Stellaris RDK-BDC24 Brushed DC Motor Control Module User`s
Contents
1. Status LED Za Ul Calibrate ID LED GRN RI Al D Green U3 433V Cl 45V SWI 100 K o ll Ze SECH be ERE e PA0 UORX PBOPWM2 p BHI gt R3 O 1UF a UOIX NB pALUOTX PBI PWM3 BLO A 5 SW B3S1000 LED RED R4 A2 LED GRN LOK SPDIN 20 PA2 PWM4 Weer SPDIN 4 3 FEMALE 1X3 150 g B CANRX PA3 PWMS PB3 I2COSDA lt PWM Speed Input iN CANI PAA CANORx PB4 CO GD_RESETi peed Inp DI PAS CANOTx PBS CI z as FANON gt AHI PAG PWMO PBO CO CR BEEN ANo e 43 3V ALO PAT PWMI PB7 NMI E Coast E Debug R5 TN S PCO TCK SWCLK PDO IDXO GL ENM H Brake default 43 3V 10K oo PCI TMS SWDIO PDI f 33V yy TDI POTD ppy ADCs LEI BRAKE EN HDR1X3 1 Tool TMS SWDIO IDO PC3 TDO SWO PD3 ADC4 f al Di i F Brak Goast Jumper 3 4 TCK SWCLK PCA PhAO R24 199 Ts TDO LOK 33V Lloses mo PC5 C0o E A C40 i OCH oT PC6 PhBO PEO ADC3 2 ____ ISENSE_193 OMIT n LED RED jo T OC EIS See POT ANA GSOTOSC Re DIR e C CON ADR 2X5 050 ae PEXADCO La IU lt VSENSE LOK J3 OMIT rr OSCH PEA FAULTO 1 Pi ZA osci POT ANA 2 Yl XOSCO NC s i Zi XOSCI NC Hi D 16 00MHz 43 3V NC k S 10K Position Pot Factory Test 433V eet 433v Lo CO y WAKE VDDA L D3 cl Tacs age 102. 12AWG Wire with 6 ring Motor oulput is not protected f against shortcircuits or spade terminals From Power i i Distribution D k eu i n u Module T E In 7 Motor In J TEXAS o Motor NSTRUMEN 1 Mounting holes f 3 50 centers User Switch Maintain 0 5 clearance 3 O8e around all vents CAN Port 6P6C CAN RS232 Port 2d GENER Status LED e Limit switch inputs SERVO PWM Use hooks to prevent wires shaking loose Encoder Input Analog input 0 3V Motor coast brake jumper Reference Design Kit Contents The RDK BDC24 contains everything needed to evaluate brushed DC motor control The RDK BDC24 includes E MDL BDC24 motor control module Suitable for motors up to 24 V 40A Uses aStellaris LM3S2616 microcontroller W Mabuchi RS 555PH 3255 Brushed DC Motor 5000 RPM 12V 3A W Universal input wall power supply 12V1 25A January 4 2012 9 Stellaris amp Brushed DC Motor Control Reference Design Kit RDK Overview Plug adaptors for US UK EU and AUST B DB9S to 6P6C adapter Connects the MDL BDC24 to a PC RS232 port H 6P 6C modular cable 7 ft Use for RS232 or CAN connection WB CAN terminator Plug in 120 Q terminator W Adapter cable for ARM JTAG SWD
3. Speed 2325 RPM Current 3 627 A Power 14 W Torque 57 5 mMm General characteristics No load speed 4650 RPM No load current 0 223 A 12 January 4 2012 Firmware Updates and Debugging The MDL BDC24 supports two methods for updating the firmware resident in the LM3S2616 microcontroller The primary method commonly used for field updates uses the CAN or RS232 interface and a Flash resident boot loader for firmware transfer During actual firmware development direct access and debug capability is preferable The MDL BDC24 included in the RDK has a JTAG SWD connector installed for this purpose General Information StellarisWare firmware revisions are referenced using four digit numbers that increase with new releases but are not necessarily contiguous that is numbers may be skipped The flash memory region between 0x0000 and 0x07FF contains a CAN RS232 boot loader The main firmware image should be loaded at 0x0800 Firmware Update Using RS232 CAN The MDL BDC24 firmware can be updated over RS232 or CAN using the BDC COMM utility and the cables included in the reference design kit See the MDL BDC24 Getting Started Guide for step by step instructions Firmware Update and Debugging Using JTAG SWD The MDL BDC24 included in the RDK has a 2 x 5 fine pitch header installed for firmware programming and debugging using JTAG SWD JTAG is a four wire interface SWD is a high performance two wire interf
4. Rds on to about 2 5 mQ and to provide additional surface area for fan cooling The fan blows directly on the TO 220 MOSFETS which are arranged radially around the DC bus capacitor A plastic ring encompasses the MOSFETSs providing mechanical support and ensuring that the tabs do not touch The gate driver provides high peak currents to rapidly switch the gates of the MOSFETs when directed by the microcontroller s PWM module An internal charge pump allows the drivers to maintain MOSFET gate voltage even under low voltage conditions Resistor R34 sets the gate drive dead time to approximately Zus Because the high side MOSFETs are N Channel types a positive Vgs is required to switch them on The gate driver uses a simple boot strapping technique to ensure that the high side Vgs remains above the Vos on threshold Whenever the low side MOSFETs are on the associated boot strap capacitor C34 or C36 charges from the internal charge pump regulator Later when the high side MOSFETS turn on the boot strap capacitor maintains power to the high side driver with respect to the Motor terminal One restriction with the boot strap capacitor method is that the capacitor voltage will decay to an unacceptable level unless a low side MOSFET is periodically switched on This state only occurs when the motor is running full forward or full reverse The gate driver has an internal sense circuit the inserts small low side pulses whenever the bootstrap voltage de
5. The PCB design has an option to populate an INA282 current sense amplifier This was done to evaluate a future build option The INA282 and supporting components are omitted from the assembly January 4 2012 19 Hardware Description Voltage Sensing A simple divider resistor network 16 and R18 scales the Vp rail down to the range of the ADC 0 3 V The full scale ADC measurement ADC 1023 corresponds to a bus voltage of 36 V Fan Control The cooling fan is self contained and uses a small 5 V brushless DC motor The MDL BDC24 supports On Off software control of the fan using Q3 The fan operates when the motor is running or when the temperature exceeds a certain threshold The LM3S2616 microcontroller has an internal temperature sensor and a simple software table correlates the microcontroller temperature to the overall system temperature Texas Instruments Featured Parts The MDL BDC24 features a range of semiconductors from Texas Instruments as shown in Table 4 1 Table 4 1 Detailed List of Texas Instruments Featured Parts LM3S2616 Stellaris System control ARM Cortex M3 core Microcontroller Motion control capabilities 64 KB Flash SN65HVD1050 High Speed EMC CAN High electromagnetic immunity EMI Optimized CAN communications Very low electromagnetic emissions EME Transceiver Bus fault protection of 27 V to 40 V Dominant time out function Power up down glitch free bus inputs and ou
6. from the bottom connector side of the circuit board CAN Communication 16 A key feature of the LM3S2616 microcontroller is its CAN module that enables highly reliable communications at up to 1 Mbits s The MDL BDC24 control board uses a Texas Instruments SN65HVD1050D CAN transceiver U2 additional ESD protection D6 and connectors The pin assignments for the 6P6C 6P4C connectors are defined in CAN in Automation CiA DS102 Figure 4 3 shows the network connector pin assignments January 4 2012 Stellaris amp Brushed DC Motor Control User s Manual Figure 4 3 Network Connector Pin Assignments CANH CANL CANH CANL V GND TXD 6P6C RS232 CAN Socket Viewed 6P4C CAN Socket Viewed from Top Tab down from Top Tab down The V signal Pin 2 is not used in the MDL BDC24 however it is passed through to support other devices that either provide or use power from this terminal The typical application for V is in providing a small amount of power to optocouplers for isolating CAN signals For 1 Mbps CAN communication over distances up to 20 feet the network should be terminated at each end with a 100Q resistor This value is slightly lower the normal 120Q terminator but it accelerates the bus return to the recessive state which is important in high data rate high node count applications RS232 Communication The MDL BDC24 supports a full set of network control and configuration functions over a standard RS2
7. important for synchronous rectification see Output Stage and Power Supplies Schematic page 2 on page 17 The LM3S2616 has an internal LDO voltage regulator that supplies 2 5 V power for internal use This rail requires only three capacitors for decoupling and is not connected to any other circuits Clocking for the LM3S2616 is facilitated by a 16 MHz crystal Although the LM3S2616 can operate at up to 50 MHz in order to minimize power consumption the PLL is not enabled in this design The 32 bit Cortex M3 core has ample processing power to support all features including 1 Mbits s CAN and RS232 with a clock speed of 16 MHz Debugging The microcontroller supports JTAG and SWD debugging as well as SWO trace capabilities To minimize the board area the MDL BDC24 uses a 0 050 pitch header footprint which matches ARM s fine pitch definition Figure 4 2 The connections are located on the bottom of the module under the serial number label The module included in the reference design kit has a header installed however the standard MDL BDC24 available as a separate item does not have the header installed Some in circuit debuggers provide a matching connector Other ARM debuggers can be used with the adapter board included in the RDK Figure 4 2 MDL BDC24 JTAG SWD Connector 12 3 3V TMS SWDIO GND TCK SWCLK GND TDO TDI GND SRSTn 10 Figure 4 2 shows the pin assignments for the JTAG SWD connector as viewed
8. options for Speed control Industry standard R C servo type PWM interface Controller Area Network CAN interface RS232 serial interface WB CAN communication Multicast shared serial bus for connecting systems in electromagnetically noisy environments 1M bits s bit rate CAN protocol version 2 0 A B Full configurability of module options Real time monitoring of current voltage speed and other parameters Firmware update W RS232 serial communication Bridges RS232 port to a CAN network Directly interfaces to a PC serial port or National Instruments cRIO Status LED indicates Run Direction and Fault conditions Motor brake coast selector Limit switch inputs for forward and reverse directions Quadrature encoder input QEI Index input 5V supply output to encoder 8 January 4 2012 Stellaris amp Brushed DC Motor Control User s Manual W Analog input Accepts 10 kO potentiometer or 0 3 V input W Screw terminals for all power wiring W Headers 0 1 inch pitch for all control signals For detailed specifications including electrical parameters see the MDL BDC24 data sheet Figure 1 2 MDL BDC24 Module Key Features top view Maintain 0 5 clearance For power wiring use around all vents
9. read before using the RDK B Use the BDC COMM to evaluate and optimize target motor operation Once the module is installed in the end application use the BDC COMM to configure and monitor motor operation Using RS232 the BDC COMM gives real time access to a range of operating parameters The MDL BDC24 Getting Started Guide covers module setup and use in customer applications W Customize and integrate the software and or hardware to suit an end application This user s manual and the RDK BDC24 Firmware Development Package User s Guide are two important references for completing hardware and software modifications New software can be programmed in the MDL BDC24 using either BDC COMM or using a JTAG SWD debug interface Power Supply Selection The MDL BDC24 is designed primarily for use with 12 V or 24 V sealed lead acid batteries Other power sources may be used as long as the MDL BDC24 s voltage range is not exceeded under any condition There are two important considerations when selecting a power supply The first is specifying a supply that can supply the starting current of the motor Even unloaded motors may have a starting current that can momentarily exceed 60 A Some switching power supplies will shut down very January 4 2012 11 Using the Reference Design Kit quickly when starting a brushed DC motor The power supply does not need to maintain regulation during start but it must ensure that the supply voltage remains above t
10. stage efficiency particularly at lower duty cycles 50 and less when the PWM_OFF time is longer that the PWM_ON time Power Supply The MDL BDC24 uses a TPS54040 based switching power supply for optimal efficiency over a wide operating range Resistor R20 sets the switching frequency at around 700kHz which allows the use of a small inductor and output capacitor The 5 V rail is used for the cooling fan CAN and RS232 transceivers current sense amplifier and quadrature encoder functions A low drop out voltage linear regulator TPS73633 generates the 3 3 V rail which is used by the MCU and peripheral circuitry Current Sensing The current sensing circuit consists of a high side shunt resistor R23 and a specialized current sense amplifier INA193 Due to the high current capabilities of the bridge the shunt resistor is just 1 mQ The INA193 amplifier has a fixed gain of 20 V V which results in a signal into the ADC of 20 mV A for a full scale reading of 150 A Because the sense resistor is in the high side of the H bridge the current through it is only positive when the high side MOSFETs are on The MDL BDC24 software takes this into consideration when sampling the current waveform When operating smaller motors or lightly loaded large motors the INA193 may be operating with a Vsense less than 20 mV This region has reduced current sense amplifier accuracy See the INA193 data sheet for full details on Low Veenge Case 1 and Case 3
11. 32C serial interface The command protocol is essentially the same as the protocol used on the CAN interface thereby allowing the MDL BDC24 to automatically bridge all commands between the RS232 and CAN interfaces A TRS3221E RS232 transceiver was selected to translate the CMOS logic levels from the LM3S2616 s UARTO to RS232 levels Its internal charge pump generates positive and negative voltages from the 5 V supply pin Integrated ESD protection means that no external protection device is necessary Other Interfaces Interfaces for an encoder or tachometer limit switches and brake control are provided on 0 1 pin headers The connections to the microcontroller are ESD protected and in most cases have 10 kQ pull up resistors The brake and user switch inputs use the LM3S2616 microcontroller s internal pull up resistor The analog input has a 0 to 3 V span In order to use a 10 kQ potentiometer a 1 kQ padding resistor is provided on J4 1 to drop 300 mV from the 3 3 V rail when the potentiometer is connected Output Stage and Power Supplies Schematic page 2 Page 2 of the schematics details the power supplies gate drivers output transistors sensing and fan control circuits January 4 2012 17 Hardware Description Motor Output Stage The motor output stage consists of an H bridge with High Low side gate drivers Each leg of the H bridge has two paralleled MOSFETs The MOSFETs are connected in parallel to reduce total
12. C 90512 003LF Flange Blk 4UCON 04911 Header 1x2 Surelock 2mm Thole Vertical shrouded nductor 47uH SMD 7mmx7mm 0 9A 0 180hm PCB RDK DD BlackJag Rev D RDK BLKJ AG D MOSFET N CH TO 220 40V 60V 80A International IRFB3206PBF Rectifier Fairchild FDPO38ANO6A0 Fairchild FDPO50ANO6A0 Q1 Q2 Q4 Q5 Q6 Q7 Q8 Q9 EES January 4 2012 Table C 1 RDK BDC24 Bill of Materials BOM continued Texas Instruments Part Number RDK BDC24 Rev D BD BDC24 Final Assembly BOM PCB Assembly Enclosure Bill Of Materials Created pene e ccr ep m Resistor 390K Ohm 1 8W 1 0805 Resistor 82K OHM 1 8W 596 0805 Thick 9 21 2011 27 26 H H H a an an ie Oo RB E 2n M D os m BR N o 21 R22 R26 27 R29 R30 DD Dp N w 3 R6 R18 L D Ww B ES m m 3 zx m s ES pe o EZ A m E er N Al wp se m zm Ss X c c c c c c c c d bel Lad co M o uo A Ww N A2 Ww N Final Assembly Bil stor 1 87K Ohm 1 8W 1 0805 istor 11K Ohm 1 8W 1 0805 Thic Resistor 150 OHM 1 8W 596 0805 Thick Panasonic Resistor 162K Ohm 1 8W 1 0805 Rohm Thic Resistor 27 OHM 1 8W 5 0805 Thick Panasonic Resistor 0 001 OHM 4W 196 2725 SMD Stackpole Electronics Panasonic HG 3 Resistor 1K Ohm 1 8W 1 0805 Thick Resistor 47K OHM 1 8W 596 0805 Thick Rohm Resistor 10K Ohm 1 8W 196 0805 Panasonic Thick Switch
13. DK BDC24 Rev D BD BDC24 Final Assembly BOM PCB Assembly Enclosure Bill Of Materials Created 9 21 2011 1 C1 C6 C7 C10 15 Capacitor O 1uF 50V 20 0805 X7R C0805C104M5RACTU C12 C13 C14 C15 C16 C17 C18 C31 C32 C39 C40 2 C11 C19 C20 Capacitor 1 0uF 25V 1096 X5R 0805 Taiyo Yuden TMK212BJ105KG T C34 C36 C37 C2 C3 C25 Capacitor 10pF 50V 596 0805 COG C0805C100J 5GACTU 18mmx20mm 5 C22 c23 Capacitor 2 2uF 50V 1096 X7R 1210 C1210C225K5RACTU C24 C30 C33 ES Capacitor 10uF 16V 1096 X7R 1210 GRM32DR71C106KA01L C38 7 C35 1 Capacitor 0 1uF 50V 20 0603 X7R E Omnem C0603C104M5RACTU Capacitor 0 01uF 50V 596 0805 X7R C0805C103J 5RACTU ES LED Green Red 5mm T hole dual Kingbright Corp WP59SRSGW CC C4 C5 C8 C9 C26 C27 C28 SPACER PCB LED T1 3 4 109Mil 8902 Diode 2 Line 5V ESD Suppressor SOT GSOTO5C GS08 Semiconductor pz fr Biode Schottky eov TA Vsey O festes FB1 Ferrite Bead 400mA 1K Ohm 100Mhz Murata BLM18AG102SN1D 4 rr Header 1x3 0 100 T Hole Vertical 00523 Female 5 Header 1x3 0 100 T Hole Vertical Unshrouded 0 230 Mate 68001 103HLF J5 J7 Combined D2 D3 D4 D5 D6 Header 1x5 0 100 T Hole Vertical 4UCON Unshrouded 0 230 Mate Header 2x2 0 100 T Hole Vertical FC Unshrouded 0 230 Mate FC 90512 001LF Connector RJ 11 Mod Jack 6 6 Vert Flange Blk 04912 E 4UCON Connector RJ 11 Mod Jack 6 4 Vert F
14. K HIB VDD33 H 1 TP2 C4 C5 C6 o SPDIN RESETn 40 oo E 3 t RST VDD33 0 01UH 0 01UH 0 1 OUP TP3 TMS SWDIO VDD33 2 o 3 JD TCK SWCLK amran oa J GSOTOSC TPS TDO of GND vBAT 32 L A S Tp Ka GND pi B r at IP FANN OD Q M FANN GND 7 n TP8 GND LDO D4 a GND o I 1 HDR 1X5 GND VDD25 23 paaa C10 CH Encoder 7 GND VDD25 oou url 1UF GND VDD25 57 2 GNDA VDD25 433v dec RS232 Transceiver LM3S2616 R U4 je 10K J5 UOTX 11 13 TXD 6 LIMIT2 DIN DOUT 5 PING Jumper Installed default UORX 9 our uw L5 RXD T PINS BY 3 pw CAN RS232 Port A L Rx 416 FORCEOFF INVALID He 2 EN aie Limit Switch 2 Reverse 12 FORCEON CANT i T EN2 Ka IHH in T TEE Tansceiver PIN 1 2 3 c 4 U2 RIIT GP VERT R12 V 10K GSOTOSC m 1 5 CI3 0 1UF CANTX x J8 LIMITI 1 1 1 V C2 Hey CANRX DD CANH f 2 Jumper Installed default Cu CD LS SE CANRX RxD CANE ad S p 0 1UF 0 1UF_14 15 T 45V HDR 1X2 GND vec gt t c6 RS ida CAN Port Limit Switch 1 Forward TRSF3221E E 5 A GND VREF ll s ZN ZNpD6 C17 s GsOTOsC L RJ11 6P VERT Date Description DIE S TI AEC Austin Sept9 09 Internal Prototype P Sept 11 09 Pre production See Round up for change list d Xi TEXAS NSTRUMENTS oe Wie Basin Fa Sept 14 09 Change to use conventional Isense resistors Austin TX 78746 Sept 21 09 Pre production release Designer Drawing
15. Stellaris amp RDK BDC24 Brushed DC Motor Control Module User s Manual Xi TEXAS INSTRUMENTS RDK BDC24 UM 04 Copyright 2010 2012 Texas Instruments Copyright Copyright 2010 2012 Texas Instruments Inc All rights reserved Stellaris and StellarisWare are registered trademarks of Texas Instruments ARM and Thumb are registered trademarks and Cortex is a trademark of ARM Limited Other names and brands may be claimed as the property of others Texas Instruments 108 Wild Basin Suite 350 Ze Austin TX 78746 i TEXAS http www ti com stellaris I NSTRUMENTS mum m m m EM ortex e u Si r a SR Intelligent Processors by ARM ARM 2 January 4 2012 Stellaris amp Brushed DC Motor Control User s Manual Table of Contents Chapter 1 Stellaris Brushed DC Motor Control Reference Design Kit RDK Overview 7 WIRT EE 8 Specification OVETVIEW MT 8 Reference Design Ki Contente o crei tede ttr kn Ete han aree T Aenea nea re y taraen ade eee qua Lecce eege 9 Chapter 2 Using the Reference Design Kit eeeeeeeeeeeesiseeeeeeees esee en nenne enne nnne nnns nantes nnn 11 Important Information aeo Edo ia ert e nite reete Fe eie nta eiu FL Reb LE ebria Chat ates ORRA 11 Developing With he RDR C 11 Power Supply Sel cti n ssiri oinin a eege eed dates 11 Mor eler HO He PER EE 12 Chapter 3 Firmware Updates and DebUgginnd csse
16. Tact 6mm SMT 160gf erminal Screw Vertical 15A Red Screw 4Keystone non captive Terminal Screw Vertical 15A Black Keystone Screw non captive Terminal Screw Vertical 15A White Screw non captive Terminal Screw Vertical 15A Green Screw non captive IC Optocoupler Schmitt Trigger SMD 6 Keystone Keystone airchild 1 CAN Transceiver 8 SOIC Texas Stellaris LM3S2616 I QR50 AO0 Texas m m lt Di 9 Di 7 Q Q o D 5 Q o 5 G v ct c 3 D 2l 5 Un Gi i c 3 D 2l RS232 Line Driver 3V to 5 5V Single Texas Channel TSSOP 16 Instrumen Texas Instrumen n 1 Regulator SWIFT Step Down 0 5A Texas 42V MSOP10 Regulator Linear 3 3V SOT23 5 DBV Texas Current Shunt Monitor INA193 20V V Texas Gain 5SOT 23 Full Bridge MOSFET Driver Allegro 24 eTSSOP Crystal 16 00MHz 5 0x3 2mm SMT Hd NDK Abracon 2 TVS Varistor 30V 30A Transguard Of Materials SE 76 dE a2 fla Lia ol S S ols ic E 3 B B D D D i d ID ID un a a ERJ 6ENF1102V RCO805FR 071K87L ERJ 6GEY 151V MCR1OEZPF1623 ERJ 6GEY 270V CSS2725FT1L00 ERJ 6ENF1001V MCR10EZP 473 ERJ 6ENF1002V B3S 1000 8191 2 8191 3 8191 4 8191 6 H11L1SR2M H11L1SR2VM SN65HVD1050D LM3S2616 I QR50 A0 TRS3221bECPWR MAX3221ECPW TPS54040DGQ TPS73633DBV INA193AIDBVR A4940KLPTR T NX5032GA 16 000000MHZ ABM3 16 000MHZ B2 T VC080530A650DP January 4 2012 Stellaris a
17. Title Oct 7 09 Adjust Isense and SMPS circuit values DAY JAG KAK Black Jaguar Brushed DC Motor Control Added INA282 current sense circuit as a Drawn by Page Title future build option INA282 parts a tt Ure DC eee Pasar omes DAY JAG KAK MCU Network and Interface Sept 9 10 Sept 21 11 Removed INA282 current sense option Approved Size Document Number Added Additional 10uF to 5V and 3 3V rail B Date 9 21 2011 Sheet of 2 1 2 3 4 5 6 cis ll 12 24V POWER IN Us Uem LI hay ie TPS54040 SE TPS73633DBV TYBAT BOOT pu He be eege lim our 3 4 VIN COMP DA R13 3 e 4 F4 390K D7 EN NR CO SS16 1800uF cn C23 A A C24 C38 E a ed Can EJ LOUF Tur e SS TR amp D vsNs 10UF 10UF 10UF sov sov 82K RT CLK 6 PwRGD 2 16v 16v cl 16v 2 2I 0 01UF Blk omg 1K 4 4 P S 5 S F TP9 S iv EBI a 45V SHUNT HAT 1K ohm 100 MHz 1 3 R23 i 35 Sech ISENSE 193 T a U7 i INAI93AID M VM ec Ql ei Q2 a VM 1 je
18. ace with similar capabilities Figure 3 1 on page 13 shows how to locate the JTAG SWD connector Figure 3 1 Locating the JTAG SWD Connector JTAG SWD Connector January 4 2012 13 Firmware Updates and Debugging When using the JTAG SWD cable pay special attention to the location of pin 1 on the connector When inserted correctly the cable runs back across the bottom of the case covering the rectangular inset See Chapter 4 Hardware Description for additional information on the JTAG SWD connector Any Stellaris evaluation boards can be used as a low cost In circuit Debug Interface ICDI for both programming and debugging The ICDI circuit is compatible with LM Flash Programmer as well as leading development tools for ARM Cortex M3 Evaluation versions for several tools are available from www ti com stellaris Figure 3 2 Firmware Debugging Using JTAG SWD Ribbon cable ADA2 10 pin to 20 pin PC running LMFlash Adapter Cable Programmer or other Develop ment tool Any Stell aris Evaluation Board No software required 14 January 4 2012 CHAPTER 4 Hardware Description The MDL BDC24 motor control module uses a highly integrated Stellaris LM3S2616 microcontroller to handle PWM synthesis analog sensing and the CAN RS232 interface Only a few additional ICs are necessary to complete the design The entire circuit is built on a simple two layer printed circuit board All design files are provi
19. bg FA n ZECA 0 1UF Pa n m OMIT R16 i Motor 11 0K 1 H worm e o Es VSENSE gt 18 0K Lcos z White OU Cou 433v _ VC080530A650DP T Q a a5 Gel I 0 1UF U8 1 1 mi ca JI 3 21 vDD VBB R26 R27 SUE 1 1 VREG n 7 OMIT SE A 4 Cooling Fan Control 10UF i AHI 20 am GHA zv i 2 19 SA 2 B Red ALO gt H ALO GLA FANN L Black 433V s de MOLEX 35362 BHT JI em GHB FANON 1 Elo R28 17 SB e ON 7 E FEDV30IN BLO L BLO GLB He Q a 10K a is lt GD_FAULTn FAULT CPI E e RESET CP2 0 1UF Gb RESER OE ak e mo a OMIT A GND 4 23 RDEAD Q GND 22 AGND GND 4 4 Motor bal E MOTOR 820K M 3 DH j D SE TEXAS INSTRUMENTS A4940 EE SE KE VCO80530A650DP SC GC e Black Jaguar Brushed DC Motor Control FE FE Page Title se 9 Power Supplies and Output Stage Size Document Number B Date 10 142011 Sheet 7 of 2 1 2 3 4 5 6 Board Drawing This appendix shows the component placement plot for top Figure B 1 Figure B 1 Component Placement Plot JAGUAR DC MOTOR cen CAN RS232 C38 Cp U6 mrt D Su i C30 p 2 PI R6 C40 of d cic cl g LIMIT COAST BRAKE ANALOG ENCODER 2 5 mle ej me e ne e mjo e e e EE A A January 4 2012 24 Bill of Materials BOM Table C 1 provides the BOM for the RDK BDC24 Table C 1 RDK BDC24 Bill of Materials BOM Texas Instruments Part Number R
20. cays The short duration has no measurable impact on motor speed The boot strap monitor capability is the reason that the gate driver controls dead time rather than the LM3S2616 microcontroller Switching Scheme To reduce power dissipation in the H bridge the MDL BDC24 uses synchronous rectification Synchronous rectification uses the complementary MOSFET rather than a diode to provide a low resistance current path during the PWM off period Figure 4 4 shows the current paths through a complete PWM ON Dead time PWM OFF cycle The motor is modelled primarily as an inductor During the PWM ON period Q1 on the high side and Q2 on the low side provide a path that increases current in the motor The 2us DEAD TIME period starts with Q1 turning OFF Current continues to flow through the load with the path being completed by the Q2 intrinsic diode and Q4 The voltage drop across Q2 is equal to a forward biased diode Next the synchronous rectification period PWM OFF occurs when Q2 is ON The voltage drop across Q2 is now greatly reduced The load current decays during this period 18 January 4 2012 Stellaris amp Brushed DC Motor Control User s Manual Figure 4 4 Synchronous Rectification VM During PWM_OFF assuming a 40 A load Q2 losses are approximately 40W without synchronous rectification This drops to just 4W if synchronous rectification is used Rds on 2 5 mQ Synchronous rectification significantly improves drive
21. cceseeceseeeeeeeeeeeenaeseneeeeessaesensneeeeeesesneaeeeeseeesnnaeeeneees 13 General MOKMMALION EE 13 Firmware Update Using RS232 CAN sssssssssessssesssrisssirssirnssttstttusttnttttn uttu natnn nnt An ttt EASE ESS SEE ES NEES SEES Ennn Ennn nnen n nnt 13 Firmware Update and Debugging Using JTAG SWD sse nnne rnnt 13 Chapter 4 Hardware Description 11 esieeeeeeeeesiiesseeeee nein senem n nnne nhan nina nn tnn asina sant nanne annene nann nna 15 System Description eai eet da eene e A Rae e eee rn aee e ness E eurn nea e NR e EE E 15 Key Hardware Components essi aratat arrano anke tee tke d eo EE axe eee kan ae deu kane en PE xa nue AEN FERA ua DE L ger eben DE 15 Schematic DescrlpLiOR eoo itio erae e RR PEU Ee Ee pa rS YR See dete Ne DAR ee AAT XN NR eru Resa EE 15 Microcontroller CAN and I O Interfaces Schematic page 71 15 Output Stage and Power Supplies Schematic page 21 17 Texas Instruments Featured Parts 20 AppendbcA Schematics 2 21 Leica ee ci edd 21 Appendix B Board Drawing ci Ee EE HEES 24 Appendix C Bill of Materials BOM neeeeeeeeeeeeeeeeeeneeee nenne nn nnne nn nnn nnnn nina sss tn nnn sn ntes sas s nnnm nnns 25 January 4 2012 3 List of Figures Figure 1 1 Figure 1 2 Figure 3 1 Figure 3 2 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure B 1 MDL BDC24 Brushed DC Motor Control Module 7 MDL BDC24 Modu
22. ded on the RDK CD System Description A unique aspect of the MDL BDC24 design is the integrated CAN interface and low cost fan cooled MOSFET array that handles high current in a small form factor The motor control consists of an H bridge arrangement which is driven by fixed frequency PWM signals Key Hardware Components Figure 4 1 shows the MDL BDC24 circuit board with the enclosure and cooling fan removed Figure 4 1 MDL BDC24 Circuit Board DC bus capacitor Current sense circuit MOSFET H bridge JTAG SWD connector Switching power other side supply Stellaris amp LM3S 2616 Microcontroller RS232 transceiver M User switch a5 4 xi 16 MHz crystal Gate driver Servo PWM input optocoupler 6P6C CAN RS232 connector Status LED CAN transceiver Schematic Description Microcontroller CAN and I O Interfaces Schematic page 1 Page 1 of the schematics shows the microcontroller CAN port RS232 port and sensor interfaces in detail January 4 2012 15 Hardware Description Microcontroller At the core of the MDL BDC24 is a Stellaris LM3S2616 microcontroller The LM3S2616 contains a peripheral set that is optimized for networked control of motors including 6 high speed ADC channels a motor control PWM block a quadrature encoder input as well as a CAN module The microcontroller s PWM module can generate two complementary PWM signal pairs that are fed to the power stage Complementary PWMs are
23. e Avionics and Defense www ti com space avionics defense Microcontrollers microcontroller ti com Video and Imaging www ti com video RFID www ti rfid com OMAP Mobile Processors www ti com omap Wireless Connectivity www ti com wirelessconnectivity TI E2E Community Home Page e2e ti com Mailing Address Texas Instruments Post Office Box 655303 Dallas Texas 75265 Copyright 2012 Texas Instruments Incorporated
24. fine pitch header Texas Instruments Part ADA2 W Reference design kit CD Complete documentation including Quickstart and user s guides LM Flash Programmer utility for firmware updates Complete source code schematics and PCB Gerber files The source code can be modified and compiled using tools from Keil IAR CodeRed CodeSourcery GCC and Code Composer Studio 10 January 4 2012 Using the Reference Design Kit This chapter provides information about using the RDK BDC24 Important Information WARNING In addition to safety risks other factors that may damage the control hardware the motor and its load include improper configuration wiring or software Minimize the risk of damage by following these guidelines Always wear eye protection and use care when operating the motor Read this guide before connecting motors other than the motor included in the RDK DC motors may not be directly interchangeable and RDK parameter changes may be necessary before the new motor will operate correctly W Damage to the control board and motor can result from improper configuration wiring or software Developing with the RDK The recommended steps for using the RDK are B Follow the README First document included on the kit CD The README First document will help you get the RS 555 motor up and running using the BDC COMM Windows application in just minutes It also contains important safety information that you should
25. he under voltage limit The second consideration is how the power supply handles back EMF and regeneration currents During rapid deceleration of loads with high inertia the motor acts as a generator This current is rectified by the MDL BDC24 back into the bus capacitor As the capacitor charges the voltage at the supply terminals may increase It is important that the power supply can handle this momentary condition without entering a fault condition The power supply must also present sufficiently low impedance so that the MDL BDC24 s voltage rating is not exceeded A sealed lead acid battery easily meets these requirements NOTE The MDL BDC24 does not have reverse polarity input protection Motor Selection The MDL BDC24 operates 12 V to 24 V brushed DC motors Typical motors include model BI802 001A from CIM and model RS 555PH 3255 from Mabuchi see Table 2 1 for motor specifications Some very small DC motors or motors in lightly loaded applications may have a limited useful speed range when controlled with PWM based voltage controls The MDL BDC24 can also drive resistive loads with some de rating to allow for increased ripple current inside the module See the MDL BDC24 board data sheet for full specifications Table 2 1 Mabuchi RS 555PH 3255 Motor Specifications Parameter Value Units At maximum efficiency Speed 3953 RPM Current 1 244 A Power 7 139 W Torque 17 25 mMm At maximum power
26. le Key Features top view 9 Locating the JTAG SWD Connechor nennen nnne nene nnns 13 Firmware Debugging Using JTAG SWD enne nre 14 MDL BDC24 Circuit Board 15 MDL BDC24 JTAG SWD Connector sss enne nennen nnns nnne 16 Network Connector Pin Aesignments eerte nnne nnne nennen nennen 17 synchronous Rectification rnm EE 19 Component Placement Plot rte meten Et RED de ete D renti indt ed 24 January 4 2012 Stellaris amp Brushed DC Motor Control User s Manual List of Tables Table 2 1 Mabuchi RS 555PH 3255 Motor Specifications ccccecceceeeeeeseeeeeeeneeeeeeaeesecaeeeseaeeseseeeeesnaeeeeaas 12 Table 4 1 Detailed List of Texas Instruments Featured Parts ccccseccceecesssesceececeessecececeanseseeeeeseeseseees 20 Table C 1 RDK BDC24 Bill of Materials BOM ssssssssssseneeeenenen enn enne nennen 25 January 4 2012 January 4 2012 Stellaris Brushed DC Motor Control Reference Design Kit RDK Overview The RDK BDC24 is a Stellaris reference design for speed control of 12 V and 24 V brushed DC motors at up to 40 A continuous current Features include high performance CAN and RS232 networking as well as a rich set of control options and sensor interfaces such as analog and quadrature encoder interfaces High frequency PWM enables the DC motor to run smoothly and quietly over a wide speed range The MDL BDC24 uses highly optimized software and a powerful 32 bit Stellaris LM3S2616 microcontro
27. ller to implement open loop speed control as well as closed loop control of speed position or motor current The Reference Design Kit RDK BDC24 contains an MDL BDC24 motor control module as well as additional hardware and software for evaluating RS232 communication After evaluating the RDK BDC24 users may choose to either customize parts of the hardware and software design or use the MDL BDC24 without modification See the MDL BDC24 board data sheet available for download from http www ti com stellaris for complete technical specifications In addition the MDL BDC24 Getting Started Guide GSG MDL BDC24 provides a step by step guide to wiring and using the module Figure 1 1 MDL BDC24 Brushed DC Motor Control Module January 4 2012 7 Stellaris amp Brushed DC Motor Control Reference Design Kit RDK Overview Feature Summary The MDL BDC24 control board provides the following features Controls brushed 12 V and 24 V DC motors up to 40 A continuous Controller Area Network CAN interface at 1 Mbit s Industry standard servo PWM speed input interface RS232 to CAN bridge Limit switch encoder and analog inputs Fully enclosed module includes cooling fan Flexible configuration options with simple source file modification Easy to customize full source code and design files available Specification Overview Key specifications of the MDL BDC24 include W Quiet control of brushed DC motors 15 kHz PWM frequency W Three
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29. mp Brushed DC Motor Control User s Manual Table C 1 RDK BDC24 Bill of Materials BOM continued Texas Instruments Part Number RDK BDC24 Rev D BD BDC24 Final Assembly BOM PCB Assembly Enclosure Bill Of Materials Created 9 21 2011 52 JP1b J5b J7b 3 Uumper 0 100 Gold Black Closed sulins SPCO2SYAN 53 1 Fan Assembly 40x40x10mm 5V SUNON KDEO504PFV2 5 3CFM 2 Lead w Molex Sherlock connector 52 f i eratosure ABS plastic 3 pieces SE HRS SC Label with Model Serial Firmware info BJ AG LABELS Screw 4 x 0 375 plastite for 90380A108 enclosure Screw 4 x 0 625 Pan Head Sheet McMaster 900774112 Metal Phillips Slotted for fan 1 BOM PCB Black Jaguar Rev D Eod E January 4 2012 27 IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries TI reserve the right to make corrections modifications enhancements improvements and other changes to its products and services at any time and to discontinue any product or service without notice Customers should obtain the latest relevant information before placing orders and should verify that such information is current and complete All products are sold subject to Tl s terms and conditions of sale supplied at the time of order acknowledgment TI warrants performance of its hardware products to the specifications applicable at the time of sale in accordance with TI s standard warranty Testing and other quality control technique
30. s are used to the extent Tl deems necessary to support this warranty Except where mandated by government requirements testing of all parameters of each product is not necessarily performed TI assumes no liability for applications assistance or customer product design Customers are responsible for their products and applications using Tl components To minimize the risks associated with customer products and applications customers should provide adequate design and operating safeguards TI does not warrant or represent that any license either express or implied is granted under any TI patent right copyright mask work right or other TI intellectual property right relating to any combination machine or process in which TI products or services are used Information published by TI regarding third party products or services does not constitute a license from TI to use such products or services or a warranty or endorsement thereof Use of such information may require a license from a third party under the patents or other intellectual property of the third party or a license from TI under the patents or other intellectual property of TI Reproduction of TI information in TI data books or data sheets is permissible only if reproduction is without alteration and is accompanied by all associated warranties conditions limitations and notices Reproduction of this information with alteration is an unfair and deceptive business practice TI is not respon
31. sible or liable for such altered documentation Information of third parties may be subject to additional restrictions Resale of TI products or services with statements different from or beyond the parameters stated by TI for that product or service voids all express and any implied warranties for the associated TI product or service and is an unfair and deceptive business practice TI is not responsible or liable for any such statements TI products are not authorized for use in safety critical applications such as life support where a failure of the TI product would reasonably be expected to cause severe personal injury or death unless officers of the parties have executed an agreement specifically governing such use Buyers represent that they have all necessary expertise in the safety and regulatory ramifications of their applications and acknowledge and agree that they are solely responsible for all legal regulatory and safety related requirements concerning their products and any use of TI products in such safety critical applications notwithstanding any applications related information or support that may be provided by TI Further Buyers must fully indemnify TI and its representatives against any damages arising out of the use of TI products in such safety critical applications TI products are neither designed nor intended for use in military aerospace applications or environments unless the TI products are specifically designated by TI as
32. tputs TRS3221E Single Channel RS232 Operates up to 250 kbits sec RS 232 communications Low standby current 1 uA Typ Compatible Line External Capacitors 4 x 0 1 UF Driver Receiver RS 232 bus pin ESD protection exceeds 15 kV using human body model HBM TPS54040 0 5 A Step Down 5V Power Supply 3 5 V to 42 V input voltage range SWIFT 200 mQ high side MOSFET Converter with High efficiency at light loads with a pulse skipping Eco Mode Eco Mode 100 kHz to 2 5 MHz switching frequency TPS73633 Cap Free NMOS 3 3V Power Stable with no output capacitor or any value or type of 400 mA Supply capacitor Bs Input voltage range of 1 7 V to 5 5 V egutalor wi Itra low dr voltage 75 mV Reverse Curren SE eee Protection Low reverse leakage current Low noise 30 iVRMS typ 10 Hz to 100 kHz 0 5 initial accuracy INA193 Voltage Output Motor current Wide common mode voltage 16 V to 80 V High Side measurement Low error 3 096 over temp max Measurement Wide bandwidth up to 500 kHz Current Shunt Monitor Low quiescent current 900 vvpA max Complete current sense solution 20 January 4 2012 Schematics This section contains the schematic diagrams for the RDK BDC24 B MCU Network and Interface on page 22 WB Power Supplies and Output Stage on page 23 January 4 2012 21
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