designing smarter motor drive systems -...
TRANSCRIPT
Designing Smarter Motor Drive Systems
Wison Zuo
Application Engineer
Motor Driver Business Unit
Texas Instruments
1
Electric Motor System Overview
2
Motor Control
Gate Driver Power Stage
Feedback
• Microcontroller
• Manages the control
system, motor
commutation, driver
settings, fault handling
• IGBT or MOSFET gate
driver
• Level shifts logic
control signals
• Power stage fault
detection and handling
• IGBT or power
MOSFET
• Interface main power
rail to electric motor
• Often in half-bridge, H-
bridge, or inverter
configuration
• Signals from
motor
• Position, torque,
voltage, current
Designing a Smarter Motor Drive System
3
Q: Are there any tools that can
make the process simpler, more
efficient?
• We now have a basic
understanding of the motor
drive system, right?
• But there are many pitfalls to
avoid, knobs to adjust, timings
to tune, circuits to implement
and debug.
VGATE
VBST
RSOURCE
RSINK DSINK RPD
VSUPPLY
RSOURCE
RSINK DSINK RPD
CBST
INL
INH
+
–VSUPPLY
+
–VGATE
VDS Monitor
+
-
OC Detect
VDS Monitor
+
-
OC Detect
To Load
DRVxxxxx
TI Smart Gate Drivers
A: Yes, the IC has given the
ability to integrate this system
into a single chip and even add
additional features outside of the
typical motor drive system
Designing a Smarter Motor Drive System
4
Q: What do TI DRV gate drivers do?
A: See this section and Application
Report for more details
http://www.ti.com/lit/an/slva714/slva714.pdf
Challenge: Designing multiple power
supplies for the motor drive system
Solution: TI gate drivers are single
supply devices that generate all the
necessary voltages for the motor drive
system
• From the motor supply (PVDD) the
device (DRV8305 generates the high-
side (VCPH) and low-side (VCP_LSD)
gate driver supplies, the analog (AVDD)
and digital (DVDD) circuitry supplies,
and an has uncommitted LDO (VREG)
for an external MCU
• DRV8305
Designing a Smarter Motor Drive System
5
• Gate driver supplies support full
enhancement (10 V) of high-side and
low-side n-channel power MOSFETs
• Supports logic level and standard level
MOSFETs
• High-side gate drive supply
• DRV8305
• Low-side gate drive supply
VSUPPLY
+
-
+
-
VGS
Monitors
Internal
Handshake &
Dead Time
Insertion
Designing a Smarter Motor Drive System
6
• The handshake is a multi step process
that ensures that optimal dead time is
utilized and cross conduction does not
occur
Challenge: Proper dead time insertion
and cross conduction (shoot-through)
protection
Solution: Incorporate automatic
handshaking so that the optimal dead
time is utilized regardless of slew rate,
voltage, MOSFET, and temperature
1. Receive signal to switch from
high to low-side MOSFET
2. Disable high-side MOSFET and
monitor the VGS to determine when
the MOSFET is disabled
3. Insert any dead time specified by
the external controller and then
enable the low-side MOSFET
+-
Designing a Smarter Motor Drive System
7
Challenge: Reduce voltage transient on
MOSFET gate due to dV/dt coupling
Solution: Enable a strong current sink
on the MOSFET opposite of the slewing
MOSFET
• As outlined earlier when the
MOSFET enables and the
switch-node voltage slews,
charge can couple into the
gate of the opposite
MOSFET through a parasitic
capacitance
VSUPPLY
CGD
OFF -> ON
Gate
Driver
ISOURCE
Gate
Driver
IPULLDOWN
VDS
VGS
• By providing a strong current
pulldown on the opposite
MOSFET during the slew,
the gate driver can reduce
the parasitic voltage seen at
the opposite gate
Source
Drain
Drain
CurrentGate
+
-+
-
VDS Trip
Point
OC
Detect
Designing a Smarter Motor Drive System
8
Challenge: Protect the system against
overcurrent events related to motor stall,
short circuits, and component failures
Solution: Incorporate VDS monitors that
can measure the voltage between the
MOSFET drain and source pins
• The driver uses monitors for
both the high and low-side
MOSFET to determine if an
overcurrent has occurred
• Current trip point can be set
through device registers or
external resistor
• Can take advantage of the
fact that the MOSFET acts
as a fixed resistance (with
variation for temperature) at
a given VGS (think sense
resistor)
Designing a Smarter Motor Drive System
9
Challenge: Adjust MOSFET slew rate in
order to optimize switching performance
Solution: Provide simple method to
adjust slew rate by creating gate drivers
with variable current settings
• Adjustable gate drivers remove the need
for multiple external components
traditionally used for slew adjustment
• Allows for experimentation of different
slew rates with the change of a register
bit by the external controller
RSOURCEGate
DriveRSINK RPULLDOWN
VDD
VGATE
VDRAIN
Gate Drive (Internal) MOSFET (External)
VGATEVGATEVGATE
12
.5 m
A
25
mA
10
0 m
A
15
0 m
A
25
mA
50
mA
20
0 m
A
30
0 m
A
ISOURCE
OFF ON OFF OFF
OFF OFF OFF OFF
Designing a Smarter Motor Drive System
10
Example of slew rate
adjustment with the DRV8305
MOSFET VDS
• Persistence capture to obtain slew
rate with different gate drive settings
(10-70 mA)
VDRAIN
VDS +
VDS -
10 mA
20 mA
30 mA
40 mA
50 mA
60 mA
70 mA
IGATE
Designing a Smarter Motor Drive System
11
Examining difference between
20 mA and 70 mA settings
MOSFET VDS
VDRAIN
VDS +
VDS -
20 mA
70 mA
IGATE
VGS +
VGS -
MOSFET VGS
IGATE
• Enable received,
start gate drive
• Miller region
• Remaining
gate charge
• Gate current (20 mA) • Gate current (70 mA)
• Miller region
• Remaining
gate charge
Designing a Smarter Motor Drive System
12
• DRV8305 triple
half-bridge gate
driver
Challenge: Minimize board area and
component count
Solution: Provide single IC that replaces
functionality of traditional gate drive
architectures
VREG
LDO
Digital
Inputs
and
Outputs
Core Logic
DRV8305
SPI
SCLK
nSCS
SDI
SDO Voltage
Monitoring
Thermal
Sensor
EN_GATE
INH_A
INL_A
nFAULT
INH_B
INL_B
INH_C
INL_C
Current
Sense
Amplifier 1
Current
Sense
Amplifier 2
Current
Sense
Amplifier 3
SN1
SP1
SN2
SP2
SN3
SP3
Ref/k
Ref/k
Ref/k
VCPH
GH_A
SH_A
GL_A
SL_A
HS
VCP_LSD
LS
VDS
VDS
VDRAIN
+
-
+
-
Phase A Pre-Driver
VCPH
GH_B
SH_B
GL_B
SL_B
HS
VCP_LSD
LS
VDS
VDS
VDRAIN
+
-
+
-
Phase B Pre-Driver
VCPH
GH_C
SH_C
GL_C
SL_C
HS
VCP_LSD
LS
VDS
VDS
VDRAIN
+
-
+
-
Phase C Pre-Driver
PVDD
PVDD
Control
Configuration
Timing
Protection
PVDD
AVDD
AVDD
AVDD
VREG
VREG
VREG
High Side Gate Drive
2-Stage Charge Pump
VDRAIN
VDRAIN
PVDD
VCPH
CP
1L
CP
1H
CP
2L
CP
2H
Low Side
Gate Drive
LDO
VCP_LSD
VCPH
VC
P_L
SD
DVDD
LDO
AVDD
LDO
AV
DD
DV
DD
AVDDDVDD
SO1
SO2
SO3
WAKE
VREG/VREF
PWRGD
GND PowerPADGND
VREG
x3
Designing a Smarter Motor Drive System
13
TI’s DRV Gate Driver Family
• DRV8301/2/3: 6 to 60 V Brushless
DC Motor Gate Driver
• DR8307/8: 8.5 to 32 V Brushless
DC Motor Controller
• DRV8711: 8 to 52 V Stepper Motor
Gate Driver
• DRV8701: 5.9 to 45 V Brushed DC
Motor Gate Driver
• DRV8305: 4.4 to 45 V Brushless DC
Motor Gate Driver
• DRV8305-Q1: 4.4 to 45 V
Automotive Brushless DC Motor
Gate Driver
MDBU BLDC/BDC Solution in Robot
BLDC Electronic Speed Control (Per Propeller):
DRV8301/2/3 6 to 60 V
BLDC gate driver w/
2 current shunt amplifiers
MSP430
DRV8305 4.4 to 45 V
BLDC gate driver w/
3 current shunt amplifiers
C2000
BLDC
Motor NexFET
Solution 1
DRV9x
BLDC gate driver w/
integrated MSP430
BLDC
Motor NexFET
Solution 2
MSP430
DRV5013 2.5 to 38 V Digital
Latch Hall Effect Sensor
BLDC Control (Per Axis):
BLDC
Motor
DRV8313 8 to 60V 2.5A
Brushless DC
Motor Driver
MSP430
DRV5013 2.5 to 38 V Digital
Latch Hall Effect Sensor
BLDC
Motor
DRV8839 0 to 11V 1.8A
Dual ½ Bridge
Motor Driver
x2
Solution 1 Solution 2
MSP430
DRV8850 2 to 5.5 V , 5 A,
Dual ½ Bridge
Motor Driver
BDC
Motor
BDC 1S to 2S LiPo
Electronic Speed Control (Per 2x Propeller):
Solution 1
BDC
Motor
MSP430
DRV8835 0 to 11 V , 1.5 A,
Dual H-Bridge
Motor Driver
BDC
Motor
Solution 2
BDC
Motor
New DRV8x for Brushed, Stepper
15
Brushed, Stepper Driver
16
DRV8880 (8881, 8885) Supper easy to use; AutoTune for Decay; Supper low noise; Supper smooth running
DRV8870 (8871, 8872) Supper easy to use; Current regulation; 8-pin; Rsense Free for DRV8871
17
DRV8880: Great AutoTune feature! Get the following waveform the first time you start the stepper in 1 min
TI Designs
Providing comprehensive design examples
18
TI Design – TIDA-00643 4.4 to 30 V, 15 A, High Performance Brushless DC Propeller Controller
Overview:
The TIDA-00643 reference design is a 4.4 to 30 V brushless DC motor controller for high
power propeller, fan, and pump applications. It uses the Texas Instrument’s DRV8305
brushless DC motor gate driver, CSD17573Q5B 30V NexFETTM power MOSFETs,
TPD4E05U06 TVS protection IC, C2000 motor control MCU, and LMR16006 3.3 V buck
converter. It utilizes InstaSPINTM-FOC for sensorless field oriented motor control and
commands the motor speed through an external reference signal from a central controller. This
design is focused on demonstrating a highly efficient and high power BLDC motor system.
Features:
• 4.4 V to 30 V input voltage range
• 15 A RMS, 23 A peak output current capability
• Small form factor (L x W): 2.2” x 1.0”
• Speed control with single reference signal
• Onboard 3.3 V, 0.6 A buck converter
• Motor control through InstaSPIN-FOCTM sensorless field oriented control
• Wide array of system protection features including MOSFET VDS overcurrent and supply
undervoltage protection
19
Visit: ti.com/tidesigns
Part number:TIDA-00643
Putting theory into practice
Complete
BLDC motor
controller in
2.2” x 1.0”
form factor
TI Design – TIDA-00643 4.4 to 30 V, 15 A, High Performance Brushless DC Propeller Controller
20
Visit: ti.com/tidesigns
Part number:TIDA-00643
TIDA-00643 Block Diagram
Designed for
compact (space
constrained), high
efficiency propeller
applications
TI Design – TIDA-00643 4.4 to 30 V, 15 A, High Performance Brushless DC Propeller Controller
21
TIDA-00643
Motor Control
Gate Driver Power Stage
Feedback
• Microcontroller
• Manages the control
system, motor
commutation, driver
settings, fault handling
• IGBT or MOSFET gate
driver
• Level shifts logic
control signals
• Power stage fault
detection and handling
• IGBT or power
MOSFET
• Interface main power
rail to electric motor
• Often in half-bridge, H-
bridge, or inverter
configuration
• Signals from
motor
• Position, torque,
voltage, current
TI Design – TIDA-00643 4.4 to 30 V, 15 A, High Performance Brushless DC Propeller Controller
22
Motor ramping
from 0 RPM to
7000 RPM in less
than 1.5s
TI Design – TIDA-00620 12 to 24 V, 27 A, High Power Brushed DC Motor Reference Design
Overview:
The TIDA-00620 reference design is a 12 to 24 V brushed DC motor controller for power tool,
pump, fan, and robotics applications. It uses the Texas Instruments DRV8701 brushed DC
motor gate driver, CSD18540Q5B 60 V NexFETTM power MOSFETs, LMT86 temperature
sensor, and MSP430G2553 microcontroller. The reference design takes advantage of the high
efficiency NexFET power MOSFET and DRV8701 to deliver peak performance with no
external heatsinking. The system is managed by the MSP430G2553 which monitors feedback
signals from the motor, motor driver, and remaining system.
Features:
• 12 V to 24 V input voltage range
• 27 A RMS output current capability
• Small form factor (L x W): 76 mm x 38 mm
• User configurable gate drive current
• Integrated 3.3 V, 30 mA LDO
• Integrated motor current regulator for startup and stall currents
• Wide array of system protection features including MOSFET VDS overcurrent and supply
undervoltage protection
23
Visit: ti.com/tidesigns
Part number:TIDA-00620
Putting theory into practice
TI Design – TIDA-00620 12 to 24 V, 27 A, High Power Brushed DC Motor Reference Design
24
Visit: ti.com/tidesigns
Part number:TIDA-00620
TIDA-00620 Block Diagram
TI Design – TIDA-00620 12 to 24 V, 27 A, High Power Brushed DC Motor Reference Design
25
25 A to Motor 27 A to Motor
TI EVMs Enabling Customer Designs
26
All Texas Instrument’s DRV motor driver
and gate drivers are supported by
comprehensive evaluation kits (EVM)
• Allow customer to connect
their motor and power supply
and instantly begin evaluating
the DRV device with a simple
GUI or hardware controls
TI EVMs Enabling Customer Designs
27
Also, recently added to the TI
BoosterPack lineup….TI Motor
Drive BoosterPacks
• Support for main DC motor
types (brushless, brushed,
stepper)
• Compatible with TI MCU
LaunchPads New
BOOSTXL-DRV8301 BOOST-DRV8848
BOOST-DRV8711 BOOSTXL-DRV8305EVM
Integrate Motor Control Solution
28
Architectural Benefits
29
Control (MCU, DSP,
FPGA…)
FETs
State
Machine
Gate Drive
Feedback
Protection
FETs
Discrete Solution
– Software and hardware design
– Significant board space
– Higher component count
DRV10x Fixed Function
– Single chip solution
– Smallest board space
– Code-free development
Current
Feedback
Gate Drive
Protection
Controller + Driver
DRV10x Fixed Function Motor Controller Overview
Family Feature Overview
Digital Core • BLDC motor control state machine
• Hall-sensored & sensorless
• True sine, pseudo-sine & enhanced trap
• Configurable for optimal performance
Motor Drive Stage • Gate driver w/ internal charge pump
• Integrated half-bridges
• Start-up / stall current limit (no current
sense resistor required)
Further Integration • PWM interface
• Configuration interface (I2C or
hardware)
• Hall comparator for Hall-sensored
devices
• BEMF handling for sensorless
devices
• Power management
• Full suite of protection
Target Applications & Customer Benefits
Target Applications • Appliances
• White goods
• Small appliances (air purifiers, vacuums,
pedestal fans etc.)
• Fan / pump motor modules
• Personal & enterprise compute • Laptops
• Servers
• General purpose BLDC motor module
Customer Benefits • Optimal efficiency, ultra-low
acoustic noise, minimal vibration
• Code free tunability
• Minimum design efforts
• Highly reliable
Speed
Battery/System Voltage
M DRV10x Fixed Function
Motor Controller
Motor Feedback
Up to 6V
DRV10x Fixed Function BLDC Roadmap
31
Se
ns
ore
d
Se
ns
orl
es
s
Tra
p
Sin
e
Tra
p
Sin
e
Up to 20V Up to 50V
Sampling Production Development Concept
DRV10963 2.1 to 5.5V BLDC controller
DRV10964 2.1 to 5.5V BLDC controller w/ external config
DRV10866 1.65 to 5.5V 150° BLDC controller
DRV10975 6.5 to 18V configurable BLDC controller
DRV11873 5 to 16V 150° BLDC controller
DRV10970 5 to 18V configurable BLDC controller
DRV10983 8 to 28V configurable BLDC controller
DRV10983-Q1 Up to 45V BLDC Controller
DRV10983 +24V, 3-phase Sensorless BLDC Motor Driver
7.8 x 6.4mm, 24-pin
TSSOP package +8 to 28V
FG Output
Speed
I2C
FAN/PUMP
Controller
Direction DRV10983
Fan / Pump
Controller M
100mA Buck
Applications
Features Benefits
• 3-Phase Brushless DC Motor Controller & Driver
• Supply voltage: 8 to 28V
• Output Current: 2A RMS / 3A Peak
• RDSON (LS + HS): 250mΩ
• 180 sensor-less control
• Highly configurable spin up profiles
• Analog, PWM, and I2C control I/F options
• On-chip, 100mA , 5V/3V step down buck
• FG output provides TACH feedback
• Ultra-low 180uA sleep current available on DRV10983Z
• Fully protected with detailed fault reporting
• Short Circuit / Open load
• Rotor Lock / Stall
• Thermal / UVLO / Shoot-through
• Supply Pumping Overvoltage
• Cooling fans, ceiling fans, blowers
• Pumps
Highly Integrated
• Integrates VREG, Control, Gate drive, and FETs
• No hall sensors or sense resistor / minimal BOM
Ultra Quiet Operation
• Patented 180° sinusoidal control algorithm
• Customize spin up profile for quiet & reliable start-up
Code Free Tunability
• Tune motor for optimal efficiency, performance, and reliable start
up. No MCU codding required.
Fully Protected
• Advanced on-chip protection reduces design complexity and
enables higher system reliability.
In Production
DRV10983: $1.95
DRV10983Z: $2.06 1K Pricing:
Programmable Spin
Up Profiles
Analog, PWM, Serial
Speed Ctrl
Advanced Rotor
Lock Protection
OCP, thermal,
UVLO, Shoot-
through,& Open
Load Protection
AVS Over-Voltage
Protection
Tach Output for
Closed-Loop Speed
Control
Adjustable
Commutation Angle
3.5mA Standby
(DRV10983)
180°Sinusoidal
Sensorless Control
2A RMS
3A Peak
180uA Sleep
(DRV10983Z)
Silent Startup /
Acceleration
Start Up Options: IPD,
Align and Go, Forward
& Reverse
V/I sensor
VCC
PGND
Logic
Core
U V W
UVLO
Over Current
Lock
Charge
Pump
Thermal W
VCP VCC
V
PGND
VCP VCC
U Gate
driver
PGND
VCP VCC
PWM & Analog
speed control
FG
SDA
SCL
Oscillator
Bandgap
3.3/5V regulator SW
VREG
3.3V LDO
1.8V LDO
V3P3
V1P8
SPEED
ADC
CPP CPN
VCP
GND
SWGND
I2C communication
DIR
Register EEPROM
GND
Gate
driver
Gate
driver
DRV10983: +24V 3-phase Sensorless BLDC Motor Driver
8 to 28V Supply
Operating Range
DRV10983: +24V 3-phase Sensorless BLDC Motor Driver
1
2
3
4
5
6
7
8
9
10
11
12
24
23
22
21
20
19
18
17
16
15
14
13
VCP
CPP
CPN
SW
SWGND
VREG
V1P8
GND
V3P3
SCL
SDA
FG
VCC
VCC
W
W
V
V
U
U
PGND
PGND
DIR
SPEED
M
Interface to microcontroller
0.1µF
0.1µF
47µH
10µF
1µF
1µF
VCC
3.3V/5V 10µF
Optional 3.3/5V 100mA
Step Down Buck
Serial, PWM, or Analog Speed
Control + FG Pin
+8 to 28V : AVS Protects
against Supply Pumping
2A RMS
3A Peak
Minimal BOM Count No
Sense Resistor
DRV5000 Hall Effect Sensors
DRV5013, DRV5023, DRV5033, DRV5053 Magnetic Hall Effect sensors for industrial and automotive applications
1k Pricing: $0.27
In Production New sensitivity options sampling
soon
Applications
Features Benefits
• 2.5V to 38V operating supply voltage
• Tolerates -22V and 40V reverse battery and load dump
• AEC-Q100 Grade 0, Grade 1, and Industrial options
• 175°C max operating junction temperature
• Low 2.7mA typical ICC
• Fast 35 µs power-on time
• Fast 13 µs propagation delay
• Two package options: SOT-23 and TO-92
• Most robust operating voltage range in the industry, to withstand transient voltage
spikes and reversed-battery.
• Suitable for the harshest automotive Grade 0 environments.
• Simple, low-cost, robust, easy motion sensor design
• Highly reliable magnetic sensors that are immune to wear, environmental
contaminants, dirt, and RF noise.
• Minimal magnetic threshold change across temperature.
• Pins are fully protected from shorts.
• Automotive control systems and body closure
• Brushless DC Motor commutation
• Power tools
• Contactless position sensing, limit switches
• Flow meters
• Robotics, industrial automation
SOT-23 TO-92
37
Typical Magnetic
Sensitivity
DRV5013
Digital Latch
FA 1.3 mT
AD 2.7 mT
AG 6 mT
BC 12 mT
DRV5023
Digital Unipolar Switch
FA 3.5 mT
FI 3.5 mT
AJ 6.9 mT
BI 14.5 mT
DRV5033
Digital Omnipolar Switch
FA 3.5 mT
AJ 6.9 mT
DRV5053
Analog Bipolar
OA -11 mV/mT
CA 23 mV/mT
PA -23 mV/mT
EA 45 mV/mT
RA -45 mV/mT
VA -90 mV/mT
DRV5013, DRV5023, DRV5033, DRV5053
*Inverted output
*
Thanks!!!
39