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Energy.Don’t loose it…REUSE it!
Freescale 2008 Motor Control Seminar Series
9.98°
A
B
C
i
b
i
a
i
c
i
q
i
dθd
d a x i s
q a x i s
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Three-Phase Line Regeneration
Single-Phase Line Regeneration
Motor Regeneration
Introduction to 4-Quadrant Systems
Freescale Solutions for Regeneration
For Today’s Webinar…
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Slide 3Dave Wilson
Second Quadrantnegative speed-positive torque
“reverse-braking”
Generating
Fourth QuadrantPositive speed - negative torque
“forward-braking”
GeneratingThird Quadrant
negative speed - negative torque“reverse-accelerating”
Motoring
First Quadrantpositive speed-positive torque
“forward-accelerating”
Motoring
T o r q u e
SpeedIII
III IV
Quadrants of Operation
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Slide 4Dave Wilson
Example 4-Quadrant SystemV+
1
2
3
4
M
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Slide 5Dave Wilson
1
2
3
4
+ -Motor
Back emf
Q1
Forward)
Motor
Voltage
Motor
Current
DC Bus
Current
1
2
3
4
+ -Motor
Back emf
Q4
Forward)
Motor
Voltage
Motor
Current
DC Bus
Current
Motoring GeneratingDC Motor Regeneration
a b a ab ba b a ab
a b a b
Positive averageimplies motoring
Appliedaverage PWM
voltage greater
than back EMFvoltage
Appliedaverage PWMvoltage less
than backEMF voltage
Negative averageimplies generating
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Slide 6Dave Wilson
Applied Voltage
Back EMF
Bus regen. can only occur when applied voltage is smaller inmagnitude than the motor back-EMF, and of the same polarity.
Plugging
Plugging
Motoring
Motoring
Regeneration
Regeneration
Conditions for DC Motor Regeneration
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Slide 7Dave Wilson
96ms 98ms 100ms 102ms 104ms 106ms 108ms 110ms 112ms 114ms-40V
-30V
-20V
-10V
0V
10V
20V
30V
40V
-10
-8
-6
-4
-2
0
2
4
6
8
100.0V
0.1V
0.2V
0.3V
0.4V
0.5V
0.6V
0.7V
0.8V
0.9V
1.0V
-10V
-8V
-6V
-4V
-2V
0V2V
4V
6V
8V
10V
V(zero) V(N017,N023) I(L1)
V(n022) V(n012) V(n013)
V(zero) V(bus_current)
IBUS
VMod
Vemf IL
Vemf
IL
AC Motor RegenerationMOTORING
(unity PF)
GENERATING(unity PF)
V+
+ _
A
B
A
BVemf
IL
Carrier Mod
IBUS
+ -
VModVemf
VL
IL
VMod
Vemf
VL
IL
96ms 98ms 100ms 102ms 104ms 106ms 108ms 110ms 112ms 114ms
-40V
-30V
-20V
-10V
0V
10V
20V
30V
40V
-10A
-8A
-6A
-4A
-2A
0A
2A
4A
6A
8A
10A
0.0V
0.1V
0.2V
0.3V
0.4V
0.5V
0.6V
0.7V
0.8V
0.9V
1.0V
-10V
-6V
-2V
2V
6V
10V
V(zero) V(N017,N023) I(L1)
V(n022) V(n012) V(n013)
V(zero) V(bus_current)
IBUS
Vemf IL
VMod
P=½Vemf ILcos(θ)θ
SPICE SIMULATION
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Slide 8Dave Wilson
Regenerative
Boost Converter
Panasonic
Ni-MH battery stack
200 - 500 V
8100 uF
1 kW
Buck
Converter
System 12V
Freescale
Dave’sMostExcellent
Motor Controller T
M
50 kW
3-phase
Traction Motor
Freescale
Dave’sMostExcellent
Motor Controller
TM
1.2 kW
Variable Speed
AC Compressor
Freescale
Dave’sMostExcellent
Motor Controller T
M
30 kW
10k RPM
3-phase
Starter/Alternator
Freescale
Dave’sMostExcellent
Motor Controller
TM
Brush DC
EPS Motor
Regeneration in Toyota Prius
7.2V x 28 = 202V
6.5 amp-hours
12V
One Thirdof Kinetic Energy
Recaptured!
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Slide 9Dave Wilson
S08or DSC
PWM1
PWM2
PWM3
PWM4PWM5
PWM6
VBus
Rectifiers block current flow back on to AC line from the dc bus, thus preventing line regeneration.All motor energy gets dumped in the bus capacitor.
Deceleration
Energy Flow
AC In
V o l t a g e
ADC
Fault1
Port Pinor PWM
Brake
Voltage
Processing
Options
- Limit deceleration rate
- Bigger capacitor
- Turn PWMs off and coast
- Brake resistor
- Dump energy onto AC line input
Freescale
Dave’sControlCenter
Where Does the Energy Go?
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Slide 10Dave Wilson
Energy Flow
Regeneration to a Single Phase AC Line
AC In
Energy Flow
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Slide 11Dave Wilson
Single Phase
AC Line Regeneration
VAC
Vbus
VoltageRegulator
(PI)
+
-
V
ref
V
bus
VAC
Current
Reference
Waveform
+
-
i
L
i
L
CurrentRegulator (P or PI)
V
bus
+
+
V
q
V
d
PWM
÷
PWM
PWM
PWM
PWM
PWM
Module
N
DCarrier
Energy Flow
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Slide 12Dave Wilson
Simulation Results of Single-Phase Regenerative System
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Slide 13Dave Wilson
PWM 1
PWM 2
PWM 3
PWM 4
PWM 5
PWM 6
VBus
v
a
v
b
v
c
PWM 7
PWM 8
PWM 9
PWM 10
PWM 11
PWM 12
Motorola
Dave’sControlCenter
PWM Module A PWM Module B
Freescale offers several controller solutions with the
required MIPS and peripherals for this application.
Freescale offers several controller solutions with the
required MIPS and peripherals for this application.
Motor Decelerating
Energy FlowEnergy Flow
2E72G56F8346
SSAC0116-A
Regeneration to a 3-Phase AC LineEnergy FlowEnergy Flow
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Slide 14Dave Wilson
D and Q Axes Representation
α
β
Field Oriented Techniques applied to three-phase systemA B C
t=now
Put current vector on this axis for unity PF.
θ
D i r e c
t A x i s
Q u a d r a t u r e A x i s
Power Factor = Cos(φ)
RotatingAC Line Voltage
Space Vector
RotatingAC Line Current
Space Vector
Where φ is the angle between thevoltage and current spacevectors
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Slide 15Dave Wilson
Measure the instantaneous AC linevoltages. These scalar values representthe instantaneous magnitudes of the
vectors along the A, B, C axes.
A
B
C
Three PhaseConverter
A B C
t=now
A
B
C
Phasor Diagram
aV
bV
cV
rotating voltage space vector
Power Flow
d θ
Assuming equal phase voltages,
-v
c
= v
a
+ v
b
FreescaleADC
Step 1: Voltage Measurement
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Slide 16Dave Wilson
c b
a
V V V
V V
23
23
2
3
−=
=
β
α
A
B
C
Phasor Diagram
α
β
α V
β V
This is sometimesreferred to as the
FORWARD CLARK
transformation
Step 2: 3-phase to 2-phase transformation
rotating voltage space vector
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Slide 17Dave Wilson
β V
Phasor Diagram
α
β
AngleDemodulator
α V
d θ
d θ
⎟⎟ ⎠
⎞⎜⎜⎝
⎛ = −
α
β θ
V
V
d
1tan
Difficult to evaluate,
especially on a fixed-
point machine
Step 3: Angle Demodulation
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Slide 18Dave Wilson
Σ Σ Σ
Z
-1
Z
-1
αβ
++
+ ++
( )nd
∧
θ
( )nd
∧
Δθ
( ) )(ˆ)(sin nnnerror θ θ −=
Integrator Integrator
+
cos sin
X
X
Σ
+
-
[ ])(nCos θ
[ ])(nSinθ
( ) ( ) )(ˆsin)(cos)(ˆcos)(sin)(ˆ)(sin n n n n n n θ θ θ θ θ θ −=−
β V
α V
Tracking Filter Used for Angle Demodulation
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Slide 19Dave Wilson
(commanded) +
-
error(t)Bus voltage
(measured)Bus voltage
VBus
PI
Regulator
3-Phase AC supply
Step 4: Bus Voltage Regulator
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Slide 20Dave Wilson
id = sqrt(2/3) * (cos(θ)*ia + cos(θ - 2*π /3)*ib + cos(θ - 4*π /3)*ic)
iq = sqrt(2/3) * (-sin(θ)*ia - sin(θ - 2*π /3)*ib - sin(θ - 4*π /3)*ic)
Forward Clark-Park Transformation
θd
d a x i s
q a x i s
i q
i d
Step 5. Establish id and iq
1mHVbus
abc
θ q
d
i q
i d
6 transistor converter
θAngle
Demodulator
-i c = i a + i b
A
B
C
si
i
c
i b
i
a
3-PhaseAC supply
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Slide 21Dave Wilson
i d
∫ I
P
++
+-
error(t)
∫ I
P++
+-
error(t)
(commanded)
i d (measured)
i q
i q (commanded)
(measured)
v
d
v
q(0 amps)
Output from bus voltage regulator
P or PI regulators work well.
Step 6. Synchronous Frame Current Regulation
St 7 S h t St ti F T f ti
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Slide 22Dave Wilson
V1 = sqrt(2/3)*(cos(θ)*Vd - sin(θ)*Vq)
V2 = sqrt(2/3)*(cos(θ - 2*π /3)*Vd - sin(θ - 2*π /3)*Vq)
V3 = sqrt(2/3)*(cos(θ - 4*π /3)*Vd - sin(θ - 4*π /3)*Vq)
Reverse Clark-Park Transformation
v 1v 2
v 3
d a x i s
q a x i s
θdv
d
vq
a
b
cθ
q
d
v q
v d
θ
AngleDemodulator
A
B
C
v
1
v
3
v
2
Step 7: Synchronous to Stationary Frame Transformation
St 8 O t t V lt M d l ti
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Slide 23Dave Wilson
Vbus
6 transistor converter
AC Line
v
1
v
2
v
3
Va
Vb
Vc
P W M 1
P W M 2
P W M 3
V 1 amplified
V 3 amplified
V 2 amplified
Step 8. Output Voltage Modulation
Th Ph S t O i
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Slide 24Dave Wilson
abc
q
d
PWM A
PWM B
PWM C
Vbus
6 transistor converter
AC Line
Three-Phase System Overview
θ
P W M A
P W M B
P W M C
+-
P
+
-
Desired Bus Voltage PI
Vbus
v d
θ
a b c
Angle
Demodulator
+-
P
v q
i q abc
q
di d
θ
Si l ti R lt f 3 Ph R ti S t
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Slide 25Dave Wilson
Simulation Results of 3-Phase Regenerative System
Bus Load Current
D-axis Current
Q-axis Current
Phase A VoltagePhase A Current
Bus Voltage
A li ti
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Slide 26Dave Wilson
ApplicationsStandby Power Supplies
Connecting asynchronous power sources
Hybrid vehicles
Combined starter/alternator
Elevator Drives
Driving high inertial loads
PowerProcessing
Unit
VariableSpeed
Generator
Variable Frequency AC
AC Utility
High-Performance Power Architecture sockets
50 or 60 HzWind Energy
Inverter Load
StaticDisconnect
Switch
Energy Flow
AC Utility
Battery
S stem Benefits
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Slide 27Dave Wilson
Bidirectional control of power
Unity Power Factor or ANY Power Factor for that matter)
Since Vbus is regulated, and currents are sinusoidal,
the semiconductor volt-amp ratings are reduced
Vbus is less sensitive to AC line fluctuations
For three-phase AC systems, FOC algorithms can be used for both
converter and inverter control
System Benefits
Sinusoidal Currents
Matrix Converters
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Slide 28Dave Wilson
Matrix Converters
Inherent regeneration to input supply
Sinusoidal line currents possible
Unity or any) power factor is possible
Direct AC to AC waveform conversion
No energy storage elements required
M t i C t T l
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Slide 29Dave Wilson
Inputs
Outputs
Matrix Converter Topology
Matrix Converter Output Waveform Example
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Slide 30Dave Wilson
Unfiltered
Filtered
Matrix Converter Output Waveform Example
Dual Converter Inverter DSC Solutions
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Slide 31Dave Wilson
Dual Converter-Inverter DSC Solutions
All devices are 60 MHz, (-40, +125)°C
56F8345 56F8346 56F8347 56F8355 56F8356 56F8357 56F8365 56F8366 56F8367
Voltage (Core / I/O) 2.5/3.3V 2.5/3.3V 2.5/3.3V 2.5/3.3V 2.5/3.3V 2.5/3.3V 2.5/3.3V 2.5/3.3V 2.5/3.3V
On-Chip Flash 144KB 144KB 144KB 280KB 280KB 280KB 560KB 560KB 560KB
Program Flash 128KB 128KB 128KB 256KB 256KB 256KB 512KB 512KB 512KB
Data Flash 8KB 8KB 8KB 8KB 8KB 8KB 32KB 32KB 32KB
Boot Flash8KB 8KB 8KB 16KB 16KB 16KB 32KB 32KB 32KB
On-Chip RAM 12KB 12KB 12KB 20KB 20KB 20KB 36KB 36KB 36KB
Program RAM 4KB 4KB 4KB 4KB 4KB 4KB 4KB 4KB 4KB
Data RAM 8KB 8KB 8KB 16KB 16KB 16KB 32KB 32KB 32KB
Flash security Yes Yes Yes Yes Yes Yes Yes Yes Yes
Ext. Memory Interface - Yes Yes - Yes Yes - Yes Yes
On-Chip Relax. Osc. No No No No No No No No No
16-bit Timers 16 16 16 16 16 16 16 16 16
Quadrature Decoder 2 x 4ch 2 x 4ch 2 x 4ch 2 x 4ch 2 x 4ch 2 x 4ch 2 x 4ch 2 x 4ch 2 x 4ch
PWM 2 x 6ch 2 x 6ch 2 x 6ch 2 x 6ch 2 x 6ch 2 x 6ch 2 x 6ch 2 x 6ch 2 x 6ch
PWM Fault Input 4 + 4 3 + 4 3 + 4 4 + 4 3 + 4 3 + 4 4 + 4 3 + 4 4 + 4
PWM Current Sense 3 + 3 3 + 3 3 + 3 3 + 3 3 + 3 3 + 3 3 + 3 3 + 3 3 + 3
12-bit ADC 4 x 4 ch 4 x 4 ch 4 x 4 ch 4 x 4ch 4 x 4ch 4 x 4ch 4 x 4 ch 4 x 4ch 4 x 4ch
Temperature Sensor Optional Optional Optional Optional Optional Optional Optional Optional Optional
CAN FlexCAN FlexCAN FlexCAN FlexCAN FlexCAN FlexCAN FlexCAN (2) FlexCAN (2) FlexCAN (2)
SCI (UART) 2 2 2 2 2 2 2 2 2
SPI (Synchronous) 2 2 2 2 2 2 2 2 2
GPIO (Ded./Shrd/Tot) 21/ 28 / 49 0 / 62 / 62 0 / 76 / 76 21 / 28 / 49 0 / 62 / 62 0 / 76 / 76 21 / 28 / 49 0 / 62 / 62 0 / 76 / 76
JTAG/EOnCE Yes Yes Yes Yes Yes Yes Yes Yes Yes
Package 128LQFP 144LQFP 160LQFP 128LQFP 144LQFP 160LQFP 128LQFP 144LQFP 160LQFP
2.5/3.3V
80KB
64KB
8KB
8KB
12KB
4KB
8KB
Yes
-
Yes
16
2 x 4ch
2 x 6ch
4 + 4
3 + 3
4 x 4ch
Optional
FlexCAN
2
2
21 / 28 / 49
Yes
128LQFP
56F8335
56F8300 Pin Compatibility
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Slide 32Dave Wilson
P e r i p h e
r a l I n t e g r a t i o n
56F8300 Pin Compatibility
Pin compatible
56F8x46
56F8x45
144 LQFP
128 LQFP
56F8357
280KB(56F835x)
272KB(56F815x)144KB
(56F834x)136KB
(56F814x)
56F8x56
560KB(56F836x)
528KB(56F816x)
128LQFP
144LQFP
160 LQFP
144LQFP
160 LQFP
128LQFP
56F8x65
128 LQFP
80KB(56F833x)
72KB(56F813x)
160 LQFP
56F8x66
56F8x67
56F8x57
56F8x35
56F8x47
56F8x55
56F8x67
56F8x57
56F8x47
160 BGA
160 BGA
160 BGA
Cost Effective 56F8000 Solutions
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Slide 33Dave Wilson
56F8011/56F8013/56F8014
32 MIPS Performance
16 K Bytes Program FLASH
4 K Bytes Program/Data RAM
Tunable Internal Relaxation Oscillator
Software Programmable Phase Locked Loop
Up to 96 MHz Peripherals – Timers and PWMs
Up to 6-Output PWM Module with up to 4Programmable Fault Inputs
• Selectable PWM frequency for eachcomplementary PWM signal pair
Two 12-bit ADCs with up to 8 Inputs , 1.125us
conversion rate Synchronization between PWM and ADC
Four 16-bit General Purpose Programmable Timers
Computer Operating Properly Timer
Serial Ports: SCI, SPI, I2C
Up to 26 GPIOs – Versatile pin usage Low Power Consumption – 59mA Max and .026mA Min
JTAG/EOnCE™ Debug Port
MSRP starting at $2.92 for 1K units•Packages:
32LQFP
System Clock ControlSystem Clock Control
(PLL, Osc)(PLL, Osc)
6 Output6 Output
PWMPWM
4 164 16--BitBit
TimersTimers66--8 Input8 Input
1212--bit ADCbit ADC
SCISCI
VoltageVoltage
RegulatorsRegulators
COPCOP
JTAG/JTAG/EOnCEEOnCE
InterruptInterrupt
Controller Controller
Power Power
Supervisor Supervisor SPISPI
IICIIC
56800E56800E
CoreCore32 MIPS32 MIPS
32 MHz32 MHz
FlashFlash RAMRAM
Key Control Peripherals
System IntegrationSystem Integration
Module (SIM)Module (SIM)
56F8000 Family Expansion
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Slide 34Dave Wilson
• 32 MHz/32 MIPS 56800E Core
• 3.0-3.6V Operation• 32K-64K Bytes Program FLASH
• 4K-8K Bytes Program/Data RAM
• Flash security
• Tunable Internal Relaxation Oscillator
• Software Programmable Phase Locked Loop
• Up to 96 MHz Peripherals – Timers and PWMs• 6 Output PWM Module with 4 Programmable Fault
Inputs
• 2-12-bit ADCs for 6-8 Inputs w/ Int. or External Vref
• Up to 2 12-bit Digital to Analog Converters
• 2 - Analog Comparators
• Synchronization between PWM and ADC• 4 or 8 16-bit General Purpose Programmable Timers
• 1 or 3 Programmable Interval Timers
• Computer Operating Properly Timer
• 2-Queued Serial Communications Interface
• 2-Queued Serial Peripheral Interface
• Optional MSCAN• I2C Communications Interface
• Up to 53 GPIOs
• JTAG/EOnCE™ Debug Port
• 4 Lead Free Packages
• Up to -40 to 125C temperature range
• MSRP starting at $3.30 for 1K units
•32 LQFP 44QFP
•48LQFP 64LQFP
VoltageVoltage
RegulatorsRegulators
COPCOP
JTAG/EOnCEJTAG/EOnCE™
InterruptInterruptController Controller
Power Power
Supervisor Supervisor
64KB Flash64KB Flash 8KB RAM8KB RAM
MSCANMSCAN
System Clock ControlSystem Clock Control
(PLL, SIM,(PLL, SIM, OscOsc))
33--PITPIT
56800E56800ECoreCore
32 MIPS32 MIPS
32 MHz32 MHz
6 Output6 Output
PWMPWM
8 16bit Timers8 16bit Timers
22--QSCIQSCI
22--QSPIQSPI
II22
CC22--12bit DACs12bit DACs
22--AnalogAnalog
ComparatorsComparators
Two 12bit ADCsTwo 12bit ADCsUp to 2x8 InputUp to 2x8 Input
New or ImprovedNew or Improved
y p56F8023/56F8025/56F8036/56F8037 Features
Anguilla White : Ultra Low cost Product:
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Slide 35Dave Wilson
g56F8002, 56F8006
32 MHz/32 MIPS 56800E Core 1.8-3.6V Operation 12K - 16K Bytes Program FLASH with Flash security 2K Bytes Program/Data RAM Tunable Internal Relaxation Oscillator and 32KHz clock Phase Locked Loop (PLL) Up to 96 MHz Peripherals – Timers, PWM & Hi-SCI
6 Output PWM Module with 4 Programmable Fault Inputs Programmable Dead timer insertion Programmable PWM generation for Power supply apps Multiple PWM Frequency outputs
Two Programmable Gain Amplifiers with x2, x4, x8, x16gains (Clocked in order to cancel input offset)
Two 12-bit ADCs with up to 24 Inputs , 2.5us Per conversion
Programmable Delay Block provides precise control ofADC/PGA sample times relative to PWM reload cycles Three High Speed Analog Comparators 2 multiple function Programmable Timers Computer Operating Properly Timer One Periodic Interval Timer (PIT) 1 High Speed Serial Communication Interface (Hi-SCI)
1 Serial Peripheral Interface (SPI) I2C Communications Interface Up to 40 GPIOs – Versatile pin usage JTAG/EOnCE™ Debug Port Lead Free “Green” Packages Industrial temp: -40C – 105C
Sampling Now!MSRP is $1.50 in 10K quantities!
56800ECore
32MHz
Power-On-Reset
Power Supervisor
COP
12-16KBProgram
Flash
6-ch PWM Output
System IntegrationModule (SIM) 1 SCI
1 SPI
1 IIC
JTAG/EOnCE
2KBProgram/Data RAM
Voltage Regulator
PLL
Interrupt Controller
Relaxation OSC
2 x ProgrammableGain Amplifiers
56F8002, 56F8006
Up to 40 GPIOs
ProgrammableDelay Block
Synch
2 x 16bit Timers
Crystal OSC3 x Analog
Comparators
1 Period Int Timer
12ch 12bit ADC
12ch 12bit ADC
•28SOIC, 32SDIP , 32LQFP, 48 LQFP
Pictus: MPC560xP
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Slide 36Dave Wilson
Pictus: MPC560xPCore• up to 60 MHz PowerPC ISA e200 zen0h core
(64MHz at 105oC)
Memory• 192k to 512k byte Program Flash with ECC• 4x16k byte Data Flash with ECC• 12k to 40k byte SRAM with ECC
I/O
• 1 x FlexCAN with 32MB• 1 x Safety port (can be used as additional FlexCAN - 32MB)• 1 x FlexRay Dual Channel with 32MB• 2 x LinFlex• 4 x DSPI (4 independent chip selects each)• 1 x FlexPWM (4x3 channels with 4 Fault Inputs)• 1 x eTimer (6 channels incl. quad decode)• 1 x eTimer (6 channels for general purpose)
• 2 x ADC• 2x13 Ch.(4 shared channels), 10bit, conversion time 760
nsec (2x6ch, 4shared on 100 pin package)• 1 x ADC triggering unit: 8 events
System• 2 x PLL (one FM-PLL, one for Flexray)• 16Ch eDMA• Fault Collection Unit• 16MHz internal RC OSC• Junction Temperature Sensor • JTAG (2 pin or 5 pin) / Nexus Class 2+• 3.3V single supply (5V mask option) with external ballast
transistor 100 and 144 pins TQFP package
• 145oC ambient temperature option with Slugdown package
NexusIEEE-ISTO5001-2003
Interrupt
Controller
Crossbar Switch
I/O
Bridge SIU 512K
Program
FLASH
40K
SRAM
D S P I
L
i nF l e x
F
l e x C A N
PowerPC™
e200z0
VLE
F l
e xP WM
S a f e t yP or t
D S P I
ADC I/F
10 bit
S&H S&H
Mux Mux
4+1 Ch.
PIT
eTimer (6Ch)
eDMA
( c ) J T A G
FlexRayF a ul t C ol l e c t i on uni t
Boot
Assist
Module
D S P I
L
i nF l e x
eTimer (6Ch)
10 bit
4x16K
Data
FLASH
D S P I
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TMFreescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names arethe property of their respective owners. © Freescale Semiconductor, Inc. 2009.
Slide 37Dave Wilson
www.freescale.com /[email protected]