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Class Objectives
After this class you should
Know the Operation of the dsPIC DSC Motor Control Peripherals Know the Fundamentals of a Brushless DC Motor Know the Different Methods to Control a Brushless DC Motor Know How to Use the Motor Control GUI
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Workshop Agenda
dsPIC DSC Overview BLDC Motor Control Theory BLDC Motor Control Algorithms Labs
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Agenda In-depth
dsPIC DSC Overview
Architecture Motor Control Peripherals Motor Control Family Theory of Operation BLDC Motor Construction Position Sensing
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Agenda In-depth
BLDC Motor Algorithms:
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Agenda In-depth
BLDC Motor Algorithms
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Agenda In-depth
BLDC Motor Algorithms
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Agenda In-depth
BLDC Motor Algorithms
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Agenda In-depth
Lab Sessions:
Lab 1 Programming a dsPIC DSC Using the PICDEM MC LV Board Lab 2 Running BLDC Motor with Forced Commutation Lab 3 Running Sensored BLDC Motor with GPIO Lab 4 Running BLDC Motor with MCPWM Lab 5 Running Closed-loop BLDC Motor Lab 6 Running Sinusoidal BLDC Motor Lab 7 BLDC Operation with Phase Advance Lab 8 Running Sensorless BLDC Motor
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dsPIC
DSC Overview
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10
dsPIC33F dsPIC30F
16-bit MCU 5 - 15 MIPS 8-bit MCU 1 - 10 MIPS
he T
SP D
ce pa
32-bit MCU
dsPIC DSC
PRICE
2007 Microchip Technology Incorporated. All Rights Reserved. 11085 MCW Slide 11
188% 180%
113% 100%
114%
100%
114%
Mitsubishi M16C
Mitsubishi M16C
Motorola HC12
Motorola HC12
Infineon C16X
FS 56F8367
Hitachi H8S
TI 320C24x
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TI 320C24x
13
Infineon C16X
Hitachi H8S
FS 56F8367
dsPIC DSC
dsPIC DSC
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Data Memory
16 bits wide Linearly addressable up to 64KB
Program Memory
24-bit wide Instructions Linearly addressable up to 12 MB
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dsPIC30F
DC to 30 MIPS 2.5 to 5.5 -40C to +125C Flash
dsPIC33F
DC to 40 MIPS 3.0 to 3.6 -40C to +85C Flash
Package sizes 18-pin SO & SP 28-pin SO, SP and QFN 40-pin SP; 44-pin TQFP, QFN 64-, 80- and 100- pin TQFP
Engine
TABLE Access Cntrl
DSP
Y AGU
W Array
16 x 16
X AGU
MCU ALU
Address Path MCU/DSP Data Path
2007 Microchip Technology Incorporated. All Rights Reserved.
23-bit PC Control
DSP Data Path Program Data/Control Path
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dsPIC
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Input Capture
(8 ch / 16-bit) Real Time Clock 16 / 32 bit Timers TIMER2 / TIMER3 16 / 32 bit Timers TIMER4 / TIMER5
16-bit, 6-8 ch
Quadrature Encoder
(TIMER6)
UART 1
4 KB
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CAN 1
CAN 2
Slide 20
SPI 1
SPI 2
I2C
DCI
UART 2
A/D Converter
10-bit High Speed A/D 10 bit resolution with 1 LSB accuracy 1 Msps conversion rate Up to 16 input channels, 4 S/H Amplifiers Synchronization to the MCPWM time base 12-bit A/D 12 bit resolution with 1 LSB accuracy 200 ksps conversion rate Up to 16 input channels, single S/H amplifier
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Conversion Control
S/H
S/H
Data Format
BUFFER 16 deep
Bus Interface
Input Muxes
S/H
S/H
AN15
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Rectifier
AN1 AN7 PWM3H PWM3L PWM2H PWM2L PWM1H PWM1L FLTA AN6 AN0 QEA QEB INDEX
BLDC Motor
3-ph Inverter
Fault
Incremental Encoder
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PHASE A
PHASE B COUNT
+1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1
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24
Tcy
QEB/UP_ DN
Clock Reset
QEA/TQCKI GATE
0 1
TQCS UP/DOWN
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25
50%
2%
50%
98%
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26
Rectifier
dsPIC30F4011
AN1 AN7 PWM3H PWM3L PWM2H PWM2L PWM1H PWM1L FLTA AN6 AN0 QEA QEB INDEX
BLDC Motor
High frequency @ more bits = better control of motor operation Fault detection for safe operation
3-ph Inverter
Fault
Incremental Encoder
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27
3 Phase BLDC
PWM1L
PWM2L
PWM3L
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28
PWM4H
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29
Dead Time
PWM1H
PWM1H
PWM1L PWM1L
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PWM1H
To A/D
PWM1L
PWM1L
T
2007 Microchip Technology Incorporated. All Rights Reserved. 11085 MCW Slide 31
Automatic or latched fault protection Fault condition overrides all other pin control
LATCHED
PWM1H
AUTOMATIC
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32
Used for motor commutation I/O pin can be PWM, active, or inactive POVD =0, I/O pin is controlled manually POUT bits set pin state for manual control If Program is halted, PWM pins are turned OFF
R/W-1 POVD4H
bit15
R/W-1 POVD4L
14
R/W-1 POVD3H
13
R/W-1 POVD3L
12
R/W-1 POVD2H
11
R/W-1 POVD2L
10
R/W-1 POVD1H
9
R/W-1 POVD1L
bit8
R/W-0 POUT4H
bit7
R/W-0 POUT4L
6
R/W-0 POUT3H
5
R/W-0 POUT3L
4
R/W-0 POUT2H
3
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R/W-0 POUT2L
2
R/W-0 POUT1H
1
R/W-0 POUT1L
bit0
Slide 33
R/W-1 POVD4L
14
R/W-1 POVD3H
13
R/W-1 POVD3L
12
R/W-1 POVD2H
11
R/W-1 POVD2L
10
R/W-1 POVD1H
9
R/W-1 POVD1L
bit8
R/W-0 POUT4H
bit7
R/W-0 POUT4L
6
R/W-0 POUT3H
5
R/W-0 POUT3L
4
R/W-0 POUT2H
3
R/W-0 POUT2L
2
R/W-0 POUT1H
1
R/W-0 POUT1L
bit0
0 0 1
1 0 x
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POVDxx POUTxx
0 1
0 0
1 x
PWMxx
dsPIC30F Products
Power Conversion & Motor Control Family
Product dsPIC DSC Pins Flash KB SRAM Bytes EE Bytes Timer 16-bit Input Cap Output Comp/ Std PWM 2 2 2 4 4 4 4 8 Motor Cntrl PWM 6 6 6 6 6 8 8 8 A/D 10-bit 1.0 Msps 6 ch 6 ch 6 ch 9 ch 9 ch 16 ch 16 ch 16 ch Quad Enc UART SPI I2CTM CAN
28 28 28 40 40 64 80 80
12 24 48 24 48 66 66 144
3 5 5 5 5 5 5 5
4 4 4 4 4 4 4 8
1 1 1 2 2 1 1 2
1 1 1 1 1 2 2 2
1 1 1 1 1 1 1 1
1 1 1 1 2
Brushless DC Motor Control AC Induction Motor Control Switch Reluctance Motor Control UPS, Inverters and Power Supplies
2007 Microchip Technology Incorporated. All Rights Reserved. 11085 MCW
dsPIC33F Products
Power Conversion & Motor Control Family
Product dsPIC DSC Flash SRAM Pins KB KB Dual Port RAM (KB) 2 2 2 2 2 2 2 2 2 2 2 2 Timer 16-bit Input Cap Output Comp/ Std PWM 8 8 8 8 8 8 8 8 8 8 8 8
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Quad Enc
UART
SPI
I2CTM
CAN
dsPIC33FJ64MC506 dsPIC33FJ64MC508
64 80
64 64 64 64 64 128
6 6 6 14 14 6 6 14 14 14 14 28
9 9 9 9 9 9 9 9 9 9 9 9
8 8 8 8 8 8 8 8 8 8 8 8
8 8 8 8 8 8 8 8 8 8 8 8
1 1 1 2 2 1 1 2 2 2 1 2
16 18 24 16 24 16 24 16 18 24 16 24
1 1 1 1 1 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2
2 2 2 2 2 2 2 2 2 2 2 2
Slide
1 1 1 2 2 2 2 2 2 2 2 2
36
1 1 1 1 2 1 1 1 1 2 1 2
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Objectives of Lab 1
Getting to know the hardware in front of you Verify your set-up Where are the Labs located?
C:\RTC\301MCW\Lab1\Lab1.mcw
How to load the lab projects Programming the dsPIC DSC devices Running the program on dsPIC DSC
2007 Microchip Technology Incorporated. All Rights Reserved. 11085 MCW Slide 38
Power cable (4 wires with white square connector) and Hall sensor cable (5 wires with 8-pin inline black connector)
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Lab 1
What we will do:
Configure board hardware connections Open a workspace in MPLAB IDE Compile or build a simple first project in MPLAB IDE Follow a procedure to program the dsPIC DSC using MPLAB ICD 2 Follow a procedure to run the program using MPLAB ICD 2
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Training Board
28-pin MC dsPIC30F
Power Reset Pot S2 DIP Switch Motor connector 3-Phase Inverter
Serial connector
2007 Microchip Technology Incorporated. All Rights Reserved.
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S2 Position
dsPIC30F3010
PGC PGD EMUC2 EMUD2 UART Rx UART Tx ICD 2 Clock ICD 2 Data
Function
Closed Open
PRGM DEBUG
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Lab 1
Instructions for Lab 1: On PICDEM MCLV board, move DIP switch to PRGM position Connect power to PICDEM MCLV board Open MPLAB IDE by double clicking on icon In MPLAB, select File -> Open Workspace Browse to C:\RTC\301MCW\Lab1\Lab1.mcw Select Lab1.mcw and open workspace Continued...
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Lab 1 (contd.)
Instructions for Lab 1:
In MPLAB IDE, Select Project -> Build All IF NO errors then ... In MPLAB IDE, Select Debugger -> Program to program dsPIC DSC On MCLV board, move DIP switch to DEBUG position In MPLAB IDE, Select Debugger -> Run Press S2 on PICDEM MCLV board and PWM LEDs will be blinking
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Lab 1 Results
Follow Lab 1 for programming and running software: Before programming dsPIC DSC, move DIP to PRGM position Before running, move DIP to DEBUG position Each lab has an already created workspace in the appropriate folder Use the created workspace for each lab
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How?
Force is developed when charge moves through a magnetic field
F=IxB
2007 Microchip Technology Incorporated. All Rights Reserved. 11085 MCW Slide 49
B N I = Current S I F=IxB
2007 Microchip Technology Incorporated. All Rights Reserved. 11085 MCW
(2nd finger)
B = Field
(1st finger)
F = Force/Motion (Thumb)
Slide 50
Motor Torque
F D B N B S I F B F
2007 Microchip Technology Incorporated. All Rights Reserved. 11085 MCW Slide 51
T=F x D
DC Motor Torque
Summary Torque = Force * Distance
F=IxB T=(IxB)*D When B and D are constant T = K * I A When field is wound B = K * I F In wound DC motors Torque and Flux B can be controlled independently
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DC Motor
Red is North Polarization Blue is South Polarization Opposite Polarities attract Rotor will rotate until North is aligned with South Just before alignment, commutator contacts and energize next winding Spark is generated when the commutator change windings
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Windings
2007 Microchip Technology Incorporated. All Rights Reserved.
Rotor
Windings
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Rotor
Slide 55
R
com
101
110
N
com g
N
g
S S
001
G r com b
010 B G
011
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BLDC Control
Mechanical commutator replaced by electronic switching BLDC is a synchronous motor
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Green Winding
Blue Winding
Sector
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3 Phase BLDC
PWM1L
PWM2L
PWM3L
Sector
3
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1
Slide 61
3 Phase BLDC
PWM1L
PWM2L
PWM3L
Sector
3
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1
Slide 62
3 Phase BLDC
PWM1L
PWM2L
PWM3L
Sector
3
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1
Slide 63
3 Phase BLDC
PWM1L
PWM2L
PWM3L
Sector
3
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1
Slide 64
Sector 0 1 2 3 4 5
OVDCON Value POVD<7:0> POUT<7:0> 00000000 00000000 00000000 00000000 00000000 00000000 00100001 00100100 00000110 00010010 00011000 00001001
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3-Phase Voltages
BLDC
Peripheral Block
Software Block
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Continued...
2007 Microchip Technology Incorporated. All Rights Reserved. 11085 MCW Slide 67
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4 Amps Peak
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Details of Program
Use MPLAB IDE to go thru sections of the code
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Lab 2 Results
First experience with a BLDC motor Understand Six-Step Commutation using the Override Feature of the dsPIC DSC Spinning a BLDC motor without position sensing Very inefficient with high currents (up to 4 amps with no load) Understanding the need of position feedback
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Resolver Output
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Hall sensors
2007 Microchip Technology Incorporated. All Rights Reserved. 11085 MCW Slide 76
Q1 Q4
Q2
R
Q3
G B
Q5
Q6
Blue Winding
+TORQUE FIRING Sector Hall States
Q3,Q5 Q1,Q5 Q1,Q6 Q2,Q6 Q2,Q4 Q3,Q4 Q3,Q5 Q1,Q5 Q1,Q6
5 5
0 4
1 6
2 2
3 3
4 1
5 5
0 4
1 6
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BLDC
Hall Sensors
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82
Start
Control Technique:
New Commutation
Continued...
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Lab 3 Running Sensored BLDC Motor with OVDCON Motor doesnt run?
Hall sensors wires might be loose Check jumper settings: dsPIC DSC Sensored Make sure that after programming the device you changed the DIP Switch from PRGM to DEBUG before hitting S2 Make sure program is not halted in MPLAB IDE Did you press S2?
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200 mA Peak
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Details of Program
Use MPLAB IDE to go thru sections of the code
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Lab 3 Results
Spinning a Sensored BLDC motor at full speed Understanding how sensors position and BLDC motor efficiency are related OVDCON will shut off the outputs if program execution is Halted, protecting the system HW With no PWM we have fixed motor speed
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Detect digital changes on a specific input pin and generates an interrupt Hall sensors A, B and C are connected to RB3, 4 and 5 or CN4, 5 and 6 respectively When CNxInterrupt occurs, all 3 Hall inputs are read and a lookup table is used to control the BLDC motor
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91
101
110
N
N
com g
Hall A Hall B
CN or IC
g B
N
CN or IC
S
r S com b
001
G
010
Hall C
CN or IC
011
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Halls C|B|A 000 001 010 011 100 101 110 111
OVDCON Value POVD<7:0> POUT<7:0> 00000000 00100000 00001000 00001000 00000010 00100000 00000010 00000000 00000000 00000001 00010000 00000001 00000100 00000100 00010000 00000000
100 2
110 3
010 4
011 5
001 0
101 1
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BLDC
GPIO
Start / Stop
Hall Sensors
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94
Control Technique:
New Commutation
Return
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Continued
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PWM1H PWM1L
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Lab 4 Results
Variable voltage using MCPWM module Maximum speed of 3600 RPM approx. BLDC Motor Speed will change if the Load Changes
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PI(D) Loop
Proportional-Integral-Differential Set Point - Process Variable = Error Control Variable = Output CV = Pe + I e dt + D de/dt
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Closed Loop
Desired Speed +-
Speed Error
Voltage
PID
Motor
Measured Speed
Speed Calculation
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Digital PID
Up
Kp * Error
Desired Speed +-
Error
Ki * Error dt
Ui
+ + +
Voltage
Measured Speed
Kd *
dError dt
Ud
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Digital PID
Up(T) = Kp * Error(T)
Kp * Error
Ki * Error dt
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Ki * Error dt
-1 * Error 1-Z
Ki
+ + +
Kd
dError dt
Kd * (1 Z ) * Error
-1
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Ki 1-Z
-1
* Error
+ + +
Error *
Kp +
Ki 1-Z
-1
+ Kd (1 Z )
-1
Kd * (1 Z ) * Error
-1
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= Controller Output
= Controller Output
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Controller Output (T) = Controller Output (T 1) + Error (T) * K1 + Error (T-1) * K2 + Error (T-2) * K3 Where: K1 = Kp + Ki + Kd K2 = -Kp -2Kd MAC Operation K3 = Kd can be used!!!
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Y prefetch source
Y prefetch destination
X prefetch destination
Basic Syntax
2007 Microchip Technology Incorporated. All Rights Reserved.
Optional Arguments
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40-bit Accumulator B
Round Logic
40-bit Accumulator A
16
Saturate Adder
Negate
40 40 16
Enable
40 40
Barrel Shifter
Sign Extend
Zero-backfill
32 33
16
16
16
To W Array
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X Data Bus
Integer Value -32768 -24576 -16384 -8192 0 8192 16384 24576 32767
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Fractional Value -1.0 -0.75 -0.5 -0.25 0.0 +0.25 +0.5 +0.75 +0.999969
Slide 113
The period from the IC Channel is used to measure the actual motor angular speed Detect digital changes on a specific input pin (Hall Sensor) and generates an interrupt One of the Hall effect sensors is connected to an IC Channel When ICxInterrupt occurs, the period between IC input transitions is buffered
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Speed Calculation
Fast Speed Calculation using dsPIC DSC Engine Small code size
2007 Microchip Technology Incorporated. All Rights Reserved. 11085 MCW Slide 115
BLDC
Measured Speed
Hall Sensors
GPIO
IC
Start / Stop
IC Period
Slide
116
Periodic ISR
Calculate Speed
Control Technique:
Process PID
Return
New Commutation
Return
2007 Microchip Technology Incorporated. All Rights Reserved. 11085 MCW Slide 117
Continued...
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Lab 5 Results
Speed Control a Sensored BLDC motor Implementing a PID digital controller using DSP engine of a dsPIC DSC Use dsPIC DSCs PWM, OVDCON, CN and IC feature to control the speed of the BLDC motor
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Q1 Q4
Q2
R
Q3
G B
Q5
Q6
50%
Blue Winding
Sine Phase
Sector Hall States
60
120
180
240
300
60
120
5 5
0 4
1 6
2 2
3 3
4 1
5 5
0 4
2%
1 6
50% 98%
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1 2 3
1 2 3
1 2 3
1 Set Sine wave Phase according to new sector 2 Calculate period of one hall effect sensor using Input Capture value 3 Apply new sine wave period according to previous Hall effect period (Op 2)
5 5
0 4
1 6
2 2
3 3
4 1
5 5
0 4
1 6
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BLDC
Measured Speed
Hall Sensors
GPIO
IC
Start / Stop
IC Period
Slide
125
Process PID
Return
Return
Return
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Continued...
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Lab 6 Results
Sinusoidal control of a BLDC motor Reduced audible noise Reduced torque ripple CE003. Driving a BLDC with Sinusoidal
Voltages using dsPIC30F.
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0
SECTOR
15 ADVANCE
1
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2
Slide 134
BLDC
Phase Advance
GPIO
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CN
Start / Stop
Angular Position
Hall Sensors
Slide
135
Control Technique:
Calculate Speed Load saved Hall values Duty Cycle = ADC Predict new Hall values Save Hall values New Commutation, Actual Sector + 1
Return Return
2007 Microchip Technology Incorporated. All Rights Reserved. 11085 MCW Slide 136
Continued...
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Details of Program
Use MPLAB IDE to go thru sections of the code
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Lab 7 Results
Phase advance control Extended speed range of up to 70% (motor dependent) Trade-off, current consumption and audible noise
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Why Sensorless?
Reliability especially aerospace, military Physical space restrictions axial length Issues surrounding sealing of connections Applications where rotor runs flooded Manufacturability alignment and duty cycle tolerance Cost especially on low power systems Even at high volumes, position sensing can add $3 to system cost
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Reliable Varies linearly with speed Works over a wide range of BLDC Motors Relatively easy to implement Works well for applications like Fan or pump speed control
Consists of monitoring the voltage of the inactive winding for zero crossing
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BEMF
Motor
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DC+ A
Back EMF B
DC- C
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0
T30 T60
0
SECTOR
2
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1
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Back EMF
Hall sensor
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149
Back EMF
AN1 AN2
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dsPIC30F3010
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150
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BLDC
VBUS Feedback
Speed Calculation
ZX Detect
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Visual tool for Tuning sensorless BLDC Applications Runs with MPLAB ICD 2 Can change any parameter specified in AN901 See GS005 for Operation Details
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Continued...
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Lab 8 Running Sensorless BLDC Motor using dsPIC DSC Click on Start in the SMTI window Press S2 to start motor Motor appears to start but does not spin WHY?
Start demand is too low to keep the motor running while ramping up Hint. Increase the start/end speed ramp demand when motor slips
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Lab 8 Running Sensorless BLDC Motor using dsPIC DSC Press S2 to stop/reset the motor Click on Halt in the SMTI window PART II Change parameters as per next slide
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The motor is vibrating in each sector while ramping up, because the demand was too high This generates a lot of start-up current and bad back EMF feedback Hint. Reduce the start/end demands when motor vibrates in every sector while ramping. If we reduce the demands more than we should, the motor will start slipping again
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Press S2 to stop/reset the motor Click on Halt in the SMTI window Part III Change parameters as per next slide
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The motor is ramping with good torque and does not slip, but the end speed is too low. Back EMF zero crossings are still not detectable by the controller. Hint. When ramping up a motor, try to set a maximum speed of 50% of the motor rated speed, which is around 2000 RPM in this Motor
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Lab 8 Running Sensorless BLDC Motor using dsPIC DSC Press S2 to stop/reset the motor Click on Halt in the SMTI window PART IV Change parameters as per next slide
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Summary
BLDC motor basics Blindly spin a BLDC motor Improve efficiency by using Hall sensors Used dsPIC DSC peripherals to spin a sensored BLDC motor Controlling BLDC Speed with Digital PID Reducing audible noise of BLDC with Sinusoidal control Extending speed range with Phase Advance control Techniques for sensorless control Modified Parameters in AN901 to spin a sensorless BLDC motor
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MICROCHIP REGIONAL TECHNOLOGY CENTER C leveland O hio 61 Rockside Road, Suit e 1 33 01 Independence, O 441 H 31 NOVEMBER 3, 2006
ABOUT YOUR INSTRUCTOR W h more t han 30 year experience in all aspect s of t he it elect ronics indust ry, St u C handler not only explains t he what and how but also t he why behind Microchips embedded t echnologies.
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Trademarks
The Microchip name and logo, the Microchip logo, Accuron, dsPIC, KeeLoq, KeeLoq logo, microID, MPLAB, PIC, PICmicro, PICSTART, PRO MATE, rfPIC and SmartShunt are registered trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. AmpLab, FilterLab, Linear Active Thermistor, Migratable Memory, MXDEV, MXLAB, SEEVAL, SmartSensor and The Embedded Control Solutions Company are registered trademarks of Microchip Technology Incorporated in the U.S.A. Analog-for-the-Digital Age, Application Maestro, CodeGuard, dsPICDEM, dsPICDEM.net, dsPICworks, ECAN, ECONOMONITOR, FanSense, FlexROM, fuzzyLAB, In-Circuit Serial Programming, ICSP, ICEPIC, Mindi, MiWi, MPASM, MPLAB Certified logo, MPLIB, MPLINK, PICkit, PICDEM, PICDEM.net, PICLAB, PICtail, PowerCal, PowerInfo, PowerMate, PowerTool, REAL ICE, rfLAB, Select Mode, Smart Serial, SmartTel, Total Endurance, UNI/O, WiperLock and ZENA are trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. SQTP is a service mark of Microchip Technology Incorporated in the U.S.A. All other trademarks mentioned herein are property of their respective companies.
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