Never stop thinking.
Microcontrollers
User’s Manual, V 1.0, June 2003
Motor Control
Development Kit
A reference design for low voltage 3-phase AC
induction and brushless DC motor control.
References
Infineon C868 User’s Manual
http://www.infineon.com/cmc_upload/documents/048/247/
UM_c868_BA_singlepage_v1.0.pdf
Infineon TLE6280GP Datasheet
http://www.infineon.com/cmc_upload/documents/014/220/TLE6280GP_P6_1.pdf
Motor Control Development Kit
Revision History:2003-06 V 1.0
Previous Version:-
Page Subjects (major changes since last revision)
1.0 June 2003: First Release
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Motor Control Development Kit
Introduction
User’s Manual 3 V 1.0, 2003-06
1 Introduction
This user manual describes the MCDK, Motor Control Development Kit reference design
board and its functions.
The MCDK reference design provides a turnkey solution for driving 3-phase low voltage
brushless DC and AC induction motors, which are usually powered by batteries. The
hardware design applies a broad range of Infineon IC products including microcontroller,
bridge driver, power transistor, temperature sensor and voltage regulator. Infineon also
makes Hall Effect sensors which often are placed inside Brushless DC motors for
position sensing. Also included in the kit is reference software. This reference solution
allows engineers to shorten the development cycle, reduce the design cost and cut the
time from concept to market significantly.
The reference software provided with the MCDK release demonstrates a variable speed
drive for a high speed brushless DC motor with hall sensors, the motor has the following
features:
• 24V DC Supply
• 3-phase, 4-pole, trapezoidal
• ¾ Horse Power
• Speed up to 30,000 RPM
The software can be trivially changed to adopt different type of 3-phase brushless DC
motors.
Motor Control Development Kit
MCDK Overview
User’s Manual 4 V 1.0, 2003-06
2 MCDK Overview
2.1 Parameters
The MCDK reference design meets the following specifications:
Low Voltage: 12V ~ 24V DC
High Current: 50A, continuous DC
Output Power: Up to 1.2KW
Power Efficiency: > 95%
2.2 Features
• 8-bit MCU: C868 with on-chip 8kB SRAM, 5 channel 8-bit ADC and powerful PWM
module CAPCOM6E
• 3-Phase Bridge Driver: TLE6280G
• 6 OptiMOS MOSFETs: SPB80N06S2-05, TO263 package, 55V / 80A / 4.8 mΩ
RDS(on)
• EEPROM: 8kB to store program + stand alone boot option
• RS232: Interface to PC for SW development + boot from PC option
• Protection: shut down protection for over current and over temperature
• Board can be used for current/torque or speed control
• Supports Hall-Effect sensors or sensor-less control
• Extension for alternative MCU like XC164
• Small foot print: 5¼” x 3” dimension (133.4mm x 76.2mm)
• SW development tools: Keil Compiler + Debugger or Mini Debugger
http://www.keil.com + free reference software
Motor Control Development Kit
MCDK Overview
User’s Manual 5 V 1.0, 2003-06
2.3 Assembly
Power Transistors
Motor
Wires
EEPROM C868 MCU
Pot for
speed
setting
Expansion I/Os for Alternate MCU
RS232
Hall Signals
DC
Supply
Current Sensor
Bridge
Driver
Figure 1 Assembly of the MCDK Board
Motor Control Development Kit
Hardware Design
User’s Manual 6 V 1.0, 2003-06
3 Hardware Design
The hardware is designed with maximum versatility and flexibility to meet fluctuating
motor drive needs:
• CPU selections between C868 and alternatives like C164, XC164 and TriCore.
• Power Transistor Packages compatible in both DPAK and D2PAK
• Bridge Driver selection between TLE6280 or TLE6287
• Motor rotor position detection through hall sensors or sensor-less calculation.
• Booting sequences via EEPROM, RS232 or on-chip ROM.
• Circuit protections for over current and over temperature conditions
The following block diagram illustrates the basic idea to drive a 3-phase AC induction or
BLDC motor.
Brid
g
e driver Power Sta
g
e Intelligence
C868
V
D
Position Feedback: Sensor or Sensor-less
Figure 2 Block Diagram of 3-phase Motor Control Circuit
The Infineon C868 microcontroller implements a powerful PWM unit CAPCOM6E, which
is able to generate optimized PWM waveform for all kind of motor controls with minimal
CPU load.
The following diagram illustrates how the CAPCOM6E can generate 6-channels of PWM
signals according to the 3 hall sensor position signals, to drive a 3-phase BLDC motor.
The CAPCOM6E is very flexible and can generate practically any pattern that is desired.
Mod
Offset Re
g
. CT1OF
Com
p
are Timer 16-bit
Period Re
g
. CT1P
CTRAP
CC0
COUT
0
CC1
COUT
1
CC2
COUT
2
F
CP
Input
Control
CC Channel 0 CC0
CC Channel 1 CC1
CC Channel 2 CC2
deadtime
Control
Compare
Timer
F
CP
Period Reg.
Com
p
Re
g
. CMP2
Burst Mode
Block
Commutation
Control
COUT
3
INT0
INT1
INT2
Hall Pattern
Signals
Co
Block
Commutation
Control
Period Reg.
Com
p
Re
g
. CMP2
Speed
Phase Delay*
Time Out (Stall Detect)
Hall Effect*
Noise Filter
Compare Timer 16-bit
PWM
Signals
Input
Control
Port
Con-
trol
Motor Control Development Kit
Hardware Design
User’s Manual 7 V 1.0, 2003-06
Figure 3 Block Diagram of the CAPCOM6E PWM Unit (with C868)
Motor Control Development Kit
Board Configurations
User’s Manual 8 V 1.0, 2003-06
4 Board Configurations
The MCDK board is pre-configured during production. The following table shows the
factory setting for circuit breaks and jumpers:
–CB1: Close
–CB2: Close
– CB3: Open
– CB4: Open
–CB5: Close
– CB6: Open
–JP1: 1+2
–JP2: 2+3
– JP3: Close
–JP4: 1+2
–JP5: 1+2
–JP6: 1+2
–JP7: 1+2
4.1 Circuit Break Settings
The circuit breaks are pre-set in the assembly process, a solder drop between the gap
makes the circuit break ‘Close’, otherwise the circuit break is ‘Open’.
The circuit breaks CB4, CB5 and CB6 are used to select two types of Infineon bridge
drivers, the factory setting is choosing the TLE6280. To choose the TLE6287, the
configuration for CB4, CB5 and CB6 will be:
Table 1 Configurations for using TLE6287 bridge driver
CB4 CB5 CB6
TLE6287 Close Open Close
The circuit breaks CB1 and CB2 make the board flexible for users who want to use the
A/D ports of the microcontroller for alternate purpose. In this case, they need to be
‘Open’. While CB3 is closed, the board can supply a DC voltage to the external RS232
connections where opto-isolation can be applied.
Motor Control Development Kit
Board Configurations
User’s Manual 9 V 1.0, 2003-06
4.2 Jumper Settings
Jumper setting is more flexible, users can change “on-the-fly” to meet specific
applications.
Table 2 Jumper setting for bootstrap mode
JP1: Bootstrap Mode Selection
1 - 2 Bootstrap Mode
2 - 3 Normal ModeTable
Table 3 Jumper setting for logic power supply voltage
JP2: Logical Power Supply Voltage Selection
1 – 2 Vcc = + 5V
2 – 3 Vcc = + 3.3V
Table 4 Jumper setting for boot enable and disable
JP3: Boot Enable/Disable
Open Boot from PC via RS232
Close Boot from EEPROM
Table 5 Jumper setting for position detection methods
JP4, JP5 and JP6: Position Detection
1 - 2 Hall Sensor
2 - 3 Sensor-less
Table 6 Jumper setting for A2D input selection
JP7: A/D Input selection
1 - 2 Temperature Input
2 - 3 Current Input
Motor Control Development Kit
Get Started
User’s Manual 10 V 1.0, 2003-06
5 Get Started
5.1 Run the Demo
The EEPROM on the board has been pre-programmed with a BLDC motor control
reference demo, the microcontroller C868 will boot from the EEPROM and automatically
fetch then execute the code after power-up. The potentiometer for speed setting is
preset at zero RPM.
To run the demo, follow these steps:
• Hook up the motor wires and hall sensor signals of the brushless DC motor to the
board.
• Connect a 12~24V battery with at least 1A output current to the board, the board is
powered up then.
• Turn on the knob of the potentiometer, the motor will starts to spin.
Since the reference code is designed for a demo motor, the code has to be fine tuned
for the right type of motor applied.
5.2 Re-program the EEPROM
Users can re-program the EEPROM with their own code, to do this, follow these steps:
• Switch off the power supply by disconnecting the battery.
• Open the jumper JP3.
• Connect a RS232 cable to the host PC, and execute the Loader program on the PC.
• Connect the battery back so the board will be powered up again.
• Close the jumper JP3.
• Download your code into the EEPROM.
Motor Control Development Kit
Utilize an Alternative Microcontroller
User’s Manual 11 V 1.0, 2003-06
6 Utilize an Alternative Microcontroller
The expansion I/O connector, JP9, allows users to apply an alternative microcontroller
to drive the motor, for example, the Infineon C166 series microcontrollers with integrated
CAPCOM6(E) PWM units such as the XC164.
The signals of the expansion I/O JP9 are described in the following table:
Table 7 Description of Expansion I/Os of JP9
Pin # Name Description
1CC0 First phase high side PWM signal
2COUT0 First phase low side PWM signal
3CC1 Second phase high side PWM signal
4COUT1 Second phase low side PWM signal
5CC2 Third phase high side PWM signal
6COUT2 Third phase low side PWM signal
7CTRAP Over current trap signal
8POS0 Rotor position signal
9POS1 Rotor position signal
10 POS2 Rotor position signal
11 Temp/
Current
Temperature or Current amplitude
12 SPEED Motor speed setting
13 MFP Multifunction control signal for bridge drive
14 ERR Error signal from bridge drive
15 TX Transmitting signal of RS232
16 RX Receiving signal of RS232
17 CS Chip select signal for EEPROM
18 SIO Serial I/O pin of EEPROM
19 SCK Serial Clock signal of EEPROM
20 GND Ground
21 RST Reset signal for CPU
22 +3.3V Logic voltage supply when C868 used
23 +5V Logic voltage supply when alternate MCU used, i.e., C164xx
24 GND Ground
25 +24V_IN DC power supply (filtered)
Motor Control Development Kit
Utilize an Alternative Microcontroller
User’s Manual 12 V 1.0, 2003-06
The expansion I/Os provide all the necessary signals for external microcontroller to
access the EEPROM, RS232 interface and motor drive circuits. There are two ways to
utilize an alternate microcontroller: One is to design a mezzanine board that can plug on
top of the MCDK board through the JP9 connector, the other way is to connect a 25pin
flat cable to an existing microcontroller board (e.g., a starter kit). For the MCDK board,
some changes have to be done: the on-board C868 device must be un-populated to
avoid signal conflicts, also the jumper JP2 should be re-positioned if the alternate
microcontroller uses a different I/O logic voltage supply, i.e., +5V.
Motor Control Development Kit
Appendix 1: Layout
User’s Manual 13 V 1.0, 2003-06
7 Appendix 1: Layout
Figure 4 Assembly Bottom
Figure 5 Assembly Top
Motor Control Development Kit
Appendix 1: Layout
User’s Manual 14 V 1.0, 2003-06
Figure 6Bottom
Figure 7Top
Motor Control Development Kit
Appendix 1: Layout
User’s Manual 15 V 1.0, 2003-06
Figure 8 Mask bottom
Figure 9 Mask top
Motor Control Development Kit
Appendix 1: Layout
User’s Manual 16 V 1.0, 2003-06
Figure 10 Silk Bottom
Figure 11 Silk Top
Motor Control Development Kit
Appendix 2: BOM
User’s Manual 17 V 1.0, 2003-06
8 Appendix 2: BOM
Table 8 Bill of Material for MCDK Reference Design
Designator Quantity Part Type Footprint
CB1->CB6 6Solder drop custom footprint
C1->C3 32.2F _0805
C4->C6 30.22µF_0805
C7 115uF / 25V D-PACK
C8, C19 2 1µF_1206
C9 112nF _0805
C10, C11 210µF-100v Radial/Bulk
C16 110nF _0603
C17, C18 222pF _0603
C20, C21, C23, C25, C26,
C27, C29, C31, C32, C33,
C35, C36
12 100nF _0603
C22, C24 210µF_1206
C28 110nF _0603
D1 11N4148 SOD-123
D2 11201:red/
orang,
1202:red
_1206
D3 1404-1059-1-
ND
_1206
JP1,JP2,JP4->JP7 6HEADER 3 SIL3
JP3 1JUMPER SIL2
JP9 1HEADER 25 SIL25
JP10 1HEADER 2 SIL2
J1 1 Motor Wires Conn Hdr Vert Mini Fit SR 3Pos
J2 1 Hall Sensor
Signals
SIL5
J3 1 DC Power
Supply
Conn Hdr Vert Mini Fit SR 2Pos
Motor Control Development Kit
Appendix 2: BOM
User’s Manual 18 V 1.0, 2003-06
M1->M6 6SPB80N06
S2-05
P- TO263 -7-3
OZ1 1CSTLA10M
6T55002-B0
SIL3
PB1 1P8075SCT-
ND
SPST
POT1 1ST7A103CT
-ND
7mm Squared SMD J-Lead-CT
POT2 13310C-1-
103-ND
9mm Squared RT ANGLE PLAS
P1 - MALE 1A2096-ND DB9-PCB
R1->R6 622ΩAxial 1/4W type ERDS2T
R13->R18, R27, R33, R34 91KΩ_0603
R19, R31 227Ω_0603
R20 122KΩ_0603
R21 147KΩ_0603
R22 1300KΩ_0603
R24 120KΩ_0603
R25, R26, R32, R36 410KΩ_0603
R28 110Ω-1.0W _2512
R29 1100Ω_0603
R30 1270Ω_0603
R35 13KΩ_0603
R37 11KΩ_0603
R38, R39 2150Ω_0603
R40 20.005Ωresistors in parallel, 0.010
ohms@5W
R41 14K7Ω_0603
TP1 1GND POINT SIL1
T1 1KT110 SIL2
U1 1C868-
TSSOP
tssop38
Table 8 Bill of Material for MCDK Reference Design
Designator Quantity Part Type Footprint
Motor Control Development Kit
Appendix 2: BOM
User’s Manual 19 V 1.0, 2003-06
U2 1EEPROM
64K 2.7V
SOIC8
U3 1TLE4274GS
V33
P-SOT223-4-1
U4 1LM6132AIM
-ND
SOIC8
U5 1TLE6280GP P-DSO36-12
U6 1MAX3221E TSSOP16
Table 8 Bill of Material for MCDK Reference Design
Designator Quantity Part Type Footprint
Motor Control Development Kit
Appendix 3: Schematics
User’s Manual 20 V 1.0, 2003-06
9 Appendix 3: Schematics
Motor Control Development Kit
Appendix 4: Waveforms
User’s Manual 21 V 1.0, 2003-06
10 Appendix 4: Waveforms
Phase
A
COUT2 (C-)
CC2 (C+)
COUT1 (B-)
COUT0 (
A
-)
CC0 (A+)
POS0 (H0)
POS1 (H1)
POS2 (H2)
CC1 (B+)
Figure 12 Waveforms of PWM and Hall Pattern Signals Driving a 3-phase BLDC
motor (Measured with a Mixed Signal Oscilloscope).
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