Table Of ContentFreescale Semiconductor, Inc.
BLDC Motor
Control Board
for Industrial
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MOTOROLA.COM/SEMICONDUCTORS
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Freescale Semiconductor, Inc.
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For More Information On This Product,
Go to: www.freescale.com
Freescale Semiconductor, Inc.
BLDC Motor Control Board
for Industrial and Appliance
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. Applications Reference Design
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Applications Engineer — Mexico Applications Lab
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Diego Garay
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Applications Engineer — Mexico Applications Lab
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Maurizio Acosta
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Applications Engineer — Mexico Applications Lab
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Motorola and the Stylized M Logo are registered trademarks of Motorola, Inc.
DigitalDNA is a trademark of Motorola, Inc.
This product incorporates SuperFlash® technology licensed from SST. ©Motorola, Inc., 2003
BLDC Motor Control Board for Industrial and Appliance Applications DRM007
MOTOROLA 3
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Freescale Semiconductor, Inc.
Revision History
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documents on the World Wide Web will be the most current. Your printed
copy may be an earlier revision. To verify you have the latest information
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http://motorola.com/semiconductors
The following revision history table summarizes changes contained in
this document. For your convenience, the page number designators
have been linked to the appropriate location.
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DRM007 BLDC Motor Control Board for Industrial and Appliance Applications
4 MOTOROLA
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Freescale Semiconductor, Inc.
Designer Reference Manual — BLDC Motor Control Board
List of Sections
Section 1. Introduction and Setup. . . . . . . . . . . . . . . . . .15
Section 2. Operational Description . . . . . . . . . . . . . . . . .37
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Section 3. Schematics and Bill of Materials. . . . . . . . . .43
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c Section 5. Software Design Considerations. . . . . . . . . .71
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n Section 6. Practical Results. . . . . . . . . . . . . . . . . . . . . . .97
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i Section 7. Source Code . . . . . . . . . . . . . . . . . . . . . . . . .103
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BLDC Motor Control Board for Industrial and Appliance Applications DRM007
MOTOROLA List of Sections 5
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List of Sections
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DRM007 BLDC Motor Control Board for Industrial and Appliance Applications
6 List of Sections MOTOROLA
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Freescale Semiconductor, Inc.
Designer Reference Manual — BLDC Motor Control Board
Table of Contents
Section 1. Introduction and Setup
1.1 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
. 1.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
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1.3 MC68HC908MR8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
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I 1.4 MC68HC908MR8 Pulse-Width Modulator . . . . . . . . . . . . . . . .21
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r 1.4.1 Fault Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
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1.4.2 PWM Output Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
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c 1.4.3 PWM Counter Timebase . . . . . . . . . . . . . . . . . . . . . . . . . . .24
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1.4.4 PWM Load Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
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n 1.4.5 Direct Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
o 1.4.6 Deadtime Insertion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
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i 1.5 Brief Overview to Brushless DC Motors. . . . . . . . . . . . . . . . . .25
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e 1.6 Washing Machine Application’s Overview . . . . . . . . . . . . . . . .28
S 1.6.1 Movement Patterns of the Washer. . . . . . . . . . . . . . . . . . . .28
e 1.6.2 Agitator Hits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
al 1.6.3 Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
c 1.6.4 User’s Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
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1.6.5 Control Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
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e 1.6.6 Target Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
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F 1.7 System Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
1.8 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
1.9 Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
1.9.1 Programming Mode Setup . . . . . . . . . . . . . . . . . . . . . . . . . .33
1.9.2 Running Mode Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
BLDC Motor Control Board for Industrial and Appliance Applications DRM007
MOTOROLA Table of Contents 7
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Table of Contents
Section 2. Operational Description
2.1 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.3 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
2.4 User Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
2.5 Connectors Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . .41
2.5.1 J1 — AC Jack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
2.5.2 J2 — 3-Phase Motor Connector. . . . . . . . . . . . . . . . . . . . . .41
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. 2.5.3 J3 — Single Phase Motor 1 Connector . . . . . . . . . . . . . . . .41
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2.5.4 J4 — Temperature Sensor Connector . . . . . . . . . . . . . . . . .41
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2.5.5 J5 — RS-232 Interface Connector. . . . . . . . . . . . . . . . . . . .42
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2.5.8 J8 — Motor Hall Effect Sensor Connector . . . . . . . . . . . . . .42
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Section 3. Schematics and Bill of Materials
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3.1 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
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mi 3.2 Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
e 3.3 Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
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c 4.1 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
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4.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
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4.4 RS-232 interface and MON08 Hardware Interface. . . . . . . . . .58
4.5 Clock Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
4.6 Hall-Effect Sensors Interface . . . . . . . . . . . . . . . . . . . . . . . . . .60
4.7 LCD Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
4.8 Reset Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
4.9 3-Phase H-Bridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
4.10 Current Feedback and Cycle-by-Cycle Limiting. . . . . . . . . . . .64
DRM007 BLDC Motor Control Board for Industrial and Appliance Applications
8 Table of Contents MOTOROLA
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Table of Contents
4.11 Voltage Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
4.12 Current and Voltage Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . .68
4.13 Heat Sink Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Section 5. Software Design Considerations
5.1 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
5.2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
5.3 Controller Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
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5.5 Commutation Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
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5.6 Data Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
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Period Measuring, and Speed Calculation . . . . . . . . . . .84
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5.6.2 Process Speed Controller . . . . . . . . . . . . . . . . . . . . . . . . . .84
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c 5.6.4 Process Washing Machine. . . . . . . . . . . . . . . . . . . . . . . . . .86
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5.7 Application State Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
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e 5.9 Description of Routines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
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a 5.9.1 Main(void). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
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5.9.1.1 Stop Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
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e 5.9.1.2 Waiting for Command . . . . . . . . . . . . . . . . . . . . . . . . . . .89
e 5.9.1.3 Displaying Actual and Reference Speed . . . . . . . . . . . . .89
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F 5.9.1.4 Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
5.9.1.5 Spin CW and Spin CCW . . . . . . . . . . . . . . . . . . . . . . . . .90
5.9.1.6 Fixed Reference Speed. . . . . . . . . . . . . . . . . . . . . . . . . .90
5.9.2 InitPLL(void). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
5.9.3 InitPWMMC(void). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
5.9.4 InitTimerA(void) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
5.9.5 InitTimerB(void) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
5.9.6 Byte ResolveButtons(void). . . . . . . . . . . . . . . . . . . . . . . . . .91
5.9.7 InitMotor(Byte Commanded_Operation) . . . . . . . . . . . . . . .91
5.9.8 TimerAOverflow_ISR(void). . . . . . . . . . . . . . . . . . . . . . . . . .91
BLDC Motor Control Board for Industrial and Appliance Applications DRM007
MOTOROLA Table of Contents 9
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Table of Contents
5.9.9 Signed Word 16 PIController(void). . . . . . . . . . . . . . . . . . . .92
5.9.10 MotorStalledProtection(void) . . . . . . . . . . . . . . . . . . . . . . . .92
5.9.11 HALLA_ISR(void) and HALLB_ISR(void). . . . . . . . . . . . . . .92
5.9.12 HALLC_ISR(void). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
5.9.13 Fault1_ISR(void) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
5.9.14 NextSequence(void). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
5.9.15 InitLCD(void) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
5.9.16 CtrlLCD(Byte ctrl). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
5.9.17 Ctrl8LCD(Byte ctrl). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
5.9.18 MovCursorLCD(Byte places, Byte dir) . . . . . . . . . . . . . . . . .93
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5.9.20 StringLCD(Byte *msgLCD). . . . . . . . . . . . . . . . . . . . . . . . . .94
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5.9.21 WaitMs(Byte milis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
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5.10 MCU Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
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Section 7. Source Code
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m 7.1 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
e 7.2 Include Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
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7.2.1 MR8IO.H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
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7.2.2 START08.H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
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a 7.2.3 MAIN.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
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7.2.4 TIMER.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
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e 7.2.5 LCD.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
e 7.2.6 TABLES.H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
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7.3 Source Code Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
7.3.1 START08.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
7.3.2 MAIN.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
7.3.3 TIMER.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
7.3.4 LCD.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
DRM007 BLDC Motor Control Board for Industrial and Appliance Applications
10 Table of Contents MOTOROLA
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Description:Designer Reference Manual — BLDC Motor Control Board. List of Sections. Section 1. Introduction and Setup 15. Section 2.
