USER’S MANUAL
HIP4086DEMO1Z
3-phase BLDC Motor Drive Demonstration Board
AN1829
Rev 0.00
March 14, 2013
corrections and for adding more switching sequences. Please
refer to Microchip for details on the use of the PIC18F2431.
Introduction
The HIP4086DEMO1Z is a general purpose 3-phase BLDC
motor drive with a microprocessor based controller. Hall effect
shaft position sensors are used to control the switching
sequence of the three 1/2 bridge outputs. The bridge voltage
can vary between 12V and 60V and the maximum summed
bridge current is 20A (with sufficient air flow). This motor drive
can be used as a design reference for multiple applications
including e-bikes, battery powered tools, electric power
steering, wheel chairs, or any other application, where a BLDC
motor is utilized. Because this demonstration board is
primarily intended to highlight the application of the HIP4086
3-phase MOSFET driver with no specific application targeted,
the control features are limited to simple functions, such as
start/stop, reverse rotation, and braking. Open loop speed
control is implemented. More advanced control features, such
as torque control, speed regulation and regenerative braking
are not implemented because these methods require close
integration with the characteristics of the load dynamics.
Physical Layout
The HIP4086DEMO1Z board is 102mm by 81mm. The tallest
component is a 470µF capacitor. The total height is 24mm
with standoffs or 18.5mm without standoffs. The Hall effect
shaft position sensor inputs are miniature terminal blocks and
the high current outputs are larger terminal blocks that are
rated for 20A.
Four push-buttons are used for reset, brake, reverse, and
start/stop functions. An on-board potentiometer is used to
adjust the duty cycle of the applied motor voltage or an
optional external potentiometer can be connected to a signal
terminal block located adjacent to the Hall terminal blocks.
The switching sequence selection dip switch is used for various
purposes but the most important function is to select the
desired switching sequence. Please refer to the “Setup and
Operating Instructions” on page 3 for more information.
For those customers who would like to modify the firmware of
the PIC18F2431 microcontroller, an RJ25 connector is
provided for easy connection with Microchip firmware
development tools (not provided or supported by Intersil).
Important Note
Because Hall sensor switching logic sequences for BLDC
motors are not all the same, this demo board supports most, if
not all, variations of sequence logic. Please refer to the
sequence charts in “Selecting the Correct Switching
Sequence” on page 9 to verify that your desired sequence is
implemented. If you require a different sequence for your
specific motor application or if you need help identifying the
correct switching sequence for your specific motor, please
contact Intersil prior to ordering this demo board for possible
support for a new switching sequence.
Specifications
Motor topology
Operating voltage range
Maximum bridge current
Hall sensor bias voltage
PWM switching frequency
3-phase BLDC motor with Hall
sensors
15VDC to 60VDC
20A (with sufficient air flow)
5V
20kHz
Scope
This application note covers the design details of the
HIP4086DEMO1Z with a focus on the design implementation
of the HIP4086 driver using recommended support circuits.
Also covered, is the design method of the bipolar current
sensing feature. Presently, current sensing on this demo board
is used only for pulse-by-pulse current limiting. However, an
analog signal proportional to the motor current is available on
board as a design reference.
The microcontroller firmware is also provided as a reference
but the only support offered by Intersil will be for bug
FIGURE 1. HIP4086DEMO1Z INPUTS AND OUTPUTS
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March 14, 2013
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HIP4086DEMO1Z
Block Diagram
15V TO 60V
HIP4086DEMO1Z
ISL6719
LINEAR +12V
REGULATOR
ISL8560
+5V
BUCK
REGULATOR
6
HIP4086
3-PHASE
MOSFET
DRIVER
6
3-PHASE
BRIDGE
3
BLDC
MOTOR
HALL
INPUTS 3
CONTROLLER
ISL28246
CURRENT
LIMIT
AND
MONITOR
2
4
PUSH
DIP
BUTTONS
SWITCHES
LEDS
FIGURE 2. HIP4086DEMO1Z BLOCK DIAGRAM
The HIP4086DEMO1Z is composed of six major circuits
illustrating the use of several Intersil products.
Bias Supplies
The ISL8560 is a buck regulator with integrated power FETs that
provides +5V bias for the microcontroller, dip switches, push
buttons, LEDs, and the current monitor/limit circuits. The
ISL6719 is a linear regulator that provides 12V bias for the
HIP4086 3-phase MOSFET driver. Please refer to the
ISL8560
datasheet or the
ISL6719
datasheet for application information.
and varies between 0% and 100% duty cycle. This proportional
duty cycle is open loop and is independent of the bridge voltage.
Consequently, any motor voltage between 15V and 60V can be
used with this demo board.
The microcontroller firmware is provided as a reference but the
only support offered by Intersil will be for bug corrections and for
adding more switching sequences. All firmware revisions for this
demo board can be found on the Intersil website. The firmware
revision of your demo board can be determined by referring to
the “Test Mode Setup” on page 24.
HIP4086
The HIP4086, the featured Intersil part, drives 3 bridge pairs of
F540NS power FETS with a PWM frequency of 20KHz. Associated
with the HIP4086 are the necessary support circuits such as the
boot capacitors and boot diodes. Recommended negative
voltage clamping diodes on the xHS pins are also provided.
Current Sensing/Current Limit
Two ISL28246 low offset, dual op-amps are used for current
monitoring and current limiting. One op-amp is configured as a
differential amplifier for Kelvin connections across the current
sensing resistor. The diff-amp is also biased so that zero bridge
current results with an output voltage that is 1/2 of the +5V bias.
Consequently, positive bridge currents results with a current
monitor signal that is greater than 2.5V (up to ~5V). Negative
bridge currents (that occur with regenerative braking) is less than
2.5V (down to a minimum of ~0V). This ‘”bipolar” analog signal
can be monitored by the microcontroller for purposes, such as
torque control and/or regenerative braking.
The output of the analog differential amplifier is also connected
to two op amps configured as outside window comparators for
pulse-by-pulse current limits for either positive or negative bridge
currents. The OR’ed comparator outputs are sent to the
microcontroller for processing.
MicroController
The Hall sensor inputs are decoded by the microcontroller to
provide the appropriate switching sequence signals to the
HIP4086 to drive the six F540NS bridge FETs that are connected
to a 3-phase BLDC motor. In addition to decoding the Hall
sensors, the microcontroller also multiplexes the dip switches
(for switching sequence options), the push buttons (for various
control functions of the motor), and the LED status lights.
The on-board potentiometer (or an optional external pot) is
monitored by the microcontroller to provide a duty cycle to the
motor that is proportional to the tap voltage of the potentiometer
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HIP4086DEMO1Z
3-phase Bridge
The 3-phase bridge is composed of six F540NS power MOSFETS
(100V, 33A). Each FET is driven by one of the six driver outputs of
the HIP4086. Dead time is provided by the controller (optionally,
dead time can be provided by the HIP4086).
Related Literature
•
FN4220
HIP4086, 80V, 500mA, 3-Phase MOSFET Driver
•
FN6555
ISL6719, 100V Linear Bias Supply
•
FN9244
ISL8560, DC/DC Power Switching Regulator
•
FN6321
ISL28246, 5MHz, Single and Dual Rail-to-Rail
Input-Output (RRIO) Op Amps
ISL6719
(+12v)
FIGURE 3. MAJOR CIRCUIT LOCATIONS
Setup and Operating Instructions
Required and Recommended Lab Equipment
Lab supply (or battery), 15V minimum to 60V absolute
maximum. The current rating of the lab supply must have
sufficient capacity for the motor being tested. If a battery is the
power source, it is highly recommended that an appropriate fuse
be used listed as follows:
• Bench fan
• Test motor
• Multichannel oscilloscope, 100 MHz
• Multimeter
• Temperature probe (optional)
CAUTION: If the HIP4086DEMO1Z is used for an extended period
at high power levels, it may be necessary that a fan be used to
keep the temperature of the bridge FETs to less than +85°C (as
measured on the heat sink plane).
1. Connect the 3-phase motor leads to the MA, MB, and MC
terminal blocks. For high current applications, it is
recommended that both terminals of each block be used. It is
also recommended that during initial setup the motor
not
be
mechanically loaded.
2. Connect the HALL sensor leads of the motor to the HA, HB,
and HC terminals. The +5V bias and ground leads must all be
connected.
3. Rotate the R13 potentiometer to the left (CCW) until it clicks.
This will set the starting voltage on the motor to a minimum.
4. Setup the dip switch for the correct switching sequence (see
the switching sequence tables at the end of this application
note).
5. With a lab supply turned off but previously set to the desired
bridge voltage, connect the lab supply (or battery) to the
+BATT and -BATT terminal block.
6. Ensure that the motor is securely mounted prior to proceeding
with the following steps. Also, do not exceed the maximum
rated RPM of your motor.
7. Turn on the lab supply. Observe that the four LEDS turn on and
off, one after another. This initial flash of the LEDs indicates
that power has been applied. After the initial flash, all LEDs
will be off. Operation of the motor is now possible. Note that
the dip switch options are read at initial turn-on and changing
the settings after power is applied will have no effect. As an
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HIP4086DEMO1Z
alternative to cycling power, the reset push button can be
pressed to re-read the dip switch settings.
led3
led2
led1
led0
15. Press again the REVERSE button. As before, the motor will
stop. But this time the REVERSE LED will turn off. After a
pause, the motor will restart but this time rotating in the
forward direction.
16. While the motor is running, the motor can be hard braked by
pressing the BRAKE push button. The BRAKE LED (LED2) will
be on without blinking. When the motor is restarted, the
BRAKE LED will turn off.
ILIMIT
led3
BRAKE
led2
REVERSE
led1
RUN
led0
At initial turn on, leds will turn on and
off one at a time starting with led0
8. Press the Start/Stop push button once. The RUN LED (led0)
will blink, indicating that the motor has been started. The
motor at this point may not be rotating because minimal
voltage is being applied to the motor.
ILIMIT
led3
BRAKE
led2
REVERSE
led1
RUN
led0
While the motor is rotating, the RUN LED is blinking
9. Slowly increase the voltage on the motor by rotating the
potentiometer, R13, to the right (CW). At some point the
motor will start to rotate slowly. The actual starting voltage is
dependent on the specific motor being used.
10. If the motor is vibrating back and forth instead of rotating, it
is possible that the Hall sensors or the motor leads were not
connected correctly. If the correct switching sequence has
been selected, all that should be necessary to correct this
misbehavior is to swap two of the motors lead (or to swap two
of the Hall sensor leads).
11. Continue to rotate the pot until the motor is running at a
moderate speed of roughly 25%. Do not run the motor with
maximum voltage until the setup check-out is completed.
12. Press again the START/STOP push button. The motor will free
wheel to a stop and the blinking led0 will turn off.
ILIMIT
led3
BRAKE
led2
REVERSE
led1
RUN
led0
CAUTION: The braking method implemented turns on all of the
low-side bridge FETs simultaneously. This will force the motor to
a very rapid stop. If the motor is loaded, or if the motor is not
designed for a rapid stop, mechanical damage to the motor or
the load can result. If you are not sure about using this braking
method, only apply the brake when the motor speed is relatively
slow.
17. If while operating, the motors turns off, and the iLIMIT LED
(led3) is blinking, the current limit shut-down has been
activated after 255 consecutive pulse-by-pulse current limits.
This may happen if the motor speed is accelerated too
quickly, or if there is a fault with the motor or connections, or
if the motor is stalled.
ILIMIT
led3
BRAKE
led2
REVERSE
led1
RUN
led0
It is now safe to proceed with testing at higher power levels
speeds.
13. Press again the START/STOP button. The motor will
accelerate to the previous run speed (assuming that the
potentiometer was not rotated). The blinking led0 will also
turn on.
ILIMIT
led3
BRAKE
led2
REVERSE
led1
RUN
led0
14. While the motor is running, press the REVERSE button. The
RUN LED (led0) will turn off and the REVERSE LED (led1) will
turn on without blinking. After a short pause while the motor
is freewheeling to a stop, the motor will restart rotating in the
opposite direction. The RUN LED will be blinking and the
REVERSE LED will continue to be on.
ILIMIT
led3
BRAKE
led2
REVERSE
led1
RUN
led0
blinking
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HIP4086DEMO1Z
Theory of Operation
The HIP4086DEMO1Z demonstration board is a general purpose
3-phase BLDC motor controller. Three half bridge power circuits
drive the motor as shown in Figure 4.
Three 6 step bridge state logic diagrams, illustrated in Figure 5,
are used to drive the motor. The bridge state logic diagrams
represents the logic status of the each half bridge but the actual
voltage applied to the motor appears much differently. Figure 6
illustrates the bridge status logic vs the actual voltage waveforms
applied to each motor lead.
The HIP4086 has 6 driver outputs, AHO, ALO, BHO, BLO, CHO,
and CLO, to control the six bridge FETs individually. If the gate
drives for both FETs of one half bridge are low, current will not
flow in the corresponding motor lead (high impedance or Hi-Z). If
the gate drive for the low FET is high and the gate drive for the
high FET is low, then the phase node of that half bridge, and the
corresponding motor lead, is connected to ground (Low). If the
low and high gate drives are complementary driven, the phase
node can be pulse width modulated (PWM) to control the
average voltage on that motor lead.
The motor rotation period and the amplitude of the bridge
voltage waveforms are modified by the microcontroller to control
the speed of the motor. Pulse width modulation is used to modify
the amplitude of the voltage waveforms and the motor rotation
period is established by the shaft position hall sensors that signal
the controller to change the switching sequence. Typical hall
sensor logic is illustrated in Figure 5. Each hall logic diagram, HA,
HB, and HC, correspond respectively to the bridge state logic
diagrams, MA, MB, and MC. For example, the transition of the
hall sensor logic, from step 1 to 2, results with the drive
waveform transition of
ZLP
to
PLZ
where
P, L,
and
Z
define the
state of each half bridge.
HALL SENSOR LOGIC
000 100 110 111 011 001 000
HC
HB
HA
0°
60°
120°
180°
240°
0°
60°
120°
180°
240°
0°
100 110 111 011 001
Bridge State Logic: P = PWM, L = Low, Z = off
ZLP PLZ PZL ZPL LPZ LZP ZLP PLZ PZL ZPL LPZ LZP
P
MC
MB
L
Z
MA
SEQUENCE STEP NUMBERS
1
2
3
4
5
6
1
2
3
4
5
6
FIGURE 5. HALL SENSOR LOGIC vs BRIDGE STATE LOGIC
Bridge State Logic: P = PWM, L = Low, Z = off
ZLP PLZ PZL ZPL LPZ LZP ZLP PLZ PZL ZPL LPZ LZP
MC
BLDC
MOTOR
AHO
CHO
MB
CLO
MA
IDEALIZED MOTOR VOLTAGE WAVEFORMS
ALO
BHO
20kHz PWM freq.
MC
+Vbat
BLO
MB
~ ½ Vbat
-Vbat
FIGURE 4. BASIC BLDC MOTOR POWER TOPOLOGY
MA
Motor rotation period
per pole
FIGURE 6. BRIDGE STATE LOGIC vs MOTOR VOLTAGE
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