Automotive 1-kW 48-V BLDC Motor Drive Reference Design

TI Designs

Automotive 1-kW 48-V BLDC Motor Drive Reference Design

Design Overview

This TI Design is a 3-Phase Brushless DC Motor Drive designed to operate in 48-V automotive applications. The board is designed to drive motors in the 1-kW range and can handle currents up to 30A. The design includes analog circuits working in conjunction with a C2000 LaunchPadTM to spin a 3Phase BLDC motor without the need for position feedback from Hall Effect sensors or quadrature encoder.

Design Resources TIDA-00281 ccstudio MOTORWARE UCC27201A-Q1 TPS40210-Q1 TPS62152-Q1 LM5060-Q1 LM74610-Q1 HVDA553-Q1 OPA2365-Q1 LMT86-Q1 DRV5013-Q1

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Design Features

? Speed Control of 3-Phase Brushless DC (BLDC) Motors With no Position Sensors Needed

? Phase Voltage and Current Sensing Scaled and Filtered Feedback for Control of 3-Phase Power

? Operates Over Wide Range of Voltages From 48-V Battery System

? Protection Against Overvoltage, Undervoltage, Overtemperature, Overcurrent, and Transient Faults

? Reverse Polarity Protection on 12-V Battery ? Isolated CAN Interface Connects to Automotive

Networks on 12-V Battery System ? Critical Components Fit in a 5-inch Diameter

Circular PCB ? Components Selected for Automotive

Temperature and Quality ? Test Points Provide Easy Access to Key Motor

Signals

Featured Applications

? Water Pump ? eTurbo ? Radiator Fan ? HVAC Blower ? Oil Pump

TIDUAY9 ? November 2015

Automotive 1-kW 48-V BLDC Motor Drive Reference Design

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Copyright ? 2015, Texas Instruments Incorporated

Contents

1 Key System Specifications.......................................................................................................................................... 5 2 System Description ...................................................................................................................................................... 6 3 Block Diagram............................................................................................................................................................... 7

3.1 Highlighted Products............................................................................................................................................ 7 3.1.1 UCC27201A-Q1............................................................................................................................................ 8 3.1.2 TPS40210-Q1 ............................................................................................................................................... 9 3.1.3 TPS62152-Q1 ............................................................................................................................................. 10 3.1.4 LM5060-Q1.................................................................................................................................................. 11 3.1.5 LM74610-Q1 ............................................................................................................................................... 12 3.1.6 HVDA553-Q1 .............................................................................................................................................. 13 3.1.7 OPA365-Q1 and OPA2365-Q1 ................................................................................................................ 14 3.1.8 LMT86-Q1.................................................................................................................................................... 15

4 System Design and Component Selection............................................................................................................. 15 4.1 PCB / Form Factor ............................................................................................................................................. 15 4.2 Overall Considerations for Component Selection ......................................................................................... 16 4.3 12-V Input Protection ......................................................................................................................................... 17 4.3.1 TVS Diodes..................................................................................................................................................... 17 4.3.2 Reverse Battery Protection ........................................................................................................................... 18 4.3.3 12-V Input filtering ........................................................................................................................................ 19 4.4 Power Supplies...................................................................................................................................................... 19 4.4.1 Flyback Supply............................................................................................................................................... 20 4.4.2 3.3-V Step-down (Buck) Regulator................................................................................................................ 21 4.5 48-V Protection ................................................................................................................................................... 22 4.5.1 48-V Filtering ................................................................................................................................................. 23 4.5.2 48-V Switching............................................................................................................................................... 23 4.6 Motor Drive .......................................................................................................................................................... 24 4.7 Motor Control Feedback.................................................................................................................................... 25 4.7.1 Motor Current Feedback............................................................................................................................... 25 4.7.2 Motor Voltage Feedback............................................................................................................................... 26 4.7.3 Motor Drive Temperature Feedback ............................................................................................................ 28 4.7.4 Motor Position Feedback (Hall effect sensors) ............................................................................................. 28 4.8 LaunchPad .......................................................................................................................................................... 29 4.9 Isolated CAN ....................................................................................................................................................... 30

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Automotive 1-kW 48-V BLDC Motor Drive Reference Design

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Copyright ? 2015, Texas Instruments Incorporated

5 Getting Started Hardware ......................................................................................................................................... 32 5.1 Install LaunchPad .................................................................................................................................................. 32 5.2 Power Connection................................................................................................................................................. 33 5.2.1 12V Supply Connection ................................................................................................................................. 33 5.2.2 48V Supply Connection ................................................................................................................................. 34 5.3 Motor Connection................................................................................................................................................. 34 5.3.1 Motor Phase Connection .............................................................................................................................. 34 5.3.2 Motor Commutation Feedback Connection ................................................................................................. 35

6 Getting Started Software ........................................................................................................................................... 35 6.1 Download and Install Code Composer StudioTM.................................................................................................... 35 6.2 Download and Install MotorwareTM...................................................................................................................... 35 6.3 Run the Example Software.................................................................................................................................... 36

7 Testing ......................................................................................................................................................................... 41 7.1 Power Supplies ................................................................................................................................................... 41 7.1.1 12V supply range of operation...................................................................................................................... 41 7.1.2 Flyback efficiency .......................................................................................................................................... 42 7.1.3 3.3V Buck Efficiency ...................................................................................................................................... 43 7.1.4 48V switching ................................................................................................................................................ 44 7.2 Motor Operation.................................................................................................................................................. 44 7.2.1 Motor Operation Test Set-Up ....................................................................................................................... 44 7.2.2 Motor no-load speed and current versus 48V supply voltage...................................................................... 46 7.2.3 Motor speed versus constant load ............................................................................................................... 47 7.3 Motor Current Feedback ................................................................................................................................... 50 7.4 Motor Phase Voltages and Feedback Signals............................................................................................... 54 7.5 Response to Speed Ramp Commands .......................................................................................................... 58 7.6 Response to Load Torque Steps ..................................................................................................................... 60 7.6.1 Load Torque Step Test Set-up ....................................................................................................................... 60 7.6.2 Load Torque Step Test Results ...................................................................................................................... 60 7.7 Dead-time Settings and PWM Signals............................................................................................................ 63 7.8 Motor Identification Algorithm Testing............................................................................................................. 66 7.9 CAN transceiver.................................................................................................................................................. 67 7.9.1 CAN transceiver test set-up .......................................................................................................................... 67 7.9.2 CAN transmitter test results ......................................................................................................................... 68 7.9.3 CAN receiver test results............................................................................................................................... 69 7.10 Thermal images .................................................................................................................................................. 70

8 Design Files.................................................................................................................................................................. 72

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Automotive 1-kW 48-V BLDC Motor Drive Reference Design

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Copyright ? 2015, Texas Instruments Incorporated

8.1 Electrical Schematics......................................................................................................................................... 72 8.2 Bill of Materials ................................................................................................................................................... 78 8.3 PCB Layout Recommendations ....................................................................................................................... 84

8.3.1 General Notes on Noise Sensitive Traces and Components ......................................................................... 84 8.3.2 PCB Layering recommendations ................................................................................................................... 85 8.3.3 General Power Supply Considerations.......................................................................................................... 85 8.3.4 12V Protection Circuitry................................................................................................................................ 87 8.3.5 Separation of 12V and 48V power ................................................................................................................ 88 8.3.6 48V power protection ................................................................................................................................... 89 8.3.7 48V Power Routing ....................................................................................................................................... 89 8.3.8 Motor Drive Circuit ....................................................................................................................................... 91 8.3.9 Differential Signals ..................................................................................................................................... 91 8.4 Layout Prints ......................................................................................................................................................... 92 8.5 Altium Project & Gerber files ............................................................................................................................ 97 9 Software Files ............................................................................................................................................................. 97 10 References .............................................................................................................................................................. 97 11 Terminology............................................................................................................................................................. 98 12 About the Authors................................................................................................................................................... 98 13 Appendix .................................................................................................................................................................. 99 13.1 TINA Simulation Models........................................................................................................................................ 99

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Automotive 1-kW 48-V BLDC Motor Drive Reference Design

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Copyright ? 2015, Texas Instruments Incorporated

1 Key System Specifications

Table 1 System Specifications

PARAMETER

COMMENTS

MIN

TYP

MAX UNIT

VIN(12V) Input voltage

12-V battery voltage range (DC)

4.5

12

30

V

IIN(12V)

Input current

9 V < VIN(12V) < 16 V

0.2

A

VIN(12V)REV Input voltage reverse Reverse battery range

?15

V

VIN(48V) Input voltage

48-V battery voltage range (DC)

24

48

60

V

IIN(48V)

Input current

Motor at full load

30

A

fPWM

PWM frequency

Motor switching frequency

15

50

kHz

VPHASE

Motor phase voltage

100

V

IPHASE

Motor phase current

30

A

to LaunchPad through connectors J5, J6,

I3.3V

3.3V supply current

J9

250

mA

12-V input to 12-V output,

Effflyback Flyback efficiency

100-mA output current

75%

12-V input to 3.3-V output, 300-mA

Effbuck

Buck efficiency

output current

50%

Signaling rate with < 3% duty cycle

CAN transmitter rate distortion

500

kbps

Signaling rate with < 3% duty cycle

CAN receiver rate

distortion

500

kbps

Motor current feedback gain

20

mV/A

Motor current feedback bandwidth

1

MHz

TIDUAY9 ? November 2015

Automotive 1-kW 48-V BLDC Motor Drive Reference Design

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Copyright ? 2015, Texas Instruments Incorporated

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