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YROTATE-IT-RX220

1. Reading mement Reading moment Three shunts In the three shunts configuration the current in one shunt is equal to the corresponding phase current when the corresponding lower switch is ON The most suitable moment to read the current in this configuration is at the trough of the PWM Single shunt In the single shunt configuration only when one or two of the lower switches are ON the current through the shunt is related with the phase current When only one of the lower switches is ON the current in the shunt is equal to the current of the corresponding inverter phase When two of the lower switches are ON the current in the shunt is equal to the sum of the currents of the corresponding phases that is it is minus the current of the third phase Important Note Software projects for each method are provided for both the High performance Embedded Workshop HEW and e2studio development environments The appropriate project for each are listed below Three shunts current for HEW MCRPO9_RX220_3_shunts_verXXX Single shunt current for HEW MCRPO9_RX220_1_ shunt_verXXX Three shunts current for e2studio YROTATE IT RX220_3_shunts_verXXX Single shunt current for e2studio YROTATE IT RX220_1_shunt_verXXX UM YROTATE IT RX220 Rev 1 00 Page 15 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 10 Control MCU overview The RX220 Group is a low power entry level 32 bit microcontroller The R
2. Motor Control Demonstrator Motor Control Demo User Interface zoon VOLTAGE Target Device RX220 UM YROTATE IT RX220 Rev 1 00 Page 1 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit Contents 1 Hardware Ee 3 2 Connectors Ee le ler EE 4 3 POWer SUPPIY SEIECTION E 5 A LEDS TURCTIOMIAESEFPtlOM eg eege ee Eee EN fe sdee dusven tds AEEKO Ea CAE EEEa Oei Ee EEE EEE ETS 6 5 Test points tor CEDUBBING reer a a E a a aaa e a a a r a aeaa 7 6 Internal power stage brief descripti sisses in r an ee a e aaae Eai TE SEEE ERSE EEE E 9 7 Interface with an external power stage 10 8 Singl sh nt c rrent reading EE 14 9 Current reading timing in three shunts and single shunt configurations ccescccceceeesssessnaececeeecessesssaeeeeeeseesenaees 15 oe e Reen ET 16 11 Permanent magnets brushless motor model 17 12 Sensorless Field Oriented Control algorithm ccccesssccecesesssscceceeecesseseaeaeecececesessesaeaeseseceseeseaeeeseesseesnssuaeeneeeseess 23 E Ee lt e e EE 24 if BRAS Tet e 9 8 6 1 0 EE 28 15 Reference system transformations in details ccccssscccccecsssssececeeecesseseaeaecescececeescsaeaeseeeeesesseaeseeeessessecsuaeeeeeeseess 30 16 ROOF POSITION SSSTIMATION NEE 31 17 Internal representation of physical ouantities 33 18 EEPROM patameterssist EE 37 19 PC Graphical User Interface cccccccccsssssssscseceeecssssseeececessenssassesececes
3. A Li A Sin A Li If the synchronous inductance L is small the current terms can be neglected if not they have to be considered In general x A COS Ag Lig Ago Wa Rsia dt Lig 0 y A sin 3 Ag Lig Agy Vg Rsip dt Lig 0 So in the system phase we obtain from the flux components v arctan ve UM YROTATE IT RX220 Rev 1 00 Page 21 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit The system speed can be obtained as the derivative of the angle 0 ae A Ht Based on this a sensorless control algorithm was developed to give the imposed phase voltages to measure phase currents to estimate the angular position and finally the system speed UM YROTATE IT RX220 Rev 1 00 Page 22 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 12 Sensorless Field Oriented Control algorithm Please find below the sensorless vector control algorithm block diagram 0 Iqrer a B gt u v w Vo vB Flux Phase estimation Ok JI d q u v w gt B BoA The main difference between the three shunts configuration and the single shunt one is in the Current Reading block the rest of the algorithm remains the same in principle even if the blocks order has been adjusted UM YROTATE IT RX220 Rev 1 00 Page 23 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor
4. Coefficient Kp 18 73 4 10 80 30 Current PI Integ Coefficient Ki 40 80 10 20 215 20 Speed Loop Kp 30 30 50 40 175 120 Speed Loop Ki 400 400 100 300 1400 50 Flux Feedback Gain 400 100 400 400 100 500 Filename in csv format EBMPAPST_ECI_24 42_24V_3000RPM DANFOSS_BD35F_24V_3500RPM MINEBEA_BLDC15_12V_12000RPM PREMOTEC_BLDC58_24V_12000RPM SPEEDERMOTION_MBOS7GA240_SO00RPM FULLING_FL28BL38_13000RPM UM YROTATE IT RX220 Rev 1 00 Page 50 of 50 Jan 15 2014 RENESAS Revision History Description Rev Date Page Summary 1 00 Jan 15 2014 First Edition General Precautions in the Handling of MPU MCU Products The following usage notes are applicable to all MPU MCU products from Renesas For detailed usage notes on the products covered by this document refer to the relevant sections of the document as well as any technical updates that have been issued for the products 1 Handling of Unused Pins Handle unused pins in accord with the directions given under Handling of Unused Pins in the manual The input pins of CMOS products are generally in the high impedance state In operation with an unused pin in the open circuit state extra electromagnetic noise is induced in the vicinity of LSI an associated shoot through current flows internally and malfunctions occur due to the false recognition of the pin state as an input signal become possible Unused pins should be handled as described under Handling of Unused Pins in the manual
5. please refer to the board schematics e Remove from the board R90 and R96 they are the shunts related to the phases U and W e Close the soldering points PS1 and PS2 those soldering points put the three inverter harms in common below the lower switches and above the shunts e Change the value of R119 and R128 from 3K3 to 1K this will adapt the gain of the over current detection circuit e Remove the capacitors C70 C72 C85 it speeds up the current reading circuit The components involved in the modifications are indicated in the figure below R90 R96 Ae eree TITT eeeeeeeceeeo eeeeoeeenooo eeooeeeooo eeeeee R119 R128 vORV Ou t 3 d PS1 PS2 Ge SCH Te KE giel WS S D me Ti C70 72 C85 SE z a lei 2 Reo ale BS We CR a sl ER ma pa Ki be gt vwe vow E S st KA Glee ei 7 vs anan Bes KS IS j e va E unie angg te CN EI e a dk ei az a UM YROTATE IT RX220 Rev 1 00 Page 14 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 9 Current reading timing in three shunts and single shunt configurations The figures below show the different situations related to the two configurations The first figure is related to three shunts current reading the other are related to the single shunt current reading Transfer moment Ietenragpt mement TENTS A ii Se d ale Ne
6. 2 Processing at Power on The state of the product is undefined at the moment when power is supplied The states of internal circuits in the LSI are indeterminate and the states of register settings and pins are undefined at the moment when power is supplied In a finished product where the reset signal is applied to the external reset pin the states of pins are not guaranteed from the moment when power is supplied until the reset process is completed In a similar way the states of pins in a product that is reset by an on chip power on reset function are not guaranteed from the moment when power is supplied until the power reaches the level at which resetting has been specified 3 Prohibition of Access to Reserved Addresses Access to reserved addresses is prohibited The reserved addresses are provided for the possible future expansion of functions Do not access these addresses the correct operation of LSI is not guaranteed if they are accessed 4 Clock Signals After applying a reset only release the reset line after the operating clock signal has become stable When switching the clock signal during program execution wait until the target clock signal has stabilized When the clock signal is generated with an external resonator or from an external oscillator during a reset ensure that the reset line is only released after full stabilization of the clock signal Moreover when switching to a clock signal produced with an
7. 8a SIND 8 e cos v a B gt d q Za 84 COSCO g sin v 8p 84 SiN g cos v d q gt a B v V cos t Q v Vcos a Q 27 3 v V cos t Q Vcos Q v V cos t Py 47 3 UM YROTATE IT RX220 Rev 1 00 Jan 15 2014 E ft v Vsin Qy ve Vsin t to Page 30 of 50 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 16 Rotor position estimation The rotor position estimation method which has been chosen is the direct integration of the back EMF Please find below the fundamental equations x A COS A Li n Wa Reig dt Li 0 y A sin 3 Ag Lig Agy Vp Rsip dt Lig 0 v arctan ve OI e Ht The challenges in this approach are the calculation of the integrals which is well known as a problematic issue in a numeric context and the choice of the initial conditions which are not known in general There are two possibilities to overcome these difficulties 1 To use a so called approximated integration which means that instead of using an integral 1 s a special transfer function is chosen which is very similar to the integral in certain conditions 2 To correct the result of the integration with a sort of feedback signal obtained combining the estimated phase with the real flux amplitude known as a parameter of the system In the first case we choose an integral approximation function which has a limited memor
8. BASE_IMPEDANCE_OHM NORMVAL BASE_CURRENT_AMP BASE_VOLTAGE_VOLT Resistance The resistance is expressed in function of the base resistance which is kept equal to the base impedance this leads usually in a poor representation of the resistance in terms of resolution but the resistance itself is highly variable with many factors and an higher resolution is usually not required BASE_RESISTANCE_OHM BASE_IMPEDANCE_OHM Resistance internal_resistance_unit KR Resistance Ohm KR KZ Inductance The base inductance value is derived from the impedance and the angular velocity BASE_INDUCTANCE_HEN BASE_IMPEDANCE_OHM BASE_SPEED_R_S so the internal representation becomes Inductance internal_inductance_unit KL Inductance Henry UM YROTATE IT RX220 Rev 1 00 Page 35 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit KL NORMVAL BASE_INDUCTANCE_HEN NORMVAL BASE_SPEED_R_S BASE_CURRENT_AMP BASE_VOLTAGE_VOLT Flux In a similar way the base flux can be chosen equal to BASE_FLUX_WEB BASE_VOLTAGE_VOL BASE_SPEED_R_S Then we can express the flux as Flux internal_flux_unit KF Flux volt sec rad KF NORMVAL BASE_FLUX_WEB Calculation relationships Please find below some useful relations derived from the previous assumptions we will indicate all the internal_xxxx_unit with int Impedance int Inductance int Omega in2 NORMVAL Flux int Inductance
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11. whatsoever for any damages incurred by you resulting from errors in or omissions from the information included herein 3 Renesas Electronics does not assume any liability for infringement of patents copyrights or other intellectual property rights of third parties by or arisingfrom the use of Renesas Electronics products or technical information described in this document No license express implied or otherwise is granted hereby under any patents copyrights or other intellectual property rights of Renesas Electronics or others 4 You should not alter modify copy or otherwise misappropriate any Renesas Electronics product whether in whole or in part Renesas Electronics assumes no responsibility for any losses incurred by you or third parties arising from such alteration modification copy or otherwise misappropriation of Renesas Electronics product 5 Renesas Electronics products are classified according to the following two quality grades Standard and High Quality The recommended applications for each Renesas Electronics product depends on the product s quality grade as indicated below Standard Computers office equipment communications equipment test and measurement equipment audio and visual equipment home electronic appliances machine tools personal electronic equipment and industrial robots etc High Quality Transportation equipment automobiles trains ships etc traffic control systems anti disaster systems an
12. Control Kit 13 Software description On YROTATE IT RX220 the software previously described is working on RX220 clocked at 32MHz Using the interrupt skipping function it is possible to regulate separately the PWM frequency and the sampling frequency allowing the user to add additional tasks to the motor control SOFTWARE BLOCKS Sensorless FOC algorithm PI flux estimation filters speed estimation modulation routines PMW generation MTU2 handling Transformations Shunt current Time delay Trigonometric af u v d q measurement management functions HW setup layer SFRs initi Communication A D converter E2PROM handling Interrupts vector layer routines layer table initi The total software uses the following resources in both three shunts case and single shunt case the first is smaller e FLASH usage below 24Kbytes e RAM usage below 3Kbytes Please Note that these data include also the communication interface and the kit board management The default program is based on the 8KHz sampling frequency i e 125us for the sampling period The PWM frequency is by default 16KHz and can be modified in the header file customize h The execution time of the motor control interrupt is a For the three shunts software lt 58 us b For the single shunt software lt 56 us UM YROTATE IT RX220 Rev 1 00 Page 24 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit The following flowcharts s
13. IT RX220 Motor Control Kit Motor Control Demo User Interface Communication Settings p gt Select board setup Serial port es i Click on the setup button and select RX220 Kit and select Autodetect and click on Connect to ensure the PC GUI is connected to the RX220 kit System Info Parameters Setting speed Control On the left hand side the new buttons appears Cu PI tuning Cu PI tuning AUTO Motor Identification and Oscilloscope Cur PI tuning Cur PI tuning AUTO Motor Identification Oscilloscope f Set the maximum current parameter n 07 as it will influence all the next steps Click on Parameters settings Enter the value 3500 the unit is in mA and click on Write to save the parameter into the EEPROM And close the window Parameters Setting i Always on top DESCRIPTION UNIT MAX VALUE VALID Reload 0 D 01 Mini rpm rpm 60 00 3000 true 400 true Write 10000 true Load 10000 true Save 24 true 15000 true 15000 true g Click now on Cu PI tuning AUTO button and press start to perform an automatic Current PI tuning PI Tuning AUTO Automatic current PI control gains determination Warning a current equal to 80 of IMAX par 7 will be injected in the motor And accept the results to be programed into the EEPROM as shown below UM YROTATE
14. IT RX220 Rev 1 00 Page 42 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit h Now click on the button Cu PI tuning to open the manual current PI tuning window and check the step answer by clicking on Apply current step button PI Tuning x Apply current step PI Tuning x ZOOM Om Reset zoom Apply current step Please use the Zoom function to check the beginning of the step UM YROTATE IT RX220 Rev 1 00 Page 43 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit Cur Apply current step You can adjust manually the parameters to obtain an even better step response and also increase the step current level by increasing the percentage of Cur to 90 The default value is 50 Once it s done the window can be closed as the proportional and integral coefficients of the PI current are tuned i Perform an auto identification of the motor parameters by clicking on Motor Identification and click start Motor Identification x Motor model parameters identification Warning the motor will be driven and rotated And accept the results to store them into the EEPROM The stator resistance the synchronous inductance and the Permanent Magnet flux have been measured and tuned j Now please click on parameters settings and enter the number of pole pairs 2 parameter n 5 and enter a minimum speed or 1000 RP
15. M 15Hz of a one pole pair motor UM YROTATE IT RX220 Rev 1 00 Page 44 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit Parameters Setting LJ Always ontop x rpm o true rpm 60 2 D 3000 true Load Save 1000 true 10000 1000 true 24 true 4pk 1000 0 15000 1000 true k Set a start up current equal to 25 of the maximum current In our case 25 of 3 5A is 0 875A Please enter the value 875 into the parameter n 6 and click on the write button on the left Parameters Setting LJ Always ontop x DESCRIPTION UNIT MIN max VALUE VALID ke Reload 00 Operation Select o true Write 0 ed rpm 0 3000 1000 true rpm 60 20000 3000 true Load i ams Save rpm s 10000 1000 true rpm s 10000 1000 true 24 15000 Let s close the window Please click on the button Speed Control zoom VOLTAGE zoom CURRENT 100 rpm Reference Measured i Quadrature L sTop UPDATE PROPERTY MONITOR D 6000 Motor speed 0 rpm 0 0 Hz 0 mA 0 mA ooy oov DC Bus Vol Alarm Code Flags Total Current Total Voltage Dummy 23 84 o o 0 mA oov 261 Save data to file To start the motor let s enter a speed which is 1 5 times the minimum speed in this case 1500 RPM UM YROTATE IT RX220 Rev 1 00 Page 45 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit_ Speed Control SPEED VOLTAGE CURRENT 1000 rpm 4 Refe
16. RENESAS USER MANUAL YROTATE IT RX220 UM YROTATE IT RX220 Rev 1 00 Low Cost Motor Control Kit based on RX220 Jan 15 2014 Introduction The Renesas Motor Control Kit YROTATE IT RX220 is based on the RX220 device from the powerful 32 bit RX microcontroller family The kit enables engineers to easily test and evaluate the performance of the RX220 in a laboratory environment when driving any 3 phase Permanent Magnet Synchronous Motor e g AC Brushless Motor using an advanced sensorless Field Oriented Control algorithm Typical applications for this type of solution are compressors air conditioning fans air extractors pumps and industrial drives The phase current measurement is done via three shunts which offers a low cost solution avoiding the need for an expensive current sensor A single shunt current reading method is also available The powerful user friendly PC Graphical User Interface GUI gives real time access to key motor performance parameters and provides a unique motor auto tuning facility The hardware is designed for easy access to key system test points and for the ability to hook up to an RX220 debugger Although the board is normally powered directly from the USB port of a Host PC connectors are provided to utilise external power supplies where required The YROTATE IT RX220 is an ideal tool to check out all the key performance parameters of your selected motor before embarking on a final end application system design
17. X220 Group of products is the slimmed down version of the higher model RX210 Group and has very high compatibility in terms of pin arrangement and on the software level The main specifications of the RX220 microcontrollers are as follows item Description CPU Max 32 MHz 1 56 DMIPS MHz max approx 50 DMIPS Operating voltage 1 62 V to 5 5 V Memory ROM 32 to 256 KB RAM 4 to 16 KB data flash 8 KB Clock frequency accuracy measurement circuit CAC data operation circuit DOC Safety functions independent watchdog timer IWDTa ADC self diagnostic function disconnection detection function CRC calculator CRC Event link controller ELC multifunction pin controller MPC three phase Peripheral functi gl eege motor control timer MTU2 12 bit A D converter S12ADb Pin count packages LQFP 48 pin to 100 pin packages small LGA wide pin pitch LQFP planned Please find below the block diagram of the RX220 microcontroller RX 32 bit CPU 32 MHz 50 DMIPS DSP Instructions Register Indirect Multiply and Accumulate egister Indirec d Kiran umu Register Direct EE EEN Result 48 bit Barrel Shifter 32 bit Communication Functions Comparator X 2 ch 12 bit A D X 16 ch L The maximum specifications for the group are shown UM YROTATE IT RX220 Rev 1 00 Page 16 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 11 Permanent magnets brushless m
18. YROTATE IT RX220 Motor Control Kit Let s analyse the motor from a mathematic point of view If we apply three voltages v t vp t v t to the stator windings the relations between phase voltages and currents are da v KL dt da v R i b S b dt da v Ri dt i is the magnetic flux linkage with the i th stator winding Rs is the stator phase resistance the resistance of one of the stator windings The magnetic flux linkages A are composed by two items one due to the stator currents one to the permanent magnets B axis C axis a axis axis b axis Real axes a b c and equivalent ones o B a fixed amplitude vector can be completely determined by its position respect the a B system angle The permanent magnet creates a magnetic field that is constant in amplitude and fixed in position in respect to the rotor This magnetic field can be represented by vector A whose position in respect to the stator is determined by the angle between the vector direction and the stator reference frame The contribution of the permanent magnets in the flux linkages depends on the relative position of the rotor and the stator represented by the mechanical electric angle 8 UM YROTATE IT RX220 Rev 1 00 Page 18 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit It is in every axis the projection of the constant flux vector Am in the direction of the axis A Li A
19. a oov parameters can be analysed Start Stop Spee DC Bus Vol Alarm Code and Direction gg s Speed Currents Voltages Torque DEMO Mode Operation and Parameters can be saved to Excel file DESCRIPTION MAX VALUE VALID POME 00 Default Parameters Setting 32767 To true Write wmd 01 Minimum Speed 5000 true GE 02 Maximun Speed 20000 true s 03 Acceleration rpm s 10000 true wech e Sen crc test 04 Deceleration rpm s 10000 true Pu Regs Test clock Test 05 Polar couples 2 Motor Alarm 06 Startup Current Apk 10 sood r Ppap PEETS Motor Tuning Parameters z 08 Stator Resistance Ohm 10 System Parameters Exit Please find below the description of the Alarm codes coming from the PC GUI Alarm 1 The alarm 1 is called EEPROM alarm and described in the software by EQP_ALL This alarm is set when one or more EEPROM parameters are higher than the maximum allowed value or lower than the minimum allowed value The LED DL4 is quickly blinking on the main board to indicate that an alarm is set The maximum and minimum values are specified in the two constants tables called par_max par_min in the ges _eqp h header file Another root cause for the alarm 1 is the EEPROM hardware failure when the error is accessed in read or write mode When this alarm is active the access to the EEPROM is restricted To reset the alarm the default parameters set should be reloaded in the EEPROM By using
20. and malfunctions under certain use conditions Further Renesas Electronics products are not subject to radiation resistance design Please be sure to implementsafety measures to guard them against the possibility of physical injury and injury or damage caused by fire inthe event of the failure of a Renesas Electronics product such as safety design for hardware and software including but not limited to redundancy fire control and malfunction prevention appropriate treatment for aging degradation or any other appropriate measures Because the evaluation of microcomputer software alone is very difficult please evaluate the safety of the final products or systems manufactured by you 8 Please contact a Renesas Electronics sales office for details as toenvironmental matters such as the environmental compatibility of each Renesas Electronics product Please use Renesas Electronics products in compliance with all applicable laws and regulations that regulate the inclusion or use of controlled substances including without limitation the EU RoHS Directive Renesas Electronics assumes no liability for damages or losses occurring as a result of your noncompliance with applicable laws and regulations 9 Renesas Electronics products and technology may not be used for or incorporated into any products or systems whose manufacture use or sale is prohibited under any applicable domestic or foreign laws or regulations You should not use Renesas Electronics products or
21. ased on the arbitrary phase 0 3 From this moment the phase estimation algorithm begins to be performed and the estimated phase Oe is used to calculate the components of the measured current referred to the d q system based on the estimated phase idmea and Ines The Components of the current referred to the arbitrary da qa system are controlled to follow the references by the current PI controllers On the other hand since the phase Ue is still not correctly estimated idmea and iqmea have no physical meaning Even if they are not shown in the graph the applied voltages are subjected to the same treatment vdmea and Vdmea are calculated in the algorithm UM YROTATE IT RX220 Rev 1 00 Page 28 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit c At t t while ig e is maintained to zero and Ida is Maintained to its value istar Speedre is increased with a ramp till the value Sstart is reached at the t tz The system phase t is obtained simply by integration of speed in the meanwhile the phase estimation algorithm begins to align with the real system phase Furthermore idmea and lues begin to be similar to the real flux and torque components of the current The real components are supposed to be do and iqo those values are obtained applying a low pass filter to idmea and iqmea The interval t2 t is the start up time and it is supposed to be large enough to allow the estimation algorithm to reach the co
22. cos A Li A cos V SC A Li A cos Aa Supposing that the rotor is rotating at constant speed that is OI wt the flux linkages derivatives can be calculated and we obtain j v R i L dt OK sin v di v Ri o ing JE di v Ri L 0A sin v 47 dt A three phases system may be represented by an equivalent two phases system So the by using specific transformations our three equations system is equivalent to a two equations system It is basically a mathematical representation in a new reference coordinates system In the two phases a B fixed system the above equations become da Vy Rig dt Ri Pel Vo l ee al For the magnetic field equations we got A Lig n Lig A COSY Ay Ligt A Lis A sin mn After performing the derivation a L OK sin pe A pn dt dt a E di di L4 OAK cos LE Ay dt dt dt Finally we obtain for the voltages in amp system UM YROTATE IT RX220 Rev 1 00 Page 19 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit Gia ai Va Reie tL dt fm di v Ri tL a B S dt am A second reference frame is used to represent the equations as the frame is turning at the rotor speed So aan the d axis is chosen in the direction of the magnetic vector A and with the q axis orthogonal to the d axis The new reference
23. e CPU supply voltage 5V STEP DOWN STEP DOWN OPTIONAL ZIGBEE MODULE INSULATION STEP_UP COMMUNICATION POWER STAGE e e e 2 e L Se gt L H CONTROL STAGE E Vi lelelelele elelele EXTERNAL POWER STAGE INTERFACE SES HALL ENCODER UM YROTATE IT RX220 Rev 1 00 Page 3 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 2 Connectors description As in the following figure you can find the position and the description of the connectors present on the board Please refer to the board schematics for the full description of the connectors The E1 connector is used for the programming and the debugging of the software running on the RX220 The external power stage connector is compatible with the power stages designed for Renesas inverter kits which are able to drive 230Vac motor up to 1 5KW MOTOR CONNECTOR st r d eco coeso wv A ERE ere E eeeg a e sees L Ze EXTERNAL POWER SUPPLY see ew K ec CH at CONNECTORS Seege d EE Lis j yo 33 Ech ea e ccoo e R a Ca kes coocoo pan ece eco HE si S SI SH EK d d e ne yee E1 CONNECTOR D X EXTERNAL POWER STAGE CONNECTOR Io D USB CONNECTOR HALL CONNECTOR ENCODER CONNECTOR UM YROTATE IT RX220 Rev 1 00 Page 4 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Moto
24. edback Gain Do the same for the parameter n 14 which is the speed loop Ki parameter Increase it until it becomes unstable In our case the critical value is reached at 2800 for Ki so the value to be used is 1400 n Test now all the speed ranges and different rotation o Finally the parameters list can be saved in a file in CSV format for further used and can also be uploaded later on UM YROTATE IT RX220 Rev 1 00 Page 48 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit Parameters Setting Lj Always ontop x Reload true Write 1000 true 20000 5000 true 10000 10000 24 Apk 1000 15000 Troubleshooting At the stage i if the motor doesn t start or generate an alarm n 3 please set the speed to 0 to clear the alarm which indicates that the software lost the phase One first test is to increase or decrease the start up current and the minimum speed or the speed PI gains When the motor is running you can verify the number of pole pairs taking measurement of the effective speed and comparing it with the imposed frequency the number of pole pairs n is n freq 60 speed if you change the number of pole pairs remember to adjust also the minimum and maximum speed values Sometimes the no load start up is easier if the inductance parameter is set to 0 All the procedure is tuned to manage motors which maximum current is close to the inverter capability whic
25. external resonator or by an external oscillator while program execution is in progress wait until the target clock signal is stable 5 Differences between Products Before changing from one product to another i e to a product with a different type number confirm that the change will not lead to problems The characteristics of an MPU or MCU in the same group but having a different part number may differ in terms of the internal memory capacity layout pattern and other factors which can affect the ranges of electrical characteristics such as characteristic values operating margins immunity to noise and amount of radiated noise When changing to a product with a different part number implement a system evaluation test for the given product Notice 1 Descriptions of circuits software and other related information in this document are provided only to illustrate the operation of semiconductor products and application examples You are fully responsible for the incorporation of these circuits software and information in the design of your equipment Renesas Electronics assumes no responsibility for any losses incurred by you or third parties arising from the use of these circuits software or information 2 Renesas Electronics has used reasonable care in preparing the information included in this document but Renesas Electronics does not warrant that such information is error free Renesas Electronics assumes no liability
26. h is around 6Arms for the external power stage shunt 0 05Ohm and 3Arms for the internal power stage shunt 0 10Ohm if you try to use it for very different motors the results will be influenced by the losses in current reading resolution Another possible trick when the things are very difficult is trying to increase the flux feedback gain sometimes used 500 instead of 100 UM YROTATE IT RX220 Rev 1 00 Page 49 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 21 List of motors tuned automatically using the PC GUI Please find below a short list of AC Brushless motors tuned automatically using the auto tuning procedure described above For each motor a specific text file is available to be loaded onto the PC GUI oS ai m Part name ECI 24 42 BD35F BLDC15P06 BLDC58 50L MB057GA240 FL28BL38 Motor maker EBM PAPST Danfoss Compressor PMDM Minebea Premoter Speeder Motion Fulling Motor Voltage 24V 24V 12V 24V 50V 24V Maximum Speed in RPM 3000 12000 5000 13000 Polar Couples 2 2 2 2 ER Startup Current in Apk 1000 1000 1000 1000 1000 875 200 Maximum Current Apk 1000 6000 3000 3000 3000 3500 400 Stator Resistance in Ohm 100 38 125 45 30 63 220 Synchronous inductance in Henry 10000 6 12 5 3 17 25 Permanent Magnets Flux in Weber 10000 178 333 42 52 264 30 Current PI Prop
27. hile running at a medium speed range 2 times the minimum speed In our example the speed is set to 2000 RPM Speed Control VOLTAGE zoom CURRENT 4000 rpm DESCRIPTION 0 Permanen Current 2 Curren peed Loop Kp Speed Loop Ki 5 Flux Feedback Gain Motor speed 1999 rpm 66 6 Hz 0 mA 208 mA Dau 10 3 DC Bus Vol Alarm Code Flags Total Current Total Voltage Dummy 23 7 V o 1280 208 mA 10 4 v 244 5000 5000 1000 1000 2000 Start by increasing the Parameter n 13 Kp until the instability that can be display in the current or phase waveform window Add a step of 50 and click write to see the effect and keep on increasing it UM YROTATE IT RX220 Rev 1 00 Page 47 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit Speed Control SPEED zoom VOLTAGE zoom CURRENT 4000 rpm _ Always on top Reload Write Load Save Motor speed 1999 rpm 66 6 Hz EE 203 mA 12v 10 5 V Li lwaysontop x 1 sample every 8 z O Phase Current In our case at 350 it started to be very unstable but the motor is still running Set the speed to O Then use half of the found value 175 in our case click on write and set the speed to 2000 RPM Parameters Setting u Always ontop x DESCRIPTION Reload r o 30000 true write Load Save 15 Flux Fe
28. how the software implementation of the motor control part of the software Please fin below the flowchart for the main loop Software organization Hardware and software initialization Interrupt enabling 10ms Main loop UM YROTATE IT RX220 Rev 1 00 Page 25 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit Main Program EEPROM parameters upload A D channels offset reading Peripherals initialization Variables initialization Interrupt enabling Main loop NO cnt_int NUM_INT Main loop body UM YROTATE IT RX220 Rev 1 00 Page 26 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit Control Interrupt P 3 H Phase currents iUmea iVmea reading three shunts current reading Transformations using the phase angle 0 iUmea iVmea gt iamea iDmea gt id mea idmea Read DC Link voltage Vpus Phase angle update Urey Current PI controls use idep Ice dmear Amea to produce vdouv ua Transformations using the phase angle vd ap Vout gt Vaoutr Maul gt VUout Wout PWM output commands generation using VUgut VVout Vous is used to calculate maximum phase voltage used in current PI controls Phase estimation based on old van Old Van iameay Ib mea Produces new estimated phase angle Ve Voltage memories update old_Vaout Vaour Old_Vbout Speed estimation produces Oest Estimation errors detection if errors a
29. igher voltage values so we choose as the base voltage value the following BASE_VOLTAGE_VOLT 2 K MAX_VOLTAGE_VOLT with K related with the application MAX_VOLTAGE_VOLT is the maximum voltage readable by the A D converter With normal applications K 1 leaves a margin for the maximum phase voltage equal to 3 times Vbus which is more than enough The voltage representation becomes Voltage internal_voltage_unit KV Voltage Vol KV NORMVAL BASE_VOLTAGE_VOLT UM YROTATE IT RX220 Rev 1 00 Page 34 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit Current The maximum current readable by the A D converter is chosen as the base value BASE_CURRENT_AMP MAX_CURRENT_AMP It is represented with NORMVAL 16384 Current internal_current_unit KI Current Amp KI NORMVAL BASE_CURRENT_AMP Impedance The base impedance value can be deduced by the base voltage and current values in fact the extended value chosen as the base voltage keeps into account the flux weakening and no other trick are required in case of PM motor in case of induction motor the current can be much higher than the ratio between voltage and the impedance due to the magnetizing inductance this would require some modification to the representation So we keep simply BASE_IMPEDANCE_OHM BASE_VOLTAGE_VOLT BASE_CURRENT_AMP The internal representation is Impedance internal_impedance_unit KZ Impedance Ohm KZ NORMVAL
30. int Current int NORMVAL Voltage int Impedance int Current int NORMVAL Voltage int Flux int Omega in2 NORMVAL As you can notice the calculations becomes particularly simple x NORMVAL is x gt gt 14 UM YROTATE IT RX220 Rev 1 00 Page 36 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 18 EEPROM parameters list Please find below the software parameters list including their full description Each parameters located in the customize h header file can be tuned by the user directly by the Graphic User Interface without re compiling the program 0 SEL_OP default parameters setting Used to perform special operations like default parameter set re loading or current PI tuning working mode setting 1 RPM_MIN minimum speed rpm 2 RPM_MAX maximum speed rpm 3 R_ACC acceleration rpm s 4 R_DEC deceleration rpm s 5 C_POLI polar couples 6 I_START start up current peak Ampere AMP_RES Used to specify the peak phase current value to be used during the start up 7 IL MAY maximum phase current peak Ampere AMP_RES 8 R_STA stator resistance Ohm OHM_RES 9 L_SYN synchronous inductance Henry HEN_RES 10 PM_FLX permanent magnets flux Weber WEB_RES The right value is needed if the exact integration flux estimation algorithm is chosen in case of approximated integration standard case this value is not taken into account 11 KP_CUR current loo
31. ith G It is this feedback which avoids the integral divergence due to the errors or offsets The higher G is the higher is the relationship between the estimated amplitude and the theoretical one but the larger can be the induced phase error The choice of G is a trade off in order to guarantee that the integral remains close to its theoretical value but free enough to estimate the correct system phase In the standard embedded software the first strategy is selected The choice to test the second one is left to the user thanks to the setting of the macros in the source code Such modifications required a compilation of the embedded software UM YROTATE IT RX220 Rev 1 00 Page 32 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 17 Internal representation of physical quantities The idea which lies under the internal representation of physical variables is to maximize the resolution keeping as simple as possible the calculations and keeping reasonably low the memory occupation So whenever it had been possible the physical variables have been represented under a per unit criteria Please find below the description of the representation for each physical quantity Angles The interval 0 2pi is represented with the interval 0 65536 with the resolution of 2pi 65536 rad Angle internal_angle_unit KA Angle rad KA 32768 pi 10430 37835 Note that in this way the angle can be considered unsigned i
32. larm is set YES Start up in progress NO Start up procedure produces idret iQret Daun Speed PI control uses ef Mest to get iqref Main loop synchronization UM YROTATE IT RX220 Rev 1 00 Page 27 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 14 Start up procedure When the motor is in stand still the phase of the permanent magnet flux vector cannot be detected with the used algorithm So an appropriate start up procedure has to be applied The idea is to move the motor in feed forward with higher current than that required to win the load till a speed at which the estimation algorithm can work Then the system can be aligned to the estimated phase and the current can be reduced to the strictly necessary quantity The following graph illustrates the strategy used the suffix er stands for reference the suffix mea stands for measured speeder Istart Referring to the graph the start up procedure in case of three shunts current reading is described below a At the beginning to the system phase is unknown No current is imposed to the motor the system phase is arbitrarily decided to be 8 0 All the references idref iret and Speedre are set to zero b From the moment to while the iqref and the speed e are maintained to zero idre is increased with a ramp till the value istart is reached at the moment ty The references are referred to an arbitrary da qa system b
33. mplete alignment with the real phase of the system d At t tz the phase estimation process is supposed to be aligned At this point a reference system change is performed from the arbitrary da qa reference to the d q reference based on the estimated phase Dect The current references are changed to the values idg and igo and all the PI controllers are initialized with these new values The speed PI integral memory is initialized with the value igo while the current PI integral memories are initialized with the analogous voltage values vdo and vqo obtained from vdmea and VQmea e After t gt t2 the normal control is performed based on the estimated phase Vest the speed reference is increased with the classical ramp the id current reference is decreased with a ramp till it reaches the value zero at the moment tz then it is maintained to zero the iq current reference is obtained as output of the speed PI controller UM YROTATE IT RX220 Rev 1 00 Page 29 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 15 Reference system transformations in details Find below the detailed equations used for the coordinates transformations in the embedded software for the RX220 microcontroller 2 1 1 Ea 3 Bu 78T gE Ba 273 3 1 1 i aU 8 w Ba 28 S S u v w gt a B Eu 8a 1 3 8 8 SE s 8a EETE 2 SS d e Eer a V38 4 2 2 g9 a B u v w 8a 8a COSCO 8 e Sin 8 T
34. n be useful for some particular calculations while when for example the speed is used to calculate voltages lesser resolution is enough To reduce the overall calculation time the most effective choice is to have a second representation of the angular speed coherent with the voltage and current representations which are per unit based So the second representation of the angular speed is based on a normalized value BASE_SPEED_R_S MAX_OMEGA_R_S The so called MAX_OMEGA_R_S is the maximum angular velocity required by the application and we will associate this to NORMVAL This value is linked to the maximum frequency MAX_OMEGA_R_S 2pi MAX_FRE_HZ The second representation is the following Omegalinternal_angular_velocity_unit2 KO2 Omegalrad sec KO2 NORMVAL BASE_SPEED_R_S To pass from a representation to the other we have the following relationship Omegalinternal_angular_velocity_unit2 KO2 KO1 Omegal internal_angular_velocity_unit1 KO2 KO1 2 pi Fs 65536 MAX_OMEGA_R_S KO1 KO2 65536 MAX_FRE_HZ Fs Voltage We can start our considerations from the maximum voltage readable by the A D converter this value is the maximum DC bus voltage and it is related to the maximum peak phase voltage by the relation Vout_pk 2 3 Vbus in case of over modulation this would already leave a good margin in voltage representation but in case of deep flux weakening the intermediate calculations can lead to h
35. n the range 0 65536 or signed in the range 32768 32768 with identical results In every case the representation requires a 16bit word Trigonometric functions sin a cos a are normalized to the value NORMVAL 16384 Internal_sin a internal_angle_unit NORMVAL sin a rad NORMVAL 16384 NORMVAL lt Internal_sin lt NORMVAL the same for Internal_cos Time The time is expressed as a multiple of the sampling period Ts Time internal_time_unit KT Time sec KT Fs Fs sampling frequency 1 Ts Angular velocity The angular velocity is expressed as a function of angles and time in order to obtain it as the subtraction of two angles in two sampling moments for resolution reasons an amplification is needed and we choose this amplification equal to NORMVAL 16384 Omegal internal_angular_velocity_unit1 KO1 Omegafrad sec KO1 KT KA Angle internal_angle_unit Time internal_time_unit Since we want Omegalinternal_angular_velocity_unit1 NORMVAL Angle internal_angle_unit Time internal_time_unit UM YROTATE IT RX220 Rev 1 00 Page 33 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit Omegalinternal_angular_velocity_unit1 NORMVAL Angle n Angle n k k We obtain KO1 NORMVAL KA KT NORMVAL 65536 2 pi Fs The entire speed range cannot in general be represented in a 16bit word but a long is needed This high resolution ca
36. ne E 055 0 gt RO DER Os y T o oe w FAULT ree a LE IOC eE TH v moca K d OE et We E sn S A KK HRS Ee AER VHM BOCAR pa an A EL Wr wiocas ees i OS hoa ars a Ff M VORVIZV mms g 7 u o ena For a comparison find below the drawing of the corresponding connector in the MCRPO7 external power stage E6108A Jz ANSLEY MV ITAI If using a different external power stage please keep present the following notes UM YROTATE IT RX220 Rev 1 00 Page 11 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit a The PWM drive signals are directly connected to the microcontroller output pins and there is no pull up or pull down resistor connected so the polarization has to be done in the power stage In case of alarm the microcontroller output pins can be placed in high impedance state so the external polarization is necessary These output commands are logic level signals with limited current output capability so an external driver is probably required A further line is connected to the microcontroller it is the external alarm signal connected to the POE input pin this pin is polarized with a 10K pull up toward the logic supply b The analog measurement signals from power stage in particular the current readings and the DC link voltage reading are clamped with diodes from logic GND and to logic Ve and weakly filtered then directly connected to the A D converter input pins of the microcont
37. nected to the output of the 12V step down DC DC converter and indicates the presence of the switches drive supply e DL5 is connected to the output of the 5V step down DC DC converter and indicates the presence of the logic power supply vum ef eeeeseeeoeoeeeoe V 666 eeeegeeeeeeeeee ous eeeeeeeeeeeeeeege g Am e eeeeeoeoeooeeo i S We Ea i AA D d V Other LEDs in the board are driven via software in particular e DL1 is the USB communication indicator and blinks when there are data exchanges between the PC and the board e DL2 is free for the user in the default software it is on when the main interrupt is active e DL3 is blinking slowly if the control section MCU RX220 is running normally In case of hardware or software alarms the LED DL3 is blinking quickly UM YROTATE IT RX220 Rev 1 00 Page 6 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 5 Test points for debugging Several specific test points are available on the board to visualize with the oscilloscope the behavior of some internal analog signals Furthermore it is possible to visualize internal variables as analog waveforms using filtered PWM outputs Finally it is very useful during the tuning process for adapting the software to a new motor to use the test points TP4 TP5 TP6 TP7 TP8 TPS TP10 TP11 TP12 TP1 TP2 TP3 TP15 TP13 TP14 Please find below the de
38. osed then the internal power stage currents measurements U V W are connected to the opportune A D converter pins e JP11 to JP16 if closed then the inverter driving signals are connected to the internal power stage drivers e JP5 if closed the external power stage 5V is connected with the internal one e JP6 it allows the following selection UM YROTATE IT RX220 Rev 1 00 Page 10 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit o if pins 1 and 2 are shorted then the external power stage low voltage supply between 15V to 24V is connected to the internal DC Bus Voltage in this case both the step down converters of the board will work o If pins 2 and 3 are shorted then the external power stage low voltage supply between 15V to 24V is connected to the internal driving circuit supply in this case only the step down converter which generates the internal logic supply will work Please be careful to take into account the following precautions 1 Please avoid to connect both the external power stage connector J6 and to close the jumpers JP5 to 16 this would produce short circuits between signals coming from different sources 2 In JP6 chose the configuration with the pins 1 and 2 shorted while pin 3 is open in order to avoid supplying some internal circuits with a too high voltage Please find below the drawing of the interface connector vv as hy rtp Mv pasa oe d a i car boo a
39. otor model The synchronous permanent magnets motor sinusoidal brushless motor is widely used in the industry More and more home appliance makers are now using such brushless motor mainly because of the intrinsic motor efficiency The permanent magnet motor is made with few components 1 A stator formed by stacking sheared metal plates where internally the copper wiring is wound constructing the stator winding 2 A rotor in which permanent magnets are fixed 3 Two covers with ball bearings that keep together the stator and the rotor the rotor is free to rotate inside the stator ann a winding aan a winding magnetic axis How current flows into a winding c winding The working principle is quite simple if we supply the motor with a three phase system of sinusoidal voltages at constant frequency in the stator windings flow sinusoidal currents which create a rotating magnetic field The permanent magnets in the rotor tend to stay aligned with the rotating field so the rotor rotates at synchronous speed The main challenge in driving this type of motor is to know the rotor position in real time so mainly implementation are using a position sensor or a speed sensor In our implementation the system is using either one or three shunts to detect the rotor position in real time UM YROTATE IT RX220 Rev 1 00 Page 17 of 50 Jan 15 2014 RENESAS RX220
40. p KP 12 KI_CUR current loop KI 13 KP_VEL speed loop KP 14 KI_VEL speed loop KI 15 FB_GAIN flux amp feedback gain Only needed if the exact integration flux estimation algorithm is chosen in case of approximated integration standard case this value is not taken into account 16 PHA_OFF phase offset deg It is used to add a phase offset to the phase estimation to reach the best alignment if needed 17 ST_TIM start up acceleration time sec SEC_RES 18 FLX_FS flux estimation filter shifts Only needed if the approximated integration flux estimation algorithm is chosen standard case if exact integration method is chosen this value is not taken into account UM YROTATE IT RX220 Rev 1 00 Page 37 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 19 PC Graphical User Interface Once the Motor Control PC GUI is installed based on the explanations of the Quick Start Guide please click on the Speed Control button to display the following window Communication Settings Disconnect zoon VOLTAGE zoon CURRENT 40Vv Algorithm information 20V Motor Operation graphs Speeds Currents and Voltages Parameters Setting System Monitor Speed Control Position Control PROPERTY MONITOR Function Tabs 3000 2 3000 0 ec Property Monitor where motor Motor Control Motorspeed Imposed Direct Curr Torque Curses z S Orem o o He oma om
41. power MOSFETs Please refer to the data sheet for the switches characteristics and to the board schematics for the details on the driving circuit The maximum current is 30A and the maximum voltage is 60V 3 PHASES BRIDGE UM YROTATE IT RX220 Rev 1 00 Page 9 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 7 Interface with an external power stage Since internal power stage allows only the management of low voltage motors an interface with an external power stage has been developed The selection between the internal power stage and the external power stages is ensured by jumpers It is a safe way to ensure that the right voltage and current signals are active When the external power stage is connected to the kit it is by default the active one So the microcontroller pins are directly connected to the external power stage connector In this case the internal power stage should be disconnected and this must be done by disconnecting the appropriate jumpers Please find below the jumpers description KITRX220 rev 1 0 Live KT A A ei JL Oe d E d 25 SC re a J a AEN i pa e Se cl ANALOG MEASUREMENT SIGNALS JP7 TO 10 INVERTER DRIVING SIGNALS JP11 TO 16 POWER SUPPLY SELECTION JP5 AND JP6 e JP7 if closed then the internal power stage DC Bus voltage is connected to the opportune A D converter pin e JP8 JP9 and JP10 if cl
42. r Control Kit 3 Power supply selection As stated before there are two ways to supply power to the board 1 The first possibility is to use directly the PC USB supply In this case the current you can give to the motor is limited by the USB current capabilities 2 The second possibility is to use an external voltage DC source to supply the board The recommended voltage value is between 12Vpc and 48Vpc In this case the communication stage is insulated from the inverter The selection between the two possibilities is made through two jumpers JP1 and JP2 Please find below the description JP2 JP1 JP Leek Se Se Ss SSS gt 8 seg JP1 EXTERNAL SUPPLY SELECTION 1 The first jumper configuration connects the USB ground to the inverter ground and the output of the step up converter to the inverter DC link Please notice that in this case there is no galvanic insulation between the device connected to the USB and the board 2 The second jumper configuration connects the external power supply ground to the inverter ground and the external Vpc to the inverter DC link UM YROTATE IT RX220 Rev 1 00 Page 5 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 4 LEDs function description Some of the LEDs available on the board are directly connected to the hardware and allow the user to understand the status of the board Please refer to the LED map for the following indications e DL4 is con
43. rence Measured BR Direct 7 Quadrature Direct D Torque E stop UPDATE RPM CONTROL D Motor speed 1498 rpm 49 9 Hz 4 mA 200 mA o3v aav DEC Bus Vol Alarm Code Flags Total Current Total Voltage Dummy 23 8 V o 256 200 mA 83v 254 Save data to file Please click on the Oscilloscope button to see the motor waveforms with the current in Y axis and the time in x axis Oscilloscope LJ Always ontop x 3000 2000 1000 Current 40 000 80 000 120 00 160 00 200 00 280 00 320 00 360 00 400 00 440 00 O Phase Current 1 sample every 64 X You can also display the phase by clicking on Phase selector Oscilloscope LJ Alwaysontop x Ai eh in ep i i A Phase 10 000 20 000 30 000 40 000 50 000 80 000 100 00 110 00 120 00 ms Current 1 sample every 16 For the oscilloscope window use an opportune time scale 1 sample every 1 should be used for extremely fast phenomena when running at very high speed The setting 1 sample every 128 should be used for extremely low phenomena when running at very low speed UM YROTATE IT RX220 Rev 1 00 Page 46 of 50 Jan 15 2014 IE gt RX220 YROTATE IT RX220 Motor Control Kit Let s start with an intermediate value and adjust it in order to see some periods of the current or the phase When the motor is running you can adjust the speed PI parameters Please follow the procedure w
44. roller so the external power Stage has to take care of the gain and the offset of these signals c The ground connection is always active and it represents the reference for all the interface signals In the next figure a simple example regarding how the power board connections have to be arranged is presented In this schema it is supposed that the power board has its own supply for the power module 15V this supply is also used to supply the microcontroller thanks to jumper JP5 in microcontroller board the 5V supply for current sensors and for the signal polarization is derived from the microcontroller board through JP5 Please refer to the complete schematics for further details UM YROTATE IT RX220 Rev 1 00 Page 12 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit W THERMAL SENSOR Current Sensor 5V Intelligent Power gt Module OUTV Current Sensor OCOCOCOCOOOAOOOOOOOOOGO UM YROTATE IT RX220 Rev 1 00 Page 13 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 8 Single shunt current reading While the normal configuration of the board and the standard software are based on three shunts current reading we also offer the possibility to configure the board for single shunt current reading Some hardware modifications are required and a different software version has to be loaded The required hardware modifications are the following
45. s motor driven in sinusoidal mode and FOC algorithm the most important parameters to tune are 1 Current PI parameters Proportional K and Integral K 2 Motor parameters Stator resistance R the synchronous inductance L and the Permanent Magnet flux Am Let s tune step by step a real low voltage PMSM motor using the internal power stage with Mosfets Important Note The auto tuning embedded software is working only on the three shunts version a The BLAC Motor selected is the following one Motor type MBO57GA240 Maximum current 3 5A Bus Voltage 50V Maximum speed 5000 RPM Number of pole pair 2 UNITS S PTO TS S O AE oo RPM Som 114 _ AMPS 10 11 9 10 10 OHMS 112 mH 3 19 UM YROTATE IT RX220 Rev 1 00 Page 40 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit b Let s setup the Motor control kit for 24Vpc external power supply the jumper JP1 and JP2 needs to be set to 1 3 position as explained in the Chapter 3 Power Supply selection IP2 BXTERMAL SUPPLY SELECTION c Let s connect the 24Vp Power supply to the RX220 motor control reference kit d Now connect the USB cable to the PC and the Kit and connect the 24V to the kit and the motor to the kit e Launch the PC GU from the folder C Program Files MCDEMO launch MotorController exe UM YROTATE IT RX220 Rev 1 00 Page 41 of 50 Jan 15 2014 RENESAS RX220 YROTATE
46. scription of the test points e TP13 TP14 are connected to the two USB communication signals for debug purposes Please refer to the board schematics for more details e TP4 TPS and TP6 they are connected to the three output of the inverter sources of the higher switches e TP7 TPS and TP9 they are connected to the sources of the lower switches of the inverter e TP10 is connected to the hardware over current signal from the power stage e TP11 TP12 they are connected to two digital ports of the microcontroller TP11 Port3Bit5 TP12 Port1Bit7 and they can be used as digital outputs or digital inputs e TP15 is connected to the board ground UM YROTATE IT RX220 Rev 1 00 Page 7 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit e TP1 TP2 TP3 are three filtered PWM outputs which can be used to visualize the behavior of internal variables o In the standard software TP1 is the output for the system phase e g estimated rotor position o TP2 is used in the current PI tuning facility to show the normalized response of the system to a current step request o TP3 is not used in the standard software UM YROTATE IT RX220 Rev 1 00 Page 8 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 6 Internal power stage brief description The power stage is a complete 3 phase bridge composed with discrete low voltage power MOSFETs The MOSFETs are the Renesas RJKO654DPB n channel
47. sed in real time Alarm 3 The alarm 3 is called loss of phase and described in the software by TRIP_ALL This alarm is produced when the sensorless position detection algorithm is producing inconsistent results It means that the rotor position is unknown due to a lack of accuracy so the motor is stopped The LED DL4 is quickly blinking on the main board to indicate that an alarm is set This alarm can be reset by setting the speed reference to zero on the PC GUI Please find below an extract of the header file const_def h define EQP_ALL 1 EEPROM alarm code define FAULT_ALL 2 overcurrent hardware alarm code POE define TRIP_ALL 3 loss of phase alarm code Finally the PC GUI button called parameters setting is used to enter and modify the motor and applications parameters UM YROTATE IT RX220 Rev 1 00 Page 39 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 20 Motor Auto calibration using the PC GUI The full calibration of any 3 phase AC Brushless motor can be performed automatically using the PC Graphical User Interface Three specific buttons are now available for and shown below Motor Control Demo User Interface Communication Settings System Info Parameters Setting Ge Speed Control mue In a few clicks the E software is tuned to n h gt the custom motor and ready to run In terms of AC Brushles
48. ssasesesanaesecessessaaesesenseeseasaausececessesesuaeanseseeeesees 38 20 Motor Auto calibration Using the PC Gul 40 21 List of motors tuned automatically Using the PC GU 50 UM YROTATE IT RX220 Rev 1 00 Page 2 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit 1 Hardware overview The inverter kit YROTATE IT RX220 is a single board inverter based on the RX series microcontroller RX220 and includes a low voltage MOSFETs power stage and a communication stage To obtain the maximum flexibility the reference kit includes e A complete 3 phase inverter on board with a low voltage motor so it becomes easy to test the powerful sensorless algorithm running on the RX220 microcontroller An insulated USB communication with the PC Connectors for hall sensors and encoder connections both encoder and hall sensors are not managed in the sensorless software but they can be supported under request Compatibility with the existing Motor Control Reference Platform external power stage USB supply possibility to avoid external power supplies where galvanic insulation is lost To achieve these aims three different DC DC converters are used 1 A step up DC DC converter to increase the voltage from the USB standard 5V up to 13 5Vpc 2 A step down converter from the DC bus which can reach up to 48Vpc in case of external supply to the power switches drive voltage 12V w A step down converter from the DC bus to th
49. system is d q The reference frame transformations from the 0 8 system to the d q system depends on the instantaneous position angle So we obtain two inter dependant equations in the d q system F v Rei Ge aLi di v Rsi Pir OK These two equations represent the mathematical motor model Va A control algorithm which wants to produce determined currents in the d q system must impose voltages given from the formulas above This is ensured by closed loop PI control on both axis d amp q Proportional Integral Since there is a mutual influence between the two axes decoupling terms can be used UM YROTATE IT RX220 Rev 1 00 Page 20 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit aan In the block scheme the mechanic part is included where p is the number of pole pairs while B represents friction J the inertia Tioaa the load torque and Tt the motor torque 3 T xXpXA 7 P The angular speed is represented in the scheme as to distinguish the electrical speed from the mechanical one Let s now consider the equations we have seen in B system d dt Ri y v R i E S dt Va Rsi These equations show that magnetic flux can be obtained from applied voltages and measured currents simply by integration A Ae Va Reig at 0 Ag Apt Vg Reig d 0 Furthermore A cos
50. technology described in this document for any purpose relating to military applications or use by the military including but not limited to the development of weapons of mass destruction When exporting the Renesas Electronics products or technology described in this document you should comply with the applicable export control laws and regulations and follow the procedures required by such laws and regulations 10 It is the responsibility of the buyer or distributor of Renesas Electronics products who distributes disposes of or otherwise places the product with a third party to notify such third party in advance of the contents and conditions set forth in this document Renesas Electronics assumes no responsibility for any losses incurred by you or third parties as a result of unauthorized use of Renesas Electronics products 11 This document may not be reproduced or duplicated in any form in whole or in part without prior written consent of Renesas Electronics 12 Please contact a Renesas Electronics sales office if you have any questions regarding the information contained in this document or Renesas Electronics products or if you have any other inquiries Note 1 Renesas Electronics as used in this document means Renesas Electronics Corporation and also includes its majority owned subsidiaries Note 2 Renesas Electronics product s means any product developed or manufactured by or for Renesas Electronics RENESAS SALES OFFICES
51. the PC GUI and the parameters setting window it becomes possible to clean the EEPROM content The first step is to write the magic number 33 in the first parameter n 00 The second step is to reset the board by pressing the reset button on the PCB or switching off the power supply At this point a coherent set of parameters is loaded and the alarm should disappear Finally if the alarm is produced by a hardware failure of the EEPROM itself then the board needs to be repaired UM YROTATE IT RX220 Rev 1 00 Page 38 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit Alarm 2 The alarm 2 is called hardware overcurrent and described in the software by FAULT_ALL This alarm is produced by the MCU peripheral called Port Output Enable POE in case of external overcurrent signal The hardware overcurrent is producing a falling edge input on the POE pin Furthermore if the hardware level of the PWM output pin is not coherent with the level imposed by software the alarm 2 will also be triggered The LED DL4 is quickly blinking on the main board to indicate that an alarm is set The only way to clear the alarm is to reset the board by using the reset button on the PCB or by switching off the supply and on again Finally one of the root causes of the Alarm 2 is a hardware defect or a wrong behavior of the current control So please also check the setting of the current PI coefficients that are stored in EEPROM or u
52. ti crime systems and safety equipment etc Renesas Electronics products are neither intended nor authorized for use in products or systems that may pose a direct threat to human life or bodily injury artificialife support devices or systems surgical implantations etc or may cause serious property damages nuclear reactor control systems military equipment etc You must check the quality grade of each Renesas Electronics product before using it in a particular application You may not use any Renesas Electronics product for any application for which it is not intended Renesas Electronics shall not be in any way liable for any damages or losses incurred by you or third parties arising from the use of any Renesas Electronics product for which the product is not intended by Renesas Electronics 6 You should use the Renesas Electronics products described in this document within the range specified by Renesas Electronics especially with respect to the maximum rating operating supply voltage range movement power voltage range heat radiation characteristics installation and other product characteristics Renesas Electronics shall have ndliability for malfunctions or damages arising out of the use of Renesas Electronics products beyond such specified ranges 7 Although Renesas Electronics endeavors to improve the quality and reliability of its products semiconductor products have specific characteristics such as the occurrence of failure at a certain rate
53. y of the errors and with a zero DC gain The goal is to reject any low frequency component preventing the result to diverge and automatically forgetting the errors noise etc This is obtained by combining a low pass filter with a high pass filter as in the following scheme First order low pass Derivative First order low pass 1 s p 5 1 s p 20 hog JF Pigs Hoken Pi i Z Vij t Lo Loo owas Lo Loo owas It is evident the relationship between Y s and the integral I s 1 s for s ja when W gt gt p UM YROTATE IT RX220 Rev 1 00 Page 31 of 50 Jan 15 2014 RENESAS RX220 YROTATE IT RX220 Motor Control Kit In the second case to prevent the integral to diverge and the errors related to wrong initial conditions are rejected by the correcting action of the feedback The block scheme of the exact BEMF integration method for flux position estimation is the following y as A g 4 SE S J P D fl LL L The inputs of the system are the imposed voltage vector V and the measured current vector The motor phase resistance R the synchronous inductance L and the permanent magnet flux amplitude m are known as parameters and motor dependant The integral operation is corrected with a signal obtained modulating accordingly with the estimated phase the error between the estimated flux amplitude and the amplitude of the permanent magnets flux The gain of this correction is indicated w

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