User Manual: - Allied Motion
Contents
1. lid Toco lc February 12 2015 Motion User Manil DPFlex 1142 Velocity Stimulus The Velocity S mulus Tool allows the user to command mato velocity fom the DPD interface Refer to the following figure and tbl for instructions E Santee erre Veivi emos D J Coa p I Pulse amplitude sliders intros em Pulse frequency slider n Figure 16 Vc Sims Tod Tibe 3 Veoh Stina Too Isrts Sinn Covet Ts aa aT REO air tal pd cae uer Ee Resa a clare Teg a iuf Grid RE ReUF TEE ariete ta comenta Fur e Viena fo aay mda tte stg pp NO mapa a nmm sy cow 0 tr Pa Fate grr nn ey oS a RE oN AT a NIE Rr tse De en at erae Ses EON TTS ana ae ewe amp en S percentage ber Manman Vly Alicia Tecos Toe Y February 12 2015 Page 20 0639 Allied Motion Mana Dx Qu 112 Motor Parameters Use the Motor Parameters Foro input the motos number of pole pairs e for a six Pole motor the number pol paies s three ndis rated peak current Choose Apply To update the moror parameters By default the DPD software wil automatically calculate a set of current lop gains for the DPFles targeting optimal control abour a ad point of 20 of the Motor Peak Current2. Current Compensator The current Woop is a discrete control lop nested inside of the discrete velocity loop thar ensures the targeted curent setpoint is achieved and maintained The Current Compensate Fem displays the current pains set or the target mator Kalso enables the user to re calculate the pains based on e moto parameters or to tune the tains manually using DP Ds tuning tob mmo mem msn sm of eg Figure I9 Current Compensatar Form Choosing Tuning Tools wil display the Oscilloscope and the Curent Stimulus foem that these fom can be arranged as desired and their positions saved hy using the View Save Windows command The fae can then be restored w their saved positions any time by choosing View gt Restore Windows Alii Moon Technologien Ic rar 12 2015 Page 22 of 39 Figure 20 Current Compensatr Tuning Tools Wien tuning the current loop make sure the melor shaft is connected othe required A rein a head stee o ant snes Pal he ret et te whe per esti prre and carage pner To manually tune the current lop gains ia the Stimulus Form choose Curent Mode and Pulse Set the desired values fr curent pulse frequency and amplitude Then select Stat to apply to the motor In the Oscilloscope Form choose Au to start triggering
3. Motion 1 User Manual DPFlex Gen 2 Sensorless Brushless Motor Drives Document Par Number 34 2008 RI Alii Moon Technologien Ic Juda rar 12 2015 M2008 RE Allied Motion User Manual DPElex Gen 2 Table of Contents TE n a MG RNG CE 50 Inspection Upon Rect S AEREE 0 Sensorless Drive Technology AO Understanding Commutation ee 32 SixSiep Trpersidal Commutation 1 3 Sensorless Sit Sep Commutation 1 Special Consdeaton for Sensoriess Commutation 5 Sensorless Sap E 9 Wiring and Installation M Power Cabling EAT Mate Cabling 93 Communications Cabling w 9A Power Dissipation 104 Included Sofware 102 Installing the 103 Connecting wo the 4 104 Saving Configurations 105 Losing New Fimare M4 Creslng Applications M IL Stimulus Took ILLI Curse Stimulus 19 Aled Motion Teck ew com rar 12 2015 342008 RE Page 2039 Motion User Manual DPElex Gen 2 1112 Velocity Stimulus 5 112 Motor Parameters 1121 Mor 113 Curen Compensar 1A Velocity Conpensate das Rente Digital Output 119 Using the Oscilloscope 120 Control Theory amp Implementation snc 021 Biquad Compostar 122 Calculating Fiter Cetin 140 Mounting Guidelines for
4. ara eae oR Sevier cape Petra al pins apy a are a HEP ADR 4 2 a Daraya na nE Foster o Desc i ce gh Ai aparat Fa lid Techslagies Ten a February 12 2015 Aiad fed Motion Mana Dx Qu Control Theory amp Implementation The drive and motor system can be modelled as shown in he diagram below Except for he plant tbe motor is od all be blocks in the diagram ane pas of the DPFex Note hat the current and velocity control logs within the DPFlex fom nested with the Velocity Joop outing commands to the current lop and he current loop cues to he noto For tbe sake of is analysis onl the inner current op s shown in the diagram note that the velocity lop surrounding the current lop shares an identical structure Also the plantis taken tobe the RL transfer function of BLDC Figure 31 Sytem Diagram In bth the and velocity contrat oops wn main goals must be achieved Keep the ouput in his case curent in the molo phases and velocity of the rotor as close as possible o the target setpoint The result e refered to as the steady sate a Maintain an acceptable response to a change in setpoint This ie called the dynumie reponse To achieve thos wo pul second order infinite pulse response fitr quad comp
5. 0 0 in dick hera interface material The mter must extend us the mounting surface by a minimum of 127 nmm 0 05 in ar the PCB edge whichever sesso ensure that no contact will occur between the PCB races and the thermally conductive mounting surface The thermal interface material should provide close fit clearance holes for the mounting screws to allow sufficient insultinn material sound those locations Once the thermal interface material bas been installed a compression clip must be fined o 1p ofthe PCB board above the power MOSFETS o ensure that adequate pressure is maintained on the board 10 minimize thermal resistance and 10 provide mechanical estrain An example design af a compression metal clip und compression rubber sirip efer to the following figures Ail Technologien lc rar 12 2015 Page 37 of 39 User Manual DPFex Gen 2 SN e E Figure 36 Dimensions Meal Compression Clip Figure 37 Dimensions Rubber Compression Strip Als mounting hardware kits can be ordered fram Allied Mato which contain the compression clip tbe Berquist thermal interface materi and 160 6632 3 16 inch length machine serews When mounting the PCB cae mast be taken thit no more than 1 43 Nan 10 ins of torque be pied to e screws during All Motion Technologien Page 38 of 39 rar 12 2015 EE TT Mot
6. a fev seconds the Oscilloscope wil display the curent sous in green and tbe actual curent draw in red Adjust the cent op pains such that rise time ringing and overshoot are minimized Alied Motion Techn ex ne February 12 2015 User Manual DPFlex Gen 2 THEO 4 M Suau g 502 FS Figure 11 Oseloscope Current Loop Tuning Velocity Conpensato Te velocity loop is a discrete con which issues command tothe curent such that he desired velocity setpoint is achieved and maintained The Velocity Compensator Form displays the velocity gains set far th motori allows the user 1 Tune the pains manually using DPD ning Figure 22 Velocity Compensear Form cag Te 5 ssa flied Motion User Manual DPFlex Ger Choosing Tuning Tool wil display the Oscilloscope and the Velocity Stimulus forms Note that these formis can be arranged as desired and their positions saved by using the View Save Windows command The fens can then be restored ta their saved positions any time by choosing View gt Restore Windows Bm aE E Figure 23 Velocity Compenstor Tuning Tool When tuning the velocity loop make sure te monar shaft is connected ta the required Joad that the load is fie to mowe and move safely and the motor self ll ut A
7. I during operation the motor is expected to operate above this 20 threshold cree the percentage to reflect the application specifie load point Note that while the Mator Verification process provides current a gaias ia some cases these should be fine tuned using the Current Conpensamr Figure 17 Motor Form 1121 Motor Verification Tool CAUTION GENERAL WARNING False sue Pat De a tued not connected al ana at staan ur fea may reaut conan ane daraga 1o sonar y o pena Alter the appropiate motor parameters have heen appliod choose Start to the Motor Verification process Motion rar 12 2015 Page 2 of 39 Allied Motion Mana Dx Can During the Motor Verification process the DPD software detects the mator s Inductance and resistance vales and determines the appropriate sensorless Startup setings To accomplis his the DPFlex wll output de motor the defined Motor Peak Current in order to saturate the motor phases Note that if Motor Verificstion fails i likely that the Mote Curen most 03 sufficiently high value To resolve increase the Motor Peak Curent sening Aler the tool has finished close the Verification Tool and save the Configuration parameters tothe DPFlex s non volatile memory by navigating o Registers gt Update Registers in the System Navigation Tree
8. ho ir cmeitt Parquet at taie Inve aan mane safey ath melo tel i nov e pear sti prope gue and carage 1 equae riy pere To manually ture the velocity loop gains inthe Velocity Stimulus Forms choose Pulse Set the desired values Far velocity pulse fequeney and ample Then select Stat 10 apply the velocity command tothe motor In the Oscilloscope Form choose Aut to Str iggering few seconds the Oscilloscope will display the ve in green and the actual velocity in red tbe elo K Allie Motion Technologie Toc February 12 2015 Page 250639 Motion User Manual DPFlex Gen 2 ixl ua mmm Figure M Oscilloscope Velocity Loop Tuning d pe The Inputs Form allow the ign DPD the dive i be monitored Note that while monitoring the input pins vou ed Figure 25 Inputs Form siam Aed Motion er Mana De na The Analog Input indicator shows te percentage of input voltage across the analog Wien 45 is selected Ow 5 V sels 100 When 20k por is selected 33 V sesles 100 Teo digital inputs ae availible on the Digita 1 provides an enable disable gual and digia input 2 signals direction Note that moto direction cannot be changed Are DPF has been enabled Input One and Input indicators turn bright ed when sig
9. simplicity and effectiveness of the method makes it an atactse choice far commutation even at high spend 3 Sensorless Commutation Once the shaft of the motors spinning sufiendy fast the induced volage caused by thee varying magnete inking the stator windings can be essed by the drive This magnetic Nux is produced from the permanent magnets of the rtr Possible to use this information to commute the mtr without any other position feedback information This is what is meant by the tcm senseless is the absence of any physical positon feedback devices in the motor Alii Motion Teck ew com rar 12 2015 siamo RE Page 7039 Motion a Mana Dx Oia on si cal ance e ce ed frat cial t pu 1 8 Figure 2 SiS Commutation Sequence The hack EME voltage induced while in the OFF phase undergoes a polarity revera during the time he phases OFF The bias voltage is the voltage of the neural point of the WYE connection the deive should shut OFF as the induced back EME coit is undergoing a polarity reversal The should then be re energized once the voltage has changed polariry ad ht coil can contribute to tongue production n order to do his The samples the voltage of the OFF phase once the curent in that phase has dropped to Once detects that the x is generating a b
10. 100 He fundamental and a 20 kHz switching frequency es Peat Cumont per Pre n Figure 3 Power Dissipation Curve DPFlex 24V 30 A Model PB LN Figure 4 Safe Operating Area DPFles 24 V 30 Model Alii Technologien lc rar 12 2015 Page of 39 Motion Mana Dx Qa 100 Getting Started 10 1 Included Software The software provided with the DPFlex drive includes DP a Microsoft Windows based application that enables a user to configure and monitor the drive and a ver that enables a PC to communicate with the drive through a standard USB To install and run the DP D and USE to eral driver software PC is need with the following timum requirements Windows XP wih SP2 or higher AUSB pos or RS 232 serial communication port capable of 115200 bps 133 MH or higher Peniune compatiie microprocessor Atleast E MB of RAM 7 SO MB available hard dive storage SVGA or higher resolution monitor 102 Installing the Software The DPF software is packaged on a CD ROM contsining he DID software and USB t il driver or may be dowloaded fram the company website To ran the instalation utility insert the CD in your CD ROM drive Wait for the installation utility to auno run Ihe installation utili
11. 2 Alii Motion Tock um rar 12 2015 32008 RE Page 33 0f 39 Motion Mana Dx Equation 8 Compenstor Coefficient Der Equations 4 through ow how each of the fiv biquad ier coefficients calculated hom th PID control loop gains Ki and Ka hose Values are DPD for both the current and velocity contol loops 130 Mounting Guidelines for the DPFlex PCB Assembly The DPFex has oen designed to also allow installtion of the printed circuit board PCB assembly slone However note that the PCB assembly requires an optimal heatsink in order 10 ale its full output power rating The following guidelines have been provided to allow designers who wish to incorporate the DPFlex PCB assembly ino their own packaging achieve uum mechanical robustness and retest out pedomance TAL Mechanical Integration During design ofthe hestsink forthe PCB assembly e to consider the following Clearance between the PCB and surrounding areas must be checked to ensure that interferences do ot occur at maximum tolerances as this might induce unexpected stresses on the that could affect component reli between the mounting surface and specified locations must meet minimam equi regulatory ageney specifications for electrical clearances or Lomo 0 0304 Te mounting surface designated as the hema transfer surface must meet given ess specif
12. a Sapun etage beso odp eed by Fra Tous Sarapu magpa deis ened Ici TETUER dd sralo Input analog put sil RON mintan oranda sept output eed Fue Vct inputa vaka Seng ae Tre saring curent a pa ret glad e To mone th ei siat postor Tns cen must be ge enap arson Sate i ef me oad ops did ie srala Tr analog put signat 0 A m s toa rara itc command of 2 at Paes o gren Maxam vaca Aso pl avast Saring Cae e cuert a arr plato e me oris ci sl posto Ths caer muat e rge enanta etme ier oth lr ps ad Sire pase segs contaod DP D to Pe men EXT Sa I AEH OFFICE TE UE ETT Pista ate mgr Use STI PCA ER Digital Output The digital output can be configured to be either sped indicator or a fault ies Wien configured to be a speed indicator tbe output wil change state once every 60 electicl degrees When configured to be fault indicator the digital output wil activate When a drive fault occur Deren z sen or Figure 29 Digital Output Form Alii Marion Teck cv lisse cam Tran 12 2018 32008 RE Page 290639 flied Motion User Manual DPFlex Gen 2 the Oscilloscope DPD features a f
13. in supporting must extend underneath the PCB Starting fom the nominal board edge locution This edge must not extend any further under the PCB c risk of an electrical short may occur and minimum creepage and clearance specifications may be breached for specified regulatory agencies Please refer oe following figure foe on edge dimensions and tolerances Note that the Supporting edge requirement is optional far the two edges that are perpendicular to he connectar side edge of the PCB soe use of economical exinssion can be used to decrease manufacturing costs if desired Ail Technologien Ic etry 1 is Page 38 of 39 Allied Motion Mana Dx Qa i s UEA i Figure 34 Edge Dimensions and Tolerance DPFlex PCB Assembly Because he primary purpose of the mounting surface i to provide an opima thermal olor heat removal from the FCB he surface directly beneath the power MOSFETS between the two mounting hole locations must maintain the fatness and spatial dimension requirements as given by the following figure Figure 35 Mounting Surface Considerations DPFlex PCB Assembly Alle Marion Technologien lc Tenali rar 12 2018 Page 360139 Allied Motion Mana Dx Qu alle vo st the flatness specification wil ed poo thermal beat wansfer out the
14. in cach plis Allied Motioa refers t this procedure at the Ping Method The rotar remains stationary during the initial ping period because the sonent pulses are short and in opposing sequence In most eases the molo teaches sufi spoed before the next commutation sector change for the hac EME leen o tke over few cases usually if the load the motor is extremely heavy tbe ping process repeats while the motor rotates at ow speeds below he buck EMP commutation threshold This is possible because the ping period ie Is negligible with respect toe time between sector unions at low motor speeds The Ping Meth guarantees unidirectional motor tat which independent of motor loading conditions Ths he system is robust with respect to system load conditions Marion Technologien ilis aleia rar 12 2015 Page of 39 Motion Mana Dx Ga Wiring and Installation To ensure safe operation af the your application must meet the following requirements CALTON GENERAL WARNING Fare comply td ale westa an cha cr Power Cabling Use twa 16 AWG twisted cables with at east one wist per centimeter made as short as possible to connect ihe DC power supply 10 the DPF Connect fuse berween the positive voltage fom the DC power supply and 13 on the DP Pex Size the fuse to be 150 DPFlex s curent M is recommended that an additional electrolytic capacitor be placed
15. PCB and ay lead o premature shutdowns of the dive or complete fure ofthe sembly Adequate thermally conducive material beneath the drive i essential for oper operation ofthe product Failing e provide either Increased surface area capable ot dissipating the maximum expected power disiparion or a sufficient bul thermally Conductive material will require the de rating of the DPFlex for reliable operation Please refer tothe power dissipation curve for the product assembly that the mounting surface is designed for Note the recommended mina thermal for mevtiag the minimun thermal taster requirements This surface can be extended to e outer edges af the PCB along the centerline of the mounting holes I this extension i made the thermaal imerface material wal need to be extended to thse additional areas at In dion to observing the constraint on the mechanical clearances and interface surfaces as explained above tis necessary use a themally conductive electrically isolating itecce material inserted between the located at the specified thermal transfer surface underneath the PCB and a compression clip to guarania proper operation ofthe DPF The thermal interface atrial must be selected to have a Jow thermal resistance while filing in all voids beween the mounting surface nd the and providing 1100 VDC of let soon Allied Medion recommends using the Berquist GAP PAD GPVOS 0020 AC 0 5
16. ack of the proper polarity it shuts OFF the coil that is just beginning to go ough this voltage reveal process and energizes th one that just iid this process The drive uses the physical properties ofthe motor assess when the ime for switching is appropriate The motor bac EME constant Ke af te motar is used to how much Mus there is per pole By iterating the induced back EMF vilae in the OFF and waiting for the proper amount of Aux accumulate drive commute alte appropriate time Since Ke is constant iis poe independent and therefore plicable aral speeds at which the of the motor can be detected by the dive Allied Moon Technologien Ic rar 12 2015 Page 8039 lied Motion Mana Dx Qu Special Considerations for Sensores Commutation During the proceso cormutation curent in one phase must drop to zero and waft the phase hat is just coming ON Because af the fact that the coils not nally coupled 100 and tht each coil has its owm leakage reactance there will be portion of ime beit bref where all ree coils have current intem During tis period lime an accurate cannot be obtained fom the volage sense circuit on the cole mediately ser commutation tbe drive wil shut OFF the phase voltage and wait unt determines that an ccu bck EMF signal an be Dom the analog input dedicated to hock EME sensing in t
17. across J344 on the DP Plex lose as possible to the 13 6 connectors Rule af thumb sizing for this capacitar is 30 pF per ampere of the DPFlens rated current Cables running o and from this aed capacitor should be twisted together using 1 wist or more per centimeter M estra capacitance is used it i bighly recommended that a pre charge crt be used to imit the ines eurent caused when charging this capacitance The limiting resistor sould then he shred out using a relay or some other appropriate means Spo round the DPF drive ibl Motor Cabling Use thee 16 AWG twisted cables with at eat one twist per centimeter made as short as possible connect the motor to the DPF 93 Communications Cabling The signal cables f r J1 must b less than 1 meter in length Use a USB cable to connect the PC to the USB UART adapter The serial communications connector on the die uses TTL signals with he drive from a devioe using standard RS 232 signals s desired a means to convert the signal levels bermeen the vo devices mast be provided Motion rr 12 2015 EE TT Page 100f 39 Kisa fed Motion tiar Maa DF Power Dissipation The DPFex generates heat as its power consumption increases Het sink the DPFIex drive using the following power dissipation curve to guide the heat sink design Note that the power dissipation curve was generated with Balanced 3 phase sinusoidal current ata
18. adopter cable Pag the end of the USB A 10 B cable into a USB port on the PC Note that if the USB o serial driver has not been installed the PC will launch a device driver install wizard when it detects the adapter cable Use the wizard w instal he driver from the driver directory on the CD Then plug th Toe end of the adapter abl into the serial communications connector on the DPFIex dive then start DPD Alii Moon Teck malinn rar 12 2015 342008 RE Page 140139 Motion Mana Dx Figure V DPFlex Connector Locations When DPD it opens a blank System Navigation Tee which is usd o create and manage DPFex configuration Figure DP D System Navigation Tree To add DPFlex configuration right click the System anch nthe System Navigation Tree and choose Connection or double click the System branch DP D then displays the Interact form which lists defined connections Choose Adi Figure I Interact Furm Alii Moon Teck malian February 12 2015 M208 RE Page 1 of 39 Allied Motion Mana Dx Can DDPD then displays the Connection Infi Ifthe port to which the DPFlex cater is connected i not displayed in the Por drop down Ist chose Sean Po DPD Sen scan the PC far serial ports or the USB o serial adapter If USB port docs not appear in the list check the following items ande scan that he USB driver is installed thar the USB to
19. cy in this manual However Allied Motion assumes no responsibility for any errors or onision The information contained iin this document is regularly reviewed and we welcome your critical evaluation ad suggestions for improvement Allied Motion reserves the ight to modify all documentation without per notice to download the most recent revision ofthis manual from the company website This manua supplied to the user with the understanding thatit will not be reproduced duplicated or disclosed in whole or in part without the express written permission of Allied Maton Technologies Table 1 Applicable Aled Motion Products TEOUTFARUY PART ROMER DESCRIPTOR Fe Gan Seres Ense So Inspection Upon Receipt Motion products are thoroughly inspected and tested before leaving the factory Although products are packaged with extreme care is important tha the user complete thorough inspection of the product upon ania Examine the condition of the shipping container and materials If damage i found notify the commercial carier involved Iris the user s responsibility to file any ncesary damage claims Wit the carrier Our produets shipped EXW ex works unless cer atrangements have been male Allied Mation is not or carrier mishandling Fled Moon Teck ew alienation com rar 12 2015 EET Page of 39 Allied M
20. ells and mills conveyors office and medical equipment automotive Subsystems and many others 30 Sensorless Drive Technology Understanding Commutation Torque in an lec moto is the af the interaction between two magnetic fom th rotor and the otber from the stator These wo magnet elds must move in Sequence with each cher ro produce torque current through the motor so as to produce torque what is ow as commutatio To accomplish this the DP Rex uses a sensorless trapezoidal commutation method whieh relies the mot back ecutive force bac EMF fr positio sensing Alei Motion Tran 12 2015 EE TT Page 6039 Motion Mana Dx Qu Trapezoid Commutation In this method thene ane only two af re phases of stator coils energized by the DC source at any one given time To complete one electrical eyele or magnetic fid rotation every Phase is energized four times two tines in the positive polarity the other two in the negative polarity BLDC motors by six 60 degree staps during each full 360 degree electrical cycle Because the tation from one sept the next is discrete the waveform of the field shaped like a trapezoid Electrical Degrees Figure 1 Six Step Commutation Phase Current and Back EME commutation is simple and can be used for many types of BLDC motors The
21. ensar is used 10 approximate lisse PID consol loop 121 Biquad Compensator A PID control lop canbe appena inde discrete time domain by 32 oder ier wit the following 2 transfer function Eto Function Had Compe Doman MO Rn tem This transfer function has following block diagram Fle Motion rar 12 2015 Page 320f 39 User Manual DPElex Gen 2 Figure 32 Biquad Filter Diagram 122 Cakeutating Filter Coefficients DPD automatically calculates the biquad iter coefficients B and An rom the chassie PID contro loop pains Kp Ki and Ka Biquad coefficients values described in QLIS format with exponent value Most good digital signal processing texts contin deseription of the QLIS numerical forma anser function of he PI compensator in the s domain is Equation 2 Transfer Function PID Compensator Domain 7 Ds 38 out how PID gains are related o bua gains assume ats approximation of the bilinear transformation Then trasformiog Equation 2 10 the 2 domain yields Equation 3 Transfer Function PID Compensator Domain Kp HER and by comparing Equation 1 and 3 Equation 4 Biquad Compensator Coefficient A Equation 5 Biquad Compensator Coefficient Az Equation iud Compensator Confit By yt Equation 7 Biquad Compenstor Coefficient
22. from the DP D interface Before using Stimulus Tools be sure to rt succesfully complete the Mutor process see Mato Parameters for instructions and appropriate and velocity loop gains see Current Comgenstor and Velocity Compensstor espocively Note thar the Motor Verification process will provide iil curent Joop sains however in some cases these settings should e ae tuned using he Curent Alii Motion Technologien ew alienation com rar 12 2015 Page 18 of 39 Aded Motion HAA Current Stimulus The Current Stimulus Tool allows the user wo command motar current or nue from the interface Refer to the following figure and abe fr instructions Pulse amplitude siders 1 Pulse frequency slider Figure 15 Current S mulus Tool Table 2 Current Stimulus Instructions SETS DESCRIPTION ren core ea ia se cut HE E His eer Curt aer mede te Fir decur tra e rr Phases bu nor omes Uae in n apta is ion rene Uem Tage tese ea a GIU Ig mu iic tom e rog rp Wen an Cue Simus t sais input b 00 fests roar he Var Supr bio ea pte sie Te cut ange qa Pek are Tus Ses are cared EGIT anders a rrr 8 ghen as apocertig eque Moi ea Curt
23. he OFF phase Iris only after this has een successfully detected abe drive will begin to use the measured bck EMF for commutation purposes Since DPFlex monitors the back EMF Feedback und activates the back EMF sensing ibl o parameter asocia with the cl cil current taster AS Sensorless Startup As the induced hack EMF i proportional to speed a sensorless controller needs a means finding the rotor position slal in onder to start the motor atd accelerate itt a Sufficiemtly high speed to be to dct the bac voltage Startup i undoubtedly the biggest hurdle for any sensorless conta grin Conventional methods drive coment through the motor winding in arder to force the oto known position to ensure proper molo This can cause up to 180 degrees of motor rotation in the direction oposite to whic i actually desired Also the seqied to orient the oor depends an the inertial and tonal load af he motor de initia current to orient the oto is to high tbere may be overshoot and tinging in the syste I tbe current i too lov the motor may not sart at all Susha system is not robust with respect o system loa conditions Mare advanced method determine rotor position sed on the moto phase saturation inductance change The drive generates six short and opposing current pulses that drive the motor phases inno saturation The drive cele the motor rotor position based on te saturation inductance change
24. ications so as wo prevent raised surfaces from wih beat To the mechanical clearance requirement between the mounting area and the edge of the PCB it is secommended thut provisions be made allow minimum o 10 un 0 0394 in o clearance from the edge of the PCB to the surrounding the PCB mounting location The PCB wil typically have a tolerance 0762 mrn 0 030 in and 0 0 mrs in on the outer dimensions Please refer to the following figure for details clearance and tolerance requirements By providing the recommended clearance t will accommodat any variations in manufacturing proces thit might occur nd wil facilitate the installation of the PCR during assembly while ensuring PCB ebay Ail Technologien Ic Tran 12 2015 Page M of 39 Allied Motion Mana Dx SWR BU COR ii d OOO OTP Sia De D mag Eo SHE S8 Figure 33 Dimensions DPFlex PCB Assembly In dion to the clearance requirement on the edge of the there is a minimum supporting outer edge requirement that is necessary for proper mechanical support of the assembly Fare to include this edge may lead to additional stresses being ced on the PCB which could cause component failures A asinum af 0 635 0 025
25. ion User Manual DPF Ge na Testing Atter completing the integration of the ito the urget location insulation test shouldbe performed io verify that the electrical insulation is ot bee reached The unit also be tested under load to verify that an adequate thermal interface has been provided 140 Revision History Table 6 Revision History REVSON DESCRIPTION OF CHANGE Techslogies lc February 12 2015 TELE
26. nal voltage is applied across the corresponding inputs Use the drop down menu To configure the digita inputs to b either Active High Active Low ats Use the Status tto view the operational stats ofthe DPFlex and motor Choose Refresh to update the display with the curent status Choose Cle Faults to clear the display anad the stats Note that fauls ane also cleared by power cycling the die Figure 26 Faults Status Form Use the Configure tubo adjust fault setings states warnings and error messages Ser esol by emering ales for temperature cumen and vollge i degrees Cols ners and volts respectively Choose Appl to save senings Ale Motion Tecnologie Tne February 12 2015 ETT Page 27 of 39 User DPFlex Gen 2 Figure 27 Faults Configure Form Registers The Register Form allows he wero eve and save DPFIx senings as fles nd lal thse eting to non volt menor Also the Regine o configure the dive Start Note that changes tothe Ao Start acting wll effect Update Rete disconnecting tbe drive on DPD and then power syeling e DPF Alii Motion Technologien Tac February 12 2015 Page 280139 Motion User Manual DPFlex Ger Table 4 Registers Form Instructions eme DESCRIPTOR usur i ri a or aT pT TEE
27. otion Mana Dn an uem a eaupmet can propery carece posta uy acea Te nal apne br CAUTION GENERAL WARNING N aa loved coner ber asertl and connssening inge use at ese ed Alec ton prius esol ato eua Ht VOLTA Whe des repost capes ae presenton soma and een a ve amd can be dangerous Te vcr ate remos wi Pa power on nd en tampon and reat s al jem compren m Overview The DPFex system includes the following components the product dataset dis user manual the DPFIes drive DP D conunissioning software and cabling foc connecting DPFex drive to power motor and personal computer PC The DPFlex deive provides sensors torque ando velocity control of rotary brushless DC BLDC motors at performance levels exceeding those of conventional Hall sensor commutated kives detects motor rotor position stall tough an innovative algorithm based on pase inductance measurement hus no commuation sensors are required The DPFIex may be integrated inno a motor e g into the bell end or mounted separately Allid Motions DP D software foc Microsoftit Windows 2000XP Vita is used to configure and program the DPFle drive t provides UO setup and configuration tols loog With moter verification ad performance analys tools is suitable fora wide range of applications including ono of fs pumps compressors centrifuges d
28. ourchannel digia ocio setpoinns and the mot actual performance To display the digital oscilloscope tke one In the Took menu choose Oscilloscope Inthe Current Compensaror frm ar Velocity Campensator forms choose Tuning Tool uam 5 vm Fm wem Figure 30 Ovellncope Technlogier Tne pm siam Motion User Manil DPFlex Table S Oscilloscope Instructions ELA TESCRION CAT CH Ua asus marge Sats ahr aaa egg ere meia we epo saw a T ST Sani Se er ting oan aniio a 7 eine par is be dpe or Pe Seen eg 100 any en feg 100 be cape erac e cope le he Dg feo feos charge one port capturas 10 ma EI Sea Re ae AHN STENT ante ll number Parts te capes og Fran ghe rut Be pad ree Base Charges eg 10 ms as ge Na Ao Traner Saans gt Simas Eige Tage ae i ee a Sas TS Tage gt ona Simas Edge Tage eg ee ST ese Oa MI Tages gt on Sims ape Tage a eg Re ae ge Te ara RON SER Tages gt venti igs Ga apg WB asa poate a Zio ote epe Tia TS aR aA TR TR SG Say ae Fa aE
29. rrent Copensator Figure 20 Curent Compensstor Tuning Toot Figure 21 Oscilloscope Curent Loop Tuning iue 22 Velocity Conpensat Form iue 23 Velocity Compensato Tuning Tools Figure 34 Oscilloscope Velocity Loop Tuning Figure 25 Inputs Fen Figure 26 Stats p iure 77 Faults Configure Form iue 28 Registers Form Figure 29 Digital Output rm Figure 30 Oscilloscope iue 31 System iue 32 Biquad Filter Diagram Figure 33 Dimensions DPFlex Assembly 2 E Alii Motion Technologien lc rar 12 2015 new alienation com Page tof 39 Motion Mana Dx Qu Figure 34 Edge Dimension and Tolerance DPFlex PCB 36 35 Mounting Surface Considerations DPFlex PCB Assembly 36 36 Dimensions Metal Compression canons Figure 37 Dimensions Rubber Compression Sui E Tables Table 1 Applicable Allied Motion Products s able 2 Current Stimulus Tool Instructions io Table 3 Velocity Stimulus Tool lstractions ere Table 4 Registers Instructions Tale 5 Oscilloscope Instructions Table 6 Revision History 4s This anal describes the installation and operation of DPFlex Gen 2 senseless brushless motor drives manufactured by Alli Motion Technologies Inc Every effort has been made to ensume accura
30. sra cables are properly connected In the Port Hist choose the pot to which the DPFlex controller is connected Figure 11 Connection Inf Form Choose Test to the connection to the controllers working Lf the test ails hoc the following items and reest that the communication cables ane properly connected tht the contol powered Choose OK o accept the connection Cancel 10 abort the operation The Interact Rom now lists the connection to contr tee nem m Figure 12 Interact Form Wik Enabled Connection Choose OK to accept the controller connection configuration or Cancel ta abort the operation DPD updates the System Navigation Tre for the new configuration Ail Moon Technologien rar 12 2015 Page ibo 39 Allied Motion Mana Dx Figure 13 DPD System Navigation Tree With Enabled Connection Each DPFlex configuration shows the enabled COM port and provides acess to the following items S mulur Tols Motor Curent Compensator Velocity Conpeneatr Inputs Faults Registers and Digital Output 10 4 Saving Configurations save DPFIex configuration choose File gt Save Mf the configuration hat not beon previously save DP wil display a browser by which to seleet puth and file for the configusnion file Tocreaeanew configuration choose File gt New I tbe current config
31. the DPFlex PCB Assembly 181 Mechanical Integration H2 Testing s 140 Reyislon History 20 a au 2 P n w 2 a Fled Maton Tectia rar 12 2015 32008 RE Page 3 ew alienation com Motion User Manual Flex Gen 2 Equstion 1 Transfer Function Biquad Compensstor 2 Domain Equation 2 Transfer Function PID Congensatr s Domain 3 Transfer Function PID Congensatr Dona Equstion 4 Biquad Compensatar Coefficient A Edison 3 Biquad Compensator Coefficient A Equation 6 Biquad Conpenstr Coefficient By Equation 7 Biquad Compemater Coefficient Bj Equation 8 Biquad Compensator Coefficient 5 Figures uel Six Step Commutation Phase Current and Back EME Figure 2 Six Step Commutation Sequence Figure 3 Power Dissipation Curve 24 V 30 A Madel iue 4 Safe Operating Area DPFlex 24 V 30 A Model Figure 5 Installation Uy Main Menu Figure 6 Installation Uy DD igure 7 Installation Uy stall USB do Sena Diver Figure amp DPFlex Connector Locations p ue 9 DPD System Navigation Tee Figure 10 Interact Form igure 11 Connection Into Form Figure 12 Interact Form With Enabled Connecti iue 13 DPD System Navigation Tee With abled Connection Figure 14 DPFlex Form Figure 15 Curent Stimulus Figure 16 Velocity Stimulus Tool itur 17 Motor Fan p iue 18 Motor Verification Toa Figure 19 Cu
32. ty does not automatically ran open the SETUP EXE program found in the soot of the CD Figure S Installation Ulli Main Alle Technologien lc rar 12 2015 Page 12 of 39 Motion Mana Dx To install DID in the installation uty choose sil The installation uty launches the DPD instalation wizard Follow the instructions in the wizard to install DPD Not thst DP D reyuires an Open Database Connectivity driver t be installed on the PC If you do not have one you can install one by running the TYPEXE program in MDAC2_8 directory found on the CD De Figure Installation Uil Install DPD To instal he driver in the installation uty choose Install USB t0 erial Driver The installation utility launches the driver installation wizard If you want o change Where the driver is installed choose Browse to select another location Then choose Next to instali the driver or Cancel to abort the operation Alii Moon Teck rar 12 2015 EET Page 13 0f 39 Allied Motion Mana Dx Ga E apoio beoe 103 Connecting tothe DPFlex To configure the DPFex dive using the installed software i must be connected 19 power 1o a motor and to the PC Connect the DPFlex tothe PC by plugging one end of the USB A to B into the USB port of the USB UART
33. uration has snot boen saved DID wili prompt to either save or discard conia To open a configuration choose ile gt Open DPD wil display a browser Select the path and file name for the desired configuration and choose Open 105 Loading New Firmware To loai new firmware and view system properties right click e Gen COM etn he navigation ee and choose Interact or double click the leaf DPD hon displays the DPFlex System Properties Forma Figure 14 DPFlex Properties Form Ail Technologien lc rar 12 2015 Page 17 of 39 Allied Motion Mana Dx na The Properties Form displays the following controller information the supply voltage dise temperature tbe firmware version including date and ine of compton and the DPFIevscureat ad voltage ratings To load new firmware lick Show Details Load New Firmware DID will hen present a browser by which to select the appropriate path and file rame Creating Applications chapter describes how to configure and deploy DPFlex for a particular aplication tich includes how 10 configure te DPFlex for a specific motor tune the current and velocity oul cheek the digital and analog inputs ennfigure the digital ouput monitor and clear ve fauls and use the DPD digital oscilloscope na Stimulus Too The Stimulus Tool allow the user to conl either motor current one velocity
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