Fully Integrated BLDC Motor Control from the Signal Generation to the Full BLDC Motor Control Chain

1. Description
The purpose of this document is to explain the theory and application of Atmels integrated BLDC driver solution. The worldwide demand for BLDC systems is increasing rapidly. To fulfill this need, Atmel provides a BLDC system with integrated output stages up to 1A. The system is suitable for under the hood applications with ambient temperatures up to 150C. Various built-in protection features make it ideal for a variety of automotive applications containing small motors. Figure 1-1. Fully Integrated BLDC Motor Control

Fully Integrated BLDC Motor Control Application Note

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2. Fully Integrated BLDC System

Figure 2-1. Fully Integrated BLDC Motor Control Application
Battery

ATA6624
VCC Regulator LIN
TRX

Protection
U

BLDC Motor

VCC

Charge Pump 16 Bit SPI, PWM

V

Watchdog LIN Diagnosis

W

ATA6832
Tx Rx

Commutation Speed Control SPI, PWM HALL

ATmega88

The system consists of three integrated circuits: Microcontroller ATmega88, Triple Half Bridge Driver ATA6832 and LIN System Basis Chip ATA6624 (Figure 2-1). The driver IC integrates three half bridges to run a BLDC motor directly. The output drivers are fully protected. Open load, overtemperature, overload, and undervoltage will be reported to the microcontroller by SPI (Serial Peripheral Interface). The outputs will also be switched with the SPI interface. The direct PWM input is independent of the SPI and can be flexibly linked to the 6 output stages. This ensures an intelligent cruise control for various movement profiles adapted to the load. The loop between motor movement and microcontroller is assured by hall sensors. The commutation is done by the microcontroller ATmega88. Furthermore, ATmega88s flash memory and computing capacity allow operation of LIN protocol 2.0. The BLDC system is connected with the LIN transceiver ATA6624 to the automotive environment. Furthermore, this device generates the digital supply voltage. No additional protection circuitry, e.g. current sensing is required due the enhanced in-circuit protection features for overload and overtemperature.

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Fully Integrated BLDC Motor Control

3. Theory of BLDC Operation
Brushless DC motors are used in a growing number of applications as they offer several advantages, including reduced noise, long lifetime (no brush erosion), reduced noise, good weight/size to power ratio, and hazardous operation environment usability (with flammable products). These types of motor have a little rotor inertia compared with other motor types. Coils are attached to the stator, and commutation is controlled by electronics using position sensors feedback or back electromotive force measurements. A BLDC motor stator basically includes three coils, which can be replicated to reduce torque ripple. In the same way, a rotor basically includes permanent magnets, composed of one to multiple pair of poles; this also affects step size (see Figure 3-1). Position can be estimated using three hall sensors, each spread at 120 around the stator. Figure 3-1. Three-coil BLDC Motor, 1 and 2 Pair Poles
A A

N S

N S N S

BLDC motor operation can be simplified by considering only three coils and one pair pole. The commutation of the phase depends on the position, in our case, the hall sensors value. When motor coils are supplied, a magnetic field is created and the rotor moves. The most elementary commutation driving method is an on-off scheme: a coil is either conducting or not. Only two coils are supplied at the same time; the third is floating. This is referred to as trapezoidal commutation or block commutation. Figure 3-2. Power Stage
HS1 HS2 HS3

A B C LS1 LS2 LS3

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Figure 3-3.

Commutation Steps for CW Operation

010 A 011 110 A A

001

100

101

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Reading the hall sensors value indicates commutation to be performed. For multiple pole motors, electrical rotation corresponds to mechanical rotation with the pair pole number factor.

Table 3-1.

Switches Commutation for CW and CCW Rotation

Switches Commutation for CW Rotation Coils A-B A-C B-C B-A C-A C-B Switches HS1 - LS2 HS1 - LS3 HS2 - LS3 HS2 - LS1 HS3 - LS1 HS3 - LS2 Switches Commutation for CCW Rotation Coils B-A C-A C-B A-B A-C B-C Switches HS2 - LS1 HS3 - LS1 HS3 - LS2 HS1 - LS2 HS1 - LS3 HS2 - LS3

Hall Sensors Value (CBA) 101 001 011 010 110 100

Commutations are updated at each step to create a rotating magnetic field as shown in Figure 3-3. This method takes full advantage of the ATA6832 as commutations can be transmitted at each step, while PWM allows magnetic field magnitude tuning to act independently on motor torque and speed.

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Fully Integrated BLDC Motor Control

4. Driver ATA6832
The ATA6832 offers a variety of diagnostic and protection features including supervised low battery voltage, overload, open load, and temperature monitoring.

4.1

Maximum Speed
The commutation is done by microcontroller. The hall sensors are the input channel, which provide the motor position feedback. The SPI interface, which is the interface to the integrated triple half-bridge driver, is the output channel. The time schedule for commutation is shown in Figure 6-1 on page 10. The data transfer rate of the SPI is restricted; 2 MHz is the maximum transfer rate to the ATA6832. 16 bit plus communication control allows a maximum theoretical SPI rate of up to 100 kHz one command every 10 s. The maximum output switch speed of the ATA6832 is up to 25 kHz. Changing the output state is possible every 40 s. A BLDC motor with a 3-pole stator and one double pole enables, with a defined control, the maximum speed. A rotor with two double poles enables half the speed. A single double-pole motor in one rotation passes through 6 different switching states of the three output half bridges (refer to Table 3-1 on page 4). Each switching state is controlled by one SPI command; therefore, six SPI commands are required for one turn. An output switch rate of 40 s and 6 times each turn results in a minimum of 240 s for one rotation.

4.2

Open BLDC Load Detection

To detect the open load, there are integrated current sources on each output stage. Turning off open-load detection bit (OLD set to low), the current sources are switched on. The low side test current is guaranteed by design to be higher than high side test current. Therefore, if no load is connected to an output, all the three low-side switches will report open load by turning their output register bit on. If one output is switched to high and the BLDC motor is connected correctly, both neighboring outputs will show high-side open load. In the event of open load on one string, this output will signal low-side open load. Under normal operation, the open load current sources should be switched off by setting OLD bit to high. Otherwise, this circuitry will produce power dissipation.

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4.3

Switching PWM
To control the outputs with PWM, there is one PWM input pin available for all six outputs. The outputs to operate with PWM can be selected by activating the corresponding bit of the six input data registers PLx/PHx. If PWM operation mode is activated for an output by these input bits, its input data register switch HSx/LSx is and-connected with the input pin PWM. The selected outputs follow the PWM input signal. For cruise control, e.g., to start or stop a BLDC motor, PWM is necessary. To control the speed, only one dedicated PWM for all three BLDC motor strings is required. Controlling the current through the strings, it is sufficient to switch only one output of a half bridge, either high side or low side. This circumstance enables running of the BLDC driver with only one PWM frequency. Only one microcontroller timer is necessary. The high-side switches of the ATA6831 and ATA6832 are faster than the low-side switches. PWM frequency up to 25 kHz is possible using the high-side switches.

4.4

Cooling Area Design

The drivers IC ATA6831/ATA6832 are housed in a special QFN package. QFN package is particularly suitable for power package because of the exposed die pad. To make use of this advantage, it has to be assured the head slug is completely soldered to the PCB. To reduce thermal resistance, vias are required down to the soldering layer. A sufficing ground plane has to be placed on the soldering layer to eliminate the thermal energy. A via diameter of 0.3 mm to 0.4 mm and a spacing of 1 mm to 1.5 mm has proven to be most suitable. Some care should be taken of the copper area's planarity, in particular, any solder bumps arising at the thermal vias should be avoided. To minimize package size down to 4 mm 4 mm, pins are only on three sides of the package.

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Fully Integrated BLDC Motor Control

5. The Application Board
The application board is run capable when connected to 12V at connector LIN (see Figure 5-1 on page 8). The board can be connected to the automotive environment over a LIN bus by a LIN clamp; however, there is no LIN protocol implemented in the microcontroller. The ATA6625 on this application board is used to generate a 5V digital supply. A switch (DIR) for run/stop, clockwise, counterclockwise, and a potentiometer (SPEED) for variable speed (PWM) input are available on the board for stand-alone prototyping. The feedback loop from BLDC motor to microcontroller ATmega88 is done by hall sensors. The three hall inputs can be linked to the connector HALL as well as the 5V supply for the hall sensors

5.1

On-board Features
The application board provides the following features: ATmega88 QFN32 MCU ATA6832 QFN Integrated triple half bridges to drive BLDC motor and check its operations ATA6625 SO8 1 x LIN interface 1.3 and 2.0 compliant 5V power supply regulator Up to 125C (Using an ATA6624 with an external transistor would allow up to 150C operation) On-Off-On switch Stand-alone commands interface: Run/stop, clockwise, and counterclockwise. Potentiometer Stand-alone speed variation command (PWM ratio) System clock Internal RC oscillator Connectors Power supply (battery voltage) and LIN BLDC Motor connector (3 phase) Hall sensor inputs and supply (3 filtered inputs and 5V regulated supply voltage) ISP/debugWire connector, for on-chip in-situ Programming (ISP) and for on-chip debugging using JTAG ICE supported by AVR Studio interface(1) Dimensions: 45 mm 45 mm

Note:

1. The ATmega88 is supported by AVR Studio, version 4.12 or higher. For up-to-date information on this and other AVR tool products, please consult our web site. The newest version of AVR Studio, AVR tools and this user guide can be found in the AVR section of the Atmel web site, http://www.atmel.com

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Figure 5-1.

Application Board Top View and Connector Usage

Vbat

LIN

PGND

Phase U Phase V
Speed

Phase W 5V Hall A

CCW Stop CW

Hall B
JP1 VCC 5V 2 4 6 MOSI GND ISP MK2 Header

Hall C GND

MISO SCK NRES

1 3 5

5.2

High Ambient Temperature

The BLDC system is designed for high temperature environments. The MCU ATmega88 and the driver ATA6832 are qualified up to an ambient temperature of 150C. The ATA6832 has enhanced temperature management; each of its output stages contains a thermal sensor. In addition to the thermal shutdown function, a thermal prewarning function is available. If the temperature exceeds the prewarning threshold, the microcontroller can react by reducing output power. The SBC (system basis chip) ATA6625 is only qualified for junction temperatures up to 150C. The power dissipation of its voltage regulator only allows for ambient temperature up to 125C. ATA6624, a member of the same SBC family, allows operation with a discrete transistor for line regulation. Transistors are available for junction temperatures higher than 150C. If such a line regulation transistor dissipates the heat, ATA6624s temperature rise is only 3C. Its possible ambient temperature is 147C. Using a high temperature voltage regulator instead of Atmels SBC enables a full 150C temperature range. All discrete components used are enabled for temperatures up to 150C. Mounted connectors, a switch, and a potentiometer on the board, enable prototyping; however, these components are not high temperature qualified. The board can be integrated in hot temperature environment by wires.

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Fully Integrated BLDC Motor Control

6. Software Description
All code is implemented in C language, except SPI interrupt subroutine, which is implemented in assembly. Source code can be compiled using IAR EWAVR 4.20A as well as AVR-GCC (WinAVR-20060421 with AVR Studio). HTML documentation is included in the package. Use the High_temp_BLDC.html file in the root directory to start viewing the documentation. Software behavior can be dispatched in three main working modes: Motor stopped In this mode, no hall sensors interrupts occurs. To maintain ATA6832 diagnostics, SPI communication is constantly performed by main loop. Command switch enables starting of the motor. A first frame has to be sent to the power driver to start the motor. This frame shall contain commutations to be applied according to motor position (hall sensors inputs) and to desired direction. While stopped, ATA6832 is switched into standby mode to decrease current consumption to lower than 20 A. Motor running Once the motor is started, SPI communications (commutations), are only handled by hall sensors ISR, each time an interrupt occurs. Command switch can be used to break the commutations evolution, and thus stop the motor. Degraded mode: two possibilities Motor has been stopped because of an overload, an over temperature, etc. Software waits for the user to clear the fault (operate switch to stop position). Motor is still running (software behavior is similar to the motor running mode). User is informed that a fault has been detected (over temperature, one or more switches are secured, etc.). Software can reduce output power and waits for a user order to clear the fault (operate switch to stop position).

6.1

Resources
Table 6-1. Code, Data, and CPU Resources (Without Compiler Optimizations)
Code Size (Flash) 1 304 bytes 1 826 bytes Data Size (Ram) 367 bytes 48 bytes CPU Load See Schedule

Compiler/Resources IAR EWAVR 4.20A AVR-GCC

The following MCU peripherals are used: SPI Commutation data and status data transfer to/from ATA6832 power driver Timer 1 PWM generation through Output Compare 1A (OC1A pin) ADC channel 0 Speed potentiometer value acquisition (Acts on PWM ratio)

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 Pin change interrupts Hall sensor edges detection are used to detect motor position evolution I/O LED, Switch operations Optional (not managed by this stand-alone software) UART and Input Capture for LIN implementation

6.2

Schedule
Software Schedule

Figure 6-1.

Hall Sensor ISR Next Commutation SPI

1st Commutation Data Tx Main Loop (Background)

Motor Stopped Motor Start Order

Motor Startup

Motor Running

CPU load while motor is running Using IAR EWAVR 4.20A The main loop is continually executed in background. It could be scheduled. Main loop measured time cycle is 21 s. For each output commutation, one hall interrupt and two SPI interrupts occur. This makes for one commutation: CPU time = Hall ISR time + Both SPI ISR time = 8.4 s + 4.8 s = 13.2 s/commutation. Using AVR-GCC The main loop is continually executed in background. It could be scheduled. The main loop measured time cycle is 30 s. For each output commutation, one hall interrupt and two SPI interrupts occur. This makes for one commutation: CPU time = Hall ISR time + Both SPI ISR time = 16 s + 4.8 s = 20.8 s / commutation. The main loop is not taken into account for CPU load computation below, as it is not scheduled and executed in background. Assuming we have 6 interrupts for a complete motor rotation and a 4-pair pole motor, we can determine the following CPU load versus rotation speed.

10

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Fully Integrated BLDC Motor Control

Figure 6-2. CPU Load versus Speed for an 8 Pole Motor
8 7 6 5

% CPL

CPU Avr GCC 4 CPU IAR 3 2 1 0 0 2000 4000 6000 8000 10 0 0 0 12 0 0 0

RPM (Rotation Per Minute)

6.3

Diagrams
Figure 6-3. Flowchart for Hall Sensors ISR
Pin Change Interrupt (Hall Sensor ISR)

Read Hall Sensor Signals from Port C

Stop? N

Select Next Commutation State from CW Sequence

Clockwise Rotation?

Select Next Commutation State from CCW Sequence

Transmit Commutation Data on SPI

Figure 6-4.

Flowchart for SPI Transfer Completed ISR

SPI Transmit Completed ISR

Read Rx Buffer Store to ATA6832 Status

Both Command Bytes (16 bits) Sent?

Read Rx Buffer Store to ATA6832 Status

Release Slave Select Pin Report Transmit Completed

Write Tx Buffer Report One Byte Transferred

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Figure 6-5.

Main Loop Flowchart

Main Loop (Background)

Initialize I/O, SPI, ADC, Hall Sensors ISR, Timer1-PWM, ATA6832

Refresh ATA6832 Status Buffer

Set PWM Ratio According to ADC

Manage Motor Status

Stopped? Start? N

Send Commutation Command According to Position and Direction

Send SPI to ATA6832 Continuously

Started CW? Stop?

Motor Status Stopped

Started CCW? Stop?

Motor Status Stopped

Over Temperature? Overload ? Under Voltage ?

Toggle LED

N Over Temperature ? Set LED Y Limit Output Power

Reset ATA6832

Stop?

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Fully Integrated BLDC Motor Control

6.4 Modules
void SPI_MasterInit(void)

Initializes SPI used to access ATA6832, configures I/O, 2MHz frequency, data sample at clock falling edge, LSB first.
SPI_status_t SPI_transmit_16(unsigned int data_16)

Sends 16 bit data on SPI (using interrupts), depending on returned SPI status. Returns SPI_Initiate_tx status if successful.
SPI_status_t SPI_get_Rx_data(unsigned int *data_16_ptr)

Puts the SPI received data into pointed buffer when data has been received. In that case it returns SPI_Completed status and changes SPI status to ready.
void ADC_Init(void)

Sets up ADC to acquire desired speed from potentiometer.

unsigned int get_speed()

Returns last acquired desired speed from potentiometer. Checks ADC end conversion flag to start new conversions and update latest desired speed.
void Hall_sensors_ISR_init(void)

Sets up pin change interrupts on hall sensor inputs.

Motor_ctrl_t BLDC_start(unsigned char direction)

Sends first commutation order to start motor according to desired direction and to hall sensors inputs. Returns started status when SPI frame has been emitted.
void Timer1_start(void)

Configures timer 1 for PWM on Output compare 1 A.

void manage_time_base(void)

Manages a general purpose time base (for LED toggling, etc.).

TIMER1_SET_OC1A_PWM(val)

Changes PWM ratio (macro).

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Figure 7-1.

10

2 3 VS1 VS2 VCC 4 LIN 4 5 7 3 CS OUT2S OUT3 OUT3S 1 HallA HallB 8 17 14 18 C7 100 nF HallC 2 PH_C 2 1 2 1 2 1 PGND GND GND PGND1 PGND2 PGND3 PWM 6 DO OUT2 13 CLK DI OUT1 OUT1S 12 PH_B 16 1 15 2 PH_A C3 MISO 4.7 F 10V SPI_SS PWM VCC 5V C5 C4 GND 100 nF 50V 10 F 50V 10 F 50V C6 SCK RXD 5 LIN_RXD MOSI GND TXD 6 LIN_TXD MOT LIN_EN GND PGND NRES

11

LIN_EN

LIN_TXD

LIN_RXD

NRES

HALL_C

HALL_B

HALL_A

32

31

30

29

28

27

26

R3

7. Application Board Full Description

25

PD1(TXD/PCINT17)

PD2(INT0/PCINT18)

PD0(RXD/PCINT16)

PC3(ADC3/PCINT11)

PC6(RESET/PCINT14)

PC2(ADC2/PCINT10)

PC5(ADC5/SCL/PCINT13)

PC4(ADC4/SDA/PCINT12)

PD5(T1/OC0B/PCINT21)

PD6(AIN0/OC0A/PCINT22)

PD7(AIN1/PCINT23)

PB0(ICP1/CLKO/PCINT0)

PB1(OC1A/PCINT1)

PB2(OC1B/SS/PCINT2)

PB3(MOSI/OC2A1/PCINT3)

10

11

12

13

14

15

MISO

SCK

NRES

MOSI

R4 330

D2

LIN_RXD

PWM

SPI_SS

MOSI

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ISP MK2 Header

GND

LED CMS Green

MISO

16

JP1

VCC 5V

VCC 5V

PB4(MISO/PCINT4)

14
U1 C1 8 7 NRES U2 ATA6832 VCC 5V 100 nF ATA6625 VCC 5V VBat VBat VCC 5V VCC 5V 1 2 VS LIN Transceiver VREG VCC5 C2 100 nF 50V

VBat

D1 30BQ040

LIN

LIN_EN

C11

LIN

LIN

PGND

220 pF

PGND

GND

VBat

3 Half Bridge

B2

HALL

PGND

R1 10 k

B4

R2

BLDC Application Board Schematic

PGND

GND

GND

AGND

VCC 5V

VCC 5V SWITCH_CCW 1 SWITCH_CW 2 PD4(T0/XCK/PCINT20) PC0(ADC0/PCINT8) ADC7 GND AREF ADC6 AVCC PB5(SCK/PCINT5) GND VCC GND VCC PB6(TOSC1/XTAL1/PCINT6) PB7(TOSC2/XTAL2/PCINT7) 3 4 5 6 C9 8 7 PD3(INT1/OC2B/PCINT19) PC1(ADC1/PCINT9) 24

VCC 5V

VCC 5V 23 Speed Set 22 21 20 19 18 17 SCK C8

R5 4.7 k
Hall_A

R6 4.7 k

R7 4.7 k R8 100
Hall_B HallA

100 k

Speed Set

R9 100
Hall_C 100 nF C12 C10 1 nF 100 nF AGND AGND AGND GND 1 nF 1 nF C13 C14

Fully Integrated BLDC Motor Control

HallB

GND

R10 100

HallC

100 nF

ON/OFF/ON Switch Right Angle

GND GND

DIR

SWITCH_CCW

SWITCH_CW

GND

Fully Integrated BLDC Motor Control

Figure 7-2.

BLDC Application Board Top View and Component Placement

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Figure 7-3.

BLDC Application Board Bottom View

Table 7-1.
Connector LIN

BLDC Application Board Connectors

Clamp 1 2 3 1 2 1 2 1 2 1 2 Function Power Ground LIN input Power 12V Motor Phase A Motor Phase B Motor Phase C Power 5V Hall A Hall B Hall C Power GND Direction Input Input Input Output Output Output Output Input Input Input Output

MOT B2 HALL B4

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Atmel Corporation
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