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HIGH PERFORMANCE BRUSHLESS DC MOTOR DRIVER
BC05 * BC05A
MICROTECHNOLOGY
HTTP://WWW.APEXMICROTECH.COM
(800) 546-APEX
(800) 546-2739
FEATURES
* 10V TO 200V MOTOR SUPPLY AT 5A CONTINUOUS AND 10A PEAK OUTPUT CURRENT * OPERATION WITH 10.8V TO 16V VCC, ALLOWING NOMINAL 12V OR 15 V VCC SUPPLIES * THREE PHASE FULL BRIDGE OPERATION WITH 2 OR 4 QUADRANT PWM * AUTOMATIC BRAKING WHEN USING 2 QUADRANT PWM * THERMAL PROTECTION www..com * ANTI SHOOT THROUGH DESIGN * 50 KHZ INTERNALLY SET PWM FREQUENCY, WHICH MAY BE LOWERED WITH EXTERNAL CAPACITORS * SELECTABLE 60 OR 120 COMMUTATION SEQUENCES * COMMUTATION TRANSITIONS OUTPUT FOR DERIVING SPEED CONTROL * MAY BE USED OPEN LOOP, OR WITHIN A FEEDBACK LOOP * ANALOG MOTOR CURRENT MONITOR OUTPUT, MAY BE USED FOR TORQUE CONTROL OR FOR TRANSCONDUCTANCE AMPLIFIER DRIVE. * ANALOG REFERENCE, FEEDBACK, AND TORQUE INPUTS
DESCRIPTION
APPLICATIONS
* 3 PHASE BRUSHLESS MOTOR CONTROL
BLOCK DIAGRAM
SSC 18 OE 19 HS1 6 HS2 7 HS3 8 120 22 REV 21 REF IN 23 + PWM COMPARATOR
X10
COMMUTATION DECODE LOGIC
- FB 24
X10
+
-
TEMP SENSING OVERTEMP
The BC05 Brushless DC Motor Controller provides the necessary functions to control conventional 3-phase brushless DC motors in an open loop or closed loop system. The BC05 is able to control motors requiring up to 1kW continuous input power. The controller drives the motor, generates the PWM, decodes the commutation patterns, multiplexes the current sense, and provides error amplification. Operation with either 60 or 120 commutation patterns may be selected with a logic input. Current sense multiplexing is used to make the current monitor output always proportional to the active motor coils current. Therefore the current monitor output may be used in generating transconductance drive for easy servo compensation. The controller may generate 4-quadrant PWM for applications requiring continuous transition through zero velocity, or 2 quadrant PWM for 2Q VCC HV HV electrically quieter 20 2 9 operation in unidirecV+ tional applications. OUT 1 TOP DRIVE 1 1/2 Direction of rotation 10 BRIDGE BOTTOM DRIVE 1 1 may be reversed in S1 13 2-quadrant mode by BRIDGE using the reverse CONTROL LOGIC command input. V+ When in 2-quadrant mode if the motor is OUT 2 TOP DRIVE 2 1/2 BRIDGE 11 stopped or decelerBOTTOM DRIVE 2 2 S2 ating dynamic brakPWM 15 ing is automatically applied. In this way V+ deceleration profiles may be followed even SHUTDOWN OUT 3 TOP DRIVE 3 when using 2-quad1/2 12 BRIDGE rant PWM. BOTTOM DRIVE 3 3
S3 14
PWM OSCILLATOR
POWER FAULT LOGIC
OVERCURRENT
CURRENT SENSING SIGNAL CONDITIONING
5 MOTOR I
HV RTN 16
HV RTN
4 TORQUE
CT 3
17 FAULT
GROUND 1
APEX MICROTECHNOLOGY CORPORATION * TELEPHONE (520) 690-8600 * FAX (520) 888-3329 * ORDERS (520) 690-8601 * EMAIL prodlit@apexmicrotech.com
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BC05 * BC05A
ABSOLUTE MAXIMUM RATINGS
MOTOR VOLTAGE, V+ CIRCUIT SUPPLY, Vcc OUTPUT CURRENT, peak OUTPUT CURRENT, continuous ANALOG INPUT VOLTAGE DIGITAL INPUT VOLTAGE TEMPERATURE, pin solder, 10s TEMPERATURE, junction2 TEMPERATURE RANGE, storage OPERATING TEMPERATURE, case, BC05 OPERATING TEMPERATURE, case, BC05A
ABSOLUTE MAXIMUM RATINGS SPECIFICATIONS
200V 16V 10A 5A -0.3V to Vcc+0.3V -0.3V to 5.3V 300C 150C -65 to 150C -25 to 85C -40 to 85C
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SPECIFICATIONS
PARAMETER ERROR AMP OFFSET VOLTAGE BIAS CURRENT DC GAIN BANDWIDTH INPUT AMP STAGE GAIN1 INPUT IMPEDANCE1 COMMON MODE VOLTAGE COMMON MODE VOLTAGE COMMON MODE REJECTI0N DIFFERENTIAL OFFSET GAIN BANDWIDTH PRODUCT OUTPUT TOTAL Ron EFFICIENCY, 5A, 200V SWITCHING FREQUENCY CURRENT, continuous CURRENT, peak POWER SUPPLY VOLTAGE, V+ VOLTAGE, Vcc CURRENT FROM Vcc POWER DISSIPATION Operating Power Dissipation2 Single FET Dissipation2 Calculated at 100V,10A, 50 kHz PWM, 12 mHy, 6.4 ohms, 95% duty cycle and 4-quadrant PWM Calculated at 100V,10A, 50 kHz PWM, 12 mHy, 6.4 ohms 95% duty cycle and 4-quadrant PWM, To each of 6 power FETs, motor stalled Set by internal and/or external resistors Applied at input terminals, Vcc = 10.8V Applied at input terminals, Vcc = 16V -0.5 -0.5 50 -3.3 700 TEST CONDITIONS MIN -3.3 19.8 15 TYP 0 20 16 20 2 5.0 5.0 0 MAX 3.3 4 20.2 17 20.2 8.5 14 3.3 UNITS mV pA db kHz db Kohm V V db mV kHz Ohms % kHz A A V V mA watts watts
Junction Temperature = 125C Dependent on individual application 45 5 10 20 10.8
0.65 93 50
55
250
200 16 500 124 62
Thermal resistance NOTES: 1. 2. Set internally Long term operation at the maximum junction temperature will result in reduced product life.
1.92
C/watt
CAUTION
The BC05 is constructed from static sensitive components. ESD handling procedures must be observed.
APEX MICROTECHNOLOGY CORPORATION * 5980 NORTH SHANNON ROAD * TUCSON, ARIZONA 85741 * USA * APPLICATIONS HOTLINE: 1 (800) 546-2739
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TYPICAL PERFORMANCE
BC05 * BC05A
PIN FUNCTION
All Logic Positive TKUC
I/O I I O O O I/O I/O www..com I/O I I I I I I I I I I O O O I I/O I SIGNAL HV HVRTN OUT1 OUT2 OUT3 S1 S2 S3 HS1 HS2 HS3 120 REV GROUND Vcc REF IN FB TORQUE MOTOR I SSC FAULT OE CT 2Q DESCRIPTION Unregulated high current motor supply voltage Return line for the motor current Half bridge output for driving motor coil Half bridge output for driving motor coil Half bridge output for driving motor coil Source of the N-rail FET in half bridge 1 Source of the N-rail FET in half bridge 2 Source of the N-rail FET in half bridge 3 Commutation sensor input 1 Commutation sensor input 2 Commutation sensor input 3 Sets commutation logic for 120 phasing Reverses direction when 2 quadrant PWM is used Signal ground Control circuit power Velocity/speed input Input for analog voltage proportional to velocity or speed Input for an analog voltage proportional to motor current Analog voltage proportional to motor current HCMOS level pulse for each sensor state change. HCMOS logic level output, a 1 indicates an over temperature or over current condition. HCMOS 1 enables power FET operation The PWM frequency may be lowered by installing a capacitor between this output and ground. A logic 1 on this input enables 2 quadrant PWM PIN 9 16 10 11 12 13 15 14 6 7 8 22 21 1 2 23 24 4 5 18 17 19 3 20
COMMUTATION AND OUTPUT TABLES
TABLE 1 TABLE 2
Position R 2Q 120 OE HS1 HS2 HS3 OUT1 OUT2 OUT3
TABLE 3
0 0 0 1 1 1 0 1 T - +
60 0 0 1 1 1 0 0 + - T
120 0 0 1 1 1 1 0 + T -
180 0 0 1 1 0 1 0 T + -
240 0 0 1 1 0 1 1 - + T
300 0 0 1 1 0 0 1 - T +
Position R 2Q 120 OE HS1 HS2 HS3 OUT1 OUT2 OUT3
TABLE 4
0 0 0 0 1 1 1 1 T - +
60 0 0 0 1 1 1 0 + - T
120 0 0 0 1 1 0 0 + T -
180 0 0 0 1 0 0 0 T + -
240 0 0 0 1 0 0 1 - + T
300 0 0 0 1 0 1 1 - T +
Position R 2Q 120 OE HS1 HS2 HS3 OUT1 OUT2 OUT3
0 0 1 1 1 1 0 1 T 0 +
60 0 1 1 1 1 0 0 + 0 T
120 0 1 1 1 1 1 0 + T 0
180 0 1 1 1 0 1 0 T + 0
240 0 1 1 1 0 1 1 0 + T
300 0 1 1 1 0 0 1 0 T +
Position R 2Q 120 OE HS1 HS2 HS3 OUT1 OUT2 OUT3
0 0 1 0 1 1 1 1 T - +
60 0 1 0 1 1 1 0 + - T
120 0 1 0 1 1 0 0 + T 0
180 0 1 0 1 0 0 0 T + 0
240 0 1 0 1 0 0 1 0 + T
300 0 1 0 1 0 1 1 0 T +
APEX MICROTECHNOLOGY CORPORATION * TELEPHONE (520) 690-8600 * FAX (520) 888-3329 * ORDERS (520) 690-8601 * EMAIL prodlit@apexmicrotech.com
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BC05 * BC05A
GENERAL
Much useful application information for these products can be obtained from Application Notes 1 (General Operating Considerations) and 30 (PWM Basics).
OPERATING CONSIDERATONS
PROTECTION CIRCUITS
There are four protection circuits in the BC05. 1. The peak current sensing circuit, which is programmed by the value of the current sense resistors placed by the user between the DMOS sources and HV return. This circuit is reset each PWM cycle. If three current sense resistors are used, as recommended, an analog multiplexer selects the current sense resistor, which has the same current as the motor coil. This technique blanks out noise and provides an excellent sensing of actual coil current. The programming of this circuit is accomplished by the folowing formula: ITRIP = 0.5/RSENSE Note that for large currents RSENSE becomes very small, therefore stray resistance in the high current path can have a large effect. Heavy etch should be used in the current sensing path, and leads should be very short between the resistors and the pins of the controller. 2. Thermal Protection The junction temperature of all power devices is sensed, and the controller is shut down when too hot. This circuit is a a latch and can be reset when OE is turned on, providing the power devices have cooled to a safe temperature. 3. There is an over-current circuit which shut down the BC05 when the current provided by the HV supply exceeds about 1.5 times the peak current rating. This circuit latches and may be reset by cycling the OE input. Although this is "top rail" protection, a short to ground will probably destroy the BC05. 4. The output circuit will shut down if a power supply is missing. This is not an alarmed fault.
PWM CONSIDERATIONS
The BC05 can be configured with a logic-input (2Q) to operate either as a 2-quadrant or 4-quadrant controller. 2-quadrant PWM holds one coil terminal at a constant level and applies PWM at the other. PWM is applied at the positive www..com terminal when in 2-quadrant mode. 4-quadrant PWM switches both terminals. 2-quadrant PWM is electrically slightly quieter and slightly more efficient, but cannot transition through zero. Therefore 4-quadrant PWM is required for applications such as position servos, phase locked motor control, or accurately following complex velocity profiles. 2-quadrant PWM is preferable for unidirectional speed control applications. The R input may be used to reverse the motor when using 2-quadrant PWM, but must be at logic "0" when in 4-quadrant mode.
COMMUTATION
The BC05 may be configured to operate with either 60 or 120 Hall sensor patterns by the state of the 120 input. (Obviously also with encoder outputs having the same logic.) When 120 is low the BC05 operates with 60 commutation; when 120 is high they operate with 120 commutation. The relationship between commutation states and motor drive output is tabulated in the following tables [See Tables 1-4 on previous page]. For the purposes of these tables PWM that is mostly positive will be designated +; PWM that is mostly low will be designated -; a constant low state will be designated by 0; a tri-state condition will be designated T; REF IN is more positive than FB; and "Forward" rotation is the only direction tabulated. Position is given in electrical degrees. Some motor manufacturers may not use the same conventions in identifying motor and Hall sense leads as Apex. In that event you may have to experimentally identify the corresponding motor and Hall Sense leads. For 3 binary square waves with equal phase shifts between the square waves, such as Hall sense outputs, there are only 8 possible states. 60 commutation fills 6 of the states and 120 commutation fills the other set of 6 states. Therefore all such patterns are truly only 60 or 120. Changing pattern is done in the Apex controller by inverting HS2 internally. Once the proper commutation patterns are obtained it is necessary to determine the motor lead orientation to the Hall sense. This may be done by turning the motor with a test fixture and observing the relationship between the HS patterns and the EMF, or by running the motor at low voltage and systematically switching motor leads until smooth running in the desired direction is obtained. The motor can be expected to run smoothly in the desired direction, run reverse, not run at all, or vibrate violently between 2 positions as this is done.
FAULT
The FAULT output is an alarm, a logic 1 indicates the outputs are disabled. Fault is at 1 when OE is at 0, and it is at logic 0 when OE is at 1 during normal operation. Outputs will latch to the disabled state and fault will be at logic 1 when any IGBT is too hot or when peak IGBT current has exceeded a safe level for the IGBT. This may be reset by setting OE to logic 0 and back to logic 1. When the coil sensing circuit senses that the average current has exceeded the level set by the selection of current sense resistors, the output will be disabled and the FAULT output will go to logic 1. (Even though the output has been disabled coil current will continue, flowing through the diodes in anti-parallel with each IGBT.) When coil current has decayed to below this set level the outputs will be enabled and FAULT will be at logic 0. Thus when limiting the average value of coil current the output will cycle between being disabled and enabled, and FAULT will cycle between logic 1 and 0. This action may cause an audible hiss when driving low inertia systems.
APEX MICROTECHNOLOGY CORPORATION * 5980 NORTH SHANNON ROAD * TUCSON, ARIZONA 85741 * USA * APPLICATIONS HOTLINE: 1 (800) 546-2739
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OPERATING CONSIDERATONS
BC05 * BC05A
amplifier. These inputs operate over a range between signal ground and +10V. However, with the addition 2 resistors, a diode, and loss of gain the circuit will operate with input voltages below ground. To operate with these inputs going to -10V the gain loss is 26.5 dB. When used with an external controller, which can compensate for this lost gain, this is insignificant. To choose a resistor to hold the input to the internal amplifier within its range, use the following formula: RIN = 2.06(4.9 + VIN) - 11.09 Where: RIN is the minimum value of the external resistor in K-ohms. VIN is the absolute value of the most negative input level. A resistor of this value should be inserted in series with both the REF IN and FB inputs. Since unbalance in these resistors affects dc offset and common mode rejection, precision resistors should be used. If the host system can produce steps to the REF IN input with less than 11 -seconds transients below ground on the internal amplifier will occur. Connecting a diode with its cathode tied to pin 23, REF IN, and its anode to ground will clamp these to a safe level. EXAMPLE: Assume an input voltage of -10V. The formula gives a minimum input resistance of 19.6K. The lowest 1% value above 19.6K is 20.0K. A nominal 20.0K resistor 2% low is 19.6K, so a 20.0K resistor whose variation to all effects is 2% is safe..
OPEN LOOP OPERATION
The normal way of operating the controller open loop is connect the input, REF IN pin 24 to a reference, and the FB input, pin 24 to an analog voltage. When this is done in conjunction with 2-quadrant PWM the voltage applied to the motor coils will be: VM = 25(HV)(VIN - VREF) + HV/2 Where: HV is the motor supoply. www..com input voltage. VIN is the VREF is the analog reference. If 4-quadrant PWM is used the equation becomes: VM = 50(HV)(VIN - VREF) The input dynamic range can be as smnall as 36mV for both 2-quadrant or 4-quadrant PWM (No larger than 40mV). The dynamic range can be extended, with the penalty of gain loss, by putting matched resistors in series with the FB and REF IN inputs. The value of these resistors for a given dynamic range is given by the following equation: RIN = (VIN MAX/0.036) - 1 Where: VIN MAX is the desired p-p input. RIN is the required minimum value for the resistors to be put in series with the FB and REF IN inputs, in kilo-ohms. When these resistors are used gain is reduced. The new motor voltage equation for 2-quadrant operation is: VM = HV/2 + (25(HV)(VIN - VREF))/(RIN + 1) The new equation for 4-quadrant operation is: VM = (50(HV)(VIN - VREF))/(RIN + 1) An alternative mode of open loop operation is to leave the FB and REF IN inputs open, and connect the input to the TORQUE input, either directly or through a series resistor. When this is done the input signal is effectively referenced to an internal 5.00V supply, VDD (This supply is not brought to a pin). Just as when using the REF IN and FB inputs, dynamic range can be increased (and gain decreased) by use of a series resistor, but only one is required. For 2-quadrant operation the equation for motor voltage is: VM = HV/2 + (25(HV)(VDD - VIN))/(RIN + 10) For 4-quadrant operation the equation for motor voltage is: VM = (50(HV)(VDD - VIN))/(RIN + 10) RIN can be determined for a linear dynamic range for both 2-quadrant and 4-quadrant PWM from the following equation: RIN = (VIN MAX/0.036) - 10
CLOSED LOOP OPERATION
The controller may be operated in a closed loop by applying the command signal to the REF IN input, pin 23, and analog feedback to FB, pin 24. Or, if operating with resistors in series with pins 23 and 24, through those resistor to pins 23 and 24. In this case the gain as a servo amplifier is given by the equation of sections 2 or 3 of the "Open Loop Operation" section.
TRANSCONDUCTANCE AMPLIFIER OPERATION
The BC05 can be operated in a transconductance amplifier mode by connecting the MOTOR I output to the TORQUE input either directly or through a resistor. It is convenient to chose the current sense resistors for the desired average current limit first, as described in section 1 of the protection circuits section, and then choose the current feedback resistor for the desired transconductance. If 2 quadrant PWM is being used the equation for calculating transconductance is: GM = 2.5(A)(V)(RFBI+10K)/(RL(RFBI+10K)+125000(V)(RS)) Where: A is the gain of the Input Amp. A=10K/(1K+RIN) GM is the overall transconductance. V is the motor supply voltage. RL is the load resistance (terminal to terminal armature resistance for the motor plus any added resistance.) RS is the sense resistance.
OPERATION WITH NEGATIVE ANALOG INPUTS
The REF IN and FB inputs are inputs to a true differential
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5
BC05 * BC05A
RFBI is the resistor from MOTOR I to TORQUE. RIN is the value of the external resistors used to reduce gain. Solving this equation for RFBI: RFBI = 125000(GM)(V)( RS)/ (2.5(A)(V) - GM(RL)) - 10K If 125000(V)(RS) is large compared to RL(RFBI + 10K), not always the case, then the equations simplify to:
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OPERATING CONSIDERATONS
of less than 2 inches.) The control circuit power supply, Vcc is internally bypassed with a 0.1 f ceramic. There is no additional bypassing in Apex test set ups, although it certainly wouldn't be harmful.
APPLICATION REFERENCES
For additional technical information please refer to the following Application Notes: AN 1: General Operating Considerations AN 30: PWM Basics
100 80
WATTS
Gm = A(RFBI + 10K)/(50000RS) RFBI = 50000(RS)(GM)/A - 10K
However the voltage gain of the PWM amplifier is twice as high when a 4 quadrant PWM is used. In this case: Gm = 5(A)(V)(RFBI +10K)/(RL(RFBI +10K) + 250000(V)(RS)) Solving this equation for RFBI: RFBI = 250000(GM)(V)( RS)/(5(A)(V) - GM(RL)) - 10K If 250000(V)(RS) is large compared to RL(RFBI +10K), not always the case, then the equations simplify to the same as in the 2 quadrant case: GM = A(RFBI +10K)/(50000RS) RFBI = (50000(RS)(GM)/A) - 10K
60 40 20 0 25 35 45 55 65 75 85 95 105 115 125 CASE TEMPERATURE, C
GROUNDING AND BYPASSING
The BC05 output switches hundreds of volts and tens of amperes with nano-second rise and fall times. Thus care in bypassing and grounding is required to eliminate noise in the system.. High voltage return and signal ground are electrically isolated in the BC05. This allows connections which avoid ground loops. However in order to avoid damaging offsets between grounds on internal components internal back to back schottky diodes are installed between signal ground and high voltage return. So, at a minimum, signal ground and high voltage must be tied together at one point in the system. Clean operation has been obtained with single point grounding, grounds tied together at the BC05, and with the combination of single point grounding for dc with grounds ac connected at the BC05 with a 1 f capacitor. The system designer should follow best practice for his system. On the high voltage supply a switching regulator grade electrolytic capacitor should be installed between high voltage and high voltage return. This capacitor should be installed at the BC05, with leads as short as practical. Apex recommends 10 f per ampere of output current for this capacitor. The voltage rating should withstand the highest transient voltage on the high voltage supply; transients should not be allowed exceed 450V for safe operation of the BC05. This is required even if large value filter capacitors are in the high voltage supply. A 1 f minimum ceramic capacitor with the same voltage rating as the electrolytic should also be installed across the high voltage supply. This capacitor should be installed directly from the high voltage pin to the high voltage return pin. (In our test set ups, this capacitor has a total lead length
Figure 2: Power Derating, Each Active FET
This data sheet has been carefully checked and is believed to be reliable, however, no responsibility*isTUCSON, ARIZONA 85741 * USA * APPLICATIONS are subject to1 (800) 546-2739 assumed for possible inaccuracies or omissions. All specifications HOTLINE: change without notice. APEX MICROTECHNOLOGY CORPORATION * 5980 NORTH SHANNON ROAD BC05U REV C MARCH 2003 (c) 2003 Apex Microtechnology Corp.
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