1kW BLDC Power Tool Kit User Manual
Contents
1. Further Information http www infineon com dave E E E oe 9999 J LI RE 89999 Saala a Baa TJE ILILILILILRLLL 64Mhz MATH On chip RTC Co Processor Oscillator SysTick WDT VREG ARM Cortex MO 39MHz Programmable 64MHz Interconnect Peripheral PRNG Matrix Clock Secure Data IP Temp Bootloader Protection Sensor 1x PWM Timers 1x PWM Timers CCU8 Hall amp Encoder I F CCU4 16 64Bit 8ch POSIF 16 64Bit 4ch Dead Time 12 bit ADC Analog Comp FLASH 200KB LED color and brightness control USIC 2ch Quad SPI SCI UART Och I2C 12S Figure 34 Block diagram of XMC microcontroller DAVE software is a free development platform which reduces software development time for XMC microcontrollers It includes a complete free tool chain including a GNU compiler debugger and a data visualization tool DAVE Apps are application components for a wide range of use which makes it easy to fully utilize flexible peripherals A resource solver ensures conflict free mapping of chip resources Application Note 31 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon Test Results 8 Test Results 8 1 Efficiency measurement For the efficiency measurement following setup is used Power Analyzer 1 V2 V3 15 w 13 Power yeas BLDC Supply T bana DC ELECTRONIC LOAD Figure35 Measurement Setup Test setup description A regulated power supply is used to p2. Figure 33 Unipolar voltage switching with synchronous rectification for all 3 phases 6 2 2 Overcurrent shut down Each phase current is monitored by measuring and amplifying the drain source voltage of the low side MOSFET during its ON state This voltage is evaluated and temperature compensated by XMC microcontroller refer to Rps on VS temperature diagram The current threshold is set to 150 A If the phase current exceeds 150 A the inverter will shut down and stay in de energized state until the next power cycle 6 2 3 Overtemperature shut down The temperature sensor is placed in vicinity of high side MOSFET of W phase When temperature of 80 C is reached the inverter will shut down until the temperature sensor cools down to 50 C When 50 C is reached the inverter will automatically turn ON again and resume the operation Application Note 29 Revision 2 0 2014 10 09 o 1 kW BLDC Power Tool Kit User Manual Infineon Software 6 2 4 Wrong hall pattern shut down If the hall patterns do not match the expected sequence wrong connection the power stage will shut down to prevent the MOSFET overstress Each time this condition is encountered the unit needs to be reset 6 2 5 Motor soft start In order to prevent high inrush current the motor control regulates the rate of duty cycle i e voltage increment applied to the motor 6 2 6 Monitoring input DC voltage The input DC voltage is monitored by the XMC microcontrolle
3. e High efficiency 99 e Maximized power density 75 W cm e Half bridge gate driver 2EDL05N06PF 0 5 A peak e Boost converter for gate driver voltage generation programmed for 12 V VY boost but it can be modified for other gate driver voltages Application Note 4 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon Power Tool Kit Package content 2 Power Tool Kit Package content The Power Tool Kit includes following items e Power Tool demo PCB programmed and ready to use e USB Serial communication adapter FTDI Cable e USB memory stick including documentation and software e 2x15cmribbon cable Figure2 Power Tool Package 2 1 PCB The PCB consists of several building blocks e Linear regulator IFX27001TFV50 DC DC converter stepping down the battery voltage to 5 V for MCU e Boost circuit used for gate drivers and an Opamp e Temperature sensor for thermal overload shutdown e 3 phase full bridge inverter implemented with 2 in parallel Infineon OptiMOS Power MOSFETs BSC010N04LSI l 100 A Rosion 1 05 MQ e Current measurement by using voltage measurement across the MOSFET when turned ON e 3x Half Bridge gate driver with integrated bootstrap diode e 32 bit XMC1302 microcontroller e Hall sensors signal input circuitry for BLDC motor commutation e Serial communication for programming and controlling the MCU e Connector for a direct access to MCU debug pins e 10 spare MCU pins which ca
4. Connecting the board to a BLDC Motors sss sss sse sese 8 4 Haridwar Des DUON sesers eE EEE EE ETE H 11 4 1 POWER Supply S Vand 2 DOOS issuer nirre ER AENEA EE e Rii 11 4 2 PONS 30d CC a E E E 11 1 Revision 2 0 2014 10 09 1 KW BLDC Power Tool Kit User Manual Cinfineon Overview 4 3 Current measuremeni c0 0002 5 14 08054 80008094 800000944 00854 80008094 860080944 8004 12 4 4 GAS DIST R EE E E S S A 14 4 4 1 Gate driver ZEDEOSNOGPE features sss seene 15 4 5 ICV O COUN O1 012 ng ga sa 15 4 5 1 XMC Microcontroller features 0333310110011 1010 1110003055 1 n0 0 0 ng 0009 17 4 6 Hall Sensors Digital yie sa issiaosesassoaoiiaiisdecbogssieas320p3ebasgtaoadhssa3geBegeb e3s3 sudsc9asbgsoazbgas4ezBagos3gag32a4 18 4 7 EI CU D Si 00100 500i E in d0 sa annno 19 5 nan 20 5 1 CCMA AEA A EEE c 20 5 2 Ay OE GUI PVC YT E TTT 21 5 3 PB OCI COU TTT 24 5 4 SIE MAEI lea E a E E E E E A 26 6 ORW a E E 4 28 6 1 G1 e E E A E EA A E E EE AE T E E A E 28 6 2 OA OSS aema E A E a 28 6 2 1 Unipolar Block Commutation with active reCtIifiCaf OFN eee 28 6 2 2 6 ehu CNG SIE e O TT aiueneniesaeceeenipurcsenes 29 6 2 3 i8i gt 8 9 ci72 971 723019109 6 0 8 k a sa a a a 29 6 2 4 Wrong IT8ILDAHTIT SITUDOWTesesaasestsassddpagodssalasiskdsssspbsSaba waadsxSs24sa0
5. D18 1SMA5931BT3 Zener Diodes 18V1 5W DO214AC SEMICONDUCT LG OR Cl C2 L1 Infineon IFX27001TFV50 LDO Voltage Regulators Linear PG TO Technologies Voltage Regulator 252 3 Infineon XMC1302 XMC1302 ARMP Cortex M0 32 SOP50P64 Technologies T038X0200_AA bit Microcontroller 0X120 38N Bourns CM453232 Fixed Inductors 82uH 10 1812 820KL Wirewound Q1 Q2 Q3 Infineon BSC010N04LSI Q4 Q5 Q6 Technologies ATMA1 MOSFET 40 V 1 05 mOhm 100A PG TDSON 8 Q7 Q8 Q9 FL Q10 Q11 Q12 Q13 Infineon BSS670S2LH63 N Channel Small Signal PG SOT 23 Technologies 27XT MOSFET 55 V 650 mOhm R7 8 9 10 11 RK73H1JTTD1 Thick Film Resistors SMD 1 10 603 Application Note 26 Revision 2 0 2014 10 09 aw 1 kW BLDC Power Tool Kit User Manual In fineon PCB Quantity Designator Manufacturer Footprint Part Number 5 26 27 501F watt 7 5 kOhm 1 R39 50 40 43 RK73H1 JTTD1 603 32 53 47 002F watts 10 kOhm 1 R73 R74 R75 RK73H1JTTD1 603 500F watts 150 Ohm 1 R33 42 51 70 RK73H1JTTD2 603 71 72 201F watt 2 2 kOhm 1 KOA RK73H1JTTD1 603 601F watt 1 6 kOhm 1 KOA RK73H1JTTD2 603 203F watt 220 kOhm 1 KOA KOA OA O C2 N C2 R34 44 52 C2 RK73H1JTTD2 603 002F watt 20 kOhm 1 RK73H1 JTTD1 603 003F watt 100 kOhm 1 003F watt 100 kOhm 1 Microchip MCP9700T Board Mount Temperature SOT 23 3 E TT Sensors Lin Active Therm 10 mV C U1 Texas LM324PWR Operational Amplifiers Quad TSSOP 14 Instruments
6. GP Opamp 3 U2 U3 U4 Infineon 2ZEDLOSNO6PF EiceDRIVER high voltage gate SOIC127P driver IC 600X175 8N 2 Dulling Elektro 9015 006 Copper plate U Teil 6 custom amp Metal GmBH made Dulling Elektro 9015_ 007 Copper plate U Teil 7 custom amp Metal GmBH made R R R R 36 13 14 15 KOA 28 29 30 RK73H1JTTD3 Thick Film Resistors SMD 1 10 603 302F watt 33 kOhm 1 Oo 38 35 41 36 T1 R R Technology 2 X1 X4 Samtec Inc HTSW 102 07 CONN HEADER 2POS 100 T H_ vertical L S GOLD single row 1 X3 Samtec Inc HTSW 103 07 CONN HEADER 3POS 100 T H vertical G S GOLD single row 1 XT Samtec Inc HTSW 106 07 CONN HEADER 6POS 1 T H vertical G S GOLD single row 1 X8 Samtec Inc HTSW 105 07 CONN HEADER 5POS 100 T H vertical G S GLD single row 27 Application Note Revision 2 0 2014 10 09 o 1 kW BLDC Power Tool Kit User Manual Infineon Software 6 Software 6 1 Overview The motor control software is based on a voltage control block commutation algorithm of the BLDC motor The microcontroller reads 3 hall switch patterns in order to determine the correct switching sequence for the phase commutation Other input variables such as phase current temperature supply voltage anda wrong hall pattern sequence are also being monitored by the microcontroller According to their values the microcontroller takes an action and controls the power inverter stage accordingly Th
7. 9 o 1 kW BLDC Power Tool Kit User Manual Infineon Test Results Table 4 Efficiency measurement with BSC010N04LSI in block commutated BLDC motor drive Input Power Efficiency Power Losses W W W 832 24 99 2 6 4 975 34 98 7 12 8 1100 6 98 2 19 8 1229 3 97 8 26 7 The table below shows the difference in power loss between BSC010N04LS and BSC010N04LSI Table 5 Efficiency summary of BSC010N04LS vs BSC010N04LSI Output Power A Power Losses Efficiency Gain W W 825 0 2 953 0 2 1076 0 3 Figure36 Phase voltage yellow trace and phase current green trace waveforms The temperature measurements are performed on BSC010N04LSI and BSC010N04LS with the infrared camera As previous efficiency tables indicates we expect a longer run time with the MOSFET with integrated monolithic Schottky like diode BSC010N04LSI Test conditions full power 100 duty Iphase 50 A rms Vba 20 V no forced air room temperature Application Note 33 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon Test Results Y ta be da amp 4 a z 90 100 110 120 130 Figure37 Temperature rise at full power with BSC010N04LSI Temperature C 44 48 52 Time s 34 Figure38 Temperature rise at full power with BSC010N04LS Application Note 34 Revision 2 0 2014 10 09 Infineon 1 kW BLDC Power Tool Kit User Manual Test Results Determining the Zin 8 1 1 Zin o
8. ATION NOTE MUST VERIFY ANY FUNCTION DESCRIBED HEREIN IN THE REAL APPLICATION INFINEON TECHNOLOGIES HEREBY DISCLAIMS ANY AND ALL WARRANTIES AND LIABILITIES OF ANY KIND INCLUDING WITHOUT LIMITATION WARRANTIES OF NON INFRINGEMENT OF INTELLECTUAL PROPERTY RIGHTS OF ANY THIRD PARTY WITH RESPECT TO ANY AND ALL INFORMATION GIVEN IN THIS APPLICATION NOTE Information For further information on technology delivery terms and conditions and prices please contact the nearest Infineon Technologies Office www infineon com Warnings Due to technical requirements components may contain dangerous substances For information on the types in question please contact the nearest Infineon Technologies Office Infineon Technologies components may be used in life support devices or systems only with the express written approval of Infineon Technologies if a failure of such components can reasonably be expected to cause the failure of that life support device or system or to affect the safety or effectiveness of that device or system Life support devices or systems are intended to be implanted in the human body or to support and or maintain and sustain and or protect human life If they fail it is reasonable to assume that the health of the user or other persons may be endangered
9. Application Note 23 Revision 2 0 2014 10 09 l gna 1 kW BLDC Power Tool Kit User Manual infi neon PB Oeil Infineon O a Direct access to E O l microcontroller pins sens O Hall Sensors O ERREG E KRE 11194 12 9 11 O GNP 3082 mm VEK U 2 E GU Ged Pot TTT UO Figure27 Bottom Overlay Control PCB ma E aa L x Ola a ime gt Ln cm S d E 1 38 INE x gt a e GND S K 4 N 4 U09UIIU gag UOSUYU 16 gan fo L gt K UOSUIJU yi EZI BRED Q Q TA C LK L L G GGG L 2 _9Zu KZH 819 gt BEH C Binge C0 1 BB DH E2Y UC d 62u Figure28 Bottom Overlay Power PCB 5 3 PCB production During the PCB production it is important to establish a good connection between the MOSFET and the PCB copper plane This will ensure a good heat transfer to the copper plates This demonstration board is produced with the solder profile shown below The results are displayed in x ray pictures which indicate an acceptable voids rate of approximetely 5 10 Application Note 24 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon 1 l 4 v s N a a eR RS RR eT Vi n Hec Fon Hh p a bs i m Ys Figure 29 Solder
10. Infineon 1 kW BLDC Power Tool Kit User Manual Application Note About this document This Application Note introduces a complete system level solution to drive a BLDC Motor for cordless power tools It also describes how to quickly get started integrating this demonstration PCB and take advantage of Infineon s SMD technology featuring 40 V OptiMOS MOSFETs and XMC1000 series microcontroller Scope and purpose To show the efficiency present a thermal solution for a power stage with SMD MOSFETs and show how to implement the control with the microcontroller to drive a BLDC motor equipped with 3 hall sensors This enables the power tool manufacturers to minimize time to market Intended audience Battery driven power tool manufacturers who intend to reduce the system cost and improve the efficiency and increase the power density which in turn provides longer run time and higher peak power pulse capability Table of Contents 1 OV EVITON oraora a 4 AAa444 3 1 1 PRO E6 756 0 6 5 25 24 34 3 2 Power Tool Kit Package content enen 5 2 1 FP GB E E E E TA E CC ga sa 5 2 2 C OFAC ALITA INET e O 22222 6 2 3 Dedicated Software for the Onboard 32 bit Microcontroller sss sese T 2 4 BLDC Motor BLDCM t1 1313185858 585858585818581818181818181811111EEEEEEEEEEEEEEEEE 1111115 EsEs se 7 3 OD DIET POWT TOOL l rrii a H 8 3 1
11. Profile temperature versus time Solder Paste type 3 Indium 8 9 Pb Free Figure 30 X ray showing voids distribution of a complete power stage left zoomed right Figure 31 Stencil patterns yellow color Stencil thickness 120 um Application Note 25 Revision 2 0 2014 10 09 o 1 kW BLDC Power Tool Kit User Manual Infineon PCB 5 4 Table 2 Quantity 12 12 Bill of Material BOM Designator Manufacturer Manufacturer Description Footprint Part Number C33 15 16 21 Murata GRM31MR71E2 MURATA 1206 22 25 29 34 3 25KA93L GRM31MR71E225KA93 L 5 30 8 5 Capacitor 1206 2 2uF 25V C1 C3 C4 Murata GRM31MR71E2 MURATA 1206 C26 C27 C31 25KA93L GERM31MR71E225KA93L Capacitor 1206 2 2uF 25V C2 NICHICON TVX1V102MCD NICHICON TVX1V102MCD 13 mm x Capacitor 1000uF 35V 31 5mm Axial TDK C12 C13 C2012X7R1E10 Multilayer Ceramic Capacitors 805 C18 C19 5K125AB MLCC SMD SMT 0805 1 uF C23 C24 25volts X7R 10 C6 C7 United Chemi EKMGG350ELL Aluminum Electrolytic Capa 5x11 mm Con 100ME citors Leaded 35 V 10uF 5X11 C10 C11 Kemet C0603C104K5R Multilayer Ceramic Capacitors 603 MLCC SMD SMT 50volts 0 1uF X7R 10 C14 C17 C20 C38 D14 D15 Infineon BAT 165 E6327 Schottky Diodes amp Rectifiers SOD 323 Technologies Med Power AF 750 mA Schottky Diode 40 V D17 D20 ON MM3Z5V1T1G ZENER DIODE 200 mW 5 1 V SOD 323 D22 SEMICONDUCT OR
12. c zel Ol Ay Q a E amp Y EI OF aw E E ka 1 p 808443 Figure 20 Complete Schematic Application Note 20 Revision 2 0 2014 10 09 1 KW BLDC Power Tool Kit User Manual Infineon PCB 5 2 Layout and Placement UpSnI if 1IDBIIJU 16 UAL ap UIDMUJU ig co R a oom 1 1 C16 U0AUIJU 74 uoauyuj 5 Figure21 PCB Top 90 mm x36 mm olololojololo olololololo o o Figure22 Gerber File Copper Top Application Note 21 Revision 2 0 2014 10 09 1 KW BLDC Power Tool Kit User Manual Infineon PCB C L Pe infir Infineon UO aza ia Cnfineon L n 9 9 sv L Ta sense To sense all Sensors U_H 6 0 UH Daji TTA Ea EI 118 EINE sa E GTH gt amp 2 6u yIa CED Oa FENNE 2314 GJ E malad TTT 720 ep GD L Otd O O t P29 229 169 929 UDGIIJU g IIHI T 9 RL i Jd oweg if II gi 4nd E UOT 0 e gt 9 G TID e CD uceuyuj cI l em p 613 J KZH CT szu CED CHP FIFEN czu L S 1 BL M cZ co Gp A 87 CC CEB L Hex 6ZY C 4 Figure23 PCB Bottom a U U U U U U e s s 6 s OO OOOO Figure 24 Gerber file Copper Bottom Application Note 22 Revision 2 0 2014 10 09 1 KW BLDC Power Tool Kit User Manual Infineon PCB 00000000 00000000 Figure26 Top Overlay Power PCB
13. ce Single cycle 32 bit hardware multiplier System timer SysTick for Operating System support Ultra low power consumption e Nested Vectored Interrupt Controller NVIC e Event Request Unit ERU for programmable processing of external and internal service requests e MATH Co processor MATH consists of a CORDIC unit for trigonometric calculation and a division unit On Chip Memories e 8 kbytes on chip ROM e 16 kbytes on chip high speed SRAM e 200 kbytes on chip Flash program and data memory Communication Peripherals e Two Universal Serial Interface Channels USIC usable as UART double SPI quad SPI IIC IIS and LIN interfaces Analog Frontend Peripherals e 12 A D Converters includes 2 sample and hold stages and a fast 12 bit analog to digital converter with adjustable gain e 8channels of out of range comparators ORC e 3 fast analog comparators ACMP e Temperature Sensor TSE Industrial Control Peripherals e Capture Compare Units 4 CCU4 for use as general purpose timers e Capture Compare Units 8 CCU8 for motor control and power conversion e Position Interfaces POSIF for hall and quadrature encoders and motor positioning e Brightness and Color Control Unit BCCU for LED color and dimming application System Control e Window Watchdog Timer WDT for safety sensitive applications e Real Time Clock module with alarm support RTC e System Control Unit SCU for system configuration and control e Pseudo
14. ce and a ready to use firmware allows the user to effectively and quickly implement this design The source code is also provided which can be modified to implement additional features In its original shape the overall PCB measures 90 mm x 36 mm and provides test points to all signals from the microcontroller This allows the user to monitor the signals of interest This board can be further split into 3 parts control PCB power PCB and capacitor PCB These individual PCBs can then be connected via ribbon cable and give users the flexibility to physically insert these boards into practically any power tool This demonstration board is more than just a reference design Its unique layout cooling concept and utilization of surface mount components will result in the highest power density reliability and a low cost product Important Notes 1 The electrolytic capacitor is provided for filtering but it is important that the battery wires are kept as short as possible Otherwise a large ripple current can flow through this capacitor leading to its premature failure If a power supply with long wires is used it is recommended to connect in addition a 4700 uF 50 V capacitor as close as possible to the power stage 2 Itis also recommended that UART FTDI communication cable is disconnected from the computer USB connector when the demo board is powered up Figure 1 1 kW BLDC Motor Control Power Tool PCB EVAL_SSO8_1kW_BLDC 1 1 Key Feature
15. e Individual control circuits for both outputs e Filtered detection of under voltage supply e Allinputs clamped by diodes e Offline gate clamping function e Asymmetric under voltage lockout thresholds for high side and low side e Qualified according to JEDEC1 high temperature stress tests for 1000 h for target applications 4 5 Microcontroller ar ar ar at 9 4 Lh 0 VSS VSSP VSSP Figure15 XMC1302 Microcontroller schematic The XMC1300 devices are members of the XMC1000 family of microcontrollers based on the ARM Cortex MO processor core The XMC1300 series is suitable for the real time control needs of the BLDC motor It also controls all input and output signals necessary for the power tool operation Application Note 15 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon Hardware Description P2 4 10 P Top View P25 2 VssPVss 9 VopgdVnp m 10 Analog system ANACTRL SFRs 1 O Skbytes of sector 0 readable only Figure 1 System Block Diagram Figure17 XMC1302 Microcontroller Block Diagram Application Note 16 Revision 2 0 2014 10 09 ae 1 KW BLDC Power Tool Kit User Manual Infineon Hardware Description 4 5 1 XMC Microcontroller features CPU Subsystem e CPU Core High Performance 32 bit ARMS Cortex M0O CPU Most of 16 bit Thumb instruction set Subset of 32 bit Thumb2 instruction set High code density with 32 bit performan
16. f the complete power inverter stage including copper elements 8 1 2 As mentioned in earlier chapter it is essential to establish a good thermal connection between the MOSFET and the PCB This ensures a good thermal connection between a MOSFET and cooling copper plates In order to determine how a system behaves thermally we refer to a Zn diagram The Zin diagram provides the information of how much power we are able to dissipate for a specified duration and what will be the resultant temperature of the MOSFET at the end of power pulse The Zu diagram below is shown for this system BRO H H S 8 L O S 8 E E A A E a a A D E a a E E O H H JJ II Ba S T H 9 9 es es H 9 e ees ee eee ee eee OCE aw ri HT SS L B n n I T LL DENMAN GL R R n 1 D Ljp T 1 oe a ee eee D L 9 TTT T NA TTT 29ST 0 gt d 104 san EA 12ousE1ep 154SOIN asn y Lwy TZ Zu diagram of the power inverter Figure 39 Note The Zi diagram above should not be confused with the MOSFET Zi diagram For power pulses less than 0 1 s please refer to MOSFET data sheet Z diagram 35 Revision 2 0 2014 10 09 Application Note aw 1 KW BLDC Power Tool Kit User Manual Infineon Properties of integrated Schottky like diode 9 Properties of integrated Schottky like diode The efficiency measurements and the temperature graphs show that the BSCO1ONO4LSI has about 20 power los
17. gies Inc USA muRata of MURATA MANUFACTURING CO MICROWAVE OFFICE MWO of Applied Wave Research Inc OmniVision of OmniVision Technologies Inc Openwave Openwave Systems Inc RED HAT Red Hat Inc RFMD RF Micro Devices Inc SIRIUS of Sirius Satellite Radio Inc SOLARIS of Sun Microsystems Inc SPANSION of Spansion LLC Ltd Symbian of Symbian Software Limited TAIYO YUDEN of Taiyo Yuden Co TEAKLITE of CEVA Inc TEKTRONIX of Tektronix Inc TOKO of TOKO KABUSHIKI KAISHA TA UNIX of X Open Company Limited VERILOG PALLADIUM of Cadence Design Systems Inc VLYNQ of Texas Instruments Incorporated VAWORKS WIND RIVER of WIND RIVER SYSTEMS INC ZETEX of Diodes Zetex Limited Last Trademarks Update 2011 11 11 www infineon com Edition 2014 10 09 Published by Infineon Technologies AG 81726 Munich Germany 2015 Infineon Technologies AG All Rights Reserved Do you have a question about any aspect of this document Email erratum infineon com Document reference ANEVAL_201410_PL11_001 Legal Disclaimer THE INFORMATION GIVEN IN THIS APPLICATION NOTE INCLUDING BUT NOT LIMITED TO CONTENTS OF REFERENCED WEBSITES IS GIVEN AS A HINT FOR THE IMPLEMENTATION OF THE INFINEON TECHNOLOGIES COMPONENT ONLY AND SHALL NOT BE REGARDED AS ANY DESCRIPTION OR WARRANTY OF A CERTAIN FUNCTIONALITY CONDITION OR QUALITY OF THE INFINEON TECHNOLOGIES COMPONENT THE RECIPIENT OF THIS APPLIC
18. gies AG AURIX C166 CanPAK CIPOS CIPURSE CoolMOS CoolSET CORECONTROL CROSSAVE DAVE DI POL EasyPIM EconoBRIDGE EconoDUAL EconoPIM EconoPACK EiceDRIVER eupec FCOS HITFET HybridPACK I7RF ISOFACE IsoPACK MIPAQ ModSTACK my d NovalithIC OptiMOS ORIGA POWERCODE PRIMARION PrimePACK PrimeSTACK PRO SIL PROFET RASIC ReverSave SatRIC SIEGET SINDRION SIPMOS SmartLEWIS SOLID FLASH TEMPFET thinQ TRENCHSTOP TriCore Other Trademarks Advance Design System ADS of Agilent Technologies AMBA ARM MULTI ICE KEIL PRIMECELL REALVIEW THUMB uVision of ARM Limited UK AUTOSAR is licensed by AUTOSAR development partnership Bluetooth of Bluetooth SIG Inc CAT iq of DECT Forum COLOSSUS FirstGPS of Trimble Navigation Ltd EMV of EMVCo LLC Visa Holdings Inc EPCOS of Epcos AG FLEXGO of Microsoft Corporation FlexRay is licensed by FlexRay Consortium HYPERTERMINAL of Hilgraeve Incorporated IEC of Commission Electrotechnique Internationale IrDA of Infrared Data Association Corporation ISO of INTERNATIONAL ORGANIZATION FOR STANDARDIZATION MATLAB of MathWorks Inc MAXIM of Maxim Integrated Products Inc MICROTEC NUCLEUS of Mentor Graphics Corporation MIPI of MIPI Alliance Inc MIPS of MIPS Technolo
19. is demonstration board is already programmed with dedicated software for cordless power drill and is ready for use 6 2 Features e Unipolar Block Commutation with active rectification e Overcurrent shut down e Over temperature shut down e Wrong hall pattern shut down e Motor soft start e Monitoring input DC voltage e Programmable boost converter 6 2 1 Unipolar Block Commutation with active rectification In a unipolar voltage control while the low side switch LS is ON the PWM pulses are applied to the high sided switch HS In addition the Synch_FET is turned ON when the body diode of the Synch_FET is conducting In this way the diode losses are minimized The dead time between HS and LS MOSFETs should be set depending on turn on and turn off time of the HS which is directly related to the value of the gate resistors In this particular example the dead time is set to 2 us using R 100 Ohm The Figure 32 below shows active components while energizing phases U and V and Figure 32 Figure 33 shows control signals for commutation of all 3 phases Application Note 28 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon Software PWM Pattern Highside active Highside inactive Buttery BLDC MOTOR synchronous rectification Figure 32 Unipolar voltage switching with synchronous rectification for a single phase Phase U HS Phase ULS Phase VHS Phase VLS Phase WHS Phase WLS
20. ky like diode Leakage current In most designs the relevance of leakage current which is important for a stand by operation is minimized since the power trigger switch separates battery from the circuit and the stand by current is virtually reduced to zero In the ON state during normal operation this leakage current is negligible compared to the load current The leakage current is greatly reduced at lower voltages For BSCO10NO04LSI at 10 V the voltage which a MOSFET will experience in a half bridge configuration connected to 20 V source is 5 uA The leakage current increases with the temperature The leakage current graph as a function of applied voltage and temperature is given below 15 Typ drain source leakage current loss f V psl Vas 0 V parameter T 107 Figure41 Leakage current versus Drain Source voltage Rps on l In case of BSC010N04LSI the Ros on is increased by 5 which increases conduction losses Nevertheless despite the slightly increased conduction losses the power loss reduction due to integrated monolithic Schottky like diode is greater Avalanche The avalanche rating of a MOSFET becomes important only if the breakdown voltage Verpss is exceeded This demonstration board has very low voltage overshoot due to low reverse recovery charge Qr of the integrated monolithic Schottky like diode and a low PCB layout parasitic inductance It is not recommended to exceed the maximum breakdown voltage Ve
21. n be configured as input or output pins e Potentiometer input for speed control e L R motor direction switch Application Note 5 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon Power Tool Kit Package content Hall Sensors Figure3 System Block Diagram 2 2 Communication Interface Communication interface is a link between PC user interface and the board It was realized with a commercially available cable from FTDI TTL 232R 5V WE BLACK BROWN CABLE 1 8m RED ORANGE YELLOW GREEN CTS Clear to Send Control input Handshake signal ND Output Transmit Asynchronous Data output Receive Asynchronous Data input RTS Output Request To Send Control Output Handshake signal Figure4 TTL 232R 5V WE FTDI Cable Connections Application Note 6 Revision 2 0 2014 10 09 o 1 kW BLDC Power Tool Kit User Manual Infineon Power Tool Kit Package content 2 3 Dedicated Software for the Onboard 32 bit Microcontroller The XMC microcontroller is already programmed with dedicated software for power drill application The following functions are implemented in the software e Block commutation for running BLDC motor with voltage control e Wrong Hall sensor shut down 2 4 BLDC Motor BLDCM The Power Tool Demo Board can run every BLDC motor equipped with 3 hall sensors Application Note T Revision 2 0 2014 10 09 1 kW BLDC Power Tool Kit User Manual infi neon f Running the Power T
22. nesiebdasa3nbslxes saadeax2s24salsfss 30 6 2 5 9 6 19118 70zi800 007 E c ae E E 30 6 2 6 Monitoring input DC VON D cueaneasisesadefbisad63a053408 661909448243840092044638a031A008 6039094282438 40092 441688 0031430340898 30 6 2 7 Programmable boostf COTIV F YF G G0000 0101010 00 10000 0000 1 0880004 45 30 6 2 8 Asymmetric Authentication Feature 2 0 sese 30 7 XMC microcontroller development platform DAVE sssssssssssssssssssssssssssssssssssssssssssssssseseesees 31 8 MOS RESU HH 32 8 1 ETC TAC MEI UN ONS TT 32 8 1 1 Determine E Zeon Eae c acc nga c 35 8 1 2 Zin of the complete power inverter stage including copper elements sss sees eee eee e 35 9 Properties of integrated Schottky like diodes sss sss sese 36 10 OGIS EEE a s 38 11 EDIT 39 11 1 RIGA PEIN INCA Le TT 39 12 LISS TU IMA LO TIA AIG INKS S002 22 E R 40 Application Note 2 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon Overview 1 Overview Infineon s Power Tool Kit EVAL_SSO8_1kW_BLDC is as complete system solution implemented with a 3 phase bridge MOSFET power stage and a control PCB featuring Infineon s low cost 32 bit microcontroller XMC1302 This demonstration unit is specifically designed for cordless power tool application by using simple plug and play system but it can easily be adopted for any 3 phase brushless DC motor application Its compact design optimized thermal performan
23. nt is calculated as Vos I HE 4 paar Rps on hot Since the measured Vos signal is small due to very low Rps on 0 6 mOhm an op amp is used to amplify this signal The op amp amplification is set to 30 V V The current information is used to detect overload condition and shut down the inverter Application Note 13 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon Hardware Description 4 4 Gate Drivers Blockdiagram Boostrap diode BIAS NETWORK VB LATCH f gree aia HV LEVEL SHIFTER COMPAT T JL REVERSE DIODE U RATOR UV Drive DETECT Q SHIFTER 1 Q O VDD UV t De z gt Optional adjustable via design Interlock Deadtime Filter times Propagation delay Drive Figure 13 Single Gate Driver Block Diagram GND 2EDLOS5NO06PF tV boost U3 GND 2EDL0SN06PF FVboost U GND 2EDL0SN06PE Figure14 Schematic of a 3 Phase Gate Driver Circuit Application Note 14 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon Hardware Description 4 4 1 Gate driver 2EDLOSNO6PF features This demonstration board is using three 2EDLO5NO6PF Half Bridge gate drivers with integrated bootstrap diode Main features e Output current 500 mA e Thin film SOI technology e Insensitivity of the bridge output to negative transient voltages up to 50 V given by SOI technology e Ultrafast bootstrap diode e Maximum blocking voltage 600 V
24. o reduce the dead time between high and low side MOSFETs leading to faster switching and lower switching losses but on the other hand the parasitic Application Note 11 Revision 2 0 2014 10 09 o 1 kW BLDC Power Tool Kit User Manual infineon Hardware Description inductance of the battery and the circuit parasitic inductance will have more effect and generate higher voltage overshoot Multilayer ceramic caps 10 x 2 2 uF 50 V MLCC are place on top side of the PCB which will filter out high frequency currents The number of MLCCs can be further optimized depending on system requirements 4 3 Current measurement Figure11 Current Measurements Schematics The current measurement is implemented by means of measuring the voltage across the Drain Source of the MOSFET Since the MOSFET behaves like a resistor when in ON state the voltage across it can be measured and the current through MOSFET can be calculated by using Ohm s law Vds Fps on l 1 Since the Ros on is dependent on temperature we need to compensate for temperature change In Figure 12 below found in datasheet of BSC010N04LSI we can see Roson dependency of temperature Two curves provided are for a typical and a maximum initial Ros on value The software which is included in this package is assuming a linear Rosjon dependency of temperature indicated with the red line The temperature information i
25. ool Kit 3 Running the Power Tool Kit In order to run the BLDC motor the following connections must be made 1 DC power supply 20 V GND 2 3 BLDC motor phases U V W 3 BLDC motor Hall Sensors 5 V GND H1 H2 H3 3 1 Connecting the board to a BLDC Motor B GND m Hall W Hall sensor E a s va ske m Hall V connection CSS D20 o R i a v m Hall U E gt c m 5V E 5V Infineon OOOOO Potentiometer connection wiper E GND x UART connection rotation Debug selection Connection Figure5 Control Board Connections Note Hall sensors must match respective phases otherwise the inverter will immediately shut down Application Note 8 Revision 2 0 2014 10 09 1 KW BLDC Power Tool Kit User Manual Infineon Running the Power Tool Kit T sense R V H IVL RB V bat E V boost E GND I GND W_H W L E GND W Q AN 4 r La kaaf a J ond an mr P r Aa kand B GND V R GND EU 4 Figure6 Interface signals between control board and power board Figure 7 Power Inverter Board Connections Application Note 9 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon Running the Power Tool Kit It is recommended that the power connection be made by means of direct soldering to the exposed copper Since the thermal conductance is very high use 450 C soldering iron with a large solder tip to effectively transfer the heat to c
26. opper parts and solder the connection wires Ensure that there are no short circuit connections between phase outputs and battery copper plates See a sample below Figure 8 Power Inverter Board Connections Application Note 10 Revision 2 0 2014 10 09 o 1 kW BLDC Power Tool Kit User Manual Infineon Hardware Description 4 Hardware Description 4 1 Power Supply 5 V and 12V_boost Vboost Figure 9 Power Supply Schematic The system input voltage range is 6 24 V The supplied voltage is stepped down to 5 V by using a low dropout voltage regulator IFX27001TFV50 This 5 V voltage is used to supply MCU hall sensors temperature sensor and as supply voltage to the boost converter The 12 V boost voltage which is used for gate drivers 2EDLOSNO6PF and the LM324 operational amplifier is generated by the boost converter built around Q13 4 2 Power Stage Figurel0 3 Phase Inverter Schematic The power stage is designed to drive a BLDC motor up to 1 kW using two BSCO1ONO4LSI MOSFETs in parallel The gate resistors have a value of 100 Ohm which can be further modified depending on desired performance Higher value of gate resistors will increase switching losses since the MOSFETs are switching slower but at the same time the slower switching will generate lower voltage overshoots and require lower filter capacitors value If the gate resistors values are reduced it is possible t
27. plication Note 38 Revision 2 0 2014 10 09 o 1 kW BLDC Power Tool Kit User Manual Infineon Accessories 11 Accessories 11 1 ORIGA Authentication This demonstration board can in addition be equipped with an authentication hardware and software which ensures usage of OEM batteries only For more information and implementation of the ORIGA go to http www infineon com origa Application Note 39 Revision 2 0 2014 10 09 o 1 kW BLDC Power Tool Kit User Manual Infineon Useful material and links 12 Useful material and links e DAVE Free Development Platform for Code Generation http www infineon com dave e OptiMOS 40V 60V Webpage http www infineon com optimos5 40v60v e Product Brief OptiMOS 40V 60V http www infineon com dgdl Infineon Product Brieft Power MOSFETs OptiMOS 5 40V and 60V pdf folderld db3a304314dca38901154c20869c1b30 amp fileld db3a3043353fdc 16013543568a1 31a e Video OptiMOS 5 40V 60V http i www edge cdn net index php ct 1353 amp vid 163276 amp setlang en e ORIGA Battery Authentication Webpage http www infienon com origa e XMC 1000 Webpage http www infineon com xmc1000 e EiceDRIVER Compact Webpage http www infineon com eicedriver compact Revision History Major changes since the last revision Page or Reference Description of change First Release Application Note 40 Revision 2 0 2014 10 09 Trademarks of Infineon Technolo
28. r A D input which reads the voltage across the resistive voltage divider connected across the battery terminals The operating voltage range is 6 24 V 6 2 7 Programmable boost converter The boost converter regulates the gate driver voltage to 12 V The XMC microcontroller A D input reads the boost voltage and regulates it accordingly The boost converter output voltage of 12 V is also used for Opamp voltage supply 6 2 8 Asymmetric Authentication Feature XMC1302 support Infineon s Asymmetric Authentication Solution ORIGA The authentication chip normally will be embedded in the battery and it can be used to detect and authenticate genuine batteries before charging or operating the tool ORIGA single wire interface SWI can be connected to P0 15 and this device can operate in 2 wire mode SWI and GND The complete host code is already integrated in the XMC1302 library would require recompilation with compiler directive If this feature is implemented the motor will not start in the event of authentication failure This authentication feature benefits the user by providing safe reliable operating and charging environment For ORIGA hardware and more information please visit http www infineon com origa Application Note 30 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon XMC microcontroller development platform DAVE XMC microcontroller development platform DAVE pang RSS _ 9999
29. random number generator PRNG provides random data with fast generation times Application Note 17 Revision 2 0 2014 10 09 o 1 kW BLDC Power Tool Kit User Manual Infineon Hardware Description Input Output Lines With Individual Bit Controllability e Tri stated in input mode e Push pull or open drain output mode e Configurable pad hysteresis Debug System e Access through the standard ARM serial wire debug SWD or the single pin debug e SPD interface e Abreakpoint unit BPU supporting up to 4 hardware breakpoints e Awatchpoint unit DWT supporting up to 2 watchpoints 4 6 Hall Sensors Digital Inputs Figure18 Hall Sensor Input Schematic Figure19 Communication Port Schematic Table 1 Communication Port Pin Out Connector X7 Pin Number TTL 232R 5V WE FTDI cable connection 5 Receive Input Rx Yellow RXD Transmit Output Orange TXD Tx 1 Ground GND Black GND Application Note 18 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon Hardware Description 4 7 Free MCU pins Since one of the objectives of this reference board is to create a very compact design the MCU free pins are directly accessible at the PCB bottom side Free MCU pins are 2 3 4 5 11 12 19 29 30 35 Application Note 19 Revision 2 0 2014 10 09 eo 1 kW BLDC Power Tool Kit User Manual Infineon PCB 5 PCB 5 1 Schemati
30. rovide the voltage to the demo board The supplied current and voltage is fed to the power analyzer At the output of the DEMO PCB all 3 phase voltages and currents are fed to the power analyzer In order to apply the load another LOAD BLDC motor is used to break the BLDC MOTOR These two motors are interconnected with a mechanical coupling When the BLDC motor spins the load motor acts as a generator and induces voltage which is rectified with a 3 phase diode bridge This output voltage is further filtered with a DC link cap A DC electronic load is connected at the output of the 3 phase diode bridge By applying different setting on the electronic load different loading conditions can be achieved In effort to improve the efficiency of the power stage Infineon has developed a MOSFET with integrated monolithic Schottky like diode which reduces the diode forward voltage drop losses and also diode reverse recovery losses In order to show the benefits of this technology two equivalent measurements are performed The Table 3 shows the measurements without the Schottky like diode and the Table 4 shows the measurements with the Schottky like diode The details of measurements are shown below Table 3 Efficiency measurement with BSC010N04LS in block commutated BLDC motor drive Input Power Output Power Efficiency Power Losses W W W 833 85 ee 8 0 968 15 0 1099 1076 23 0 1172 1142 30 0 Application Note 32 Revision 2 0 2014 10 0
31. rpss of a MOSFET at any time The avalanche energy contained in a voltage overshoot is difficult to quantify thus it present a risk to exceed the maximum avalanche Eas rating of a MOSFET if the Verpss is exceeded Application Note 37 Revision 2 0 2014 10 09 o 1 kW BLDC Power Tool Kit User Manual Infineon Conclusion 10 Conclusion The presented demonstration board provides a plug and play solution for driving BLDC motors in cordless power tool applications The optimized size allows a quick integration in cordless power drills With Infineon developed dedicated software and a free software development platform DAVE the user is able to integrate additional functions The generated Zu diagram for the inverter power stage allows the designer to determine the MOSFET temperature for a given condition This can be very useful especially for motor start up and locked rotor conditions It was shown that in BLDC motor power inverter the body diode plays a key role The power loss and temperature measurements show an improvement of up to 20 of BSC010N04LSI MOSFET with integrated Schottky like diode The Infineon s patented Schottky like diode MOSFET technology enables the tool manufacturers to implement their solution with a cost effective packages such as SuperSO8 and achieve more motor torque higher current operation and up to 20 saving in power losses which is directly proportional to longer operation time in the application Ap
32. s e B6 Inverter for 3 phase BLDC motor e Nominal voltage 20 V e Continuous phase current 50 A Application Note 3 Revision 2 0 2014 10 09 o 1 kW BLDC Power Tool Kit User Manual Infineon Overview e 1 kW output power Test conditions 100 duty 50 A RMS per phase Vsuppy 20 V 50 A open frame no forced air 26 C room temperature resulting in 60 C temperature rise above ambient in 1 min e Operation down to 6 V battery supply e Peak current capability up to 200A e Overcurrent detection by measuring Vpsonacross the MOSFET on all 3 phases e Duty cycle controlled BLDC motors with 3 hall sensors e 2 parallel MOSFETs BSCO1ONO4LSI in SuperSO8 package 40 V 1 05 mOhm Rosion max With integrated monolithic Schottky like diode low reverse recovery charge Qr and low forward voltage diode drop Vsp e Low PCB parasitic inductance e PCB 90 mmx 36 mm overall dimensions Power stage PCB L 45 mm x W 36 mm x H 10 mm Material FR4 2 layers 20z copper 70 um e Low conduction losses e Low diode losses and low reverse recovery charge with an integrated Shottky like diode MGD e Low voltage overshoot and low ringing e Accessible signals at the PCB interface e Good thermal dissipation e Temperature sensor e 32 bit XMC motor control optimized microcontroller e Provides all connections for power tool functions hall sensors speed controller pot motor direction switch UART communication port debugger connection
33. s obtained from the temperature sensor RT1 If more accurate current measurements are required one can create a curve fit formula instead of linear approximation Also in effort to reduce the measurement error we can factor out the variation of initial Roson and op amp offset by initial calibration In a calibration process it is advisable to set a known current on the power supply and cycle through all 3 phases The readings on microcontroller A D inputs can be then correlated with this current suggested range 10 A The provided demonstration board is not calibrated Application Note 12 Revision 2 0 2014 10 09 o 1 kW BLDC Power Tool Kit User Manual Infineon Hardware Description 9 Drain source on state resistance R osten f T a 5U A Vaz 10 V _ S E a L Figure 12 Rasian dependency of temperature for BSC010N04LSI From the graph above typical curve we can see that with increased temperature Ros on is increasing For example if the temperature rises from 25 C to 100 C the Robs jon will change from 0 8 mOhm to 1 25 mOhm In order to compensate for temperature change we can calculate the Rosjon hot aS Rps on hot Rps on cold N 1 a Thot 7 T cota 2 where ais a temperature coefficient Since we have 2 MOSFETs in parallel and assuming a typical Ros on 0 9 mOhm at 25 C and T 100 C we can estimate the Rosvon hot 1 1 mm 1 100 C 25 C 0 60 mOhm 3 The curre
34. s reduction or 20 longer running time as compared to BSC010N04LS under the same loading conditions This efficiency gain is due to integrated monolithic Schottky like diode If we take a closer look at the diode forward voltage graph we can see that the BSC010N04LSI diode has a lower forward voltage drop and also lower recovery charge which account for higher efficiency 12 Forward characteristics of reverse diode lV sp parameter 12 Forward characteristics of reverse diode Iz f V so parameter T 1000 Van V Vo V BSC010N04LSI BSC010N04LS Figure 40 Forward characteristics of reverse diode for BSC010N04LSI and BSC010N04LS The positive effect of the integrated Schottky like diode has also some drawbacks Some of the parameters of interest are Leakage current Roson and avalanche capability The summary is shown in the table below Table 6 Comparison of parameters of interest for BSCOLONO4LS and BSC010N04LSI Parameter Test conditions BSC010N04LS BSC010N04LSI loss Zero gate voltage drain Ves 0 Vps 32 V T 25 C 1 mA 500 mA current Rbs on max Drain source on state Ves 10 V Ip 50 A 1 00 mOhm 1 05 mOhm resistance Ens Avalanche energy single Ip 50 A Res 25 Ohm 330 mJ 230 mJ pulse Nevertheless in power tool application the advantage of integrated diode outweighs its drawbacks Application Note 36 Revision 2 0 2014 10 09 o 1 kW BLDC Power Tool Kit User Manual infineon Properties of integrated Schott
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