need the best performance in speed tracking and estimation in
sensorless mode.
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Motor
code
Motor Name
Maximum Speed in Closed-loop mode
Speed and
Position
Controller
Sampling Rate
0
DC brushed
Depends on BEMF constant of the Motor, but it
will go to nominal speed at 5V or 100% input
duty-cycle
1kHz
1
Normal Brushless Motors
(BLDC, PMSM)
8000RPM at 5V or 100% PWM input
duty-cycle
1kHz
2
AC Induction Motors (ACIM)
4000RPM at 5V or 100% input duty-cycle
1kHz
3
Ultra Fast Brushless Motors
(BLDC, PMSM)
30000 RPM at 5V or 100% PWM input
duty-cycle
1kHz
SOLO BETA User Manual
“S/T” and “P/F” PINs in Open_loop Mode:
In Open-loop Mode to control the speed of 3 phase Motors, you need to set both “S/T” and “P/F”
voltage values to apply the desire speed and power respectively, and for each of them you can find
the explanation below:
the speed of the motors in RPM can be derived from the following formulas based on the motor
type selected on Piano Switch, Section 6:
Number of Motor Pole Pairs = Number of Motor Poles / 2
In case of using Analogue Voltages on “S/T”:
●Normal Brushless Motor = (voltage applied at “S/T”)/(5.0* Number of Pole pairs)*8000
●Ultrafast Brushless Motor = (voltage applied at “S/T”)/(5.0* Number of Pole pairs)*30000
●AC induction Motors = (voltage applied at “S/T”)/(5.0* Number of Pole pairs)*4000
In case of using PWM inputs on “S/T”:
●Normal Brushless Motor = (PWM duty-cycle Percentage at “S/T”)/(100%* Number of Pole
pairs)*8000
●Ultrafast Brushless Motor = (PWM duty-cycle Percentage at “S/T”)/(100%* Number of
Pole pairs)*30000
●AC induction Motors = (PWM duty-cycle Percentage at “S/T”)/(100%* Number of Pole
pairs)*4000
Three phase Motors “Power” Notation in Open-loop Mode:
The “P/F” input in open loop mode of 3 phase motors acts as the output voltage adjuster, so by
going all the way up from 0V of Analogue voltage or 0% duty-cycle of PWM inputs at this pin to
+5V or 100%, you will increase the peak 3 phase voltage resulted by SVPWM modulation on
SOLO to the motor linearly from 0V to Vbus/sqrt(3) or equivalently to Vbus*0.577 at maximum,
Vbus here refers to the DC supply input voltage ( or battery voltage ),the action of increasing the
output voltage peak, will result in higher consumption by the motor depending on their phase
resistance and finally having more power for their rotation.
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SOLO BETA User Manual
Section 4 and 5_ Speed Controller Kp and Ki :
These are two potentiometers, defining the speed controller gains in closed-loop mode, You can
increase their values by rotating them in Counter ClockWise direction, subsequently by rotating
them in Clockwise direction their value reduces until they get blocked in that direction which
means a value of ZERO, to work with SOLO, in closed-loop speed mode you need to tune these
two poetntio-meters, their simple definitions can be given as following :
Kp Potentiometer :
This potentiometer defines for you how fast your motor should react and reach the speed you
asked, so if you increase this value, your motor will be more reactive, but too much of this gain
might make vibrations, so you need to tune it enough. Also another effect of this gain will be how
“harshly” the controller ( here SOLO ) should react to the variation of the load on the shaft of the
motor to keep the speed constant. It's not always good to increase this gain randomly, since it
might cause instability and it totally depends on your system.
Ki Potentiometer :
This potentiometer defines how good your motor during time should reach the goal and stay in
steady state, so by increasing this value your motor might reach the goal slower but more
consistently. Also by increasing this gain too much your motor might get unstable. So you need to
tune this similar to Kp with patience and accuracy, to have zero error at steady state this gain must
be anything greater than zero, and zero error in steady state means, the controller reaches to
desired speed and remains there with zero error in theory ( in practice with minimum possible
error)
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Table of contents
Other Solo Controllers manuals
