ID 610C: Introduction to BLDC Motor Control
Avnet
Jim Carver
Technical Director, Advanced Architectures
12 October 2010
Version 1.0
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* MCU: 31% revenue
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"Semiconductor
Applications Worldwide
Annual Market Share:
Database" 25
March 2010
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on unit basis from
Marketing Eye 2009
(17.1% on unit basis).
2
Renesas Technology and Solution Portfolio
Microcontrollers
& Microprocessors
#1 Market share
worldwide *
Solutions
for
Innovation
ASIC, ASSP Analog and
& Memory Power Devices
Advanced and #1 Market share
proven technologies in low-voltage
MOSFET**
* MCU: 31% revenue
basis from Gartner
"Semiconductor
Applications Worldwide
Annual Market Share:
Database" 25
March 2010
** Power MOSFET: 17.1%
on unit basis from
Marketing Eye 2009
(17.1% on unit basis).
3
Microcontroller and Microprocessor Line-up
Up to 1200 DMIPS, 45, 65 & 90nm process
Superscalar, MMU, Multimedia Video and audio processing on Linux
Server, Industrial & Automotive
Up to 500 DMIPS, 150 & 90nm process
High Performance CPU, Low Power 600uA/MHz, 1.5 uA standby
Medical, Automotive & Industrial
Up to 165 DMIPS, 90nm process
High Performance CPU, FPU, DSC 500uA/MHz, 2.5 uA standby
Ethernet, CAN, USB, Motor Control, TFT Display
Legacy Cores
Next-generation migration to RX
General Purpose Ultra Low Power Embedded Security
Up to 10 DMIPS, 130nm process Up to 25 DMIPS, 150nm process Up to 25 DMIPS, 180, 90nm process
350 uA/MHz, 1uA standby 190 uA/MHz, 0.3uA standby 1mA/MHz, 100uA standby
Capacitive touch Application-specific integration Crypto engine, Hardware security
4
Microcontroller and Microprocessor Line-up
Up to 1200 DMIPS, 45, 65 & 90nm process
Superscalar, MMU, Multimedia Video and audio processing on Linux
Server, Industrial & Automotive
Up to 500 DMIPS, 150 & 90nm process
High Performance CPU, Low Power 600uA/MHz, 1.5 uA standby
Medical, Automotive & Industrial
Up to 165 DMIPS, 90nm process
High Performance CPU, FPU, DSC 500uA/MHz, 2.5 uA standby
Ethernet, CAN, USB, Motor Control, TFT Display
Legacy Cores
Next-generation migration to RX
General Purpose Ultra Low Power Embedded Security
Up to 10 DMIPS, 130nm process Up to 25 DMIPS, 150nm process Up to 25 DMIPS, 180, 90nm process
350 uA/MHz, 1uA standby 190 uA/MHz, 0.3uA standby 1mA/MHz, 100uA standby
Capacitive touch Application-specific integration Crypto engine, Hardware security
5
Agenda
Motor Types Overview
BLDC Motor Applications
Comparison of DC to Brushless DC Motors
Hall Sensors
Six-Step Commutation
Sensorless Commutation with Back-EMF
Vector Motor Control basics
Closed-Loop Speed Control
Introduction to BLDC Motor Control Evaluation Kit
Summary
6
Motor Types
7
Expanding BLDC Motor Control Applications
Transition to
AC, DC As consumers demand BLDC
and more energy efficient
Universal products, more BLDC
Motors motors are being used.
8
Brushed DC Motors Review
A winding assembly (armature) within a
stationary magnetic field
Brushes and Commutators switch current
to different windings in correct relation to
the outer permanent magnet field.
Pros:
Electronic control is simple, no need to
commutate in controller
Requires only four power transistors
Cons:
A sensor is required for speed control
The brushes and commutator create sparks
and wear out
Sparks limit peak power
Heat in armature is difficult to remove
Low power density
9
Brushless DC Motors
Permanent magnet rotor within
stationary windings
Pros: Stator
No brushes or commutator to wear out windings
No sparks and no extra friction
More efficient than DC motor
Higher speed than DC motor
Permanent
Higher power density than DC motor Magnet
Cons:
Rotor sensor OR sensorless methods Rotor
needed to commutate
Requires six power transistors
10
Brushed DC Commutation
The windings in the
armature are switched to
the DC power by the
brushes and armature
Each winding sees a +
positive voltage, then a
disconnect, then a negative
voltage
The field produced in the
armature interacts with the
stationary magnet, N S
producing torque and
rotation
+
- -
11
DC Motor Bridge
The DC motor needs four
transistors to operate the DC 1 0
motor
The combination of transistor
is called an H-Bridge, due to 0 1
the obvious shape
Transistors are switched
diagonally to allow DC current
to flow in the motor in either
direction
The transistors can be Pulse
Width Modulated to reduce the 0 1
average voltage at the motor,
useful for controlling current
and speed
0
12
Three-Phase Bridge to Drive BLDC Motor
The Brushless DC motor is really a DC motor constructed
inside-out, but without the Brushes and Commutators
The mechanical switches are replaced with transistors
The windings are moved from the armature, to the stator
The magnet is moved from the outside to become the rotor
U N S
V
N S W
13
Six-step Commutation
STEP1 STEP2 STEP3 STEP4 STEP5 STEP6 STEP1 STEP2 STEP3
U
V
W
14
Six-Step Current Waveform
Here we see the individual steps in a real trapezoidal
current waveform
The PWM ripple is visible when the phase is active
The rising and falling edges are sloped, giving the
trapezoidal shape
The amount of slope is a function of the winding inductance
15
Hall Sensors
Hall Sensors detect magnetic fields, and
can be used to sense rotor angle
The output is a digital 1 or 0 for each
sensor, depending on the magnetic field
nearby
Each is mounted 120-degrees apart on
the back of the motor
As the rotor turns, the Hall sensors H1 H2
output logic bits which indicate the angle N
H1
S
H2
H3
H3
16
Hall Sensor Commutation
STEP1 STEP2 STEP3 STEP4 STEP5 STEP6 STEP1 STEP2 STEP3
H1
The combination of all
H2
three sensors produce
six unique logic H3
combinations or steps
U
These three bits are
decoded into the motor
phase combinations V
17
3-Phase PWM
We can divide up the V
phase data into
individual transistor W
gate signals
Now we can see how UP
we can modulate one
transistor at a time to UN
regulate the motor VP
voltage, and also the
VN
speed
WP
WN
18
Sensorless Commutation
Instead of using sensors like Halls, we can let the motor tell
us which phase should be energized
The Brushless DC motor acts as a generator when it rotates,
creating voltages
The three phases produce three voltages 120-degrees apart
The voltage generated by the motor is called Back Electro-
Motive Force, a.k.a. Back-EMF or just BEMF
19
Brushless DC Motor BEMF
The Back-EMF is the voltage generated in stator windings as the
rotor moves
BEMF voltages are more or less sinusoidal (depending on the
motor) and are symmetrical from phase to phase
We detect the zero crossings of each phase to commutate
The motor MUST be moving to generate BEMF voltages
20
Brushless DC Motor BEMF
The Back-EMF is the voltage generated in stator windings as the
rotor moves
BEMF voltages are more or less sinusoidal (depending on the
motor) and are symmetrical from phase to phase
We detect the zero crossings of each phase to commutate
The motor MUST be moving to generate BEMF voltages
21
Startup of BEMF System
Since only a spinning motor generates BEMF signals
Start the motor in open loop
First align rotor to a known angle
Then energize the windings to step rotor to next
step
Accelerate steps until speed is sufficient to see
BEMF zero crossings reliably
Switch to BEMF commutation
Once operating, this is almost identical to six-step
operation with Hall sensors
22
Sinusoidal Methods
Stepped commutation methods work well, but
The Back-EMF waveform is more sinusoidal than trapezoidal
If we can match the sinusoidal waveform, we can improve
performance
We will show two sinusoidal methods:
180-Degree Sinusoidal
Field Oriented or Vector control
23
180 Sinusoidal Commutation
Modulates sine waves in all three windings
Pros:
No square edges
Lower Torque Ripple then six-step drive
Lower audible noise
Higher efficiency and torque
Stator angle is rotated smoothly rather
than in 60 degree jumps
Each phase is utilized all of the time
Cons:
Needs higher resolution feedback to
calculate sine waves with low distortion
Needs more sophisticated processing to
calculate sine PWM values on the fly
Bandwidth of currents are limited due to
motor impedance, this hurts high speed
performance
24
Vector (Field Oriented Control) Drive
This method mathematically converts the 3-phase voltage
and current into a simple DC motor representation
Uses this data to calculate the best angle for commutation
Creates new 3-phase sinusoidal PWM based on calculation
Repeats the calculations at PWM frequency
Pros:
Highest Torque efficiency
Highest Bandwidth DC Bus
Widest Speed Range
* *
r r iq Uq
*
*
PWM1~6
iq PI U
Speed Regulator
Regulator d,q , Voltage
iq SIN
to
Lowest Audible Noise
, to Source
*
id 0
r *
Ud
* U PWM
a, b, c 3-phase
id PI T 1 ( )
Regulator Inverter
id
Cons: Motor Model
Complicated Algorithm Based Flux and
Position Observer
Needs powerful processor iq
,
ia
a,b,c
to i ib
id d,q i to
T ( ) ,
r
Speed Estimation 3-phase
PMSM
25
BLDC Motor Speed Control
The goal of most Electronic Motor Control Systems is Speed
Control
Speed Control systems are more or less complicated,
depending on accuracy required
The simplest speed control is Open-Loop, that is, without
speed feedback
In this configuration, a speed command is converted to a
fixed voltage (PWM duty) which is sent to the motor
The motor may go the right speed, or it may not, it depends
on the load
Without feedback, there is no way to tell internally what the
real speed is and so may require outside adjustment
Speed Pulse Width
Transistors Motor Load
Command Modulator
26
Closed-Loop Control
To get automatic speed control, feedback is needed
Feedback systems could be Hall Sensors, Encoders,
Resolvers, tachometers or other devices
The resolution and bandwidth of the feedback sensor limit
the resolution and bandwidth of the speed loop
Below is a block diagram of a simple control loop
Our Reference Command is the speed we desire, and the
Control Mechanism is our motor and motor control
Feedback
-
Reference Control Sensor
Command + Mechanism
27
Closed Loop Speed Control
The generic terms can be replaced with terms common to
motor control
The speed is often referred to as the Greek Letter Omega
and motor angle is Theta
The Reference input is shown as Omega star *
The Control Mechanism is a mathematical function, usually
a Proportional-Integral (PI) algorithm
The speed sensors can be the same Hall sensors used for
commutation, where the speed is calculated from the time
between steps Motor
* PI PWM
Controller Generation
Hall
Sensors
Speed
Calculation
28
Closed Loop Speed Control
The way the loop works is to first measure the difference
between the commanded speed and the actual speed
If the speed is to low, the PI controller increases the PWM
duty which sends more voltage to the motor, correcting
speed
If the speed to too high, the PI controller reduces the PWM,
reducing the average voltage, so the motor slows down to
the correct speed
The Proportional and Integral parameters have to be tuned
to optimized the speed loop response-prevent speed Motor
oscillations
* PI PWM
Controller Generation
Hall
Sensors
Speed
Calculation
29
Motor Kit for Trapezoidal Control
BLDC Motor, Board, Software, Schematics, Tool and GUI
R8C/25
30
Motor Control Evaluation Kit
In order to help users decide on what kind of motor control
they need, Renesas has introduced the YMCRPR8C25 Motor
Control Evaluation Kit
The kit includes all that is needed to try Hall and BEMF
commutated Brushless DC motor control with closed speed
loops including, the control board, motor, debugger, power
supply and software
31
YMCRPR8C25 Block Diagram
R8C25 MCRP Kit
V
CN-4
B
Power Supply U TP-1
24v DC & S
Supply Conditioning
TP-5
BLDC
Motor
CN-1
Speed International
R8C/25 6-PWM
Control
MCU
Rectifier
(IPM)
M
Shutdown
RS232
I/F
Comparators
( Back-EMF)
E8 TP-2
Debug OP-AMP
I/F (Signal Conditioning)
Jumper-1
TP-3 CN-2
TP-4
4-LED
Hall Sensor
PWM / PWR
Inputs
Status
Shunt
LCD Segment Current
Display
CN-3 Push-Button
Switch
32
Motor Control Board
IGBT module capable of 10
amps.
3-Phase output capable of
running DC and BLDC
motors
15V and 5V regulators on
board.
Voltage input from a single
24V (18-36VDC) supply,
no shock hazard.
33
Board User Interface
Large potentiometer
for speed control
setting
2x8 LCD display with
contrast pot for
monitoring speed,
current, etc.
Four push-buttons
Bus voltage monitoring
to MCU
Current monitoring to
the module for
automatic protection
34
Commutation Options
Back-EMF detection
comparators
Jumper selection (no
soldering) between
Hall and BEMF
modes
Input connector for
Hall signals from
motor
35
Debugging Capabilities
Optically Isolated RS-
232 communication
Optically Isolated
E8(a) connector
Prototyping areas
(under LCD)
LEDs for monitoring
PWM lines, and GPIO
Abundant test points
36
Motor Control Graphical User Interface
Speed Slider
Target Speed Actual Speed
Stop
Motor
Current
System
Status
37
HEW Development Environment
Project Navigator
Source Code Editor
Output Window
38
Summary
DC and BLDC motors were compared
BLDC motors were shown to offer better performance
A large number of applications are moving from other motor
types to BLDC motors
Electronic BLDC motor control can be as simple as six-step
or as complicated as Vector Control
Closed Loop Speed Control was explained
The Renesas BLDC Motor Control Evaluation Kit was
introduced as a way to help get started in BLDC motor
control development
39
Questions?
40
Appendix
41
Renesas MCU and MPU Solutions
32-bit
SH-4
32-bit
32-bit
Application SH-4A SH-3
Processor 600MHz 240MHz 200MHz
32-bit
High-end
32-bit
RX600 V850ES
32-bit
SH-2A
Connectivity 200MHz 100MHz 50MHz
SH-2A
32-bit
32-bit
TFT LCD RX600 H8S/SX
32-bit
Control 200MHz 100MHz 50MHz
Ultra Low
32-bit
16-bit
V850ES 78K0R 78K0
8-bit
Power 20MHz 20MHz 10MHz
General
32-bit
R32C 16-bit M16C R8C
8-bit
Purpose 50MHz 32MHz 20MHz
Application Focused Solutions
Motor Control Capacitive
WiFi Industrial CAN Lighting
SH, V850, RX, Touch
SH, RX, R8C R8C, R32C, SH 78K0
78K0R, R8C R8C
42
Motor Control Applications & Renesas Solutions
SuperH
RX
V850 Medical
Industrial, Washers,
78K0R Compressors
Motion Control
R8C
Pool Pumps, Washers
Health-Equipment
Compressors
Fans, Kitchen Appliances,
Pumps, Power-Tools
SPEED + TORQUE SPEED + DYNAMIC TORQUE
SPEED CONTROL + MOTION CONTROL
CONTROL
Torque Control (Limited)
Low-Range Mid-Range High-End
43
Renesas Motor Control Solutions
Renesas covers every motor control application from low-
end to high-end
Renesas can provide all motor algorithms from Trapezoidal
control to Sensor-less Vector control
Wide product portfolio
16bit MCU (20MHz): R8C, 78K0R
32bit MCU (48MHz to 200MHz): RX, V850, SH
These products have peripherals dedicated for Motor
Control such as Timers and ADC
44
Motor Control Solution Summary
SH2/
Motor Type Algorithm R8C 78K0R V850 RX SH2A
1- ACIM (PSC) V/f, Open Loop Y
Fixed Duty (Hall) Y
1- BLDC
Closed Loop (Hall) Y
TRIAC Control ( speed loop
Universal w/Tachometer) Y
(Brushed) DC PWM Chopper (speed loop
w/Tachometer) Y
V/f, Open Loop Y Y
3- ACIM Speed Loop w/Tachometer Y
Sensorless Vector Control Y Y * Y
120-deg Trapezoidal (Hall) Y Y
120-deg Trapezoidal (BEMF) Y
180-deg Sine (HALL) Y
3- BLDC Sensor based Vector Control Y * Y
Position Control (Encoder + Hall) Y
Sensorless Vector Control, *
2 DCCT, 3-shunt, 1-shunt Y Y Y Y
*: Under development
45
