industrial motor control roadmap (part 1) · industrial motor control market ... implement variable...

TM

Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2009.

Industrial Motor Control Roadmap (Part 1)AZ116

July 2009

►Alexandra Dopplinger►Global Industrial Segment Lead – Factory Automation & Drives

TMFreescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2009. 2

Agenda

►Industrial motor control market• Target applications• Market trends• Freescale alignment with trends

►Industrial motor control solutions• Generic applications• Freescale motor control processors• Application examples

Universal, stepper, BLDC, ACIM, PMSM, sensorless switch reluctance

►Motor control tools and enablement


Industrial Motor Control Target Applications

►Pumps and fans – pool pumps, factory systems

►HVAC – heating fans, air-conditioners

► Industrial drives – manufacturing assembly, robotics, wind turbines, printing presses

►Appliances – washers, dryers, power tools

►Medical – scanners, pumps, diagnostic and therapy equipment


Industrial Motor Control – Market Trends

Market Trend Customer RequirementsReduce power consumption

►Intelligent motor control improves efficiency by 30% or more►Implement variable speed motor control with inverter-based drive systems►Smarter systems to sense environment and react in real time

Reduce system and development cost

►More on-chip peripherals to reduce component count►Libraries and reference designs for common functions►Expert customer support

Reuse software, hardware and tools across platforms

►Support multiple motor types with one unified platform►Ease software migration across wide performance range►Tools to develop increasingly complex algorithms

Cost-effective safety, reliability and security

►IEC regulatory approval requires single-bit failure detection►On-chip protection against IP cloning and network data hacking►Easier product certification to meet safety standards


Industrial Motor Control – Freescale Alignment with Trends

Market Trend Freescale Alignment with Customer RequirementsReduce power consumption

►Vector and sensorless control technology designed into every motor control processor

Reduce system and development cost

►8- and 16-bit MCUs start at <$0.70►16-bit DSCs for ACIM and PMSM solutions►32-bit Power Architecture MCUs for standard/premium drives

Reuse software, hardware, and tools across platforms

►Rich tools, training, reference designs and libraries►Devices are ruggedized with long life and reliability►Industrial products ship 10+ years, with high quality and expert customer support

Cost-effective safety, reliability and security

►Secure SRAM, on-chip data fusing to protect against IP cloning►Hardware encryption to protect against network data hacking ►Watchdog and ECC protection against soft errors►Certified IEC software modules


Industrial Motor Control Solutions

Generic Applications


Key Elements of Generic Drive Control

Motor control (DSC, DSP, FPGA)Real-time motor control

• Start, stop, speed-up, slow-down• Detect problems with motor• PID loop

Application (MPU, MCU, FPGA)Control algorithm

• Position elevators • Coordinate motion in conveyors• Decide what happens next

Input and output (I/O)• Communications

• Fieldbus, Ethernet, CAN• Human interfaces

• LED, LCD, keypad, HMI• Sensor inputs

• Temperature, current, position

Fieldbus or Ethernet link to HMI, higher-level control or factory network

Monitor, configure, or run diagnostics MotorAppli-

cation

MPU, MCU, FPGA

Motor Control

DSC, DSP, FPGA

Could be a one-chip or a two-chip solution


Basic Compact AC Drive

Basic compact AC drive (large fan, conveyor, simple pump):• Combine motor control and I/O on one DSP/DSC or MCU with on-chip flash• Simple or no application algorithm with minimal I/O and no operating system• Hardware security to prevent application software cloning• Optional sensors, network or fieldbus interfaces, keypad and display require galvanic isolation

CAN PHY(isolated)

RS-232 and/orRS-485

Fieldbus or Ethernet link to HMI, higher-level control, or factory network

Local power rail management

Monitor, configure, or run diagnostics

2-button keypad

(opt)

SegmentLCD (opt)

Processor for I/O and

motor control

30 to 50 MMIPS

GPIO

UART

Galvanicisolation

SPI

Motor

IGBT full bridge600V, >10A, not earth grounded Position encoder

Pre

-driv

er

PFC (1 or 3-phase)Signalconditioning

Fault

Current

Sensors (opt)

PWM

ADC

UART GPIO

External AC to high voltage DC

Internal DC-DC conversion


Compact AC Drive

Compact AC drive (material handling, factory machine control):• Motor control on DSP/DSC and basic I/O on separate MCU with on-chip flash• Simple or no application algorithm with minimal I/O and no operating system• Hardware security to prevent application software cloning• Optional sensors, network or fieldbus interfaces, keypad and display require galvanic isolation

USB FS OTG (opt)

RS-232 and/orRS-485

EthernetPHY (opt)

CAN PHY (isolated)




Keypad (opt)

SegmentLCD (opt)

Motor

IGBT full bridge600V, >10A, not earth grounded Position encoder

Pre

-driv

er

PFC (1 or 3-phase)

Signalconditioning

Processor for motor control, basic

application, and

isolatedI/O and/or

serial interface

30 to 50 MMIPS

Fault

Current

MII

GPIO

USB

UART

Sensors (opt)

PWM

CAN

Processor for system

application, display, user

I/O, and network or

fieldbus interfaces

Local power rail

management

ADC



Galvanicisolation


Standard or Premium AC Drive

Standard or premium AC drive (elevator, paper mill):• Isolate motor control on DSP/DSC from application and I/O on separate MCU• Application processor CPU performance 200 to 1500+ MIPS with optional external flash and/or RAM• Might support multiple motor controllers• Wide range of I/O -fieldbus or CAN migrating to Industrial Ethernet

CAN PHY (isolated)

USB FS OTG (opt)

RS-232 and/orRS-485

EthernetPHY (opt)


Memorybootflash

MemoryDDR2

SDRAM


Keypad (opt)

SegmentLCD (opt)

Motor

IGBT full bridge600V, >10A

Position encoder

Pre

-driv

er

PFC (1 or 3-phase)

ADCProcessor for I/O and application

200 to 1500+ MIPS

(MPU, MCU, FPGA) Fault

Current

MII

GPIO

USB

UART

Sensors (opt)

PWM

Processor for motor control

30 to 80 MMIPS

(DSC, DSP, FPGA)

SPI,UARTor I2C


Local power rail

management



CAN

Galvanicisolation

GPIO



Freescale Motor Control Processors


Typical Motor Control MCU Peripheral Functions

►Timer:• PWM signals < 20Khz• Dead time insertion• Commutation (mask-out)• ADC triggering• Fault control

►ADC• Measure current

►Delay block• Set ADC measurement at

specific times►Position decoder

• Quadrature decoder inputs if not sensorless

6 ch PWMtimer

12 bit ADC

Fault inputs

Prog delay

Positiondecoder


Choosing your MCU therefore depends upon …

►The same application may perform differently if implemented on different MCUs

►Peripheral features can significantly impact target application performance, not just CPU

► Application features should be considered• Type of motor• Type of load• Operational mode• Minimal speed• Maximal speed

• Current control• Speed control and/or position control• Number of PID controllers• Fault control• System Cost!


Key Differentiators for MC56F8006/2 DSC

14

► Cost-optimized solution for mathematically-intensive, power-sensitive real-time control applications

► Highest DSC performance per dollar • Dual Harvard Architecture + MAC and high

operating frequency enable outstanding performance in single-cycle multiply-accumulate for filters and real-time feedback calculations

► Lowest DSC power stop modes in the market

► Twice the operating frequency of competitive DSCs• 96 MHz for key peripherals (timers, SCI, PWM)

► More resolution and channels• 2x high speed 12-bit x 24 channel ADC module with

integrated temperature sensor

► Three analog comparators – more than any similar offering

► Programmable gain amplifier increases ADC input dynamic range• Shielded inputs in ADC reduce noise in conversion


56800E Core/32MIPS JTAG/EOnCE™

ProgrammableDelay Block (PDB)SPIVoltage Regulators

6 Output PWMI2CInterrupt Controller

2x 12-bit ADCsHigh Speed SCIFlash/RAM

1x 16-bit PeriodicInterval TimerCOPTwo 2X-16X

Wideband PGAs

2x 16-bit TimersPower SuperVisor3 AnalogComparators

Memory Options

16 KBFlash

12 KBFlash

2 KBSRAM

2 KBSRAM

System Integration Module(SIM)

System Clock Control（PLL, SIM, Osc)

Features• Low power stop modes• Up to 96 MHz for peripherals – timers,

PWM & SCI• 6 output PWM module with up to 4

programmable fault inputs• Two wideband clocked programmable

gain amplifiers• 10/12-bit conversion done in 3.03 μs @32

MHz SysClk (8-bit conversion done in 2.65 μs @32 MHz SysClk )

• Up to three analog comparators• Custom timer for precise control of ADC/PGA

sample times relative to PWM reload cycles• Two multiple-function programmable timers• One periodic interval timer (PIT)• Computer operating properly (COP) timer• One serial communications interface (SCI)• One serial peripheral interface (SPI)• I2C communications interface• Up to 40 GPIOs – versatile pin usage• JTAG/EOnCE debug port

MC56F8006/2 Family

Core32 MHz/32 MIPS 56F800E core1.8V to 3.6V operating range

MemoryUp to 16 KB flash with flash security, 2 KB SRAM


Freescale Motor Control Processors

Low-end Compact6 – 30 MMIPS< 0.5 W< $1

Mid-range Motor Control30 – 80 MMIPS< 0.5 – 1 W$1 - $3

High-end Motor Control60 – 100 MMIPS< 0.5 – 1 W> $3

MC9S08MP16

MPC5604P

DSC56F83xx

DSC56F8037

DSC56F8013

MC9RS08KA MC9S08QD/QE

MC9S08SH MC9S08AC

PoE MC34670H-bridges

MC33880, 87, MC33926, 32

CAN PHY MCZ33897

Power SupplyMC34727, 26

Linear RegulatorMC33742, MC33910, 11,12

Signal ConditioningMC33972, 75

Analog

2 0 0 8 2 0 0 9

DSC 16-bit S08 8-bit

Power® e200

DSC56F8006/2

DSC56F82xx

AnalogLED backlightMC34844, 45

Pre-driver MC33937



Application Examples


Many Different Motor Types …

DC motor

AC induction motor

Brushless DC motor

Stepper motor (full step)

Stepper motor (half step)

Permanent magnet synchronous motor (PMSM)

Switched reluctance motor


Universal Motor

Recommended devices

►8-bit MCU: MC9RS08KA MC9S08SH MC9S08ACMC9S08QD MC9S08QE

Applications► Small kitchen appliances, e.g. food mixers, blenders► Power tools► Fans and simple pumps


Stepper Motor

Recommended devices► Full and half-step function:

• 8-bit: MC9RS08KA, MC9S08QD, MC9S08QE, MC9S08SH, MC9S08AC

• MCF51QE ColdFire® MCU• MM908E625/626• Dual H-bridge motor driver IC:

MPC17C724, MPC17530, MPC17550

► Micro-step function:• DSC: MC56F80xx• ColdFire MCU: MCF51AC256 • MC9S12XH• Dual H-bridge motor driver IC:

MPC17C724, MPC17530, MPC17550

• Gauge drivers: MC33970/976/977

• Field-effect transistor (FET) driver: MC33937

Applications► Printers► Instrumentation► Medical pumps and scanners► Simple robotics and positioning


Brushless DC Motor

Recommended devices► Hall sensors (commutated)

function:• 8-bit: MC9S08AW and

MC9S08AC

► Sensorless function:• DSC: MC56F8006

MC56F8013 MC56F8037 MC56F8025 (MC56F83xx for servo)

• ColdFire 32-bit: MCF5234 with 16-channel enhanced time processing unit (eTPU)

• Dual H-bridge (12V): MC33932

• FET driver: MC33937

Applications► Fans and pumps► HVAC, compressors, blowers► Computer disk drives and peripherals► Robotics, traction control, servo systems► Office equipment, sewing machines, treadmills


AC Induction Motor (ACIM)

Recommended devices►DSC: MC56F8006

MC56F8013 MC56F8037 MC56F8025 MC56F83xx

►ColdFire 32-bit MCU: MCF51AC256 MCF5234 with eTPU

►Power Architecture® 32-bit MCU: MPC5604P Applications

► Large appliance, e.g. washer, dryer► HVAC, blowers► Fan, pumps► Industrial lifts, cranes, elevators, conveyors


Permanent Magnet Synchronous Motor (PMSM)


MC56F8013 MC56F8037 MC56F8025 MC56F83xx

►ColdFire 32-bit MCU: MCF51AC256 MCF5234 with eTPU

►Power Architecture 32-bit MCU: MPC5604P

Applications► Large appliances, e.g. washer, dryer► HVAC, blowers, fan, pumps► Industrial lifts, cranes, elevators, conveyors► Robotics, industrial motion control► Elevators, servo drivers, traction systems, automotive


Sensorless Switched Reluctance Motor Drive


MC56F8013 MC56F8037 MC56F8025 MC56F83xx

Applications► Vacuum cleaners, food processors, appliances► High-speed power tools► Industrial machines, medical scanners► Computers, office equipment


Industrial Motor Control

Tools and Enablement


Development Tools to Speed Time-to-Market► Demo Boards

► CodeWarrior™ Development Studio for 56800/E Digital Signal Controllers• Enables designers to build and deploy sophisticated DSC systems quickly and easily• IDE with optimizing C compiler, extensive SW libraries built into IDE• Processor Expert with free drivers and libraries• Instruction-set simulation• Free Special Edition with up to 32 KB code size [CWX-568-SE]

► FreeMASTER - remote real-time control and monitoring tool

► Accessories• USB Tap - JTAG to USB adaptor (CWH-UTP-ONCE-HE)• Motor control socket board (APMOTOR56F8000E) • Includes ultra-small 3-phase BLDC motor• MC56F80xx socket board (CPA56F8013)

26

$99 MSRP$49 MSRP

MC56F8006DEMO MC56F8006DEMO-T(USB Tap included)


Build things faster using Processor Expert

A rapid application design tool with …► Graphical user interface that allows an application to be specified by the functionality needed► Automatic code generator that creates tested, optimized C code tuned to the application

needs and selected Freescale MCU► Built-in knowledgebase that immediately flags resource conflicts and incorrect settings

Creating…► Hardware abstraction layer (HAL) – hardware-dependent, low-level drivers with a known

application programming interface (API)

Benefits► Eases migration between Freescale devices► Designers don’t have to be intimately familiar with every page of a specification► Errors are caught early in design cycle; therefore designers get to market faster with higher

quality product

Motor control library with Embedded Beans► Embedded Beans easily incorporate software components of Freescale’s motor control library► The Freescale motor control library includes

• Transcendental functions• PID controllers• Clark and Park transform and inverse transforms• Algorithmic support for space vector modulation, and more..

► Embedded Bean Store is now available at http://www.freescale.com/BeanStore

27


FreeMASTER Interface

Application control and monitor

Real-time eTPU operation monitor

Live graphs, variable watches, and graphical control page


System infrastructure

Application Implementation

User application SW

FMaster*support

On-chip driversefficient reflecting the chip feature

MC

cIB

Mot

or C

ontr

ol

ACLI

PAd

vanc

ed c

ontr

ol

GFLIBGeneral functions

GDFLIBDigital filtering

FSL Library Set

External appl.*support

Doc

umen

tatio

n

On-chip peripherals

On-chip driver

Libraries

External HW

Pins

Application SW

Application

External connections

*optional

MC

56F8

0XX


Low Cost BLDC Motor Control Demo Board

► Brushless motor, Maxon EC-200187, 6W 9V

► Motor interface connector ► Input power connector ► Daughter card connector for

connecting the 56F8013 demonstration board

► LED power indicator ► Motor bus voltage sense logic ► Motor bus current sense logic ► Back EMF phase voltage sense logic ► Zero-crossing logic ► Hall-effect/zero-crossing selector ► 3-phase H-bridge power stage ► Power regulation logic ► (Optional) Five on-board real-time

user debugging LEDs Order Number: APMOTOR56F8000


BLDC Control Using MC56F8013

► 3-phase brushless DC motor sensorless drive

► Designed to fit into fan, pump and compressor applications

► Using MC56F8013 32 MIPS hybrid controller

► Avaliable for two power stages and two motors

► Input power supply voltage +12 Vdc for power stages

► Control technique incorporates: • Sensorless, trapezodial control of 3-

phase brushless DC motor with back-EMF sensing

• Using A / D converter zero-cross sensing for sensorless control

• Speed and current closed loop with PI controller

► Speed range: 200 – 2000 and 500 –5000 RPM (depending on the motor used)

► Manual interface (run/stop switch, up/down pushbuttons)

DSC 56F8013 56F8013

motor control board

UNI-3 motor control interface

DC motor3-phase

power stage

FreeMASTER connection

DRM070


BLDC Control Using MC56F8013 (Continued)

► FreeMASTER interface for monitoring, control and tuning

► Fault protection (DC-bus over-current, DC-bus under-voltage, DC-bus over-voltage)

► Automatic calibration of phase back-EMF measurements

► Easy to tune for different power stages and motors

► Applications• Compressors • Fans • Pumps • Washing machines • Automotive drives • Industrial drives • Air conditioning units • Appliances

DSC 56F8013 56F8013

motor control board

UNI-3 motor control interface

DC motor3-phase

power stage

FreeMASTER connection

DRM070


Enablement for Factory Automation – Industrial AC Driveswww.freescale.com/motorcontrol

Type Title Weblink

Docum

ent

“Motor Control Product Brochure” http://www.freescale.com/files/motor_control/doc/brochure/BRMOTORCONTROL.pdf?tid=tMCfd

“Motor Control FACT” lists >20 application notes & reference designs http://www.freescale.com/files/motor_control/doc/brochure/BRMOTORCONTROLOct.pdf

“Processor Expert FACT” describes a rapid application development tool integrated into the CodeWarrior™ Development Studio

http://www.freescale.com/files/microcontrollers/doc/fact_sheet/PROXPRTBNSTFS.pdf?fsrch=1

Dem

o

MC56F8006DEMO; MC56F8006DEMO-T (includes USB Tap)

DEMO56F8013-EE DSC development platform http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=DEMO56F8013&parentCode=56F8013&nodeId=01624686366292&tid=t16hft

APMOTOR56F8000 motor control demo http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=APMOTOR56F8000&nodeId=01624686366292

MC56F8037EVM evaluation platform http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=MC56F8037EVM&parentCode=56F803X&fpsp=1&nodeId=01624686366292582B

Reference

Design

Reference Designs page, lists > 20 reference designs http://www.freescale.com/webapp/sps/site/overview.jsp?nodeId=02nQXGzm8L&tid=tMCdrRD

PMSM Vector Control with Single-Shunt Current-Sensing Using MC56F8013/23 http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=RDDSCPMSMVC&nodeId=016246fNrglP4YnQXGrrlPglzQMszYj6MJ

3-Phase PM Synchronous Motor Torque Vector Control Using 56F80X or 56F8300 Digital Signal Controllers

http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=RDDSP56F8SMTVC&nodeId=016246fNrglP4YnQXGrrlPglzQMszYj6MJ

Software &

Tools

FreeMASTER Real-Time Control/Debug Tool for 8-, 16-, 32-bit MCUs http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=FREEMASTER&fpsp=1

QuickStart Initialization and Development Tool (MC56F80xx, MPC55xx) http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=DSP56800EQUICKSTART&nodeId=016246fNrglP4YnQXGrrlPglzQMszYj6MJ

CodeWarrior for 56800/E Digital Signal Controllers, includes Processor Expert with 56800MC with Math, Filters and Motor Control Software Library for MC56F80xx and MCF51ACxx

http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=CW-56800E-DSC&nodeId=016246fNrglP4YnQXGrrlPglzQMszYj6MJ

eTPU Graphical Configuration Tool (MCF523x, MPC55xx) www.freescale.com/etpu

3rd

Party Solution

IXXAT (IEEE 1588, CANopen, POWERLINK) www.ixxat.com

Real-Time Automation (Modbus TCP, EtherNet/IP, DeviceNet) www.rtaautomation.com

National Semiconductor (Precision PHYTER - 10/100 Ethernet PHY for IEEE 1588) www.national.com/analog/interface/ethernet

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http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=RDDSP56F8SMTVC&nodeId=016246fNrglP4YnQXGrrlPglzQMszYj6MJ�

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http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=FREEMASTER&fpsp=1�

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TMFreescale Confidential Proprietary. Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2007. 34

Additional Information

Freescale:►Motor Control Homepage – www.freescale.com/motorcontrol►8-bit Microcontrollers – www.freescale.com/8bit►16-bit DSC – www.freescale.com/dsc►16-bit Microcontrollers – www.freescale.com/16bit►32-bit ColdFire Microcontrollers – www.freescale.com/coldfire►32-bit Power Architecture Processors – www.freescale.com/powerpc►Analog Products – www.freescale.com/analog►Connectivity – www.freescale.com/connectivity►Industrial Segment – www.freescale.com/industrial

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http://www.freescale.com/8bit�

http://www.freescale.com/dsc�

http://www.freescale.com/16bit�

http://www.freescale.com/coldfire�

http://www.freescale.com/powerpc�

http://www.freescale.com/analog�

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Freescale Introduces Product Longevity Program

►The embedded market needs long-term product support, which allows OEMs to provide assurance to their customers.

►Freescale has a longstanding track record of providing long-term production support for our products.

►Freescale is pleased to introduce a formal product longevity program for the market segments we serve. ►For the automotive and medical segments, Freescale will manufacture

select devices for a minimum period of 15 years. ►For all other market segments in which Freescale participates,

Freescale will manufacture select devices for a minimum period of 10 years.

►A list of applicable Freescale products is available at www.freescale.com.


Summary

►Cutting Edge. Cost Effective. Complete.Freescale offers technology for every motor control application

►Energy efficient motor controlVector and sensorless control technology in motor control processors

8- and 16-bit MCUs start at <$0.7016-bit DSCs for ACIM and PMSM solutions32-bit Power Architecture MCUs for standard and premium drives

►Strong technical supportRich tools, training, reference designs, librariesDevices are ruggedized with long life and reliabilityIndustrial products ship 10+ years with high quality and expert support

►Cost-effective safety and security on-chipProtect against IP cloning, network data hacking and soft errors


Q&A

►Thank you for attending this presentation. We’ll now take a few moments for the audience’s questions and then we’ll begin the question and answer session.

industrial motor control roadmap (part 1) · industrial motor control market ... implement variable...

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