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YROTATE-IT-RX62T

1. ue of gevigineer tre it PC USB SUPPLY SELECTION EXTERNAL SUPPLY SELECTION The first jumper configuration connects the USB ground to the inverter ground the USB 5Vdc to the logic 5Vdc and the output of the step up converter around 13Vdc to the inverter DC link The second jumper configuration connects the external power supply ground to the inverter ground the output of the step down converter 5Vdc to the logic 5Vdc and the external Vdc from 12 to 24 Vdc to the inverter DC link UM YROTATE IT RX62T Rev 1 00 Page 6 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 4 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 it is very useful during the tuning process for adapting the software to a new motor to use the test points There are specific 3 PWM debug test points TP5 TP6 amp TP7 as shown below eo e E La gt t gt e ET ve gt e y 11111 z z a ili iiio TP6 TP5 TP7 DEBUG PWM OUTPUTS MTIOCIA UP36 gt MTIOCIB UP37 MTIOCOD UP35 4K7 1 0603 4K7 1 0603 4K7 1 0603 E e x e z r x GD S D GND UM YROTATE IT RX62T Rev 1 00 Page 7 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 5 LEDs function description Three LEDs available on the board are directly connected to the hardware and allows th
2. UM YROTATE IT RX62T Rev 1 00 Page 4 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit This stage uses the PC USB power lines as power supply Furthermore the possibility to supply all the board using the PC USB port was added realizing a step up converter to obtain the inverter Vays necessary for the motor obviously if this feature is used the system is no more insulated from the PC If external power supply is used for the inverter the logic power supply is obtained through a step down converter in order to reduce heating and power consumption Please refer to the electrical drawings or schematics to get the hardware implementation in more details UM YROTATE IT RX62T Rev 1 00 Page 5 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 3 Power supply selection As stated before there are two ways to supply power to the board One possibility is to use directly the PC USB supply and in this case the current you can give to the motor is limited by the USB possibilities A dual power USB cable is recommended to give enough power to the board The second possibility is to use an external voltage DC source to supply the board The recommended voltage values are between 12Vpc and 24Vpc In this case the communication stage is insulated from the inverter The selection between the two possibilities is made through three jumpers in the J2 connector as described in the following figure
3. 10 OZ IN AMPS 10 V K RPM 88 10 OHMS 112 mH O TU UN INDUCTANCE L L L ROTOR INERTIA Jo WEIGHT 38 35 106 8 Ti B 319 0 0017 DZ IN SEC UM YROTATE IT RX62T Rev 1 00 Jan 15 2014 RENESAS Page 36 of 51 RX62T YROTATE IT RX62T Motor Control Kit b Let s setup the Motor control kit for 24V external power supply the jumper JP2 needs to be set to 2 3 position C Let s connect the 24Vpc Power supply to the RX62T 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 UM YROTATE IT RX62T Rev 1 00 Page 37 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit e Launch the PC GU from the folder C Program Files MCDEMO launch MotorController exe Motor Control Demo User Interface Communication Settings Select board setup Serial port j Click on the setup button and select RX62T Kit and select Autodetect and click on Connect to ensure the PC GUI is connected to the RX62T kit System Info Parameters Setting Speed conto 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 curr
4. 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 Renesas Electronics Corporation http www renesas com Refer to http www renesas com for the latest and detailed information Renesas Electronics America Inc 2880 Scott Boulevard Santa Clara CA 95050 2554 U S A Tel 1 408 588 6000 Fax 1 408 588 6130 Renesas Electronics Canada Limited _ 1101 Nicholson Road Newmarket Ontario L3Y 9C3 Canada Tel 1 905 898 5441 Fax 1 905 898 3220 Renesas Electronics Europe Limited Dukes Meadow Millboard Road Bourne End Buckinghamshire SL8 5FH U K Tel 44 1628 651 700 Fax 44 1628 651 804 Renesas Electronics Europe GmbH Arcadiastrasse 10 40472 D sseldorf Germany Tel 49 211 65030 Fax 49 211 6503 1327 Renesas Electronics China Co Ltd 7th Floor Quantum Plaza No 27 ZhiChunLu Haidian District Beijing 100083 P R China Tel 86 10 8235 1155 Fax 86 10 8235 7679 Renesas Electronics Shanghai Co Ltd Unit 204 205 AZIA Center No 1233 Lujiazui Ring Rd Pudong District Shangh
5. lt 30000 flux amplitude feedback gain Hdefine PHA OFF DEF 0 s 0 X lt 360 offset angle 2 File name MCRPO7 RX62T extPS v7 zip has to be used with an external power stage e g 1 5KW as the embedded software is using other channels of the Motor control timer In the software driving the power stage the customize h file contains the parameters of the motor called MB057GA240 Please find below a snapshot of the header file customize h where all the motor parameters are located MB057GA240 motor default parameters Hdefine RPM MIN DEF 300 200 X 5000 min speed in rpm Hdefine RPM MAX DEF 3000 i000 X 20000 max speed in rpm define R ACC DEF 1000 1 lt X lt 10000 accel ramp in rpm sec define R_DEC_DEF 1000 1 X lt 10000 accel ramp in rpm sec define C POLI DEF 2 f a ay 24 polar couples number define I START DEF i000 0O lt X lt 15000 startup current in A pk AMP RES define I MAX DEF 3000 0O lt X lt 15000 max current in A pk AMP RES define R STA DEF 70 tf 0 lt X lt 30000 stator phase resistance in Ohm OHM RES define L SYN DEF 20 Pd 0 lt X lt 30000 synchronous inductance in Henry HEN RES define PM FLX DEF 260 AN 0 lt X lt 30000 permanent magnet flux in Weber WEB DIV define KP CUR DEF 50 fE 0 lt X lt 30000 K prop current control define KI_CUR_DEF 100 0 lt X lt 30000 K integ current control define KP_
6. q Proportional Integral Since there is a mutual influence between the two axes decoupling terms can be used ann In the block scheme the mechanic part is included where p is the number of pole pairs while B represents friction J the inertia Tioag the load torque and t the motor torque 3 T xXpXxA 2 p The angular speed w 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 a B system UM YROTATE IT RX62T Rev 1 00 Page 20 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit dA Va Ri dt Ri os v Ri 4 B SB dt These equations show that magnetic flux can be obtained from applied voltages and measured currents simply by integration Aa Ang v Reig dt 0 Ag Argo vg Rsip d 0 Furthermore A cos A Li A sin 9 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 8 A Li Ago v Reig dt Lig 0 y A sin Ag Lig A Vg Rsig dt Lig 0 So in the a8 system phase we obtain from the flux components 2 arctan vA The system speed can be obtained as the derivative of the angle 0 d M Based on this a sensorless control algorithm was developed to give the imposed phase voltages
7. the stator un a winding Motor axis shaft aan a winding magnetic axis How current flows into a winding awn 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 Let s analyse the motor from a mathematic point of view If we apply three voltages v t v t v t to the stator windings the relations between phase voltages and currents are UM YROTATE IT RX62T Rev 1 00 Page 17 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit dA v R lt dt dA y R i b S b dt dA y 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 are composed by two items one due to the stator currents one to the perma
8. the suffix mea stands for measured speed Referring to the graph the startup 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 9 20 All the references id iq and speed are set to zero b From the moment to while the idre and the speedet are maintained to zero id is increased with a ramp till the value istart is reached at the moment t4 The references are referred to an arbitrary da qa system based on the arbitrary phase From this moment the phase estimation algorithm begins to be performed and the estimated phase O 4 is used to calculate the components of the measured current referred to the d q system based on the estimated phase idmea and iqq 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 9 is still not correctly estimated idme and iqq have no physical meaning Even if they are not shown in the graph the applied voltages are subjected to the same treatment Vdmea and vq are Calculated in the algorithm c Att t while iq is maintained to zero and id is maintained to its value i 44 speed is increased with a ramp till the value Sstart is reached at the t t The system phase t is obtained simply by
9. to measure phase currents to estimate the angular position 9 and finally the system speed UM YROTATE IT RX62T Rev 1 00 Page 21 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 11 Sensorless Field Oriented Control Algorithm Please find below the sensorless FOC algorithm block diagram 0 Ide Current Reading z Speed Flux Phase estimation estimation LEX Mir The only 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 UM YROTATE IT RX62T Rev 1 00 Page 22 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 12 Flux Feedback Gain The block scheme of the exact BEMF integration method for flux position estimation is the following The inputs of the system are the imposed voltage vector V and the measured current vector I The motor phase resistance R the synchronous inductance L and the permanent magnet flux amplitude m are known as parameters and motor specific 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 with G and it is this feedback which avoids the integral divergence due to the errors offsets and so on The higher G is the higher is the correspon
10. 1000 true rpm 60 20000 3000 true Load i mI 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 E STOP UPDATE RPM CONTROL PROPERTY MONITOR 0 0 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 8 V 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 RX62T Rev 1 00 Page 41 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit_ Speed Control x SPEED VOLTAGE CURRENT 1000 rpm 4 Reference Measured J Direct J Quadrature Direct Ji Torque stop UPDATE RPM CONTROL 0 Motor speed 1498 rpm 49 9 Hz 4 mA 200 mA 03v sav DE Bus Vol Alarm Code Flags Total Current Total Voltage Dummy 23 8 V 0 256 200 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 1sample every 64 X You can also display the phase by click
11. 48 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit Label s Type Description Unit errint float Speed PI integral memory ampere kp cur ki cur float Proportional and integral constant in current PI controllers volt ampere kp vel ki vel float Proportional and integral constant in speed PI controller ampere rad s freq float Electrical frequency hertz mec rpm float Mechanical speed rpm rpmrif x float Reference speed speed ramp input value rpm rpmrif y float Reference speed speed ramp output value rpm rpmrif abs float Absolute value of rpmrif y rpm r acc r dec float Acceleration ramp deceleration ramp rpm s rpm min float Minimum and maximum allowed speed rpm rpm max min speed float Minimum and maximum electrical speed rad s max speed min speed trip float Minimum and maximum electrical speed values used for rad s max speed trip estimation error detection Speed est float Estimated electrical speed rad s omrif f omrif float Reference electrical speed instant and filtered values rad s omegae float Imposed electrical speed instant and filtered values rad s omegae f omf maxerr float Maximum electrical speed error rad s vbus ulpkt slow float One divided by K where K is the time constant of the vbus low 1 s vbus ulpkt fast pass filter slow and fast speedref ulpkt float One divided by K where K is th
12. 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 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 full
13. MTU is used those signals are UM YROTATE IT RX62T Rev 1 00 Page 11 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit clamped with a diode directly connected with the microcontroller power supply so a suitable series resistance is needed in the power stage to avoid damages to the board c A further connector J12 can be used to supply the board from the power stage or vice versa making a short circuit between the pins 1 and 2 of the jumper JP5 also the board 5V can be made available to the power board making a short circuit between the pins 3 and 4 of JP5 but not vice versa because they are directly connected to the step down switching supply of the board The ground connection is always on and it represents the reference for all the interface signals In the next figure a simple example regarding how the power board has to be arranged is presented the power supply comes from the supply connector and the supply for power module is derived from it The external supply is also used to supply the microcontroller board through the connector J12A and the jumper JP5 in microcontroller board the 5V supply for current sensors and for the signal polarization is derived from the microcontroller board through J12A and JP5 The PWM drive signals are taken from J11A while the current sensing signals and the bus voltage measurement are brought to J13A the phase commutation signals and the temperature sensing signal are n
14. RENAA 23 13 Software description eneee aea a a a E a ende saute eee aede eec Ie exe eve Devo EEEE 24 14 Application customization using customize h file cee cesceesseeescecseececseecesseeceseeeceaeceesaecsesseceesecsaeessauesseasecseneess 28 15 Start up PDroc d Te s scseisie RIS I om m 30 16 Reference system transformations in details ccccssssccccscssessececececesseseaesecescecsceesesaeaeeeeeceseesuaeeeceesseesesseaeeeeeesenss 32 17 PWM modulation technique urit teta de tense e aene Ede eec ge bene d caue ere secdselsbailce de eR ERR dTa EEE 33 18 PC Graphical User Interface 2 x otf oeac ie toes acto sdse seges aa e a cda ao Rees eee xc ae DX SER REEERE A 34 19 Motor Auto calibration using the PC GUI lsssseesseseeeseee seen eene enne ene nnns seen ne sistens essei sien en inis ssa 36 20 List of motors tuned automatically using the PC GUI essen enne nn nnn nn nnns sensn nias a nsns 46 21 List of variables used in the file name motorcontrol c sesssssssssssseseseeeeee teen tentent enne enne nnne 47 UM YROTATE IT RX62T Rev 1 00 Page 2 of 51 Jan 15 2014 RENESAS RX62T 1 Key features YROTATE IT RX62T Motor Control Kit Brushless AC e g Permanent Magnet AC Sinusoidal waveform control Field Oriented Control Sensorless using three Shunts RX62T 32 bit 165DMIPS 9KB for motor control algorithm 2 5KB RAM 30ps with CPU at 100MHz Up to 50KHz Up to
15. 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 Q 5 Part name ECI 24 42 BD35F BLDC15P06 BLDC58 50L MB057GA240 FL28BL38 Motor maker EBM PAPST Danfoss Compressor PMDM Minebea Premotec 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 2 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 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 MB057GA240 5000RPM FULLING FL28BL38 13000RPM UM YROTATE IT RX62T Rev 1 00 Page 46 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 21 List of variables used in the file name motorcontrol c The file called mot
16. reference is obtained as output of the speed PI controller UM YROTATE IT RX62T Rev 1 00 Page 31 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 16 Reference system transformations in details Find below the detailed equations used for the coordinates transformations 2 1l 1l j 8a 3 gu 25 25 8a PEE 43 1 1 Spee Oe 8 9 Uu EUIS OA 3 3 2 WE 43 u v w gt a B Sib 1 NE 8 7584 HT 8p Cu 3812 1 J3 8 7 2 8 85 C8 4385 2 2 2 o B u v w Za Ea COSCO g sin 2 8 7 38 sin 2 g p cos a B gt d q 8a ga COSCO g sin v 8p 8a SINO g cos v d a gt a B v V cos t v V cos t 9 27 3 y V cos at 9 y Vcos Q v V cos t 9 4z 3 TRU Vsin t 9 al Vsin Q UM YROTATE IT RX62T Rev 1 00 Page 32 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 17 PWM modulation technique Among the various possibilities a particular form of PWM modulation was chosen In this modulation technique the voltages to be imposed are shifted in order to have in every moment one of the three phases of the motor connected to the system ground This allows reducing the commutations of the power bridge of one third in respect to other modulation techniques In fact the phase that is connected to the system ground doesn t require any commutation having the lower arm always on and the upper arm always off The method is b
17. waveform window Add a step of 50 and click write to see the effect and keep on increasing it UM YROTATE IT RX62T Rev 1 00 Page 43 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T 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 0 mA 203 mA 12V 10 5 V Li Alwaysontop x 1 sample every 8 hd Q 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 0 0 0000 true L write Load Save 15 Flux Feedback 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 RX62T Rev 1 00 Page 44 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit Parameters Setting LJ Always ontop x Reload true Write 1000 true 20000 50
18. 00 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 which is around 6Arms for the external power stage shuntz0 05Ohm and 3Arms for the internal power stage shuntz0 1O0hm 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 I used 500 instead of 100 UM YROTATE IT RX62T Rev 1 00 Page 45 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 20 List of motors tuned automatically using the PC GUI Please find below a short list of AC Brushless
19. 25KHz USB connection PC GUI interface Tool E1 for debug amp development UM YROTATE IT RX62T Rev 1 00 Page 3 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 2 Hardware overview The Motor Control kit is a single board inverter based on the new RX series microcontroller RX62T The hardware includes a low voltage MOSFETs power stage and a communication stage The ordering part name of the kit is YROTATE IT RX62T The latest updates of the kit material are available on the webpage http tinyurl com YROTATE IT RX62T To obtain the maximum flexibility the reference board includes e A complete 3 phase inverter on board with a low voltage motor so it becomes easy to test the powerful sensorless algorithm on the RX62T e USB communication with the PC via a H8S2212 microcontroller e Connectors for hall sensors and encoder connections e Compatibility with the existing Motor Control Reference Platforms MCRP05 06 power stage available at Renesas To achieve these aims an independent communication stage was implemented based on the Renesas microcontroller H8S2212 which performs the USB to serial conversion The two serial lines RX and TX are fully insulated Signals conditioning POWER STAGE 4 DEA S700004 Y E VEIT drap ie dn A STEP DOWN STEP UP EXTERNAL POWER STAGE INTERFACE ERAR Ann a pee EN CONTROL STAGE HALL ENCODER ISOLATION COMMUNICATION
20. ESAS RX62T YROTATE IT RX62T Motor Control Kit Main Program Main loop synchronization cnt int NUM INT Main loop body UM YROTATE IT RX62T Rev 1 00 Page 25 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit Control interrupt Phase currents iUmea iVmea reading Transformations using the phase angle 9 Umes iVmea gt iamear iDmea gt id mea id mea Read DC Link voltage vy Phase angle update 9 Urey Current PI controls use id idrer id meariGmea to produce Vdout Vout Transformations using the phase angle 9 Vdous VAout gt Vaout Vbou gt Vuous Wout PWM output commands generation using VUogut VVout Vgu Is used to calculate maximum phase voltage used in current PI controls Phase estimation based on old va old vb iamear ib produces new estimated phase angle Dect Voltage memories update old va vas old vb VD out Speed estimation produces West Estimation errors detection if errors an alarm is produced YES Start up in progress NO Start up procedure produces id idref Ostup Speed PI control uses yet West to obtain idref Main loop synchronization UM YROTATE IT RX62T Rev 1 00 Page 26 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit The CD ROM of the motor control kit YROTATE IT RX62T contains two projects available in zipped files called 1 File name MCRPO07 RX62T intPS v7 zip loaded by default on th
21. IT RX62T Rev 1 00 Page 28 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 130 startup timing definitions 131 define STUP_CUR_RT_MS 1000 current rising time during startup alignment ms 132 define STUP SPE RT MS 1000 speed rising time from 0 to min speed during startup ms 133 define STUP CUR FT MS 1000 d current falling time after startup ms assuming id i start 134 135 rotation direction 136 define ROT REV 137 138 modulation 139 define DTC REF uses current references in calculations else uses measurements 140 define ICOMP uses the currents to compensate modulation 141 define CENTERED centered modulation 142 define OVERMOD overmodulation 143 144 inverter non linearities compensation 145 define INLCOMP inverter non linearities compensation 146 define INL DET non linearity table determination comment in final release 147 148 other control parameters 149 define MAXERR RPM 300 0f maximum error for ramp limitation and PI clamping 150 define K MARGVO 0 90f max d vol t max volt ratio Isi 152 speed PI error clamping 153 define SPEEDPI ERRCLAMP input to speed PI is clamped to MAXERR RPM 154 155 DC bus voltage limit for ramp limitation 156 define VB RAMP comment this to avoid ramp limitation due to vbus 157 define VBUS LIM 360 0f dc bus voltage limit V 158 define VBUS LIMH 370 0f dc bus voltage limit V 159
22. ONAL FEATURE current PI manual tuning comment if not used 59 define CPI TUN 60 61 ADDITIONAL FEATURE current PI automatic tuning comment if not used 62 define CPI AUT 63 64 ADDITIONAL FEATURE motor parameters auto identification comment if not used 65 define MOT IDENT 66 67 ADDITIONAL FEATURE oscilloscope window in GUI management comment if not used 68 define OSC WIN 69 70 sampling period and modulation setting 71 NOTE This relation MUST be satisfied PWM FREQ CUSTOM N SAM FREQ CUSTOM where 1 N 8 72 define PVM FREQ CUSTOM 16000 PHM Frequency Hz 2000 PWM FREQ CUSTOM lt 20000 73 define SAM FREQ CUSTOM 16000 Sampling Frequency Hz 2000 SAM FREQ CUSTOM lt 20000 74 75 lower arms ON when not rotating 76 define DEF LOW ON fat 78 PI gains amplification 79 define AMP KPCUR 4 0f 80 define UAMP KICUR 128 0f B1 define AMP_KICUR i float 1 0 UAMP_KICUR 0 0078125f 82 define AMP_KPVEL 16384 0f 83 define ANP KIVEL 2048 0f 84 85 parameters measurement units resolution 86 define AMP RES 1000 0f current parameters expressed in ampere AMP RES 87 define VOL RES 10 0f voltage parameters expressed in volt VOL RES 88 define OHM RES 100 0f resistance parameters expressed in ohm OHM RES 89 define HEN RES 10000 0f inductance parameters expressed in henry HEN RES 90 define WEB RES 10000 0f flux parameters expressed in weber WEB RES i UM YROTATE
23. RENESAS USER MANUAL YROTATE IT RX62T UM YROTATE IT RX62T Rev 1 00 Low Cost Motor Control Kit based on RX62T Jan 15 2014 Introduction The Renesas Motor Control Kit YROTATE IT RX62T is based on the RX62T device from the powerful 32 bit RX microcontroller family The kit enables engineers to easily test and evaluate the performance of the RX62T 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 RX62T 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 RX62T is an ideal tool to check out all the key performance parameters of your selected motor before embarking on a final end application system desig
24. SES BRIDGE CURRENT READING SHUNTS 35 L z v i Vi a a z Go i qa The current reading shunts are also in the bottom side of the board while the signal conditioning circuit is in the upper side The inverter has the classical schema with the three shunts on the lower arms UM YROTATE IT RX62T Rev 1 00 Page 9 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 7 Interface with an external power stage Since internal power stage allows only the management of small motors an interface with an external power stage was added to the PCB This was made easy due to the presence in the microcontroller of several timer sections that make it possible to manage up to two 3 phase Brushless AC motors at the same time Please find below the schematics of the connectors present in the board used for connecting an external power stage CONN J12 100R 1 e N NM UM YROTATE IT RX62T Rev 1 00 Page 10 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit AN103 UP84 VBUS VOLTAGE SIGNAL AN101 UP86 V PHASE CURRENT SIGNAL AN102 UP85 U PHASE CURRENT SIGNAL 100R 100R 100R 7S SZ 7S SZ 7S SZ Q 1N 1N 1N 5V 5V 5V S o 1K A g 15K 13 5V iK IN Go 15K 5V G3 1K G5 AS Y L 5V 5V 1K 10K 10K 75 c 5V 100N 5V The interface between the board and an external power stage is organized as follows a A 16 pins c
25. VEL_DEF 30 4h 0 lt X lt 30000 K prop speed control define KI VEL DEF 400 0 lt X lt 30000 K integ speed control define FB_GAIN_DEF 100 ti 0 lt X lt 30000 flux amplitude feedback gain define PHA OFF DEF 0 vf 0 lt X lt 360 offset angle Furthermore both projects are compiled and the object code is available on the CD ROM and can be directly loaded into the RX62T microcontroller The file name is called MCRPO7_RX62T mot in each project Such feature is used to avoid launching the full IDE and recompiling the full project UM YROTATE IT RX62T Rev 1 00 Page 27 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 14 Application customization using customize h file Please find below snapshot of the file customize h which contents many interesting options and details about the RX62T embedded software Feel free to modify it and recompile the source code in order to use the new values The customize h is a file containing some macros used to specify important program parameters The most important of them are listed below E 46 eeprom comment if not used 47 define EEPROM USED 48 49 debug comment after first control 50 define MACRO DEBUG 51 i 52 open loop debug comment in final release 53 fidefine DEBUG OPENLOOP 54 55 DC current vector setting debug mode comment in final release 56 idefine DCCUR SETTING S7 58 ADDITI
26. age in single shunt operation vs off is the volt total starting value total voltage at zero speed vs inc float It is the quantity added at every zero speed ramp step to obtain volt vs off vs del float Total voltage quantity added during startup in single shunt volt operation added to vs off it gives the voltage applied when the voltage and speed ramp is finished vs dela float Voltage quantity added at every voltage and speed ramp step volt during startup in single shunt operation istart float Startup current in three shunts operation during startup first a ampere current ramp at zero speed is imposed then a speed ramp with constant current istart is inc float Startup current increment at every step ampere UM YROTATE IT RX62T Rev 1 00 Page 47 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit Label s Type Description Unit omegae s float Electrical speed during startup instant value rad s delta om float Speed quantity added at every step during startup ramp rad s om chg float Speed to reach during the startup when this speed is reached rad s the startup ramp ends startup phase float Electrical phase during startup rad delta ph float Phase variation at every step during startup rad vdx vqx vdxf vqxf float D and q axis voltages instant and filtered during startup volt id
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28. an even better step response and also increase the step current level by increasing the percentage of Cur 96 to 9096 The default value is 5096 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 RPM 15Hz of a one pole pair motor UM YROTATE IT RX62T Rev 1 00 Page 40 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit Parameters Setting LJ Always ontop x rpm 0 true rpm 60 2 3000 true Load Save 1000 true 10000 1000 true 24 true Apk 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 Reload 00 Operation Select Do true Write 0 ed rpm 0 3000
29. ased on the fact that having no neutral connection we are interested only in phase to phase voltages or in the voltage differences between the phases not in the voltage level of the single phases This allows us to add or subtract an arbitrary quantity to the phase voltages on condition that this quantity is the same for all the three phases So obtained from the algorithm the three phase voltages requests the minimum is chosen and it is subtracted to all the three requests With this method the applied voltage star center is not at a fixed level but it is moving The maximum phase to phase voltage that can be obtained without distortion of the sinusoidal waveform with this method is equal to the DC Link voltage as in other methods like Space Vector Modulation UM YROTATE IT RX62T Rev 1 00 Page 33 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 18 PC Graphical User Interface The User Interface is easily installed via the CD ROM installer The PC Interface is using the optically isolated USB connection to powered the board and communicate with it 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 sn i c H M s Disconnect zoon VOLTAGE zoo CURRENT PI Algor
30. ating supply voltage range movement power voltage range heat radiation characteristics installation and other product characteristics Renesas Electronics shall have naliability 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 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 us
31. define VBUS LIML 360 0f dc bus voltage limit V 160 define K RAMPLIM 0 9f ramp limitation gain 161 162 ramp clamp comment if you don t want it 163 define RAMP CLO clamp if heavy speed error 164 165 flux weakening 166 define FLUXWEAK comment to avoid flux weakening 167 define K MARGV1 0 95f percent of available voltage at which FW begins 168 define K MARGIO 0 80f max d cur max cur ratio 169 define DCUR DT 1 50f d current variation rate A s during FW 170 171 speed lowpass filter cut off frequency fO time constant will be tau i w0 1 2PIf0 172 define SPEED LP CUTOFF HZ 100 0f cut off frequency Hz 173 174 flux estimation method selection 175 define APP INT uncomment this if you prefer approximated integration 176 UM YROTATE IT RX62T Rev 1 00 Page 29 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 15 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 stands for reference
32. dence between the estimated amplitude and the theoretical one but the larger can be the induced phase error The choice of G is a compromise in order to guarantee that the integral remains close to its theoretical value but free enough to estimate the correct system phase UM YROTATE IT RX62T Rev 1 00 Page 23 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 13 Software description The software of the YROTATE IT RX62T kit is working on the RX62T microcontroller clocked at 100MHz It is a fast and powerful device for this class of algorithm This allows the user to realize virtually what he wants in addition Sensorless FOC algorithm PI flux estimation filters speed estimation modulation routines Transformations Shunt current Time delay Trigonometric PMW generation a u v w d q measurement management functions MTU2 handling Communication A D converter E2PROM handling Interrupts vector HW setup layer layer routines layer table initi SFRs initi The total software uses the following resources 1 FLASH 18Kbytes 2 RAM 3Kbytes Please note that these data include also the communication interface and the reference board management The following flowcharts show the software implementation of the motor control part of the software Software organization Hardware and software Interrupt enabling 100ys Interrupt UM YROTATE IT RX62T Rev 1 00 Page 24 of 51 Jan 15 2014 REN
33. e kit PCB to manage low voltage motor using the internal power stage made of MOSFETs and available on the board By default the embedded software is tuned to drive the low voltage motor called FL28BL38 and delivered in the kit Please find below a snapshot of the header file customize h where all the motor parameters are located FL28BL38 HS motor default parameters define RPM MIN DEF 3000 200 X lt 5000 min speed in rpm define RPM MAX DEF 13000 1000 X 20000 max speed in rpm define R ACC DEF 2000 1 lt X lt 10000 accel ramp in rpm sec define R DEC DEF 2000 lt X lt 10000 accel ramp in rpm sec define C POLI DEF 2 IZA 1 lt X lt 24 polar couples number define I START DEF 200 rod 0O lt X lt 15000 startup current in A pk AMP DIV define I MAX DEF 400 0 lt X 15000 max current in A pk AMP DIV define R ST DEF 220 ff 0 lt X lt 30000 stator phase resistance in Ohm OHM DIV Hdefine L SYN DEF 25 ZA 0 lt X 30000 synchronous inductance in Henry HEN DIV define PM FLX DEF 30 vf 0O lt X lt 30000 permanent magnet flux in Weber WEB_DIV define KP CUR DEF 20 Jz 0 lt X lt 30000 K prop current control define KI_CUR_DEF 120 FE O lt X lt 30000 K integ current control define KP_VEL_DEF 50 yy 0 lt X lt 30000 K prop speed control define KI VEL DEF 100 y 0O lt X lt 30000 K integ speed control define FB_GAIN_DEF 500 y 0 lt X
34. e 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 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 Itis 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
35. e time constant of the speed 1 s reference low pass filter startup ulpkt float One divided by K where K is the time constant of the startup 1 s low pass filter off ulpkt float One divided by K where K is the time constant of the current 1 s offsets low pass filter vr ulpkt float One divided by K where K is the time constant of the board 1 s reference voltage low pass filter duty u duty v signed PWM duty cycles for the three phases MTU pulses duty w short UM YROTATE IT RX62T Rev 1 00 Jan 15 2014 RENESAS Page 49 of 51 RX62T YROTATE IT RX62T Motor Control Kit Label s Type Description Unit vbus ad signed A D conversion result of the DC link voltage reading short iss off signed A D conversion offsets of measured single shunt current the short value is around 2048 that corresponds to one half of the A D converter supply voltage 5Vdc 12bit A D iaad ibad signed A D conversion result of the first and the second single shunt short current reading deadtim unsigned Dead time MTU pulses short semiper unsigned PWM half period MTU pulses short semiperdead unsigned PWM half period plus dead time MTU pulses short cr_ss unsigned Status variable for single shunt current reading short trip cnt unsigned Counter for estimation error detection short startup cnt unsigned Counter for startup short startup_val unsigned Startup t
36. e user to understand the status of the supply of the board Please refer to the LED map for the following indications e DL8 is connected to the USB supply so it indicates that the USB port is supplied and by consequence all the communication section e DL7 is connected to the step down converter output and it is on only if an external power supply is connected e DLI is connected to the logic supply so it indicates that the control section is supplied E S 4 a E amp 2 5 a 3 3 f Al HET mua io E 7 Designed er i Renesas Products MADE IM ITALY ei MCROOZ RX62 The other LEDs in the board are driven via software in particular e DLl6is blinking if there is a communication between the PC and the board e DL1 is blinking if the control section microcontroller RX62T is running normally e DL4 is quickly blinking if an alarm has been detected UM YROTATE IT RX62T Rev 1 00 Page 8 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T 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 mounted on the bottom side of the board The MOSFETs are the Renesas RJKO654DPB n channel power MOSFETs please refer to the data sheet for the characteristics On the upper side of the board is mounted the MOSFETs driving circuit composed with discrete elements refer to the electric drawings 3 PHA
37. ent 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 J Always ontop x DESCRIPTION UNIT MAX VALUE CN Reload 01 Minimum Speed rpm t 3000 true Write rpm 60 3000 true rpm s 0 1000 true Load Save s 10000 1000 true 15000 true Apk 1000 0 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 8096 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 IT RX62T Rev 1 00 Page 38 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T 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 Apply current step PI Tuning x Zoom e Reset zoom Apply current step Please use the Zoom function to check the beginning of the step UM YROTATE IT RX62T Rev 1 00 Page 39 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit Cur 99 Apply current step You can adjust manually the parameters to obtain
38. h PWM with dead time Inverter control PFC etc 1ph PWM with dead time Inverter control PFC etc Serial communication lt gt 1 i MTU3 Protection External input POE 3ph PWM with dead time Use two 16 bit timer ch6 amp 7 Clock d 1 or 2 Encoder Input Clock stop detection Use 1or2 16 bit timer ch1 2 Clock monitoring Hall sensor BEMF Input 6 OpAmp 12bit AD Use one 16 bit timer chO 7 fault comp Self diagnostic 12bit AD 4ch Self diagnostic Maximum current amp Vgus management Shunts reading 3ph PWM with dead time gt P M Use two 16 bit timer ch3 amp 4 gt PMAC Motor UM YROTATE IT RX62T Rev 1 00 Jan 15 2014 RENESAS Page 16 of 51 RX62T YROTATE IT RX62T Motor Control Kit 10 Permanent magnets AC Brushless motor model The synchronous permanent magnets motor e g sinusoidal Brushless motor is widely used in the industry More and more home appliance makers are now using such AC Brushless motor mainly because of the intrinsic motor efficiency The permanent magnet motor is made with few components 1 Astator formed by stacking sheared metal plates where internally the copper wiring is wound constructing the stator winding 2 Arotor 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
39. 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 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 RX62T Rev 1 00 Page 34 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T 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 microcontroller 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 boa
40. igh 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 anti 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 oper
41. ime N of sampling short periods stp_tim unsigned Startup time ms short XXXXXX_ep unsigned Many variables with suffix ep they are copies of various short parameters used for EEPROM management enc_ind unsigned Index in encoder filter table short enc_sam unsigned Encoder sample short enc_ang unsigned Encoder angular position 2Pl is 65536 short mec ang float Mechanical position rad ele ang float Electrical angular position rad off ang float Electrical position offset rad UM YROTATE IT RX62T Rev 1 00 Jan 15 2014 RENESAS Page 50 of 51 RX62T YROTATE IT RX62T Motor Control Kit Label s Type Description Unit tele ang float Corrected electrical position rad om mec float Mechanical angular speed rad s om eme float Electro mechanical angular speed rad s enc buf float Encoder filter buffer rad UM YROTATE IT RX62T Rev 1 00 Jan 15 2014 RENESAS Page 51 of 51 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 g
42. in a new reference coordinates system In the two phases 4 3 fixed system the above equations become a Rs a dt Ri Ma yg 2 Roig t SU ae y For the magnetic field equations we got A Li em Li COS Ay Li Ag Lig sin After performing the derivation dA pes OK sin v pem WA pn dt dt dt da di di E ak cos v LA sar dt dt dt Finally we obtain for the voltages in o B system di v R i L a a S a dt fm di v R i L al S Bp dt am A second reference frame is used to represent the equations as the frame is turning at the rotor speed So the d axis is chosen in the direction of the magnetic vector Am and with the q axis orthogonal to the d axis The new reference system is d q UM YROTATE IT RX62T Rev 1 00 Jan 15 2014 RENESAS Page 19 of 51 RX62T YROTATE IT RX62T Motor Control Kit The reference frame transformations from the o B system to the d q system depends on the instantaneous position angle 9 So we obtain two inter dependant equations in the d q system di v Rsi t L aLi dt di y Rsi Vg te OA These two equations represent the mathematical motor model Va IY 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
43. ing on Phase selector Oscilloscope LJ 4lways ontop x Ai FI E ep i i i Phase 10 000 20 000 30 000 40 000 50 000 80 000 100 00 110 00 120 00 m 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 UM YROTATE IT RX62T Rev 1 00 Page 42 of 51 Jan 15 2014 i RX62T YROTATE IT RX62T Motor Control Kit The setting 1 sample every 128 should be used for extremely low phenomena when running at very low speed 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 while running at a medium speed range 2 times the minimum speed In our example the speed is set to 2000 RPM Speed Control zoom VOLTAGE zoom CURRENT 4000 rpm 0 rpm Parameters Setting 4000 rpm 4 0 Permanen Current 2 Current Li peed Loop Kp Speed Loop Ki 5 Flux Feedback Gain Motor speed 1999 rpm 66 6 Hz 0 mA 208 mA 09y 10 3 V DE Bus Vol Alarm Code Flags Total Current Total Voltage Dummy 28 2 V o 1280 208 mA 10 4 V 244 5000 5000 i 3000 1000 1000 2000 3000 Start by increasing the Parameter n 13 Kp until the instability that can be display in the current or phase
44. integration of speedrer in the meanwhile the phase estimation algorithm begins to align with the real system phase UM YROTATE IT RX62T Rev 1 00 Page 30 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit Furthermore idmea and iqmea begin to be similar to the real flux and torque components of the current The real components are supposed to be id and iqo those values are obtained applying a low pass filter to idmea and iqq The interval t t is the start up time and it is supposed to be large enough to allow the estimation algorithm to reach the complete alignment with the real phase of the system d Att t 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 9 The current references are changed to the values id and iqo and all the PI controllers are initialized with these new values The speed PI integral memory is initialized with the value iqo while the current PI integral memories are initialized with the analogous voltage values vd and vdo obtained from Vdmea and VOmea e After t gt t the normal control is performed based on the estimated phase Ves 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 t5 then it is maintained to zero the iq current
45. ithm information ny Motor Operation graphs Speeds Currents and Voltages Parameters Setting ov 20v LI System Monitor d d bo Speed Control Position Control RPM CONTROL PROPERTY MONITOR Function Tabs 3000 a 3000 Motor speed Property Monitor where motor eee speld 9 rpm 9 0 He oma oma oov parameters can be analysed Start Stop Spee a A and Direction AA Speed Currents Voltages Torque DEMO Mode Operation and Parameters can be saved to Excel file DESCRIPTION Reload j 00 Default Parameters Setting 01 Minimum Speed 02 Maximun Speed 03 Acceleration rpm s 10000 true 04 Deceleration rpm s 10000 true Pu Regs Test lock Test 05 Polar couples 4 2 Motor Alarm 06 Startup Current Apk 10 i Motor Tuning Parameters 07 Maximum Current Apk 10 a System Parameters 08 Stator Resistance Ohm 10 Exit LL A 4 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
46. iven 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 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
47. lt stored into the EEPROM and define in the customize h file Please check that the first parameters like the speed range and the number of polar couples are in line with the motor to be tuned UM YROTATE IT RX62T Rev 1 00 Page 35 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 19 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 Communication Settings System Info Parameters Setting Speed Control Cur PI tuning Cur PI tuning AUTO g Motor identification Motor Control Demo User Interface In a few clicks the software is tuned to the custom motor and ready to run In terms of AC Brushless motor driven in sinusoidal mode and FOC algorithm the most important parameters to tune are 1 Current PI parameters Propotional K and Integral K 2 Motor parameters Stator resistance R the synchronous inductance L and the Permanent Magnet flux An Let s tune step by step a real low voltage PMSM motor using the internal power stage with Mosfets a The BLAC Motor selected is the following one Motor type MB057GA240 Maximum current 3 5A Bus Voltage 50V Maximum speed 5000 RPM Number of pole pair 2 MOTOR PARAMETERS 925 C ee OZ IN
48. n Target Device RX62T 63T Microcontroller Series UM YROTATE IT RX62T Rev 1 00 Page 1 of 51 Jan 15 2014 RENESAS C RX62T YROTATE IT RX62T Motor Control Kit ontents MCA aia aiea 3 2 Hardware Overvie W e 4 3 Power supply sel ctiOn reiten tates etc cds e aea ea eder vage d deer a a EE a EEEa or ae Ea TEKEE oaii 6 4 Test points for deDugglrmng srra aaa aa deaa N 7 5 LEDS FUNCTION descriptiOD reote a i a a iaee de aa ped au aE EAE Eara E dE RE ge ed redes 8 6 Internal power stage brief description sessi enne nennen nennnnnn nnne nente ta ranas eser seti a assa ases sess riga dans 9 7 Interface with an external power stage ccccesssssecececessesseceeececeeseeaeeeeeecsseeesesesaeeeseceseeeaaeaecesceesesaeaeeeeeesseeseesauaeess 10 8 Connection with a 1 5KW external power stage cccccccccesssssssececeecesseseeaeceeeescesseeaaaeseeeescessuseuaeseeeeseesesaaaeeeeeeeseeseaaeas 14 9 Control microcontroller OVervieW 2 eerie ette sence ia e sh eek e ERROR Hd e 3E EHE aaa aaaea 15 10 Permanent magnets AC Brushless motor MOE cccccccccessssesssecececessesneaecececeseseeesseaeseeeescessesesaeeesesseeseaeeeeeeseeeees 17 11 Sensorless Field Oriented Control Algorithm ssssesssseesesee eene nennen nennen nnne ennt nnns enses aiina 22 12 Flux Feedback G iNissei E
49. nent magnets B axis c axis a axis a axis b axis Real axes a b c and equivalent ones a B a fixed amplitude vector can be completely determined by its position respect the a D system angle 8 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 Am whose position in respect to the stator is determined by the angle 9 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 9 It is in every axis the projection of the constant flux vector A in the direction of the axis A Li cos v A Li A cos 0 20 A Li cos 0 A UM YROTATE IT RX62T Rev 1 00 Page 18 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit Supposing that the rotor is rotating at constant speed that is 9 t t the flux linkages derivatives can be calculated and we obtain P y R i L dt sin v ESL NN sin 277 b Sb dt m 3 s di j Ac Ri c II 7 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
50. onnector J11 is used for the PWM drive signals the 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 note that 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 not polarized so if the POE is enabled and the input is left unconnected undesired alarms can occur All the free pins of the connector are connected to the board ground to minimize the cross talking of the lines if a flat cable is used b A 26 pins connector J13 is used to collect some signals from the power stage in particular the current readings and the DC link voltage reading those signals are clamped and weakly filtered then directly connected to the A D converter input pins of the microcontroller so the external power stage has to take care of the gain and the offset of these signals An input is dedicated also to a thermal sensor and a pull up resistor is present Three further signals are managed they are the commutation signals from the output phases useful if the hardware compensation of dead times facility of the
51. orcontrol c includes the motor control algorithm routines Please find below the description of the variables used in this file Label s Type Description Unit ium off ivm off float A D conversion offsets of measured u v w phase currents the iwm off value is around 2048 that corresponds to one half of the A D converter supply voltage 5Vdc 12bit A D vol ref float A D conversion result of the reading of the reference voltage 4 25V used for compensate the effects of the power supply variations in the A D conversions the ideal value is 870 10bit A D if the A D converter supply voltage is exactly 5V kadi kadv float Current and voltage conversion constants they are corrected on the grounds of vol ref and they are used to convert the A D results in the used measurement units multiplying the A D result by the conversion constant the current voltage in Ampere Volt is obtained ex iu kadi iuad ium_off r sta float Stator resistance ohm sync float Synchronous inductance henry c poli float Number of polar couples krpmocp float Conversion constant between mechanical speed and electrical rad s rpm ukrpmocp speed and its reciprocal ukrpmocp 1 krpmocp rpm rad s vstart float Startup voltage in single shunt operation during startup first a volt voltage ramp at zero speed is performed then a voltage and speed ramp vstart is the actual value vs off float Offset startup volt
52. ot reported for sake of simplicity Please refer to the complete schematics for further details UM YROTATE IT RX62T Rev 1 00 Page 12 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit Intelligent Power Module SUTTY f SUPPLY UM YROTATE IT RX62T Rev 1 00 Page 13 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 8 Connection with a 1 5KW external power stage The interface for an external power supply was designed to be compatible with the power stages of previous Renesas motor control platforms MCRP05 06 So it becomes possible to use the same power stage and connect any Motor Control board using RX62T RL78 G14 or RX220 microcontroller families The schematics of a 1 5KW power stage are included into the documentation on the CD ROM delivered with the Kit Please find below the details to connect the power stage to the RX62T motor control kit MOTOR CONNECTOR DC BUS CONNECTOR POWER SUPPLY CONNECTOR The power supply of 24Vpc is delivered by the 1 5KW power board on the left hand side It s directly connected to the RX62T control board thanks to the Jumper JP5 on the right hand side The pin 1 and 2 of the jumper JP5 are short circuited while the pin 3 and 4 are left open In the microcontroller board the supply configuration jumper JP2 is configured in order to select the external supply not the USB one In the power stage board a DC bus connector allo
53. rd 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 used 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 The list of parameters that can be changed in real time are displayed in the PC GUI In case of issue or inconsistent parameters please enter the magic number 33 in the first line called OO Default Parameters setting and click the button Write and perform a Reset of the microcontroller board Click on the Reload button to get the parameters by defau
54. w current consumption only 50mA 100MHz Single precision floating point unit FPU barrel shifter MAC RMPA 256kB Flash 16kB RAM to 64kB Flash 8kB RAM Zero wait access to Flash memory 64pin 112pin package options Gomparatoras 2 BiIDADDE Functions Enhanced PWM resolution with MTU3 enhanced PWM functionality with GPT 12 bit A D converter 1us 4 channels x 2 unit 10 bit A D converter 1s 12 channels x 1 unit Three S H circuits for each unit Three shunts control enable Double data registers for each unit 1 shunt control enable Programmable gain Operational amplifier Window comparator for Voltage monitoring CAN option UM YROTATE IT RX62T Rev 1 00 Page 15 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit Large capacity flash memory units capable of high speed operation are included as on chip memory significantly reducing the cost of configuring systems The main application fields of this microcontroller are industrial equipment household electrical appliances machines requiring motor control and inverter powered machines Please find below the block diagram of the RX62T and the role of each peripherals RX CPU 100MHz 9 2 7 3 6V 4 0 5 5V SCI x 3 ch Moparts SPI x 1ch POR LVD 16 bit timer x 4 ch CMT Watchdog timer x 2 ch One of two includes the LOCO 1ph PWM with dead time OCO Low speed Inverter control PFC etc DT 1p
55. ws the user to provide a higher external DC voltage in such way high voltage motors can be managed UM YROTATE IT RX62T Rev 1 00 Page 14 of 51 Jan 15 2014 RENESAS RX62T YROTATE IT RX62T Motor Control Kit 9 Control microcontroller overview The RX62T 63T Group is a set of microcontrollers featuring the high speed high performance RX CPU as the 100MHz processor core Each basic instruction of the processor is executable in one cycle of the system clock Calculation functionality is enhanced by the inclusion of a single precision floating point calculation unit as well as a 32 bit multiplier and divider Additionally code efficiency is improved by instructions with lengths that are variable in byte units to cover an enhanced range of addressing modes A multi functional timer pulse unit 3 for motor control general PWM timer compare match timers watchdog timer independent watchdog timer serial communications interfaces I2C bus interfaces CAN module serial peripheral interface LIN module 12 bit A D converters with three channel simultaneous sampling function and 10 bit A D converter are incorporated as peripheral functions which are essential to motor control devices In addition the 12 bit A D converters include a window comparator and programmable gain amplifier for additional functionality Please find below the summary of the RX62T features RX600 CPU High speed 100MHz clock High performance 1 65MIPS MHz Lo
56. x iqx idxf iqxf float D and q axis currents instant and filtered during startup ampere SystemPhase float Imposed electrical phase rad Phase est float Estimated electrical phase rad vbus vbusf float DC link voltage instant value and filtered one volt xvbf float DC link voltage min ripple value used for voltage clamping volt vfmax float Maximum allowed phase voltage star volt vdmax vdmax float Maximum d and q axis allowed voltages i max iq max float Max allowed total current maximum allowed q axis current ampere vdc vac vdcf vqcf float D and q axis imposed voltages instant and filtered values volt vac vbc float Alpha and beta axis voltages volt VUC VVC VWC float Phase voltages star volt old_va old_vb float Previous step alpha and beta axis voltages volt ium ivm iwm float Measured phase currents ampere iam ibm float Measured alpha and beta axis currents ampere idm iqm idmf float Measured d and q axis currents instant and filtered values ampere iqmf idr iqr float D and q axis reference currents ampere id_dec float After the startup the d axis current residual is decreased till ampere zero id dec is the variation at every step idint igint float Current Pl integral memories volt idimem iqdimem float Current PI integral memories this values are used in single volt shunt operation to stop the integral action when the current reading is not possible UM YROTATE IT RX62T Rev 1 00 Page
57. y 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 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 H

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