designing smarter motor drive systems -...

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


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




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


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

+-


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


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)


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


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


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


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


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

http://www.ti.com/product/drv8301





http://www.ti.com/product/drv8305-q1



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

http://www.ti.com/tool/TIDA-00643




20



TIDA-00643 Block Diagram

Designed for

compact (space

constrained), high

efficiency propeller

applications





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


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



Putting theory into practice





24



TIDA-00620 Block Diagram





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

*

Questions

38

Q: Any questions?

Wilson Zuo

M: 18510086411

O: 010 59029127

[email protected]

Thanks!!!

39

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