Solo PICO User manual
SOLO PICO User Manual
Part Number: SLP0123_5816
Product Description
Power Range
SOLO PICO with part number of
SLP0123_5816 is a member of the SOLO motor
controllers family of devices capable of driving
and controlling various types of electrical
motors like DC brushed, BLDC, PMSM and EC
coreless motors in a single platform. They are
made to be easy to use with state of art
technologies and Dual Core parallel processing
architecture on top of FOC control methods.
SOLO PICO supports sensor-based Torque,
Speed and Position controlling plus other
options like full digital and analog controls and
active safety measures to keep the
applications safe from unforeseen behaviors.
Supply Voltage Range : 8- 58 VDC
Peak Current: 32A peak to peak
Continuous Current: 16A
Features
●Easy to use
●Drives and Controls DC brushed,
BLDC, PMSM and EC coreless motors
●Torque, Speed and Position controlling
●Four Quadrant Regenerative operation
●Automatic parameter Identification
and self-tuning
●Safe Torque off (STO) input
●USB, UART and CANopen
●Supports PT1000 temperature sensors
●Sleep mode with current consumption
of 200µA
●Field Oriented Control with Nested
Position-Speed-Torque loops
●Dual Core with Parallel Processing
Architecture
●Bus over-voltage, Bus under-voltage ,
over-current and over temperature
protections
●Full Digital and Analogue Control
●Space Vector Modulation (SVPWM)
●Embedded Motion Profile (St-Curve)
for Position and Speed
Modes of Operation
Commands and feedbacks Source
●Analogue or Digital commanding
●Torque Control
●Speed Control
●Position Control
●0-5V Analogue/ PWM inputs for Speed
or Torque control
●Analogue torque and speed feedbacks
●Quadrature Encoder and Hall sensor
inputs
●Isolated UART, USB and CAN bus
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SOLO PICO User Manual
Part Number: SLP0123_5816
Applications
●Industrial Automations
●Robotics and Traction Units
●Drones
●Automotive Industries
●Household Appliances
●Medical Devices
●Aerospace
●Textile Industry
●Automated Guided Vehicles (AGVs)
●Heating, Ventilation and Air-Conditioning (HVAC)
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SOLO PICO User Manual
Part Number: SLP0123_5816
Identification of hazards and instructions on how to prevent them
Danger
Immediate dangers which can lead to death or serious injuries.
Warning
Hazards that can cause serious damages or injuries.
Caution
Hazards that can cause minor injuries or material damage.
Recommendations, tips, references to other documentation.
Essential or useful accessories.
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SOLO PICO User Manual
Part Number: SLP0123_5816
Table of Contents
Power Specifications: 7
Control and Timings specifications: 8
Thermal Specifications: 9
Mechanical Specifications: 9
Mechanical Dimensions ( No Heatsink ): 10
Mechanical Dimensions ( With Heatsink ): 11
Absolute Maximum Voltage Ratings: 12
Overview of the product 13
Functional Block Diagram: 14
Theory of Operation: 15
FOC control Architecture in SOLO PICO for 3-phase Motors: 16
Cascade control Architecture in SOLO PICO for DC Motors: 17
SOLO PICO’s Interactional Sections: 18
Connectors and Sections: 19
Sections [4, 5, 6] - Motor Outputs 19
Sections [2, 3] - Supply Inputs 20
Section [10] - Control I/O Port 21
Section [9] - USB Connection 27
Sections [7,8] - Functionality LEDs 28
Section [1] - Power Up LED 29
Connectors and their Matings Part Number: 30
Analogue versus Digital Control in SOLO PICO 31
SOLO PICO Wirrings 32
Wiring Legend: 32
Safe Torque Off (STO) Wiring: 33
1- Wire STO to a safety relay using external +5V DC supply voltage: 33
2- Wire STO to a safety relay using internal +5V supply voltage: 34
3- By Passing STO without external commanding devices: 35
Analogue wiring in SOLO PICO: 36
1- Analogue wiring in case of controller with NPN outputs: 36
2- Analogue wiring in case of controller with PNP outputs: 37
3- Analogue wiring in case of Embedded MCU Boards: 38
Wiring with HALL Sensors: 39
Wiring with Incremental Encoders: 40
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SOLO PICO User Manual
Part Number: SLP0123_5816
1- Wiring in case of Single Ended Incremental Encoders: 40
2- Wiring in case of Differential Incremental Encoders: 41
Wiring of Sleep Mode input: 42
Wiring of DFU Mode input: 42
Steps to put SOLO on DFU mode: 43
PT1000 temperature sensor wiring: 44
Analogue Torque and Speed Feedbacks and Wiring: 46
Digital Mode Wirings: 48
USB Interface Wiring 48
UART Interface Wiring 49
CAN bus Interface Wiring 50
Full Wirings of SOLO PICO: 51
Standalone Wiring (No External Modules): 51
Embedded MCU Boards using Analogue/PWM: 53
Embedded MCU Boards Using UART: 54
Embedded MCU Boards Using CANopen: 55
General Wiring Considerations in SOLO PICO: 56
1- Avoid running feedbacks and power wires together 56
2- Avoid making ground loops 56
Temperature and Max Current Behaviour: 58
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SOLO PICO User Manual
Part Number: SLP0123_5816
Power Specifications:
Description
Units
Values
DC Supply Voltage Range (continuous)
VDC
8 to 58
Software Overvoltage Activation Voltage
VDC
59.5V
DC Bus Undervoltage Limit
VDC
7
Maximum Peak Output Current
A
32 peak to peak
Maximum Continuous Output Current
A
16
Maximum Continuous Output Power
W
300
Internal Bus Capacitance
µF
440
Switching Frequency (Output PWM Frequency)
kHz
8 to 80
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SOLO PICO User Manual
Part Number: SLP0123_5816
Control and Timings specifications:
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 - 3.3/5
Modes of Operation
-
Torque - Speed- Position
Motors supported
-
DC brushed - BLDC - PMSM - EC Coreless
Hardware Protections
-
Bus under-voltage, over-current and over
temperature
Current (Torque) Loop sampling time
µs
Synched to PWM frequency ( Min 7 µs)
Current (Torque) Loop execution time
µs
7
Speed controller Loop sampling time
µs
500
Speed controller Loop execution time
µs
75
Position controller Loop sampling time
µs
500
Position controller Loop execution time
µs
75
Maximum Encoder Frequency (Pre-Quad)
MHz
18
Current Measurement Resolution
mA
16
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SOLO PICO User Manual
Part Number: SLP0123_5816
Thermal Specifications:
Description
Units
Values
Board Temperature Range
°C
-20 to 85
Heatsink (base) Temperature Range
°C
0 - 85
Cooling system
-
Natural Convection
Mechanical Specifications:
Description
Units
Values
Size (H x W x D)
mm
19.2 x 67.73 x 56.82
Weight (without heatsink)
gr
28
Form Factor
-
Wall Mount
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SOLO PICO User Manual
Part Number: SLP0123_5816
Absolute Maximum Voltage Ratings:
- All The sections are referred to Figure 5 below
-The +3.3V parts are NOT +5V tolerant, and in case of applying more than 3.3V, the device
might get permanently Damaged.
-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.
Section
PIN/Connector name
Input / Output
Units
Min
Typical Max
Absolute Max
]3,2[
Supply Input
Input
VDC
+8
+58
+63
[10]
S/T (speed/torque)
Input
VDC
0
+5
+5.25
[10]
P/F (current limit/power/flux)
Input
VDC
0
+5
+5.25
[10]
SF (Speed feedback)
Output
VDC
0
+5
+5.25
[10]
TF (Torque feedback)
Output
VDC
0
+5
+5.25
[10]
TS (PT1000 input)
Input
VDC
0
+3.3
+3.75
[10]
DF (DFU mode input)
Input
VDC
0
+3.3
+3.75
[10]
Dir (Direction control)
Input
VDC
0
+5
+5.25
[10]
STO(Safe Torque off input )
Input
VDC
0
+5
+5.25
[10]
5V (External supply)
Output
VDC
+4.95
+5.0
+5.05
[10]
EA (Encoder channel A)
Input
VDC
0
+5
+5.25
[10]
EB (Encoder channel B)
Input
VDC
0
+5
+5.25
[10]
EC (Encoder channel C)
Input
VDC
0
+5
+5.25
[10]
RX
Input
VDC
-0.5
-
+5.5
[10]
TX
Output
VDC
-0.5
-
+5.5
[10]
CH
-
VDC
-2
-
+7
[10]
CL
-
VDC
-2
-
+7
[10]
O1
Output
VDC
0
-
+5.5
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SOLO PICO User Manual
Part Number: SLP0123_5816
Overview of the product
SOLO PICO is a family of low-power motor controllers that are designed for low-current
applications. This product is designed to support various types of electrical motors like DC
brushed, Brushless DC and PMSM motors up to 58V DC with the supply voltage and the
continuous current of up to 16 Amps, this will enable SOLO PICO to be utilized in wide range of
products and projects and eventually speeding up the developments and time to market for its
users.
SOLO PICO can be commanded in two different ways, either by sending Analogue voltages or
PWM pulses which is called Analogue Mode, or totally by sending Digital data packets through
UART, USB or CAN bus lines. This will give a high flexibility in terms of system setup to the users
and they can choose the best way to wire up their systems using SOLO, The main features of SOLO
PICO are listed as below:
●Wide input voltage supply range from 8V to 58V
●The continuous output current of 16 Amps
●Capable of controlling DC brushed, BLDC and PMSM motors
●Dual Core with parallel processing architecture
●CAN, USB and UART Communications
●STO(Safe Torque off) for safe emergency stops
●Extremely fast F.O.C loop-rate up to 140kHz (7µs complete execution time)
●Over-current, Over-voltage, Over-Temperature and Under-voltage Protection
●Selectable output PWM switching frequency from 8kHz to 80kHz
●Automatic self-tuning and identification of Motor parameters
●Closed-loop Torque, Speed or Position control
●Advance Field Oriented Control
●PWM and Analogue voltage input for Controlling Speed and Torque
●Pure Analogue feedbacks output for Speed and Torque
●Encoder and Hall Sensor Input with up to +5V supply
●+5V/500mA (5W) outputs to supply external modules
●200µA current consumption in sleep mode
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SOLO PICO User Manual
Part Number: SLP0123_5816
Architecture:
Figure 2 - Architecture of SOLO PICO
Theory of Operation:
SOLO PICO is designed to operate in closed-loop fashion with nested Torque, Speed and Position
controlling loops, this type of topology gives the possibility of controlling each of these
phenomenons (Torque, Speed, Position) separately and almost independently, resulting in very
robust and smooth control for systems with variable dynamics and loads, for 3-phase motors like
Brushless DC and PMSM this topology is known as Field Oriented Control or Vector Control.
In general we can divide the whole control architecture of SOLO for two different types of Motors,
the 3-phase motors that can be seen in Figure 3 and Brushed DC motors that can be seen in Figure
4 below. As can be seen in these figures, the main foundation of the architecture of motor
controlling in SOLO is based on three fundamental controllers:
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SOLO PICO User Manual
Part Number: SLP0123_5816
1- The Torque Controller: This is the closest controller to the motor and the fastest one, it will
only control the Torque of the Motor which is generated by injection of Current into the stator,
that’s why this controller is known as Current Controller too, this controller will try to stabilize the
required torque (current) in the motor to make the whole system capable of overcoming the
dynamics changes in the load.
2- The Speed Controller: The Speed Controller comes behind the Torque Controller, it is slower
than the Torque controller (at least around tenfold) and it basically tries to fix the Speed on a
desired value, this controller will keep the rotational speed fixed regardless of the load variation
and it will adjust the torque accordingly. One might ask why the Speed controller comes after the
Torque controller, this is a big topic, but to simplify it drastically , in principle an Electrical Motor is
a Torque Generation machine, even the Speed is controlled finally by controlling the Torque, so the
Speed commands to the Torque Controller to increase or decrease the Torque on the Motor to
stabilize the motor on a specific desired Speed based on the effect of the load on the shaft.
3- The Position Controller: This is the last controller coming behind the speed controller, it
basically tries to set the exact position of the Motor on a specific value, so to make this loop
functional, the user needs to make sure the Torque and Speed loops are firstly tuned and ready.
FOC control Architecture in SOLO PICO for 3-phase Motors:
Figure 3 - FOC Control Architecture of SOLO PICO for 3-phase Motors
As can be seen in Figure 3, to control any of the Torque, Speed and even position of a 3-phase
motor in FOC fashion, there is a need to have at least 4 different feedbacks:
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SOLO PICO User Manual
Part Number: SLP0123_5816
1- Current Feedback: This feedback is necessary to control the current inside of the motor and for
Torque Controlling and it’s measured internally by SOLO, the accuracy of current measurement is
16mA in SOLO PICO.
2- Speed Feedback: This feedback is measured using the sensors mounted on the motor
(Encoders, Halls, …), and it’s used for Speed Controlling purposes.
3- Position Feedback: This feedback comes from external sensors like Encoders, and it enables the
Servo-Driving Capabilities of SOLO
4- Motor Electrical Angle: This feedback is essential for any type of closed-loop control on SOLO,
this feedback is Measured by SOLO internally.
Cascade control Architecture in SOLO PICO for DC Motors:
Figure 4 - Control Architecture of SOLO PICO for DC Brushed Motors
As can be seen in Figure 4, the main architecture of Motor Controlling for DC brushed motors in
SOLO follows a very similar pattern to 3-phase Motors Controlling with FOC, however the
architecture is generally simple with only one cascade loop of Torque, Speed and Position.
Similar to 3-phase motors, for DC brushed Motors, SOLO offers Sensor-based controls as well as
Servo-Driving in case an Incremental Encoder is attached to the Motor, so the whole control
strategy and tunings are identical to the 3-phase motors with minor differences on the processing
methods.
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SOLO PICO User Manual
Part Number: SLP0123_5816
SOLO PICO’s Interactional Sections:
SOLO PICO can be decomposed into 10 main interactional sections as shown in Figure 5, all the
sections will be explained in detail and their electrical and maximum ratings will be mentioned
later in this user manual, the user has to make sure they don’t exceed those maximum ratings to
avoid damaging themselves or the SOLO PICO unit.
Figure 5 - SOLO PICO’s interactional sections
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SOLO PICO User Manual
Part Number: SLP0123_5816
Connectors and Sections:
Sections [4, 5, 6] - Motor Outputs
Name
Descriptions / Notes
I/O
A
Motor Output 1
-
B
Motor Output 2
-
C
Motor Output 3
-
Description
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 “SOLO PICO Wirings” Section, 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.
- While wiring SOLO PICO avoids connecting power supply cables into motor outputs,
this can cause serious damages to the unit.
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SOLO PICO User Manual
Part Number: SLP0123_5816
Sections [2, 3] - Supply Inputs
Name
Descriptions / Notes
I/O
++
Positive Voltage Input
-
- -
Negative Voltage Input ( Ground )
-
Description
This is the Power Supply input of SOLO and it can be supplied with any DC input voltages from 8
to 58 volts in continuous mode, depending on the voltage rating of the Motor Connected at the
output. The max rating for supply input is 59.5V, meaning that SOLO PICO will go into
over-voltage protection mode in case the supply or BUS voltage rises above almost 59.5 volts.
- SOLO PICO doesn't have Reverse Polarity Protection, thus the user has to make sure
their supply is correctly connected to the unit before turning it ON. By applying the
supply reversely, the damage to the unit is imminent.
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