HIGH PERFORMANCE BRUSHLESS DC MOTOR DRIVER
BC10 • BC10A
M I C R O T E C H N O L O G Y
HTTP://WWW.APEXMICROTECH.COM
(800) 546-APEX
(800) 546-2739
FEATURES
• 10V TO 100V MOTOR SUPPLY AT 10A CONTINUOUS AND
20A PEAK OUTPUT CURRENT
• OPERATION WITH 10.8V TO 16V VCC, ALLOWING
NOMINAL 12V OR 15 V VCC SUPPLIES
• THREE PHASE FULL BRIDGE OPERATION WITH
2 OR 4 QUADRANT PWM
• AUTOMATIC BRAKING WHEN USING 2 QUADRANT PWM
• THERMAL PROTECTION
• ANTI SHOOT THROUGH DESIGN
• 50 KHZ INTERNALLY SET PWM FREQUENCY, WHICH MAY
BE LOWERED WITH EXTERNAL CAPACITORS
• SELECTABLE 60° OR 120° COMMUTATION SEQUENCES
• COMMUTATION TRANSITIONS OUTPUT FOR DERIVING
SPEED CONTROL
• MAY BE USED OPEN LOOP, OR WITHIN
A FEEDBACK LOOP
• ANALOG MOTOR CURRENT MONITOR OUTPUT, MAY BE
USED FOR TORQUE CONTROL OR FOR TRANSCONDUC-
TANCE AMPLIFIER DRIVE.
• ANALOG REFERENCE, FEEDBACK, AND TORQUE INPUTS
24-pin DIP
PACKAGE STYLE CK
DESCRIPTION
APPLICATIONS
• 3 PHASE BRUSHLESS MOTOR CONTROL
BLOCK DIAGRAM
SSC
18
OE
19
HS1
6
HS2
7
HS3
8
120
22
REV
21
REF IN
23
+
PWM
COMPARATOR
X10
COMMUTATION
DECODE
LOGIC
∑
–
FB
24
X10
+
∑
–
TEMP
SENSING
OVERTEMP
The BC10 Brushless DC Motor Controller provides
the necessary functions to control conventional 3-phase
brushless DC motors in an open loop or closed loop system.
The BC10 is able to control motors requiring up to 1kW
continuous input power.
The controller drives the motor, generates the PWM,
decodes the commutation patterns, multiplex the current
sense, and provides error amplification. Operation with
either 60° or 120° commutation patterns may be selected
with a logic input.
Current sense multiplexing is used to make the current
monitor output always proportional to the active motor
coils current. Therefore the current monitor output may
be used in generating transconductance drive for easy
servo compensation.
The controller may generate 4-quadrant PWM for
applications requiring continuous transition through zero
velocity, or 2 quadrant PWM for electrically quieter operation in
unidirectional applica-
2Q
VCC
HV
HV
20
2
9
tions. Direction of rota-
tion may be reversed
V+
OUT 1
TOP DRIVE 1
in 2-quadrant mode by
1/2
10
BRIDGE
BOTTOM DRIVE 1
using the reverse com-
1
S1
mand input. When in
13
2-quadrant mode if the
BRIDGE
CONTROL
motor is stopped or
LOGIC
decelerating dynamic
V+
braking is automatically
OUT 2
TOP DRIVE 2
1/2
BRIDGE
11
applied. In this way
BOTTOM DRIVE 2
2
S2
deceleration profiles
PWM
15
may be followed even
when using 2-quadrant
V+
PWM.
TOP DRIVE 3
1/2
BRIDGE
3
OUT 3
12
S3
14
SHUTDOWN
BOTTOM DRIVE 3
PWM
OSCILLATOR
POWER
FAULT
LOGIC
OVERCURRENT
CURRENT
SENSING
SIGNAL
CONDITIONING
5
MOTOR I
HV RTN
16
HV RTN
4
TORQUE
CT
3
17
FAULT
GROUND
1
APEX MICROTECHNOLOGY CORPORATION
• TELEPHONE (520) 690-8600 • FAX (520) 888-3329 • ORDERS (520) 690-8601 • EMAIL prodlit@apexmicrotech.com
1
BC10 • BC10A
ABSOLUTE MAXIMUM RATINGS
MOTOR VOLTAGE, V+
CIRCUIT SUPPLY, Vcc
OUTPUT CURRENT, peak
OUTPUT CURRENT, continuous
ANALOG INPUT VOLTAGE
DIGITAL INPUT VOLTAGE
TEMPERATURE, pin solder, 10s
TEMPERATURE, junction
2
TEMPERATURE RANGE, storage
OPERATING TEMPERATURE, case,
BC10
OPERATING TEMPERATURE, case,
BC10A
ABSOLUTE MAXIMUM RATINGS
SPECIFICATIONS
100V
16V
20A
10 A
–0.3V to Vcc+0.3V
–0.3V to 5.35V
300°C
150°C
–65 to 150°C
–25 to 85°C
–40 to 85°C
SPECIFICATIONS
PARAMETER
ERROR AMP
OFFSET VOLTAGE
BIAS CURRENT
DC GAIN
1
BANDWIDTH
INPUT AMP
STAGE GAIN
INPUT IMPEDANCE
1
COMMON MODE VOLTAGE
COMMON MODE VOLTAGE
COMMON MODE REJECTI0N
DIFFERENTIAL OFFSET
GAIN BANDWIDTH PRODUCT
OUTPUT
TOTAL R
on
EFFICIENCY, 5A, 200V
SWITCHING FREQUENCY
CURRENT, continuous
CURRENT, peak
POWER SUPPLY
VOLTAGE, V+
VOLTAGE, Vcc
POWER DISSIPATION
Operating Power Dissipation
2
Single FET Dissipation
2
Calculated at 100V,10A,
50 kHz PWM, 12 mHy, 6.4 ohms,
95% duty cycle and 4-quadrant PWM
Calculated at 100V,10A,
50 kHz PWM, 12 mHy, 6.4 ohms
95% duty cycle, 4-quadrant PWM
To each of 6 power FETs and 150°C
junction temperature
Set by internal and/or external resistors
Applied at input terminals, Vcc = 10.8V
Applied at input terminals, Vcc = 16V
–0.5
–0.5
50
–3.3
700
TEST CONDITIONS
MIN
–3.3
19.8
15
TYP
0
20
16
20
2
5.0
5.0
0
MAX
3.3
4
20.2
17
20.2
8.5
14
3.3
UNITS
mV
pA
db
kHz
db
Kohm
V
V
db
mV
kHz
Ohms
%
kHz
A
A
V
Junction Temperature = 125°C
Dependent on individual application
45
10
20
10
10.8
0.28
86
50
55
100
16
128
60
watts
watts
Thermal resistance
1.95
°
C/watt
NOTES: 1.
2.
Set internally
Long term operation at the maximum junction temperature will result in reduced product life.
CAUTION
The BC10 is constructed from static sensitive components. ESD handling procedures must be observed.
APEX MICROTECHNOLOGY CORPORATION
• 5980 NORTH SHANNON ROAD • TUCSON, ARIZONA 85741 • USA • APPLICATIONS HOTLINE: 1 (800) 546-2739
2
TYPICAL
PERFORMANCE
BC10 • BC10A
PIN FUNCTION
All Logic Positive TKUC
I/O
I
I
O
O
O
I/O
I/O
I/O
I
I
I
I
I
I
I
I
I
I
O
O
O
I
I/O
I
SIGNAL
HV
HVRTN
OUT1
OUT2
OUT3
S1
S2
S3
HS1
HS2
HS3
120
REV
GROUND
Vcc
REF IN
FB
TORQUE
MOTOR I
SSC
FAULT
OE
CT
2Q
DESCRIPTION
Unregulated high current motor supply voltage
Return line for the high motor current
Half bridge output for driving motor coil
Half bridge output for driving motor coil
Half bridge output for driving motor coil
Source of the N-rail FET in half bridge 1
Source of the N-rail FET in half bridge 2
Source of the N-rail FET in half bridge 3
Commutation sensor input 1
Commutation sensor input 2
Commutation sensor input 3
Sets commutation logic for 120° phasing
Reverses direction when 2 quadrant PWM is used
Signal ground
Control circuit power
Velocity/speed input
Input for analog voltage proportional to velocity or speed
Input for an analog voltage proportional to motor current
Analog voltage proportional to motor current
HCMOS level pulse for each sensor state change.
HCMOS logic level output, a 1 indicates an over temperature
or over current condition.
HCMOS 1 enables power FET operation
The PWM frequency may be lowered by installing a
capacitor between this output and ground.
A logic 1 on this input enables 2 quadrant PWM
PIN
9
16
10
11
12
13
15
14
6
7
8
22
21
1
2
23
24
4
5
18
17
19
3
20
COMMUTATION AND OUTPUT TABLES
TABLE 1
TABLE 2
Position
R
2Q
120
OE
HS1
HS2
HS3
OUT1
OUT2
OUT3
TABLE 3
0
0
0
1
1
1
0
1
T
–
+
60
0
0
1
1
1
0
0
+
–
T
120
0
0
1
1
1
1
0
+
T
–
180
0
0
1
1
0
1
0
T
+
–
240
0
0
1
1
0
1
1
–
+
T
300
0
0
1
1
0
0
1
–
T
+
Position
R
2Q
120
OE
HS1
HS2
HS3
OUT1
OUT2
OUT3
TABLE 4
0
0
0
0
1
1
1
1
T
–
+
60
0
0
0
1
1
1
0
+
–
T
120
0
0
0
1
1
0
0
+
T
–
180
0
0
0
1
0
0
0
T
+
–
240
0
0
0
1
0
0
1
–
+
T
300
0
0
0
1
0
1
1
–
T
+
Position
R
2Q
120
OE
HS1
HS2
HS3
OUT1
OUT2
OUT3
0
0
1
1
1
1
0
1
T
0
+
60
0
1
1
1
1
0
0
+
0
T
120
0
1
1
1
1
1
0
+
T
0
180
0
1
1
1
0
1
0
T
+
0
240
0
1
1
1
0
1
1
0
+
T
300
0
1
1
1
0
0
1
0
T
+
Position
R
2Q
120
OE
HS1
HS2
HS3
OUT1
OUT2
OUT3
0
0
1
0
1
1
1
1
T
0
+
60
0
1
0
1
1
1
0
+
0
T
120
0
1
0
1
1
0
0
+
T
0
180
0
1
0
1
0
0
0
T
+
0
240
0
1
0
1
0
0
1
0
+
T
300
0
1
0
1
0
1
1
0
T
+
APEX MICROTECHNOLOGY CORPORATION
• TELEPHONE (520) 690-8600 • FAX (520) 888-3329 • ORDERS (520) 690-8601 • EMAIL prodlit@apexmicrotech.com
3
BC10 • BC10A
GENERAL
Much useful application information for these products can
be obtained from Application Notes 1 (General Operating
Considerations) and 30 (PWM Basics).
OPERATING
CONSIDERATONS
PROTECTION CIRCUITS
There are four protection circuits in the BC10.
1. The peak current sensing circuit, which is programmed by
the value of the current sense resistors placed by the user
between the DMOS sources and HV return. This circuit is
reset each PWM cycle. If three current sense resistors are
used, as recommended, an analog multiplexer selects the
current sense resistor, which has the same current as
the motor coil. This technique blanks out noise and
provides an excellent sensing of actual coil current.
The programming of this circuit is accomplished by the
folowing formula:
I
TRIP
= 0.5/R
SENSE
Note that for large currents R
SENSE
becomes very small,
therefore stray resistance in the high current path can have
a large effect. Heavy etch should be used in the current
sensing path, and leads should be very short between the
resistors and the pins of the controller.
2. Thermal Protection
The junction temperature of all power devices is sensed,
and the controller is shut down when too hot. This
circuit is a a latch and can be reset when OE is turned
on, providing the power devices have cooled to a safe
temperature.
3. There is an over-current circuit which shut down the BC10
when the current provided by the HV supply exceeds
about 1.5 times the peak current rating. This circuit latches
and may be reset by cycling the OE input. Although this
is “top rail” protection, a short from output to ground will
probably destroy the BC10.
4. The output circuit will shut down if a power supply is
missing. This is not an alarmed fault.
PWM CONSIDERATIONS
The BC10 can be configured with a logic-input (2Q) to
operate either as a 2-quadrant or 4-quadrant controller.
2-quadrant PWM holds one coil terminal at a constant level
and applies PWM at the other. PWM is applied at the positive
terminal when in 2-quadrant mode. 4-quadrant PWM switches
both terminals. 2-quadrant PWM is electrically slightly quieter
and slightly more efficient, but cannot transition through
zero. Therefore 4-quadrant PWM is required for applications
such as position servos, phase locked motor control, or
accurately following complex velocity profiles. 2-quadrant
PWM is preferable for unidirectional speed control applications.
The R input may be used to reverse the motor when
using 2-quadrant PWM, but must be at logic “0” when in
4-quadrant mode.
COMMUTATION
The BC10 may be configured to operate with either 60°
or 120° Hall sensor patterns by the state of the 120 input.
(Obviously also encoder outputs with the same logic.) When
120 is low the BC10 operates with 60° commutation; when 120
is high they operate with 120° commutation.
The relationship between commutation states and motor
drive output is tabulated in the following tables [See Tables
1-4 on previous page]. For the purposes of these tables
PWM that is mostly positive will be designated +; PWM that
is mostly low will be designated −; a constant low state will
be designated by 0; a tri-state condition will be designated
T; REF IN is more positive than FB; and “Forward” rotation
is the only direction tabulated. Position is given in electrical
degrees.
Some motor manufacturers may not use the same
conventions in identifying motor and Hall sense leads as
Apex. In that event you may have to experimentally identify
the corresponding motor and Hall Sense leads. For 3 binary
square waves with equal phase shifts between the square
waves, such as Hall sense outputs, there are only 8 possible
states. 60° commutation fills 6 of the states and 120°
commutation fills the other set of 6 states. Therefore all such
patterns are truly only 60° or 120°. Changing pattern is done in
the Apex controller by inverting HS2 internally.
Once the proper commutation patterns are obtained it is
necessary to determine the motor lead orientation to the
Hall sense. This may be done by turning the motor with a
test fixture and observing the relationship between the
HS patterns and the EMF, or by running the motor at low
voltage and systematically switching motor leads until smooth
running in the desired direction is obtained. The motor
can be expected to run smoothly in the desired direction,
run reverse, not run at all, or vibrate violently between 2
positions as this is done.
FAULT
The FAULT output is an alarm, a logic 1 indicates the
outputs are disabled. Fault is at 1 when OE is at 0, and it is at
logic 0 when OE is at 1 during normal operation. Outputs will
latch to the disabled state and fault will be at logic 1 when any
IGBT is too hot or when peak IGBT current has exceeded a
safe level for the IGBT. This may be reset by setting OE to
logic 0 and back to logic 1.
When the coil sensing circuit senses that the average
current has exceeded the level set by the selection of current
sense resistors, the output will be disabled and the FAULT
output will go to logic 1. (Even though the output has been
disabled coil current will continue, flowing through the diodes
in anti-parallel with each IGBT.) When coil current has
decayed to below this set level the outputs will be enabled
and FAULT will be at logic 0. Thus when limiting the average
value of coil current the output will cycle between being
disabled and enabled, and FAULT will cycle between logic
1 and 0. This action may cause an audible hiss when driving
low inertia systems.
APEX MICROTECHNOLOGY CORPORATION
• 5980 NORTH SHANNON ROAD • TUCSON, ARIZONA 85741 • USA • APPLICATIONS HOTLINE: 1 (800) 546-2739
4
OPERATING
CONSIDERATONS
BC10 • BC10A
OPERATION WITH NEGATIVE ANALOG INPUTS
The REF IN and FB inputs are inputs to a true differential
amplifier. These inputs operate over a range between signal
ground and +10V. However, with the addition 2 resistors,
a diode, and loss of gain the circuit will operate with input
voltages below ground. To operate with these inputs going
to -10V the gain loss is 26.5 dB. When used with an external
controller, which can compensate for this lost gain, this
is insignificant.
To choose a resistor to hold the input to the internal amplifier
within its range, use the following formula:
R
IN
= 2.06(4.9 + V
IN
) - 11.09
Where:
R
IN
is the minimum value of the external resistor in K-ohms.
V
IN
is the absolute value of the most negative input level.
A resistor of this value should be inserted in series with both
the REF IN and FB inputs. Since unbalance in these resistors
affects dc offset and common mode rejection, precision
resistors should be used. If the host system can produce steps
to the REF IN input with less than 11
µ-seconds
transients
below ground on the internal amplifier will occur. Connecting
a diode with its cathode tied to pin 23, REF IN, and its anode
to ground will clamp these to a safe level.
EXAMPLE: Assume an input voltage of -10V. The formula
gives a minimum input resistance of 19.6K. The lowest
1% value above 19.6K is 20.0K. A nominal 20.0K resistor
2% low is 19.6K, so a 20.0K resistor whose variation to
all effects is 2% is safe..
OPEN LOOP OPERATION
The normal way of operating the controller open loop is
connect the input, REF IN pin 24 to a reference, and the
FB input, pin 24 to an analog voltage. When this is done
in conjunction with 2-quadrant PWM the voltage applied
to the motor coils will be:
V
M
= 25(HV)(V
IN
- V
REF
) + HV/2
Where:
HV is the motor supoply.
V
IN
is the input voltage.
V
REF
is the analog reference.
If 4-quadrant PWM is used the equation becomes:
V
M
= 50(HV)(V
IN
- V
REF
)
The input dynamic range can be as smnall as 36mV for
both 2-quadrant or 4-quadrant PWM (No larger than 40mV).
The dynamic range can be extended, with the penalty of gain
loss, by putting matched resistors in series with the FB and
REF IN inputs. The value of these resistors for a given dynamic
range is given by the following equation:
Where:
V
IN MAX
is the desired p-p input.
R
IN
is the required minimum value for the resistors to be put in
series with the FB and REF IN inputs, in kilo-ohms.
When these resistors are used gain is reduced. The new
motor voltage equation for 2-quadrant operation is:
V
M
= HV/2 + (25(HV)(V
IN
- V
REF
))/(R
IN
+ 1)
The new equation for 4-quadrant operation is:
V
M
= (50(HV)(V
IN
- V
REF
))/(R
IN
+ 1)
An alternative mode of open loop operation is to leave the
FB and REF IN inputs open, and connect the input to the
TORQUE input, either directly or through a series resistor.
When this is done the input signal is effectively referenced to
an internal 5.00V supply, V
DD
(This supply is not brought to a
pin). Just as when using the REF IN and FB inputs, dynamic
range can be increased (and gain decreased) by use of
a series resistor, but only one is required. For 2-quadrant
operation the equation for motor voltage is:
V
M
= HV/2 + (25(HV)(V
DD
- V
IN
))/(R
IN
+ 10)
For 4-quadrant operation the equation for motor voltage is:
V
M
= (50(HV)(V
DD
- V
IN
))/(R
IN
+ 10)
R
IN
can be determined for a linear dynamic range for
both 2-quadrant and 4-quadrant PWM from the following
equation:
R
IN
= (V
IN MAX
/0.036) - 10
R
IN
= (V
IN MAX
/0.036) - 1
CLOSED LOOP OPERATION
The controller may be operated in a closed loop by applying
the command signal to the REF IN input, pin 23, and analog
feedback to FB, pin 24. Or, if operating with resistors in
series with pins 23 and 24, through those resistor to pins
23 and 24. In this case the gain as a servo amplifier is
given by the equation of sections 2 or 3 of the "Open Loop
Operation" section.
TRANSCONDUCTANCE AMPLIFIER OPERATION
The BC10 can be operated in a transconductance amplifier
mode by connecting the MOTOR I output to the TORQUE
input either directly or through a resistor.
It is convenient to chose the current sense resistors for
the desired average current limit first, as described in section
1 of the protection circuits section, and then choose the
current feedback resistor for the desired transconductance.
If 2 quadrant PWM is being used the equation for calculating
transconductance is:
G
M
= 2.5(A)(V)(R
FBI
+10K)/(R
L
(R
FBI
+10K)+125000(V)(R
S
))
Where:
A is the gain of the Input Amp.
A=10K/(1K+R
IN
)
G
M
is the overall transconductance.
V is the motor supply voltage.
APEX MICROTECHNOLOGY CORPORATION
• TELEPHONE (520) 690-8600 • FAX (520) 888-3329 • ORDERS (520) 690-8601 • EMAIL prodlit@apexmicrotech.com
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