TM
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Industrial Motor Control Roadmap (Part 1)AZ116
July 2009
►Alexandra Dopplinger►Global Industrial Segment Lead – Factory Automation & Drives
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Agenda
►Industrial motor control market• Target applications• Market trends• Freescale alignment with trends
►Industrial motor control solutions• Generic applications• Freescale motor control processors• Application examples
Universal, stepper, BLDC, ACIM, PMSM, sensorless switch reluctance
►Motor control tools and enablement
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Industrial Motor Control Target Applications
►Pumps and fans – pool pumps, factory systems
►HVAC – heating fans, air-conditioners
► Industrial drives – manufacturing assembly, robotics, wind turbines, printing presses
►Appliances – washers, dryers, power tools
►Medical – scanners, pumps, diagnostic and therapy equipment
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Industrial Motor Control – Market Trends
Market Trend Customer RequirementsReduce power consumption
►Intelligent motor control improves efficiency by 30% or more►Implement variable speed motor control with inverter-based drive systems►Smarter systems to sense environment and react in real time
Reduce system and development cost
►More on-chip peripherals to reduce component count►Libraries and reference designs for common functions►Expert customer support
Reuse software, hardware and tools across platforms
►Support multiple motor types with one unified platform►Ease software migration across wide performance range►Tools to develop increasingly complex algorithms
Cost-effective safety, reliability and security
►IEC regulatory approval requires single-bit failure detection►On-chip protection against IP cloning and network data hacking►Easier product certification to meet safety standards
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Industrial Motor Control – Freescale Alignment with Trends
Market Trend Freescale Alignment with Customer RequirementsReduce power consumption
►Vector and sensorless control technology designed into every motor control processor
Reduce system and development cost
►8- and 16-bit MCUs start at <$0.70►16-bit DSCs for ACIM and PMSM solutions►32-bit Power Architecture MCUs for standard/premium drives
Reuse software, hardware, and tools across platforms
►Rich tools, training, reference designs and libraries►Devices are ruggedized with long life and reliability►Industrial products ship 10+ years, with high quality and expert customer support
Cost-effective safety, reliability and security
►Secure SRAM, on-chip data fusing to protect against IP cloning►Hardware encryption to protect against network data hacking ►Watchdog and ECC protection against soft errors►Certified IEC software modules
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Industrial Motor Control Solutions
Generic Applications
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Key Elements of Generic Drive Control
Motor control (DSC, DSP, FPGA)Real-time motor control
• Start, stop, speed-up, slow-down• Detect problems with motor• PID loop
Application (MPU, MCU, FPGA)Control algorithm
• Position elevators • Coordinate motion in conveyors• Decide what happens next
Input and output (I/O)• Communications
• Fieldbus, Ethernet, CAN• Human interfaces
• LED, LCD, keypad, HMI• Sensor inputs
• Temperature, current, position
Fieldbus or Ethernet link to HMI, higher-level control or factory network
Monitor, configure, or run diagnostics MotorAppli-
cation
MPU, MCU, FPGA
Motor Control
DSC, DSP, FPGA
Could be a one-chip or a two-chip solution
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Basic Compact AC Drive
Basic compact AC drive (large fan, conveyor, simple pump):• Combine motor control and I/O on one DSP/DSC or MCU with on-chip flash• Simple or no application algorithm with minimal I/O and no operating system• Hardware security to prevent application software cloning• Optional sensors, network or fieldbus interfaces, keypad and display require galvanic isolation
CAN PHY(isolated)
RS-232 and/orRS-485
Fieldbus or Ethernet link to HMI, higher-level control, or factory network
Local power rail management
Monitor, configure, or run diagnostics
2-button keypad
(opt)
SegmentLCD (opt)
Processor for I/O and
motor control
30 to 50 MMIPS
GPIO
UART
Galvanicisolation
SPI
Motor
IGBT full bridge600V, >10A, not earth grounded Position encoder
Pre
-driv
er
PFC (1 or 3-phase)Signalconditioning
Fault
Current
Sensors (opt)
PWM
ADC
UART GPIO
External AC to high voltage DC
Internal DC-DC conversion
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Compact AC Drive
Compact AC drive (material handling, factory machine control):• Motor control on DSP/DSC and basic I/O on separate MCU with on-chip flash• Simple or no application algorithm with minimal I/O and no operating system• Hardware security to prevent application software cloning• Optional sensors, network or fieldbus interfaces, keypad and display require galvanic isolation
USB FS OTG (opt)
RS-232 and/orRS-485
EthernetPHY (opt)
CAN PHY (isolated)
Fieldbus or Ethernet link to HMI, higher-level control, or factory network
External AC to high voltage DC
Monitor, configure, or run diagnostics
Keypad (opt)
SegmentLCD (opt)
Motor
IGBT full bridge600V, >10A, not earth grounded Position encoder
Pre
-driv
er
PFC (1 or 3-phase)
Signalconditioning
Processor for motor control, basic
application, and
isolatedI/O and/or
serial interface
30 to 50 MMIPS
Fault
Current
MII
GPIO
USB
UART
Sensors (opt)
PWM
CAN
Processor for system
application, display, user
I/O, and network or
fieldbus interfaces
Local power rail
management
ADC
Internal DC-DC conversion
Internal DC-DC conversion
Galvanicisolation
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Standard or Premium AC Drive
Standard or premium AC drive (elevator, paper mill):• Isolate motor control on DSP/DSC from application and I/O on separate MCU• Application processor CPU performance 200 to 1500+ MIPS with optional external flash and/or RAM• Might support multiple motor controllers• Wide range of I/O -fieldbus or CAN migrating to Industrial Ethernet
CAN PHY (isolated)
USB FS OTG (opt)
RS-232 and/orRS-485
EthernetPHY (opt)
Fieldbus or Ethernet link to HMI, higher-level control, or factory network
Memorybootflash
MemoryDDR2
SDRAM
Monitor, configure, or run diagnostics
Keypad (opt)
SegmentLCD (opt)
Motor
IGBT full bridge600V, >10A
Position encoder
Pre
-driv
er
PFC (1 or 3-phase)
ADCProcessor for I/O and application
200 to 1500+ MIPS
(MPU, MCU, FPGA) Fault
Current
MII
GPIO
USB
UART
Sensors (opt)
PWM
Processor for motor control
30 to 80 MMIPS
(DSC, DSP, FPGA)
SPI,UARTor I2C
External AC to high voltage DC
Local power rail
management
Internal DC-DC conversion
Internal DC-DC conversion
CAN
Galvanicisolation
GPIO
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Industrial Motor Control Solutions
Freescale Motor Control Processors
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Typical Motor Control MCU Peripheral Functions
►Timer:• PWM signals < 20Khz• Dead time insertion• Commutation (mask-out)• ADC triggering• Fault control
►ADC• Measure current
►Delay block• Set ADC measurement at
specific times►Position decoder
• Quadrature decoder inputs if not sensorless
6 ch PWMtimer
12 bit ADC
Fault inputs
Prog delay
Positiondecoder
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Choosing your MCU therefore depends upon …
►The same application may perform differently if implemented on different MCUs
►Peripheral features can significantly impact target application performance, not just CPU
► Application features should be considered• Type of motor• Type of load• Operational mode• Minimal speed• Maximal speed
• Current control• Speed control and/or position control• Number of PID controllers• Fault control• System Cost!
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Key Differentiators for MC56F8006/2 DSC
14
► Cost-optimized solution for mathematically-intensive, power-sensitive real-time control applications
► Highest DSC performance per dollar • Dual Harvard Architecture + MAC and high
operating frequency enable outstanding performance in single-cycle multiply-accumulate for filters and real-time feedback calculations
► Lowest DSC power stop modes in the market
► Twice the operating frequency of competitive DSCs• 96 MHz for key peripherals (timers, SCI, PWM)
► More resolution and channels• 2x high speed 12-bit x 24 channel ADC module with
integrated temperature sensor
► Three analog comparators – more than any similar offering
► Programmable gain amplifier increases ADC input dynamic range• Shielded inputs in ADC reduce noise in conversion
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56800E Core/32MIPS JTAG/EOnCE™
ProgrammableDelay Block (PDB)SPIVoltage Regulators
6 Output PWMI2CInterrupt Controller
2x 12-bit ADCsHigh Speed SCIFlash/RAM
1x 16-bit PeriodicInterval TimerCOPTwo 2X-16X
Wideband PGAs
2x 16-bit TimersPower SuperVisor3 AnalogComparators
Memory Options
16 KBFlash
12 KBFlash
2 KBSRAM
2 KBSRAM
System Integration Module(SIM)
System Clock Control(PLL, SIM, Osc)
Features• Low power stop modes• Up to 96 MHz for peripherals – timers,
PWM & SCI• 6 output PWM module with up to 4
programmable fault inputs• Two wideband clocked programmable
gain amplifiers• 10/12-bit conversion done in 3.03 μs @32
MHz SysClk (8-bit conversion done in 2.65 μs @32 MHz SysClk )
• Up to three analog comparators• Custom timer for precise control of ADC/PGA
sample times relative to PWM reload cycles• Two multiple-function programmable timers• One periodic interval timer (PIT)• Computer operating properly (COP) timer• One serial communications interface (SCI)• One serial peripheral interface (SPI)• I2C communications interface• Up to 40 GPIOs – versatile pin usage• JTAG/EOnCE debug port
MC56F8006/2 Family
Core32 MHz/32 MIPS 56F800E core1.8V to 3.6V operating range
MemoryUp to 16 KB flash with flash security, 2 KB SRAM
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Freescale Motor Control Processors
Low-end Compact6 – 30 MMIPS< 0.5 W< $1
Mid-range Motor Control30 – 80 MMIPS< 0.5 – 1 W$1 - $3
High-end Motor Control60 – 100 MMIPS< 0.5 – 1 W> $3
MC9S08MP16
MPC5604P
DSC56F83xx
DSC56F8037
DSC56F8013
MC9RS08KA MC9S08QD/QE
MC9S08SH MC9S08AC
PoE MC34670H-bridges
MC33880, 87, MC33926, 32
CAN PHY MCZ33897
Power SupplyMC34727, 26
Linear RegulatorMC33742, MC33910, 11,12
Signal ConditioningMC33972, 75
Analog
2 0 0 8 2 0 0 9
DSC 16-bit S08 8-bit
Power® e200
DSC56F8006/2
DSC56F82xx
AnalogLED backlightMC34844, 45
Pre-driver MC33937
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Industrial Motor Control Solutions
Application Examples
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Many Different Motor Types …
DC motor
AC induction motor
Brushless DC motor
Stepper motor (full step)
Stepper motor (half step)
Permanent magnet synchronous motor (PMSM)
Switched reluctance motor
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Universal Motor
Recommended devices
►8-bit MCU: MC9RS08KA MC9S08SH MC9S08ACMC9S08QD MC9S08QE
Applications► Small kitchen appliances, e.g. food mixers, blenders► Power tools► Fans and simple pumps
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Stepper Motor
Recommended devices► Full and half-step function:
• 8-bit: MC9RS08KA, MC9S08QD, MC9S08QE, MC9S08SH, MC9S08AC
• MCF51QE ColdFire® MCU• MM908E625/626• Dual H-bridge motor driver IC:
MPC17C724, MPC17530, MPC17550
► Micro-step function:• DSC: MC56F80xx• ColdFire MCU: MCF51AC256 • MC9S12XH• Dual H-bridge motor driver IC:
MPC17C724, MPC17530, MPC17550
• Gauge drivers: MC33970/976/977
• Field-effect transistor (FET) driver: MC33937
Applications► Printers► Instrumentation► Medical pumps and scanners► Simple robotics and positioning
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Brushless DC Motor
Recommended devices► Hall sensors (commutated)
function:• 8-bit: MC9S08AW and
MC9S08AC
► Sensorless function:• DSC: MC56F8006
MC56F8013 MC56F8037 MC56F8025 (MC56F83xx for servo)
• ColdFire 32-bit: MCF5234 with 16-channel enhanced time processing unit (eTPU)
• Dual H-bridge (12V): MC33932
• FET driver: MC33937
Applications► Fans and pumps► HVAC, compressors, blowers► Computer disk drives and peripherals► Robotics, traction control, servo systems► Office equipment, sewing machines, treadmills
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AC Induction Motor (ACIM)
Recommended devices►DSC: MC56F8006
MC56F8013 MC56F8037 MC56F8025 MC56F83xx
►ColdFire 32-bit MCU: MCF51AC256 MCF5234 with eTPU
►Power Architecture® 32-bit MCU: MPC5604P Applications
► Large appliance, e.g. washer, dryer► HVAC, blowers► Fan, pumps► Industrial lifts, cranes, elevators, conveyors
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Permanent Magnet Synchronous Motor (PMSM)
Recommended devices►DSC: MC56F8006
MC56F8013 MC56F8037 MC56F8025 MC56F83xx
►ColdFire 32-bit MCU: MCF51AC256 MCF5234 with eTPU
►Power Architecture 32-bit MCU: MPC5604P
Applications► Large appliances, e.g. washer, dryer► HVAC, blowers, fan, pumps► Industrial lifts, cranes, elevators, conveyors► Robotics, industrial motion control► Elevators, servo drivers, traction systems, automotive
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Sensorless Switched Reluctance Motor Drive
Recommended devices►DSC: MC56F8006
MC56F8013 MC56F8037 MC56F8025 MC56F83xx
Applications► Vacuum cleaners, food processors, appliances► High-speed power tools► Industrial machines, medical scanners► Computers, office equipment
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Industrial Motor Control
Tools and Enablement
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Development Tools to Speed Time-to-Market► Demo Boards
► CodeWarrior™ Development Studio for 56800/E Digital Signal Controllers• Enables designers to build and deploy sophisticated DSC systems quickly and easily• IDE with optimizing C compiler, extensive SW libraries built into IDE• Processor Expert with free drivers and libraries• Instruction-set simulation• Free Special Edition with up to 32 KB code size [CWX-568-SE]
► FreeMASTER - remote real-time control and monitoring tool
► Accessories• USB Tap - JTAG to USB adaptor (CWH-UTP-ONCE-HE)• Motor control socket board (APMOTOR56F8000E) • Includes ultra-small 3-phase BLDC motor• MC56F80xx socket board (CPA56F8013)
26
$99 MSRP$49 MSRP
MC56F8006DEMO MC56F8006DEMO-T(USB Tap included)
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Build things faster using Processor Expert
A rapid application design tool with …► Graphical user interface that allows an application to be specified by the functionality needed► Automatic code generator that creates tested, optimized C code tuned to the application
needs and selected Freescale MCU► Built-in knowledgebase that immediately flags resource conflicts and incorrect settings
Creating…► Hardware abstraction layer (HAL) – hardware-dependent, low-level drivers with a known
application programming interface (API)
Benefits► Eases migration between Freescale devices► Designers don’t have to be intimately familiar with every page of a specification► Errors are caught early in design cycle; therefore designers get to market faster with higher
quality product
Motor control library with Embedded Beans► Embedded Beans easily incorporate software components of Freescale’s motor control library► The Freescale motor control library includes
• Transcendental functions• PID controllers• Clark and Park transform and inverse transforms• Algorithmic support for space vector modulation, and more..
► Embedded Bean Store is now available at http://www.freescale.com/BeanStore
27
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FreeMASTER Interface
Application control and monitor
Real-time eTPU operation monitor
Live graphs, variable watches, and graphical control page
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System infrastructure
Application Implementation
User application SW
FMaster*support
On-chip driversefficient reflecting the chip feature
MC
cIB
Mot
or C
ontr
ol
ACLI
PAd
vanc
ed c
ontr
ol
GFLIBGeneral functions
GDFLIBDigital filtering
FSL Library Set
External appl.*support
Doc
umen
tatio
n
On-chip peripherals
On-chip driver
Libraries
External HW
Pins
Application SW
Application
External connections
*optional
MC
56F8
0XX
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Low Cost BLDC Motor Control Demo Board
► Brushless motor, Maxon EC-200187, 6W 9V
► Motor interface connector ► Input power connector ► Daughter card connector for
connecting the 56F8013 demonstration board
► LED power indicator ► Motor bus voltage sense logic ► Motor bus current sense logic ► Back EMF phase voltage sense logic ► Zero-crossing logic ► Hall-effect/zero-crossing selector ► 3-phase H-bridge power stage ► Power regulation logic ► (Optional) Five on-board real-time
user debugging LEDs Order Number: APMOTOR56F8000
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BLDC Control Using MC56F8013
► 3-phase brushless DC motor sensorless drive
► Designed to fit into fan, pump and compressor applications
► Using MC56F8013 32 MIPS hybrid controller
► Avaliable for two power stages and two motors
► Input power supply voltage +12 Vdc for power stages
► Control technique incorporates: • Sensorless, trapezodial control of 3-
phase brushless DC motor with back-EMF sensing
• Using A / D converter zero-cross sensing for sensorless control
• Speed and current closed loop with PI controller
► Speed range: 200 – 2000 and 500 –5000 RPM (depending on the motor used)
► Manual interface (run/stop switch, up/down pushbuttons)
DSC 56F8013 56F8013
motor control board
UNI-3 motor control interface
DC motor3-phase
power stage
FreeMASTER connection
DRM070
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BLDC Control Using MC56F8013 (Continued)
► FreeMASTER interface for monitoring, control and tuning
► Fault protection (DC-bus over-current, DC-bus under-voltage, DC-bus over-voltage)
► Automatic calibration of phase back-EMF measurements
► Easy to tune for different power stages and motors
► Applications• Compressors • Fans • Pumps • Washing machines • Automotive drives • Industrial drives • Air conditioning units • Appliances
DSC 56F8013 56F8013
motor control board
UNI-3 motor control interface
DC motor3-phase
power stage
FreeMASTER connection
DRM070
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Enablement for Factory Automation – Industrial AC Driveswww.freescale.com/motorcontrol
Type Title Weblink
Docum
ent
“Motor Control Product Brochure” http://www.freescale.com/files/motor_control/doc/brochure/BRMOTORCONTROL.pdf?tid=tMCfd
“Motor Control FACT” lists >20 application notes & reference designs http://www.freescale.com/files/motor_control/doc/brochure/BRMOTORCONTROLOct.pdf
“Processor Expert FACT” describes a rapid application development tool integrated into the CodeWarrior™ Development Studio
http://www.freescale.com/files/microcontrollers/doc/fact_sheet/PROXPRTBNSTFS.pdf?fsrch=1
Dem
o
MC56F8006DEMO; MC56F8006DEMO-T (includes USB Tap)
DEMO56F8013-EE DSC development platform http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=DEMO56F8013&parentCode=56F8013&nodeId=01624686366292&tid=t16hft
APMOTOR56F8000 motor control demo http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=APMOTOR56F8000&nodeId=01624686366292
MC56F8037EVM evaluation platform http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=MC56F8037EVM&parentCode=56F803X&fpsp=1&nodeId=01624686366292582B
Reference
Design
Reference Designs page, lists > 20 reference designs http://www.freescale.com/webapp/sps/site/overview.jsp?nodeId=02nQXGzm8L&tid=tMCdrRD
PMSM Vector Control with Single-Shunt Current-Sensing Using MC56F8013/23 http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=RDDSCPMSMVC&nodeId=016246fNrglP4YnQXGrrlPglzQMszYj6MJ
3-Phase PM Synchronous Motor Torque Vector Control Using 56F80X or 56F8300 Digital Signal Controllers
http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=RDDSP56F8SMTVC&nodeId=016246fNrglP4YnQXGrrlPglzQMszYj6MJ
Software &
Tools
FreeMASTER Real-Time Control/Debug Tool for 8-, 16-, 32-bit MCUs http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=FREEMASTER&fpsp=1
QuickStart Initialization and Development Tool (MC56F80xx, MPC55xx) http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=DSP56800EQUICKSTART&nodeId=016246fNrglP4YnQXGrrlPglzQMszYj6MJ
CodeWarrior for 56800/E Digital Signal Controllers, includes Processor Expert with 56800MC with Math, Filters and Motor Control Software Library for MC56F80xx and MCF51ACxx
http://www.freescale.com/webapp/sps/site/prod_summary.jsp?code=CW-56800E-DSC&nodeId=016246fNrglP4YnQXGrrlPglzQMszYj6MJ
eTPU Graphical Configuration Tool (MCF523x, MPC55xx) www.freescale.com/etpu
3rd
Party Solution
IXXAT (IEEE 1588, CANopen, POWERLINK) www.ixxat.com
Real-Time Automation (Modbus TCP, EtherNet/IP, DeviceNet) www.rtaautomation.com
National Semiconductor (Precision PHYTER - 10/100 Ethernet PHY for IEEE 1588) www.national.com/analog/interface/ethernet
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Additional Information
Freescale:►Motor Control Homepage – www.freescale.com/motorcontrol►8-bit Microcontrollers – www.freescale.com/8bit►16-bit DSC – www.freescale.com/dsc►16-bit Microcontrollers – www.freescale.com/16bit►32-bit ColdFire Microcontrollers – www.freescale.com/coldfire►32-bit Power Architecture Processors – www.freescale.com/powerpc►Analog Products – www.freescale.com/analog►Connectivity – www.freescale.com/connectivity►Industrial Segment – www.freescale.com/industrial
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Freescale Introduces Product Longevity Program
►The embedded market needs long-term product support, which allows OEMs to provide assurance to their customers.
►Freescale has a longstanding track record of providing long-term production support for our products.
►Freescale is pleased to introduce a formal product longevity program for the market segments we serve. ►For the automotive and medical segments, Freescale will manufacture
select devices for a minimum period of 15 years. ►For all other market segments in which Freescale participates,
Freescale will manufacture select devices for a minimum period of 10 years.
►A list of applicable Freescale products is available at www.freescale.com.
TMFreescale Confidential Proprietary. Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2007. 36
Summary
►Cutting Edge. Cost Effective. Complete.Freescale offers technology for every motor control application
►Energy efficient motor controlVector and sensorless control technology in motor control processors
8- and 16-bit MCUs start at <$0.7016-bit DSCs for ACIM and PMSM solutions32-bit Power Architecture MCUs for standard and premium drives
►Strong technical supportRich tools, training, reference designs, librariesDevices are ruggedized with long life and reliabilityIndustrial products ship 10+ years with high quality and expert support
►Cost-effective safety and security on-chipProtect against IP cloning, network data hacking and soft errors
TMFreescale Confidential Proprietary. Freescale™ and the Freescale logo are trademarks of Freescale Semiconductor, Inc. All other product or service names are the property of their respective owners. © Freescale Semiconductor, Inc. 2007. 37
Q&A
►Thank you for attending this presentation. We’ll now take a few moments for the audience’s questions and then we’ll begin the question and answer session.