DRM021, 3-Phase ACIM Volt per Hertz Using 56F80x Control
Contents
1. SWITCH MODE PFC CONTROL POWER SUPPLY dc BUS BRAKE 3 PHASE IGBT POWER MODULE GATE DRIVERS ee PHASE CURRENT PHASE VOLTAGE WA BUS CURRENT BUS VOLTAGE MONITOR BOARD ID BLOCK ZERO CROSS BACK EMF SENSE 3 PHASE AC TO MOTOR The electrical characteristics in Table 4 2 apply to operation at 25 C with a 160 Vdc power supply voltage Designer Reference Manual MOTOROLA Hardware For More Information On This Product Go to www freescale com 35 Freescale Semiconductor Inc Hardware Table 4 2 Electrical Characteristics of Power Stage Characteristic Symbol Min Typ Max Units dc input voltage Vdc 140 160 230 V ac input voltage Vac 100 208 240 V Quiescent current loc 70 mA Min logic 1 input voltage Vin 2 0 V Max logic 0 input voltage ViL Za 0 8 V Input resistance Rin 10 kQ Analog output range Vout 0 3 3 V Bus current sense voltage Isense 563 mV A Bus voltage sense voltage VBus 8 09 mV V Peak output current Ipk 2 8 A Brake resistor dissipation Pek 50 w continuous o T dissipation PEREN M 100 Total power dissipation Puiss 85 4 6 Optoisolation Board Motorola s embedded motion control series optoisolation board links signals from a controller to a high voltage power2. 20 Speed Close Loop System 21 Section 3 System Concept System Design Concept 23 Section 4 Hardware CONES IA AAA Kia 27 PUGS IAA AA EEA EE AA 27 The High Voltage Hardware Set 27 DSP56F805EVM Control Board 29 3 Phase AC BLDC High Voltage Power Stage 34 Optoisolation Board 36 Motor Brake Specifications 37 Designer Reference Manual MOTOROLA 7 For More Information On This Product Go to www freescale com Designer Reference Manual Freescale Semiconductor Inc Table of Contents SA 5 2 5 3 6 1 6 2 6 3 6 4 6 5 Section 5 Software Design Contents 41 Dara at an aa aa ee ee ate wien a es 41 State DiagiaAM dae tener reek eens beeen a ele ead s 50 Section 6 Application Setup Is hr ee Shee GES ADE ehowaaa Genes edn sees 57 Application Description 57 Applicaton SetuP III WA AWA 63 PU EIA KE 66 Application Build amp Execute 68 Appendix A References Appendix B Glossary DRM021 Rev 0 8 MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Designer Reference Manual 3 Phase ACIM V Hz Control DRM021 Rev 0 List
3. Software Design e The update of PWM value registers e The Start of the ADC conversion The name of the callback function in the code void isrPWM_A_Reload void 5 3 5 PWM A Fault ISR This disables the PWM module and sets DriveFaultStatus l DC_Bus_OverVoltage or DC_Bus_OverCurrent according to the fault input pin level in the case of the overvoltage or the overcurrent in the DC Bus line The name of the callback function in the code void isrPWM_A_Fault void This subroutine is called at the PWM A Fault Interrupt 5 3 6 ADC End Of Scan ISR The following analog inputs are read e DC Bus Voltage e DC Bus Current e Temperature of the Power Stage Module Also the detection of faults caused by the overheating and the undervoltage is performed in this subroutine The name of the callback function in the code void isrADC_A_EndOfScan voiad This subroutine is called at the ADC conversion completion 5 3 7 ADC High And Low Limit ISR s This subroutine turns on and off the resistive brake in the DC Bus link When the actual voltage of DC Bus u_dc_bus is higher than Designer Reference Manual DRM021 Rev 0 54 Software Design MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Software Design State Diagram BRAKE_HIGH_LIMIT the brake is turned on When the actual voltage of DC Bus u_dc_bus is lower than BRAKE LOW LIMIT the brake is turned off The Name
4. following references e U1 Controller board for DSP56F805 supplied as DSP56805EVM described in DSP56F805EVMUM D DSP Evaluation Module Hardware User s Manual e U2 3 ph AC BLDC high voltage power stage supplied in kit with optoisolation board as ECOPTHIVACBLDC described in MEMC3BLDCPSUM D 3 Phase Brushless DC High Voltage Power Stage e U3 Optoisolation board supplied with 3 ph AC BLDC high voltage power stage as ECOPTHIVACBLDC Designer Reference Manual DRM021 Rev 0 28 Hardware For More Information On This Product Go to www freescale com MOTOROLA Freescale Semiconductor Inc Hardware DSP56F805EVM Control Board or supplied alone as ECOPT optoisolation board described in MEMCOBUM D Optoisolation board User s Manual e MB1 motor brake AM40V SG40N supplied as ECMTRHIVAC WARNING Itis strongly recommended to use an opto isolation optocouplers and optoisolation amplifiers during the development time to avoid any damage to the development equipment NOTE The detailed description of individual boards can be found in comprehensive users manuals belonging to each board The user manual incorporates the schematic of the board description of individual function blocks and bill of materials Individual boards can be ordered from Motorola as a standard product from http mot sps com motor devtools index html This section describes the
5. DRM021 Rev 0 The system configuration is shown in Figure 4 1 Designer Reference Manual MOTOROLA Hardware 27 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Hardware 12VDC gt GND gt __ 40w flat ribbon U2 40w flat cable gri ribbon ay U1 U3 cable gray JP1 1 JP1 2 L Black mi 3ph AC BLDC N gt Light Blue J12 High Voltage Optoisolation PES Green Yellow Power Stage 314 Ji Board ECOPT J13 1 913 2 p13 3 Controller Board MB1 able Motor Brake ECOPTHIVACBLDC Incremental Encoder Baumer Electric 7 BHK16 05A 1024 I2 5 Hall Sensor Encoder 00126A Not used in application Incremental Encoder Cable gt Connector Table Cable Wire Color Desc Brown 5VDC White Shielding _ Ground and Shielding Green Phase Yellow Phase B Pink Index Unused Unused ECMTRHIVAC DSP56F803 Encoder Conn Tabl Controler Conn pin conn AMP A2510 DSP56F805 DSP56F807 Figure 4 1 High Voltage HW System Configuration All the system parts are supplied and documented according to the
6. Software programmable phase lock loop based frequency synthesizer for the DSP core clock Memory configuration 32252 x 16 bit words of program flash 512 x 16 bit words of program RAM DRM021 Rev 0 14 Introduction MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Introduction Motorola DSP Advantages and Features 2K x 16 bit words of data RAM 4K x 16 bit words of data flash 2K x 16 bit words of boot flash The pulse width modulation PWM block offers high freedom in its configuration enabling to control the AC induction motor in efficient way The PWM block has the following features Three complementary PWM signal pairs or six independent PWM signals Features of complementary channel operation Deadtime insertion Separate top and bottom pulse width correction via current status inputs or software Separate top and bottom polarity control Edge aligned or center aligned PWM reference signals 15 bits of resolution Half cycle reload capability Integral reload rates from one to 16 Individual software controlled PWM output Programmable fault protection Polarity control 20 mA current sink capability on PWM pins Write protectable registers The PWM outputs are configured in the complementary mode in this application DRM021 Rev 0 Designer Reference Manual MOTOROLA Introduction 15 For More Information On This Pr
7. The control technique sets the speed rpm Hz of the magnetic field and calculates the phase voltage amplitude according to a V Hz table This table is private to the application and reflects AC induction motor parameters Base Voltage frequency Boost Voltage frequency DC Boost Voltage The incremental encoder is used to derive the actual rotor speed The closed loop system is characterized by a feedback signal Actual speed derived from a quadrature decoder in the controlled system This signal monitors the actual behavior of the system and is compared with the reference signal Required Speed The magnitude and polarity of the resulting error signal are directly related to the difference between required and actual values of the controlled variable which may be the speed of a motor The error signal is amplified by the controller and the controller output makes a correction to the controlled system reducing the error signal Overcurrent Overvoltage Undervoltage and Overheating protections are provided Designer Reference Manual MOTOROLA Application Setup 57 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Application Setup The Volt per Hertz control algorithm is calculated on the Motorola DSP56F805 The algorithm generates the 3 phase PWM signals for AC induction motor inverter according to the user required inputs measured and calculated signals The concept of
8. amp PWM DC Bus Voltage Over Voltage Temperature 5 Faults F amp Voltage 4 Processing Processing i DC Bus Voltage i V1 Dc Bus V2 V Hz Ripple Generator Cancel with Dal eae ee Dead Time Regulator F E Speed eeu UP TF F SQ Actual Speed Speed Processing lt gt Incremental Decoder Processing Figure 3 1 System Concept The Control Process When the start command is accepted using the Start Stop switch the state of the inputs is periodically scanned According to the state of the DRM021 Rev 0 Designer Reference Manual MOTOROLA System Concept 25 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc System Concept Designer Reference Manual control signals Start Stop switch speed up down buttons or PC Master set speed the speed command is calculated using an acceleration deceleration ramp The comparison between the actual speed command and the measured speed generates a speed error E The speed error is brought to the speed PI controller that generates a new corrected motor stator frequency With the use of the V Hz ramp the corresponding voltage is calculated and then DC bus ripple cancellation function eliminates the influence of the DC bus voltage ripples to the generated phase voltage amplitude The PWM generation process calculates a 3 phase voltage system at the required amplitude and frequency includes dead time Finally
9. e Initializes the analog to digital converter e Initializes the timers for the speed ramp and the LED handler e Initializes the PWM module Center aligned complementary PWM mode positive polarity Sets callback for the PWM reload to every 4th PWM pulse Sets callback for the PWM faults Sets the PWM modulus defines the PWM frequency enables the fault interrupts e Sets up I O ports push buttons switch brake e Initializes the quadrature decoder for the speed measurement e Initializes algorithms V Hz look up table sinewave generator e Enables interrupts The board identification routine identifies the connected power stage board by decoding the identified message sent from the power stage If the wrong power stage is identified the program goes to the infinite loop displaying the fault status on the LED The state can be left only by the RESET DRM021 Rev 0 Designer Reference Manual MOTOROLA Software Design 51 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Software Design reset Quad Timer D1 for LED handling Interrupt Quad Timer D1 LED Subroutine Initialization Application Quad Timer D2 for Speed Ramp Interrupt State Machine Quad Timer D2 Speed Ramp Subroutine Check Run Stop Switch done ADC A high or low limit Interrupt PWM A Reload Interrupt PWM A Reload Interrupt Subrout
10. this option may be selected in the PC master software window under Project Select Other Map FileReload cf who rif py Machar sjalom Hala eleal 2 Ea ee Designed By AR MOTOROL znov p Radh Czech Republic 3 Phase AC Ind Drive with V Hz Algorithm Close Loop 2 250 rpm a ApplicationMode Amplitude Temperature MeasuredSpeed DriveFaultStatus LoopMode Figure 6 3 PC Master Software Control Window Designer Reference Manual DRM021 Rev 0 62 Application Setup MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Application Setup Application Setup 6 3 Application Setup Figure 6 4 illustrates the hardware set up for the AC Induction Motor V Hz Control Application The system consists of the following components e AC Induction motor Type AM40V EM Brno s r o Czech Republic e Load Type SG 40N EM Brno s r o Czech Republic e Encoder BHK 16 05A1024 12 5 Baumer Electric Switzerland e 3 ph AC BLDC HV Power Stage 180 W e Optoisolation Board e DSP56F805 Board DSP56F805 Evaluation Module supplied as DSP56F805EVM or DSP56F805 Controller Board e The serial cable needed for the PC master software debugging tool only e The parallel cable needed for the Metrowerks Code Warrior debugging and s w loading DRM021 Rev 0 Designer Reference Manual MOTOROLA Application Setup 63 For More Information On This Pro
11. Analog Temperature Input unused 1 2 JG11 Use Host power for Host Target Interface 1 2 DRM021 Rev 0 Designer Reference Manual MOTOROLA Hardware 31 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Hardware Table 4 1 DSP56F805EVM Default Jumper Options Continued Jumper Comment Jumpers Group Connections JG12 Primary Encoder Input Selected 2 3 5 6 amp 8 9 JG13 Secondary Encoder Input Selected 2 3 5 6 amp 8 9 JG14 Primary UNI 3 3 Phase Current Sense Selected as Analog Inputs 2 3 5 6 amp 8 9 JG15 Primary UNI 3 Phase A Over Current Selected for FAULTA1 1 2 JG16 Secondary UNI 3 Phase B Over Current Selected for FAULTB1 1 2 JG17 CAN termination unselected NC JG18 Use on board crystal for DSP oscillator input 1 2 An interconnection diagram is shown in Figure 4 4 for connecting the PC and the external 12V DC power supply to the DSP56F805EVM board Parallel Extension Cable DSP56F805EVM PC compatible Computer ji Connect cable P2 to Parallel Printer port External with 2 1mm 12V receptacle Power connector Figure 4 4 Connecting the DSP56F805EVM Cables Perform the following steps to connect the DSP56F805EVM cables 1 Connect the parallel extension cable to the Parallel port of the host computer 2 Connect the other end of the parallel extension cable to P1 shown in Figure 4 4 o
12. Figure 5 4 The phases B and C are shifted by 120 with respect to the Phase A PEDI MOSE KAA AAA SM AN ActualPhase n 100 Serre EEE EE PhaseIncrement ActualPhase n 1 amplitude Eiers aN DutyCycle PhaseA _ 0x0000 0x8000 180 0 Ox7fff 180 Figure 5 4 Sinewave generation Each time the waveform generation function is called Actual Phase from the previous step is updated by Phase ncrement and according to the calculated phase the value of sine is fetched from the sine table using the function SinPIx from the algorithms library Then it s multiplied by the amplitude and passed to the PWM For the explanation of the a 3 phase waveform generation with the 3rh harmonic addition see the following formulas Designer Reference Manual MOTOROLA Software Design 47 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Software Design PWMA L Amplitude sina sin3a 0 5 B 6 PWMB ya Amplitude sin a 1200 sin30 0 5 5 2 3 PWMC T Amplitude sin o 2400 sina 0 5 3 Where PWMA PWMB and PWMC are calculated dutycycles passed to the PWM driver and the amplitude determines the level of the phase voltage amplitude The process that is performed in the PWM reload callback function isrPWM_A_Reload is accessed regularly at the rate given by the set PWM reload frequency This process is repeated often
13. Manual DRM021 Rev 0 4 MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Designer Reference Manual 3 Phase ACIM V Hz Control DRM021 Rev 0 List of Sections Section 1 Introduction 13 Section 2 Control Theory 17 Section 3 System Concept 23 Section 4 Hardware 27 Section 5 Software Design 41 Section 6 Application Setup 57 Appendix A References 71 Appendix B Glossary 73 Designer Reference Manual MOTOROLA 5 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc List of Sections Designer Reference Manual DRM021 Rev 0 6 MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Designer Reference Manual 3 Phase ACIM V Hz Control DRM021 Rev 0 1 2 1 3 ZA 2 2 2 3 24 3 1 4 1 4 2 4 3 4 4 4 5 4 6 4 7 Table of Contents Section 1 Introduction COINS taku the thes EIA 13 MOOI AA KIKE WAA 13 Motorola DSP Advantages and Features 13 Section 2 Control Theory ec oh sane IA ee eee teow eS ess ew as ee 17 Target Motor Theory 17 Volt per Hertz Control
14. More Information On This Product Go to www freescale com DRM021 Rev 0 Freescale Semiconductor Inc Application Setup Application Build amp Execute Metrowerks CodeWarrior File Edit Search amag Debug DSP56800 Window Help a Wa za Add Witt dow 2 0O Add Files Create New Group Sag Heck syntar ot 5 Prenroacess YO Codec Rrecompile La me compie a Gules VEE Depender Disassemble EAC Sources Bring Up To Date Ctrl U g AA codec 12 files Stop ewid Die Break a mi aa a wa Figure 6 7 Execute Make Command To execute the 3 Phase AC Induction Motor V Hz Control application select ProjectiDebug in the CodeWarrior IDE followed by the Run command For more help with these commands refer to the CodeWarrior tutorial documentation in the following file located in the CodeWarrior installation folder lt gt CodeWarrior Documentation PDF Targeting_DSP56800 pdf If the Flash target is selected CodeWarrior will automatically program the internal Flash of the DSP with the executable generated during Build If the External RAM target is selected the executable will be loaded to off chip RAM Once Flash has been programmed with the executable the EVM target system may be run in a stand alone mode from Flash To do this set the JG5 jumper in the 1 2 configuration to disable the parallel port and press the RESET button Once the application is running
15. enough to compare it to the wave frequency Wave length comparisons are made to generate the correct wave shape Therefore for the 16kHz PWM frequency it is called each 4th PWM pulse thus the PWM registers are updated in the 4kHz rate each 250usec Figure 5 5 shows the dutycycles generated by the Gen3PhWaveSine3rdHintp function when Amplitude is 1 100 1st Harmonic A 1st Harmonic B 1st Harmonic B 3rd Harmonic DutyCycle PhaseA DutyCycle PhaseB 7 DutyCycle PhaseC Figure 5 5 3 ph Sine Waves with 3rd Harm Injection Amp 100 Designer Reference Manual DRM021 Rev 0 48 Software Design For More Information On This Product Go to www freescale com MOTOROLA 5 2 6 Fault Control DRM021 Rev 0 Freescale Semiconductor Inc Software Design Data Flow Figure 5 6 defines the dutycycles generated by the Gen3PhWaveSine3rdHintp function when Amplitude is 0 5 50 1st Harmonic A 1st Harmonic B 1st Harmonic B 3rd Harmonic DutyCycle PhaseA DutyCycle PhaseB DutyCycle PhaseC Figure 5 6 3 ph Sine Waves with 3rd Harm Injection Amp 50 Input process e Amplitude obtained from DC bus ripple elimination process e Omega_required obtained from acceleration deceleration ramp process Output process Results calculated by the Gen3PhWaveSine3rdHintp function are dire
16. move the RUN STOP switch to the RUN position and set the required speed using the UP DOWN push buttons Pressing the UP DOWN buttons should incrementally increase the motor speed until it reaches maximum speed If successful the induction motor will be spinning Designer Reference Manual MOTOROLA Application Setup 69 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Application Setup NOTE Ifthe RUN STOP switch is set to the RUN position when the application starts toggle the RUN STOP switch between the STOP and RUN positions to enable motor spinning This is a protection feature that prevents the motor from starting when the application is executed from CodeWarrior You should also see a lighted green LED which indicates that the application is running If the application is stopped the green LED will blink at a 2Hz frequency If any fault occurs the green LED will blink at a frequency of 8Hz Designer Reference Manual DRM021 Rev 0 70 Application Setup MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Designer Reference Manual 3 Phase ACIM V Hz Control DRM021 Rev 0 Appendix A References Bose K B 1997 Power Electronics and Variable Frequency Drives IEEE Press ISBN 0 7803 1061 6 New York Caha Z Cerny M 1990 Elektricke pohony SNTL ISBN 80 03 00417 7 Praha Subrt J 19
17. of Figures Figure Title Page 2 1 Torque Speed Characteristic at Const Voltage amp Frequency 18 2 22 AA YI os nda ws ee eed he oso cows ep aeened 19 2 3 Pulse Width Modulation 20 2 4 Volts per Hertz Control Method 21 2 5 Closed Loop Control System 22 Se System AA saca avarar cee ROE knk A AA 25 4 1 High Voltage HW System Configuration 28 4 2 Block Diagram of the DSP56F805EVM 30 4 3 DSP56F805EVM Jumper Reference 3i 4 4 Connecting the DSP56F805EVM Cables 32 4 5 3 Phase AC High Voltage Power Stage 35 Sik a ee ee eee hee Or ee ee 42 5 2 VoltperHerrzRamp 44 5 3 3 ph Waveforms with DC Bus Voltage Ripple Elimination 46 5 4 Sinewave generation 47 5 5 3 ph Sine Waves with 3rd Harm Injection Amp 100 48 5 6 3 ph Sine Waves with 3rd Harm Injection Amp 50 49 5 7 State Diagram General Overview 52 5 8 State Application State Machine 53 6 1 RUN STOP Switch and UP DOWN Buttons 59 6 2 USER and PWM LEDs at DSP56F805EVM 60 6 3 PC Master Software Control Window 62 6 4 Set up of the 3 Phase ACIM V Hz Control Application 64 6 5 DSP56F805EVM Jumper Reference 65 6 6 Target Bui
18. of the callback function in the code void isrADC_A_Limit void 5 3 8 Quad Timer D1 Compare ISR This subroutine takes care of the LED handling The name of the callback function in the code void isrQT_D1 void Access frequency is defined by constant TMR_1_PERIOD in definition section of program 5 3 9 Quad Timer D2 ISR DRM021 Rev 0 This subroutine takes care of Speed ramp calculation Name of callback function in code void isrQT_D2 void Access frequency is defined by constant TMR_2_PERIOD in the definition section of the program Designer Reference Manual MOTOROLA Software Design 55 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Software Design Designer Reference Manual DRM021 Rev 0 56 Software Design MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Designer Reference Manual 3 Phase ACIM V Hz Control 6 1 Contents Section 6 Application Setup 6 2 Application Description 57 6 3 Application SHU IIIA 63 6 3 1 Application Set Up Using DSP56F805EVM 64 04 PROC PSs 0456444066586 0G 0b ind LEN een eter ae ekien 66 6 5 Application Build amp Execute 68 6 2 Application Description DRM021 Rev 0 This application performs a principal control of the 3 phase AC Induction motor using the DSP56F805 processor
19. of the position if required by the control algorithm Detailed motor brake specifications are listed in Table 4 4 Designer Reference Manual DRM021 Rev 0 38 Hardware MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Hardware Motor Brake Specifications Table 4 4 Motor Brake Specifications Set Manufactured EM Brno Czech Republic Motor Specification eMotor Type 3 Phase caren Motor Pole Number 4 Nominal Speed 1300 rpm Nominal Voltage 3 x 200 V Nominal Current 0 88 A Brake Specification Brake Type ete ee Motor Nominal Voltage 3x27V Nominal Current 2 6A Pole Number 6 Nominal Speed 1500 rpm Position Encoder Type Baumer Electric BHK 16 05A 1024 12 5 Pulses per Revolution 1024 DRM021 Rev 0 Designer Reference Manual MOTOROLA Hardware For More Information On This Product Go to www freescale com 39 Freescale Semiconductor Inc Hardware Designer Reference Manual DRM021 Rev 0 40 Hardware MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Designer Reference Manual 3 Phase ACIM V Hz Control 5 1 Contents 5 2 Data Flow DRM021 Rev 0 5 2 5 2 1 5 2 2 5 2 3 5 2 4 5 2 5 5 2 6 5 3 5 3 1 5 3 2 5 3 3 5 3 4 5 3 5 5 3 6 5 3 7 5 3 8 5 3 9 Section 5 Software Desig
20. stage The board isolates the controller and peripherals that may be attached to the controller from dangerous voltages that are present on the power stage The optoisolation board s galvanic isolation barrier also isolates control signals from high noise in the power stage and provides a noise robust systems architecture Signal translation is virtually one for one Gate drive signals are passed from the controller to the power stage via high speed high dv dt digital optocouplers Analog feedback signals are passed back through HCNR201 high linearity analog optocouplers Delay times are typically Designer Reference Manual DRM021 Rev 0 36 Hardware MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc 250 ns for digital signals and 2 us for analog signals Grounds are Hardware Motor Brake Specifications separated by the optocouplers galvanic isolation barrier Both input and output connections are made via 40 pin ribbon cable connectors The pin assignments for both connectors are the same For example signal PWM_AT appears on pin 1 of the input connector and also on pin 1 of the output connector In addition to the usual motor control signals an MC68HC705JJ7CDW serves as a serial link which allows controller software to identify the power board Power requirements for the controller side circuitry are met with a single external 12 Vdc power supply Po
21. the 3 phase PWM motor control signals are generated The DC bus voltage and power stage temperature are measured during the control process They are overvoltage undervoltage and overheating protection of the drive Both undervoltage protection and overheating are performed by ADC and software while the DC bus overcurrent and overvoltage fault signals are connected to PWM fault inputs If any of the above mentioned faults occurs the motor control PWM outputs are disabled in order to protect the drive and the fault state of the system is displayed in PC Master control page DRM021 Rev 0 26 System Concept MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Designer Reference Manual 3 Phase ACIM V Hz Control 4 1 Contents 4 2 Introduction 4 2 4 3 4 4 4 6 4 7 Section 4 Hardware IIIA Ia 27 The High Voltage Hardware Set 27 DSP56F805EVM Control Board 29 Optoisolation Board 36 Motor Brake Specifications 37 The motor control system is designed to drive the 3 phase AC motor in a speed close loop The designed software is capable to run only on high voltage HW set described below Other power module boardswill be denied due to board identification build in SW This feature protects misuse of the HW module 4 3 The High Voltage Hardware Set
22. the ACIM drive incorporates the following hardware components e AC induction motor brake set e 3 phase AC BLDC high voltage power stage e DSP56F805EVM boards e Optoisolation box which is connected between the Power stage board and the DSP56F805EVM The AC induction motor brake set incorporates a 3 phase AC induction motor and attached BLDC motor brake The AC induction motor has four poles The incremental position sensor encoder is coupled on the motor shaft The detailed motor brake specifications are listed in Table 6 1 This 3 Phase AC Induction Motor V Hz Control Application can operate in two modes 1 Manual Operating Mode The drive is controlled by the RUN STOP switch S6 The motor speed is set by the UP S2 IRQB and DOWN S1 IRQA push buttons see Figure 6 1 If the application runs and motor spinning is disabled i e the system is ready the USER LED LED3 shown in Figure 6 2 will blink When motor spinning is enabled the USER LED is On Refer to Table 6 2 for application states Table 6 1 Motor Brake Specifications Set Manufactured EM Brno Czech Republic Designer Reference Manual DRM021 Rev 0 58 Application Setup MOTOROLA For More Information On This Product Go to www freescale com DRM021 Rev 0 Freescale Semiconductor Inc Application Setup Application Description Table 6 1 Motor Brake Specifications Motor Specification Motor Type 3 Phase Re
23. 87 Elektricke regulacni pohony II VUT Brno Brno Vas P 1998 Sensorless Vector and Direct Torque Control Oxford University Press ISBN 0 19 856465 1 New York Motorola Inc 2000 DSP56800 Family Manual DSP56F800FM D Rev 1 Motorola Inc 2001 DSP56F80x User s Manual DSP56F801 7UM D Rev 3 0 Motorola Inc 2001 DSP Evaluation Module Hardware User s Manual DSP56F805EVMUM D Rev 3 0 Motorola Inc 2001 DSP Evaluation Module Hardware User s Manual DSP56F803EVMUM D Rev 3 0 Motorola Inc 2001 DSP Evaluation Module Hardware User s Manual DSP56F807EVMUM D Rev 0 Motorola Software Development Kit documentation available on the web page www motorola com CodeWarrior for Motorola DSP56800 Embedded Systems CWDSP56800 Metrowerks 2001 DSP56F805 Evaluation Module Hardware User s Manual DSP56F805EVMUM D Motorola 2001 Evaluation Motor Board User s Manual MEMCEVMBUM D Motorola 3 Phase AC BLDC High Voltage Power Stage Designer Reference Manual MOTOROLA References 71 For More Information On This Product Go to www freescale com Designer Reference Manual Freescale Semiconductor Inc References 16 17 18 ECOPTHIVACBLDC Motorola Motorola Embedded Motion Optoisolation Board User s Manual MEMCOBUM D Motorola 2000 User Manual for PC master software Motorola 2001 DSP56800_Quick_Start Users Manual MCSL 2002 Motor Control Algorithms Description MCS
24. Freescale Semiconductor Inc elo ji oye MOTOKOLA digital dna intelligence everywhere 3 Phase ACIM Volt per Hertz Control Using 56F80x Designer Reference Manual 56800 Hybrid Controller DRM021 D Rev 0 03 2003 MOTOROLA COM SEMICONDUCTORS For More Information On This Product o to www freescale com Freescale Semiconductor Inc For More Information On This Product Go to www freescale com Freescale Semiconductor Inc 3 Phase ACIM V Hz Control Using 56F80x Designer Reference Manual Rev 0 by Jaroslav Musil Motorola Czech Systems Laboratories Roznov pod Radhostem Czech Republic Original code by Petr Uhlir DRM021 Rev 0 Designer Reference Manual MOTOROLA 3 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Revision history To provide the most up to date information the revision of our documents on the World Wide Web will be the most current Your printed copy may be an earlier revision To verify you have the latest information available refer to http www motorola com semiconductors The following revision history table summarizes changes contained in this document For your convenience the page number designators have been linked to the appropriate location Revision history Revision mee Page Date Level Description Number s January ss 200 1 Initial release N A Designer Reference
25. L 2002 DRM021 Rev 0 72 References MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Designer Reference Manual DRM021 DRM021 Rev 0 Appendix B Glossary AC Alternating Current ADC See analogue to digital converter brush A component transfering elektrical power from non rotational terminals mounted on the stator to the rotor BLDC Brushless dc motor commutation A process providing the creation of a rotation field by switching of power transistor electronic replacement of brush and commutator commutator A mechanical device alternating DC current in DC commutator motor and providing rotation of DC commutator motor COP Computer Operating Properly timer DC Direct Current DSP Digital Signal Prosessor DSP56F80x A Motorola family of 16 bit DSPs dedicated for motor control DT see Dead Time DT Dead Time DT short time that must be inserted between the turning off of one transistor in the inverter half bridge and turning on of the complementary transistor due to the limited switching speed of the transistors duty cycle A ratio of the amount of time the signal is on versus the time it is off Duty cycle is usually represented by a percentage GPIO General Purpose Input Output Designer Reference Manual MOTOROLA Glossary 73 For More Information On This Pro
26. Reference Manual DRM021 Rev 0 20 Control Theory MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Control Theory Speed Close Loop System current The command and feedback signals are DC quantities and are proportional to the respective variables The purpose of the volt per hertz control scheme is to maintain the air gap flux of AC Induction motor in constant in order to achieve higher run time efficiency In steady state operation the machine air gap flux is approximately related to the ratio V fs where V is the amplitude of motor phase voltage and f is the synchronous electrical frequency applied to the motor The control system is illustrated in Figure 2 4 The characteristic is defined by the base point of the motor Below the base point the motor operates at optimum excitation because of the constant V f ratio Above this point the motor operates under excited because of the DC Bus voltage limit A simple close loop volts hertz speed control for an induction motor is the control technique targeted for low performance drives This basic scheme is unsatisfactory for more demanding applications where speed precision is required Volt per Hertz Characteristic Motor Base Point Amplitude Base Frequency Frequency Frequency Frequency Figure 2 4 Volts per Hertz Control Method 2 4 Speed Close Loop System DRM021 Rev 0 To improve the system
27. STER SETTING ENCODER u_dc_bus Omega_desired Speed Measurement Acceleration Deceleration Ramp Omega_required PI Controller Omega_command Omega_actual Temperature Drive Fault Status AmplitudeVoltScale PWM Faults OverVoltage OverCurrent DC Bus Voltage Ripple Elimination Amplitude PWM Generation PVALO PVAL2 PVAL4 Figure 5 1 Data Flow 5 2 1 Acceleration Deceleration Ramp The process calculates the new actual speed command based on the required speed according to the acceleration deceleration ramp The desired speed is determined either by push buttons or by the PC Master During deceleration the motor can work as a generator In the generator state the DC bus capacitor is charged and its voltage can easily exceed its maximal voltage Therefore the voltage level in the DC bus link is controlled by a resistive brake operating in the case of overvoltage Designer Reference Manual DRM021 Rev 0 42 Software Design MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Software Design Data Flow The process input parameter is Omega_desired the desired speed The process output parameter is Omega_required used as an input parameter of the PWM generation process 5 2 2 Speed Measurement 5 2 3 PI Controller 5 2 4 V Hz Ramp DRM021 Rev 0 The speed measurement process uses the on chip quadrature decoder T
28. able on board parallel JTAG Command Converter NC Interface JG6 Use on board crystal for DSP oscillator input 2 3 JG7 Select DSP s Mode 0 operation upon exit from reset 1 2 JG8 Enable on board SRAM 1 2 JG9 Enable RS 232 output 1 2 DRM021 Rev 0 Designer Reference Manual MOTOROLA Application Setup 65 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Application Setup Table 6 3 DSP56F805EVM Jumper Settings Jumper Group Comment Connections JG10 Secondary UNI 3 Analog temperature input unused NC JG11 Use Host power for Host target interface 1 2 JG12 ae input selected for quadrature encoder 2 3 5 6 8 9 JG13 Secondary Encoder input selected 2 3 5 6 8 9 JG14 jet UNI 3 3 Phase Current Sense selected as Analog 2 3 5 6 8 9 JG15 Secondary UNI 3 Phase A Overcurrent selected for FAULTA1 1 2 JG16 Secondary UNI 3 Phase B Overcurrent selected for FAULTB1 1 2 JG17 CAN termination unselected NC JG18 Use on board crystal for DSP oscillator input 1 2 6 4 Project Files When running the EVM target system in a stand alone mode from Flash the JG5 jumper must be set in the 1 2 configuration to disable the command converter parallel port interface The 3 Phase AC Induction Motor V Hz Control application is composed of the following files Designer Reference Manual 3acim_vhz_sa 3acim_vhz c main program 3acim_vhz_sa 3acim_vhz_sa mep applica
29. ace Secondary UNI 3 Low Freq Power Supply Crystal XTAL EXTAL 3 3 V amp GND 3 3V 5 0V amp 3 3VA Figure 4 2 Block Diagram of the DSP56F805EVM 4 4 1 DSP56F805EVM Configuration Jumpers Eighteen jumper groups JG1 JG18 shown in Figure 4 3 are used to configure various features on the DSP56F805EVM board Table 4 1 describes the default jumper group settings Designer Reference Manual DRM021 Rev 0 30 Hardware MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Hardware DSP56F805EVM Control Board Figure 4 3 DSP56F805EVM Jumper Reference Table 4 1 DSP56F805EVM Default Jumper Options Jumper Jumpers Group comment Connections JG1 PDO input selected as a high 1 2 JG2 PD1 input selected as a high 1 2 JG3 Primary UNI 3 serial selected E m amp JG4 Secondary UNI 3 serial selected A sa JG5 Enable on board Parallel JTAG Host Target Interface NC JG6 Use on board crystal for DSP oscillator input 2 3 JG7 Selects DSP s Mode 0 operation upon exit from reset 1 2 JG8 Enable on board SRAM 1 2 JG9 Enable RS 232 output 1 2 JG10 Secondary UNI 3
30. c BLDC motors Input connections are made via 40 pin ribbon cable connector J14 Power connections to the motor are made on output connector J13 Phase A phase B and phase C are labeled PH_A Ph_B and Ph_C on the board Power requirements are met with a single external 140 to 230 volt dc power supply or an ac line voltage Either input is supplied through connector J11 Current measuring circuitry is set up for 2 93 amps full scale Both bus and phase leg currents are measured A cycle by cycle over current trip point is set at 2 69 amps The high voltage ac power stage has both a printed circuit board and a power substrate The printed circuit board contains IGBT gate drive circuits analog signal conditioning low voltage power supplies power factor control circuitry and some of the large passive power components All of the power electronics which need to dissipate heat are mounted on the power substrate This substrate includes the power IGBTs brake resistors current sensing resistors a power factor correction MOSFET and temperature sensing diodes Figure 4 5 shows a block diagram Designer Reference Manual DRM021 Rev 0 34 Hardware MOTOROLA For More Information On This Product Go to www freescale com DRM021 Rev 0 Freescale Semiconductor Inc HV POWER INPUT SIGNALS TO FROM CONTROL BOARD Figure 4 5 3 Phase AC High Voltage Power Stage Hardware 3 Phase AC BLDC High Voltage Power Stage
31. ce Manual MOTOROLA Control Theory 17 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Control Theory Motor Torque Torque Load Torque Working Point 0 Speed Motor Generator lt gt lt Figure 2 1 Torque Speed Characteristic at Const Voltage amp Frequency In adjustable speed applications the AC motors are powered by inverters The inverter converts DC power to AC power at required frequency and amplitude The typical 3 phase inverter is illustrated in Figure 2 2 Designer Reference Manual DRM021 Rev 0 18 Control Theory MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Control Theory Target Motor Theory DC Bus O 3 Phase AC Motor Figure 2 2 3 Phase Inverter The inverter consists of three half bridge units where the upper and lower switch is controlled complementarily meaning when the upper one is turned on the lower one must be turned off and vice versa As the power device s turn off time is longer than its turn on time some dead time must be inserted between the turn off of one transistor of the half bridge and turn on of it s complementary device The output voltage is mostly created by a pulse width modulation PWM technique where an isosceles triangle carrier wave is compared with a fundamental frequency sine modulating wave and the natural points of intersection determ
32. cond chart delineates the duty cycles generated by one of the 3 phase wave generation functions The third chart contains symetrical sine waves of the phase to phase voltages actually applied to the 3 phase motor Designer Reference Manual MOTOROLA Software Design 45 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Software Design 0 20 t u dc bus U max 0 10 AmplitudeVolt Scale U max Amplitude Ampl max 0 00 Figure 5 3 3 ph Waveforms with DC Bus Voltage Ripple Elimination 5 2 5 PWM Generation Process Description This process generates a system of 3 phase sine waves with addition of the third harmonic component shifted by 120 to each other using Designer Reference Manual DRM021 Rev 0 46 Software Design MOTOROLA For More Information On This Product Go to www freescale com DRM021 Rev 0 Freescale Semiconductor Inc Software Design Data Flow Gen3PhWaveSine3rdHintp function from the motor control function library The function is based on a fix wave table describing the first quadrant of sine wave stored in data memory of the DSP Due to the symmetry of the sine function the data in other quadrants are calculated using the data of first quadrant It saves the data memory The sine wave generation for the phase A simplicity is explained in
33. ct folder Quick_Start libraries are e 3acim_vhz_sa src include folder for general C header files e 3acim_vhz_sa src dsp56805 folder for the device specific source files e g drivers e 3acim_vhz_sa src pc_master_support folder for PC master software source files e _ 3acim_vhz_sa src algorithms folder for algorithms DRM021 Rev 0 Designer Reference Manual MOTOROLA Application Setup 67 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Application Setup 6 5 Application Build amp Execute When building the 3 Phase AC Induction V Hz Control Application the user can create an application that runs from internal Flash or External RAM To select the type of application to build open the 3acim_vhz_sa mcp project and select the target build type as shown in Figure 6 6 A definition of the projects associated with these target build types may be viewed under the Targets tab of the project window bldc_sensor mcp I Link Order Targets e External RAM Hwy BS Pp Pash Le External RAM 115K 75K i 1K 289 i 19 files 116K 76K Figure 6 6 Target Build Selection The project may now be built by executing the Make command as shown in Figure 6 7 This will build and link the 3 Phase AC Induction Motor V Hz Control Application and all needed Metrowerks Designer Reference Manual DRM021 Rev 0 68 Application Setup MOTOROLA For
34. ctly passed to the PWM value registers using the PWM driver This process is responsible for the fault handling The software accommodates five fault inputs the overcurrent the overvoltage the undervoltage the overheating and the wrong identified hardware Designer Reference Manual MOTOROLA Software Design 49 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Software Design Overcurrent In the case of the overcurrent in DC Bus link the external hardware provides a rising edge on the fault input pin FAULTA1 of the DSP This signal immediately disables all the motor control PWM s outputs PWM1 PWM6 and sets the DC_Bus_OverCurrent bit of DriveFaultStatus variable Overvoltage In the case of the overvoltage in DC bus link the external hardware provides a rising edge on the fault input pin FAULTAO of the DSP This signal immediately disables all motor control PWM s outputs PWM1 PWM6 and sets the DC_Bus_OverVoltage bit of the DriveFaultStatus variable Undervoltage The DC bus voltage sensed by the ADC is compared with the limit within the software In the case of the undervoltage after a period defined by UNDERVOLTAGE_COUNT all the motor control PWM outputs are disabled and the DriveFaultStatus variable is set to DC_Bus_UnderVoltage Overheating The temperature of the power module sensed by the ADC is compared with the limit within the software In the case of the ove
35. ded or authorized for use as components in systems intended for surgical implant into the body or other applications intended to support or sustain life or for any other application in which the failure of the Motorola product could create a situation where personal injury or death may occur Should Buyer purchase or use Motorola products for any such unintended or unauthorized application Buyer shall indemnify and hold Motorola and its officers employees subsidiaries affiliates and distributors harmless against all claims costs damages and expenses and reasonable attorney fees arising out of directly or indirectly any claim of personal injury or death associated with such unintended or unauthorized use even if such claim alleges that Motorola was negligent regarding the design or manufacture of the part MOTOROLA Motorola and the Stylized M Logo are registered in the U S Patent and Trademark Office digital dna is a trademark of Motorola Inc All other product or service names are the property of their respective owners Motorola Inc is an Equal Opportunity Affirmative Action Employer Motorola Inc 2003 DRM021 D For More Information On This Product Go to www freescale com
36. design of the software blocks of the drive The software will be described in terms of data flow and state diagrams 4 4 DSP56F805EVM Control Board The DSP56F805EVM facilitates the evaluation of various features present in the DSP56F805 part The DSP56F805EVM can be used to develop real time software and hardware products based on the DSP56F805 The DSP56F805EVM provides the features necessary for a user to write and debug software demonstrate the functionality of that software and interface with the customer s application specific device s The DSP56F805E VM is flexible enough to allow a user to fully exploit the DSP56F805 s features to optimize the performance of their product as shown in Figure 4 2 DRM021 Rev 0 Designer Reference Manual MOTOROLA Hardware 29 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Hardware DSP56F805 4 Channel 10 bit D A MODE IRQ RS 232 LOGIC MODE IRQ Interface Address CAN Interface Data amp Control Program Memory 64Kx16 bit Debug LEDs Peripheral Expansion Connector s PWM LEDs Data Memory 64Kx16 bit Over V Sense Over Sense Memory Expansion z Connector s mae g JTAG Connector JTAG OnCE Parallel JTAG Interf
37. duct Go to www freescale com Freescale Semiconductor Inc Application Setup Induction Motor 3 ee E I Incremental 4 Sensor Connector Motor Power Connector Optoisolatio Board AC Power Line 4 3 ph ACBLDC Serial Cable Connector Power Stage A Da lo PC p Figure 6 4 Set up of the 3 Phase ACIM V Hz Control Application 6 3 1 Application Set Up Using DSP56F805EVM To execute the AC Induction Motor V Hz Control the DSP56F805EVM board requires the strap settings shown in Figure 6 5 and Table 6 3 Designer Reference Manual DRM021 Rev 0 64 Application Setup MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Application Setup Application Setup JG9 JG3 1 fl 1 a Ge JG18 JG17 JG11 7 8 Figure 6 5 DSP56F805EVM Jumper Reference Table 6 3 DSP56F805EVM Jumper Settings Jumper Group Comment Connections JG1 PDO input selected as a high 1 2 JG2 PD1 input selected as a high 1 2 JG3 Primary UNI 3 serial selected 1 2 3 4 5 6 7 8 JG4 Secondary UNI 3 serial selected 1 2 3 4 5 6 7 8 JG5 En
38. duct Go to www freescale com Freescale Semiconductor Inc Hall Sensors A position sensor giving six defined events each 60 electrical degrees per electrical revolution for 3 phase motor HV High Voltage 115 V AC or 230 V AC interrupt A temporary break in the sequential execution of a program to respond to signals from peripheral devices by executing a subroutine input output I O Input output interfaces between a computer system and the external world A CPU reads an input to sense the level of an external signal and writes to an output to change the level on an external signal JTAG Interface allowing On Chip Emulation and Programming LED Light Emitting Diode logic 1 A voltage level approximately equal to the input power voltage Voo logic 0 A voltage level approximately equal to the ground voltage Vss LV Low Voltage 12 V DC PI controller Proportional Integral controller phase locked loop PLL A clock generator circuit in which a voltage controlled oscillator produces an oscillation which is synchronized to a reference signal PM Permanent Magnet PMSM Permanent Magnet Synchronous Motor PWM Pulse Width Modulation Quadrature Decoder A module providing decoding of position from a quadrature encoder mounted on a motor shaft Quad Timer A module with four 16 bit timers reset To force a device to a known condition Designer Reference Ma
39. e RUN STOP switch which can be used to safely stop the application at any time PC master software enables to set the required speed of the motor PC master software displays the following information e Applied Voltage e Required Voltage e Speed e RUN STOP Switch Status e Application Mode Measured quantities include e DCBus voltage e Power module temperature e Rotor speed The faults used for drive protection e Overvoltage PC master software error message Overvoltage fault e Undervoltage PC master software error message Undervoltage fault e Overcurrent PC master software error message Overcurrent fault e Overheating PC master software error message Overheating fault e Wrong hardware PC master software error message Wrong HW used Start the PC master software window s application 3acim_vhz pmp Figure 6 3 illustrates the PC master software control window after this project has been launched DRM021 Rev 0 Designer Reference Manual MOTOROLA Application Setup 61 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Application Setup NOTE Ifthe PC master software project pmp file is unable to control the application it is possible that the wrong load map e f file has been selected PC master software uses the load map to determine addresses for global variables being monitored Once the PC master software project has been launched
40. erated phase voltage sine waves In fact it lowers the 50 or 60Hz acoustic noise of the motor Another positive aspect due to this function is that the generated phase voltage is independent of the level of DC bus voltage So the application is well adaptable in worldwide power supply system The process is performed by the ElimDCVoltRipple function converting the phase voltage amplitude Amplitude VoltScale to the sine wave amplitude Amplitude based on the actual value of the DC bus voltage Designer Reference Manual DRM021 Rev 0 44 Software Design MOTOROLA For More Information On This Product Go to www freescale com NOTE DRM021 Rev 0 Freescale Semiconductor Inc Software Design Data Flow u_dc_bus and inverse value of the modulation index ModulationindexInverse The modulation index is the ratio between the maximum amplitude of the first harmonic of the phase voltage in voltage scale and half of DC bus voltage in voltage scale which is defined by the following formula UA phasemax _ WA l B 5 1 2 UDCBus The modulation index is specific to a given 3 phase generation algorithm and in the case of the application it is 1 27 The result of the modulation index is based on the third harmonic injection PWM technique The first chart in Figure 5 3 demonstrates how the Amplitude in scale of generated sine wave amplitude is counter modulated in order to eliminate the DC bus ripples The se
41. he process output is MeasuredSpeed and is only used as an information value in PC Master The PI controller process takes the input parameters actual speed command Omega_required and actual motor speed measured by an incremental encoder Omega_actual The PI controller calculates a speed error and performs the speed PI control algorithm The output of the PI controller is a frequency of the first harmonic sine wave to be generated by the inverter Omega_command The drive is designed as a volt per hertz drive It means the control algorithm keeps the constant motor s magnetizing current flux by varying the stator voltage with frequency The commonly used volt per hertz ramp of a 3 phase AC induction motor is illustrated in Figure 5 2 Designer Reference Manual MOTOROLA Software Design 43 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Software Design Vboost lt start base f Hz Figure 5 2 Volt per Hertz Ramp The volt per hertz ramp is defined by the following parameters e Base point defined by fbase usually 50Hz or 60Hz e Boost point defined by Vboost and fboost e Start point defined by Vstart at the zero frequency The ramp profile fits to the specific motor and can be easily changed to accommodate different ones Process Description The voltage ripple elimination process eliminates the influence of the DC bus voltage ripples to the gen
42. he quadrature decoder The speed controller constants have been tuned experimentally according to the actual load Designer Reference Manual DRM021 Rev 0 22 Control Theory MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Designer Reference Manual 3 Phase ACIM V Hz Control Section 3 System Concept 3 1 System Design Concept The system is designed to drive a 3 phase AC induction motor The application meets the following performance specifications e Targeted for DSP56F80XEVM platforms e Running on 3 phase ACIM motor control development platform at variable line voltage 115 230V AC e Control technique incorporates motoring and generating mode bi directional rotation V Hz speed close loop e Manual Interface Start Stop switch Up Down push button speed control LED indication e PC Master Interface motor start stop speed set up e Power stage identification e Overvoltage undervoltage overcurrent and overheating fault protection The introduced AC drive is designed as a DSP system that meets the following general performance requirements Table 3 1 Motor Drive Specifications 4 poles three phase star connected Motor Type squirrel cage AC motor standard industrial motor Motor Characteristics Speed Range lt 5000 rpm Base Electrical Frequency 50 Hz Max Electrical Power 180 W Delta V
43. ine ADCA High or Low Limit Int Subroutine ADC A end of scan Interrupt PWM A Fault Interrupt PWM A Fault Interrupt Subroutine ADCA Interrupt Subroutine Figure 5 7 State Diagram General Overview 5 3 2 Application State Machine This state controls the main application functionalities depicted in Figure 5 8 Designer Reference Manual DRM021 Rev 0 Software Design MOTOROLA For More Information On This Product Go to www freescale com 52 Freescale Semiconductor Inc Software Design State Diagram Application State Machine Begin Test Drive Fault Status NO_FAULT Test Application Mode RUN Enable PWM Calculate V Hz Ramp RESET Speed 0 Disable PWM done Application State Machine End Figure 5 8 State Application State Machine 5 3 3 Check Run Stop Switch In this state the Run Stop switch is checked according to the Application Mode setting whether set to RUN or STOP 5 3 4 PWM A Reload ISR This subroutine is called at the PWM A reload interrupt It provides e The measurement of the actual speed WeasuredSpeed e The elimination of DC bus voltage ripples ElimDCBVoltRipple function e The calculation of the waveform generator Gen3PhWaveSine3rdHintp function DRM021 Rev 0 Designer Reference Manual MOTOROLA Software Design 53 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc
44. ine the switching points of the power devices of a half bridge inverter This technique is shown in Figure 2 3 The 3 phase voltage waves are shifted 120 to each other and thus a 3 phase motor can be supplied DRM021 Rev 0 Designer Reference Manual MOTOROLA Control Theory 19 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Control Theory Generated PWM Carrier Sine Wave Wave gt Al 1 PWM Output Tj Upper Switch 0 1 ot PWM Output T Lower Switchf Lo joti L_ L_ L iE ot Figure 2 3 Pulse Width Modulation The most popular power devices for motor control applications are Power MOSFETs and IGBTs A Power MOSFET is a voltage controlled transistor It is designed for high frequency operation and it has a low voltage drop thus it has low power losses However the saturation temperature sensitivity limits the MOSFET application in high power applications An insulated gate bipolar transistor IGBT is a bipolar transistor controlled by a MOSFET on its base The IGBT requires low drive current has fast switching time and is suitable for high switching frequencies The disadvantage is its higher voltage drop of the bipolar transistor causing higher conduction losses 2 3 Volt per Hertz Control Volt per Hertz control methods is the most popular method of Scalar Control controls the magnitude of the variable like frequency voltage or Designer
45. ld Selection 68 6 7 Execute Make Command 69 Designer Reference Manual MOTOROLA 9 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc List of Figures Designer Reference Manual DRM021 Rev 0 10 MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Designer Reference Manual 3 Phase ACIM V Hz Control DRM021 Rev 0 Table List of Tables Title Page Motor Drive Specifications 23 DSP56F805EVM Default Jumper Options 31 Electrical Characteristics of Power Stage 36 Electrical Characteristics oF Motor Brake Specifications 39 Motor Brake Specifications 58 Motor Application States 60 DSP56F805EVM Jumper Settings 65 Designer Reference Manual MOTOROLA 11 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc List of Tables Designer Reference Manual DRM021 Rev 0 12 MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Designer Reference Manual 3 Phase ACIM V Hz Control 1 1 Contents 1 2 Introduction Section 1 Introducti
46. n Daa hs do bb aOR A OO eie EES AEEA 41 Acceleration Deceleration Ramp 42 Speed Measurement 43 Sb AAA AE 43 Wee SA 5d 694 OO Ee KUNIUA 43 PWM Generation cintad ee cb cele ddd ee Shee ee eee Bas 46 gli feo a eae ee eee ae ne meena reer ae 49 Ee er a e kedidir rd r ee ee ae ere 50 i eel Wl iG Cae ee hed Lake ee E EE eee 51 Application State Machine 52 Check Run Stop Switch 53 PWM A Reload ISR Wi WA 53 PWM A FaUIRISA 2cacssscci cece e dew eeacaeteonns 54 ADG End Of Sania 54 ADC High And Low Limit ISR S 54 Quad Timer D1 Compare ISR 55 Quad TimerD2ISR 55 The requirements of the drive dictates the software gather some values from the user interface and sensors process them and generate 3 phase PWM signals for the inverter The control algorithm of a closed loop AC drive is described in Figure 5 1 The control algorithm contains the processes described in the following subsections The detailed description is given to the subroutines 3 phase PWM calculation and the volt per hertz control algorithm Designer Reference Manual MOTOROLA Software Design 41 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Software Design Temperature DC Bus Voltage PC SPEED INCREMENTAL A D A D MA
47. n the DSP56F805EVM board This provides the connection which allows the host computer to control the board Designer Reference Manual DRM021 Rev 0 32 Hardware MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Hardware DSP56F805EVM Control Board 3 Make sure that the external 12V DC 4 0A power supply is not plugged into a 120V AC power source 4 Connect the 2 1mm output power plug from the external power supply into P2 shown in Figure 4 4 on the DSP56F805EVM board Apply power to the external power supply The green Power On LED LED10 will illuminate when power is correctly applied DRM021 Rev 0 Designer Reference Manual MOTOROLA Hardware 33 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Hardware 4 5 3 Phase AC BLDC High Voltage Power Stage Motorola s embedded motion control series high voltage HV ac power stage is a 180 watt one fourth horsepower 3 phase power stage that will operate off of dc input voltages from 140 to 230 volts and ac line voltages from 100 to 240 volts In combination with one of the embedded motion control series control boards and an optoisolation board it provides a software development platform that allows algorithms to be written and tested without the need to design and build a power stage It supports a wide variety of algorithms for both ac induction and brushless d
48. nual DRM021 Rev 0 74 Glossary MOTOROLA For More Information On This Product Go to www freescale com DRM021 Rev 0 Freescale Semiconductor Inc Glossary RPM Revolutions per minute SCI See serial communication interface module SCl serial communications interface module SCI A module that supports asynchronous communication serial peripheral interface module SPI A module that supports synchronous communication software Instructions and data that control the operation of a microcontroller software interrupt SWI An instruction that causes an interrupt and its associated vector fetch SPI See serial peripheral interface module SPI timer A module used to relate events in a system to a point in time Designer Reference Manual MOTOROLA Glossary 75 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Designer Reference Manual DRM021 Rev 0 76 Glossary MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc For More Information On This Product Go to www freescale com Freescale Semiconductor Inc HOW TO REACH US USA EUROPE LOCATIONS NOT LISTED Motorola Literature Distribution P O Box 5405 Denver Colorado 80217 1 303 675 2140 or 1 800 441 2447 JAPAN Motorola Japan Ltd SPS Technical Information Center 3 20 1 Minami Azabu Minat
49. o ku Tokyo 106 8573 Japan 81 3 3440 3569 ASIA PACIFIC Motorola Semiconductors H K Ltd Silicon Harbour Centre 2 Dai King Street Tai Po Industrial Estate Tai Po N T Hong Kong 852 26668334 TECHNICAL INFORMATION CENTER 1 800 521 6274 HOME PAGE http motorola com semiconductors Information in this document is provided solely to enable system and software implementers to use Motorola products There are no express or implied copyright licenses granted hereunder to design or fabricate any integrated circuits or integrated circuits based on the information in this document Motorola reserves the right to make changes without further notice to any products herein Motorola makes no warranty representation or guarantee regarding the suitability of its products for any particular purpose nor does Motorola assume any liability arising out of the application or use of any product or circuit and specifically disclaims any and all liability including without limitation consequential or incidental damages Typical parameters which may be provided in Motorola data sheets and or specifications can and do vary in different applications and actual performance may vary over time All operating parameters including Typicals must be validated for each customer application by customers technical experts Motorola does not convey any license under its patent rights nor the rights of others Motorola products are not designed inten
50. oduct Go to www freescale com Freescale Semiconductor Inc Introduction Designer Reference Manual DRM021 Rev 0 16 Introduction MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Designer Reference Manual 3 Phase ACIM V Hz Control Section 2 Control Theory 2 1 Contents 2 2 Target Motor TREO ts ch ce dead ee iew hie nnsnke dees 17 2 3 Volt per Hertz Control 20 2 4 Speed Close Loop System 21 2 2 Target Motor Theory The AC induction motor is a workhorse of an adjustable speed drive systems The most popular type is the 3 phase squirrel cage AC induction motor It is maintenance free lower noise and efficient motor The stator is supplied by a balanced 3 phase AC power source The synchronous speed n of the motor is given by a rpm 2 1 Ny where f is the synchronous stator frequency in Hz and p is the number of stator poles The load torque is produced by slip frequency The motor speed is characterized by a slip s eae ij 2 2 where n is the rotor mechanical speed and ng is the slip speed both in rpm Figure 2 1 illustrates the torque characteristics and corresponding slip As it can be seen from Equation 2 1 and Equation 2 2 the motor speed is controlled by variation of a stator frequency with influence of the load torque DRM021 Rev 0 Designer Referen
51. oduct Go to www freescale com Designer Reference Manual Freescale Semiconductor Inc Introduction set such as pulse width modulation PWM modules analog to digital converter ADC timers communication peripherals SCI SPI CAN on board flash and RAM The DSP56F805 provides the following peripheral blocks Two pulse width modulator modules PWMA amp PWMB each with six PWM outputs three current status inputs and four fault inputs fault tolerant design with deadtime insertion supports both center and edge aligned modes Two 12 bit analog to digital convertors ADCs supporting two simultaneous conversions with dual 4 pin multiplexed inputs ADC and can be synchronized by PWM modules synchronized Two quadrature decoders Quad DecO amp Quad Dec1 each with four inputs or two additional quad timers A amp B Two dedicated general purpose quad timers totalling 6 pins Timer C with 2 pins and Timer D with 4 pins CAN 2 0 A B module with 2 pin ports used to transmit and receive Two serial communication interfaces SCIO amp SCI1 each with two pins or four additional MPIO lines Serial peripheral interface SPI with configurable 4 pin port or four additional MPIO lines Computer operating properly COP timer Two dedicated external interrupt pins Fourteen dedicated multiple purpose I O MPIO pins and 18 multiplexed MPIO pins External reset pin for hardware reset JTAG on chip emulation OnCE
52. oltage rms 200V Star DRM021 Rev 0 Designer Reference Manual MOTOROLA System Concept 23 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc System Concept Drive Characteristics Transducers IRC 1024 pulses per rev Speed Range lt 2250 rpm 230 V lt 1200 rpm 115 V Line Input 230V 50Hz AC pus 115V 60Hz AC Max DC Bus Voltage 400 V Control Algorithm Close Loop Control Optoisolation Required Load Characteristic Type Varying The DSP runs the main control algorithm According to the user interface input and feedback signals it generates 3 phase PWM output signals for the motor inverter A standard system concept is chosen for the drive and illustrated in Figure 3 1 The system incorporates the following hardware boards Designer Reference Manual Power supply rectifier 3 phase inverter Feedback sensors speed DC bus voltage DC bus current temperature Optoisolation Evaluation board DSP56F805 DRM021 Rev 0 24 System Concept For More Information On This Product Go to www freescale com MOTOROLA Freescale Semiconductor Inc System Concept System Design Concept Rectifier Three Phase Inverter Line Voltage 230V 50Hz j VA AM M Temperature IRC Current amp Isolation Barrier Voltage Sensing Optoisolation Optoisolation VA AM M Temperature Over Current amp
53. on 1 2 PEC ION ss ohh aes ea DP ae mie dd a wn arden ody 13 1 3 Motorola DSP Advantages and Features 13 This section describes the design of a 3 phase AC induction motor drive with volt per hertz control in closed loop hereinafter called V Hz OL It is based on Motorola s 56F80x digital signal processor DSP which is dedicated for motor control applications The system is designed as a motor control system for driving medium power 3 phase AC induction motors The part is targeted toward applications in both industrial and home appliance industries such as washing machines compressors air conditioning units pumps or simple industrial drives The software design takes advantage of Quick_Start developed by Motorola The drive introduced here is intended as an example of a 3 phase AC induction motor drive The drive serves as an example of AC V Hz motor control system design using Motorola DSP This document includes the basic motor theory system design concept hardware implementation and software design including the PC Master visualization tool inclusion 1 3 Motorola DSP Advantages and Features DRM021 Rev 0 The Motorola DSP56F805 is well suited for digital motor control combining the DSP s calculation capability with MCUs controller features on a single chip This DSP offers a rich dedicated peripherals Designer Reference Manual MOTOROLA Introduction 13 For More Information On This Pr
54. performance a closed loop volts per hertz control was introduced In this method a speed sensor measures the actual motor speed and the system takes this input into consideration A Designer Reference Manual MOTOROLA Control Theory 21 For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Control Theory number of applications use the closed loop volts per hertz method because of its simple and relatively good speed accuracy but it is not suitable for systems requiring servo performance or excellent response to highly dynamic torque speed variations Figure 2 5 illustrates the general principle of the speed PI control loop Reference Corrected Speed Speed Speed O d Omega_required Error PI Omega_command Controlled Controller gt System Actual Motor Speed Omega_actual Figure 2 5 Closed Loop Control System The speed closed loop control is characterized by the measurement of the actual motor speed This information is compared with the reference speed while the error signal is generated The magnitude and polarity of the error signal correspond to the difference between the actual and required speed Based on the speed error the PI controller generates the corrected motor stator frequency in order to compensate for the error In a case of AC V Hz closed loop application the feedback speed signal is derived from incremental encoder using t
55. rheating after a period defined by OVERHEATING_COUNT all the motor control PWM outputs are disabled and the DriveFaultStatus variable is set to OverHeating Wrong Hardware In the case the wrong hardware is identified a different power module or missing an optoisolation board during initialization the DriveFaultStatus variable is set to Wrong_Hardware If any of the above mentioned faults occurs program run into infinite loop and waits for reset Fault is signalled by user LEDs on the controller board and on the PC Master control screen 5 3 State Diagram The general state diagram incorporates the main routine entered from reset and the interrupt states The main routine includes the initialization of the DSP and the main loop The main loop incorporates the initialization state the application state machine and the check run stop switch state Designer Reference Manual DRM021 Rev 0 50 Software Design MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Software Design State Diagram The interrupt states provides calculation of the actual speed of motor the PWM reload interrupt the ADC service the limit analog values handling the overcurrent and the overvoltage PWM fault handler and so on 5 3 1 Initialization The main routine provides the initialization of the DSP e Initializes the PLL clock e COP and LVI are disabled e Identifies the connected hardware
56. ser caer Noto Pole Number 4 Nominal Speed 1300 rpm Nominal Voltage 3 x 200V Nominal Current 0 88A Brake Specification Brake Type Rae tne Motor Pole Number 6 Nominal Speed 1500rpm Nominal Voltage 3x 27V Nominal Current 2 6A Position Sensor Type Baumer Electric Encoder BHK 16 05A 1024 12 5 Pulses per revolution 1024 Y UP DOWN Ki RUN STOP WA Buttons LK A Switch RUKY STOP Figure 6 1 RUN STOP Switch and UP DOWN Buttons Designer Reference Manual 59 MOTOROLA Application Setup For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Application Setup A E em m oan mo PWM Output LEDs Figure 6 2 USER and PWM LEDs at DSP56F805EVM Table 6 2 Motor Application States Application State Motor State Green LED State Blinking at a frequency of 2Hz red led Stopped stopped status is off Running Spinning On red led status is off Fault Stopped Blinking at a frequency of 8Hz red led status is on 2 PC master software Remote Operating Mode The drive is controlled remotely from a PC through the SCI Designer Reference Manual DRM021 Rev 0 60 Application Setup MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Application Setup Application Description communication channel of the DSP device via an RS 232 physical interface The drive is enabled by th
57. tion project file 3acim_vhz_sa ApplicationConfig appconfig h application configuration file 3acim_vhz_sa SystemConfig ExtRam linker_ram cmd linker command file for external RAM 3acim_vhz_sa SystemConfig Flash linker_flash cmd linker command file for Flash 3acim_vhz_sa SystemConfig Flash flash cfg configuration file for Flash DRM021 Rev 0 66 Application Setup MOTOROLA For More Information On This Product Go to www freescale com Freescale Semiconductor Inc Application Setup Project Files e 3acim_vhz_sa PCMaster 3acim_vhz pmp PC Master software file These files are located in the application folder Motor Control algorithms used in the application e controller c h source and header files for PI controller e ramp c h source and header files for ramp controller e sinquad c h source and header files with the sine look up table e _ trigon c h source and header files for sine calculation funcion e mcgen c h source and header files for three phase sine wave generation e Mlut c h source and header files for look up table algorithm e _ ripelim c h source and header files for DC bus voltage ripple elimination algorithm Other functions used in the application e boardld c h source and header files for the board identification function This application runs stand alone i e all the needed files are concentrated in one proje
58. wer for power stage side circuitry is supplied from the power stage through the 40 pin output connector The electrical characteristics in Figure 4 3 apply to operation at 25 C and a 12 Vdc power supply voltage Table 4 3 Electrical Characteristics Characteristic Symbol Min Typ Max Units Notes Power Supply Voltage Vdc 10 12 30 V Quiescent Current loc 700 20012 50013 mA dc dc converter Min Logic 1 Input Voltage Vi 2 0 V HCT logic Max Logic 0 Input Voltage VIL 0 8 V HCT logic Analog Input Range Vin 0 3 3 V Input Resistance Rin 10 KQ Analog Output Range Vout 0 3 3 V Digital Delay Time TDDLY 0 25 us Analog Delay Time taDLy 2 us 1 Power supply powers optoisolation board only 2 Current consumption of optoisolation board plus DSP EMV board powered from this power supply 3 Maximum current handled by dc dc converters 4 7 Motor Brake Specifications DRM021 Rev 0 The AC induction motor brake set incorporates a 3 phase AC induction motor and attached BLDC motor brake The AC induction motor has four Designer Reference Manual MOTOROLA For More Information On This Product Hardware Go to www freescale com 37 Freescale Semiconductor Inc Hardware poles The incremental position encoder is coupled to the motor shaft and position Hall sensors are mounted between motor and brake They allow sensing
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