Dt 2 Design Fall 2004

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FEC Motor Driver

Project Design Report

Design Team #2

Brad JohnsonKarl Kerstetter

David Nikkel

Steven StoneMichael Walsh

Faculty Advisor

Dr. Iqbal Husain

Submitted onNovember 23, 2004

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Table of contents

List of figures .................................................................................................................... iii

List of Tables ..................................................................................................................... iv

Table of Code Listings ........................................................................................................v

Abstract............................................................................................................................... 1

1. Introduction.................................................................................................................... 2

1.1 Statement of Need................................................................................................................2

1.2 Problem Definition .............................................................................................................. 21.2.1 Goals.............................................................................................................................................21.2.2 Objectives .....................................................................................................................................21.2.3 Constraints ....................................................................................................................................2

2. Design Requirements ..................................................................................................... 4

2.1 Requirement Specifications ................................................................................................ 4

3. Alternative Design Analysis........................................................................................... 5

3.1 Motors: ................................................................................................................................. 5

3.2 Switching Topographies: .................................................................................................... 6

3.3 Control System: ................................................................................................................... 6

3.4 Communication: .................................................................................................................. 7

4. Accepted Technical Design............................................................................................ 8

4.1Hardware Design ................................................................................................................. 84.1.1 AC/DC Converter .........................................................................................................................94.1.2 DC/DC converter ..........................................................................................................................94.1.3 Inverter........................................................................................................................................104.1.4 Motor ..........................................................................................................................................114.1.5 Transformer ................................................................................................................................114.1.6 Power Factor Preregulator ..........................................................................................................114.1.7 Linear Regulator .........................................................................................................................124.1.8 Digital Signal Processor..............................................................................................................13

4.2 Software Design:................................................................................................................154.2.1 Speed/Position Module...............................................................................................................154.2.2 Speed Controller .........................................................................................................................154.2.3 Current Controller.......................................................................................................................164.2.4 PWM Generator..........................................................................................................................16

4.2.5 Fault Monitoring.........................................................................................................................164.3State Diagram .................................................................................................................... 16

4.3.1 Fault monitoring .........................................................................................................................174.3.2 Initialize ......................................................................................................................................174.3.3 Stop.............................................................................................................................................184.3.4 Startup.........................................................................................................................................184.3.5 Normal Operation .......................................................................................................................184.3.6 Fault............................................................................................................................................18

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4.4 Software Implementation..................................................................................................19

4.5 PC Diagnostics ................................................................................................................... 22

5. Testing Procedures....................................................................................................... 24

5.1 Initial System Checks/No Load Testing........................................................................... 24

5.1.1 Input Power Phase-Rectifier/DC-DC converter..........................................................................245.1.2 PWM signals from the DSP........................................................................................................245.1.3 Inverter switching outputs...........................................................................................................245.1.4 No load testing............................................................................................................................24

5.2 FEC Motor Drive Specifications ...................................................................................... 24

5.3 Drive System Testing Procedures .................................................................................... 255.3.1 Output Power..............................................................................................................................255.3.2 Torque.........................................................................................................................................255.3.3 Efficiency....................................................................................................................................255.3.4 Power Factor...............................................................................................................................255.3.5 Speed Control .............................................................................................................................255.3.6 Acoustic Noise............................................................................................................................255.3.7 EMI.............................................................................................................................................26

6. Financial Budget.......................................................................................................... 27

7. Project Schedule........................................................................................................... 28

8. Design Team Information ........................................................................................... 29

9. Conclusions and Recommendations ........................................................................... 30

10. References .................................................................................................................. 31

Appendix A Parts List ................................................................................................... 32

Appendix B Relevant Data Sheet Portions................................................................... 35

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List of figuresFigure 1: Hardware block diagram................................................................................................................8Figure 2: Power Supply and Power Factor Correction Circuit......................................................................8Figure 3: Inrush current into the inductor of the boost converter. ...............................................................10

Figure 4: IRAMX16UP60B - Integrated Current Shunt Configuration.......................................................11Figure 5: Steady-state ripple of the boost Power Factor Correction output ................................................12Figure 6: Controller Circuit..........................................................................................................................13Figure 7: RS-232 Circuit...............................................................................................................................14Figure 8: Software Functional Block Diagram.............................................................................................15Figure 9: Motor Control State Diagram.......................................................................................................17Figure 10: PC Application Main Panel ........................................................................................................23Figure 11: PC Application Graphing Panel .................................................................................................23Figure 12: Project Gantt Chart.....................................................................................................................28Figure 13: dsPIC overview ...........................................................................................................................36Figure 14: dsPIC block diagram...................................................................................................................37Figure 15: Power Module Data Sheet...........................................................................................................38Figure 16: Development Board for Power Module.......................................................................................39Figure 17: LM317 Voltage Regulator (U1, U2)............................................................................................40Figure 18: Power Factor Correction IC (U3)...............................................................................................41Figure 19: Reset IC (U3)...............................................................................................................................42Figure 20: DRC01 Input isolated, output-regulated DC/DC converter (U7) ..............................................43Figure 21: RS232 Driver IC..........................................................................................................................44Figure 22: Rectifier Bridge Data Sheet.........................................................................................................45Figure 23: Bridge Rectifier Data Sheet.........................................................................................................46Figure 24: Transistor (Q1)............................................................................................................................47Figure 25: Capacitors (C1, C2, C5, C35-C43).............................................................................................48Figure 26: Diode (D6, D7 use 1N4002-T) ....................................................................................................49Figure 27: Resistors (R2-R8, R13, R14, R22, R30-R39 USE THIS TYPE OF RESISTOR - 1/2W)..............50Figure 28: Power Switch...............................................................................................................................51Figure 29: AC input plug with built-in fuse holder .......................................................................................52Figure 30: BNC speed input connector.........................................................................................................53

Figure 31: Used to connect controller board to RS232 board......................................................................54Figure 32: DB9 connector to interface with PC ...........................................................................................55Figure 33: Connector for In-Circuit Debugger ............................................................................................56Figure 34: Terminal strip to connect motor to controller board ..................................................................57Figure 35: Encoder connection.....................................................................................................................58

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List of TablesTable 1: Labor costs......................................................................................................................................27Table 2: Funding Sources .............................................................................................................................27Table 3: Complete Parts list..........................................................................................................................32

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Table of Code ListingsListing 1: Declarations..........................................................................................................................19Listing 2: State: Stop..............................................................................................................................20Listing 3: State: Start.............................................................................................................................20

Listing 4: State: Normal Operation .......................................................................................................20Listing 5: State: Fault ............................................................................................................................21Listing 6: Low Priority Interrupts..........................................................................................................21Listing 7: High Priority Interrupts ........................................................................................................21Listing 8: Functions...............................................................................................................................22

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Abstract

Many applications exist today for variable speed drives. Both industrial and residential applicationsutilize these types of drives for heating and ventilation, automation, and many other applications.

However, the universal motor brush machines currently in widespread use in home appliances areinefficient, wasting power and resources. The 2005 Future Energy Challenge (FEC) set forth ambitiousgoals for a motor drive system to improve on the efficiency and cost for these applications. The followingdesign intends to meet the requirements of the FEC with a novel, low cost solution to these problems.The design is based on the permanent magnet brushless DC motor, a technology proven reliable inindustry and ideal for this application due to its efficiency, cost, and power/torque capabilities. The motordrive is powered from a standard wall socket and controlled by a digital signal processor utilizing pulsewidth modulation to control the speed of the motor.

Key Design Features:

Permanent Magnet Brushless DC Motor (PM BLDC)

Digital Signal Processor (DSP) to control inverter AC/DC rectifier for AC input from wall socket DC/DC boost converter to attain necessary motor voltage 6-Switch inverter to control motor speed Power factor pre-regulator

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1. Introduction

1.1 Statement of Need

From their introduction into the consumer appliance and recreation market, brushed based electricalmotors have dominated with their ease of control, price/performance ratio, and reliability. The brushlessmotor, as a more recent newcomer, has been too expensive to implement for consumer appliance andrecreational applications. However, with the falling prices of power electronic devices and digital controlsystems, these motors are now on the verge of becoming a viable, economic replacement for theantiquated brush based motor. Brushless motors exhibit similar torque and power properties whencompared to similar sized brushed motors. However, brushless motors require more power electronicsand a more complex control system than similar brushed motors. This drawback is easily made up by thereliability of brushless motors. Brushless motors have no electrical contact points to the rotor, which is acommon failure point for brushed motors. This also leads to less friction and corresponds to higherefficiency of the drive. With the motor bearings as the only physical failure point, brushless motors arethe king in reliability, especially in todays warranty and price driven consumer market.

1.2 Problem Definition

1.2.1 Goals

The goal of this project is to produce a prototype brushless motor that, when mass produced, will meet anaggressive budget of forty dollars for the drive, power electronics, and control system. This drive mustmeet criteria that will make it cost effective alternative to the industry standard brushed motor. Theprototype will be produced in such a way that all requirements are met with several percentage pointscushion.

A secondary goal is to be competitive in the 2005 International Future Energy Challenge studentcompetition. Since this competition sets the minimum standards to which the prototype will be built,exceeding these standards is the primary goal.

1.2.2 Objectives

Produce an efficient, reliable brushless motor that runs off of a standard 120 volt, 60 hertz powersource.

Meet all the FEC competition requirements. Contain a self-protection system that will react to continuous stall, over temp, and loss of input

without damage to any system.

Be packaged in a way that is easily implemented and serviceable.

1.2.3 Constraints

Produce 500 watts @ 1500 RPM Draw power from a standard single phase household wall supply Cost no more than $40 per unit to build based on 1 millions units produce per year Have a usable operating range of 150 to 5000 RPM Exhibit an efficiency of at least 70% for 50 to 500 watt loads across the operating range

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Use no more than 4 liters of space Weigh no more than 8 kilograms Produce 3.18 N-M of torque in from 150 to 1500 RPM Maintain a power factor of 80% and conform to IEC1000-3-2 across the operating range Have a standard 0 to 10 volt BNC style input to control the motor speed in a linear fashion

Maintain 5% speed accuracy to the control input signal. Produce less than 50 dB A-weighted at 0.5 meters Meet FCC Class A regulations for radiated and conducted EMI Conform to a maximum of NEMA frame size of #48 Be suitable and fully operational in an indoor and outdoor domestic environment. A mean time to failure of 90,000 hours

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2. Design Requirements

2.1 Requirement Specifications

Produce an efficient, reliable brushless motor that runs off of a standard 120 volt, 60 hertz power source.Many applications such as home heating and ventilation require a 120VAC 60Hz motor. This project willcater to these applications. The motor will be capable of maintaining speeds from 150 to 5000 RPM andproduce 3.18 N-m of torque from 150 to 1500 RPM.

Meet all the FEC competition requirements. This project is being submitted to the 2005 Future EnergyChallenge. The requirements are listed in section 1.2.3, Constraints. It is the hope of this design teamto produce a successful design while representing the University of Akron during this project.

Contain a self-protection system that will react to continuous stall, over temp, and loss of input withoutdamage to any system. To increase cost efficiency, every effort has been taken to reduce the possibility ofany system failure which would require unit replacement or maintenance. Component failure will likelyrequire unit replacement, as well as downtime while a replacement unit is located and installed. This isboth an inconvenience and unnecessary cost to the end user.

Be packaged in a way that is easily implemented and serviceable. The unit should conform to amaximum frame size of NEMA #48 and weigh less than 8 kilograms. This will allow the unit to beinstalled in a variety of locations and allow for easy installation and if necessary, replacement.

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3. Alternative Design Analysis

There are many of options available to simply build a motor drive. The goal of the FEC competition,however, is to construct an efficient, inexpensive, and novel system. With this in mind, several different

configurations have been researched which could feasibly be used to achieve the goals of the FECcompetition. These configurations include alternative classes of motors, Pulse Width Modulation (PWM)switching topographies, controllers, and communication protocols. This section will explore the pros andcons for each alternative.

3.1 Motors:

Motor selection is arguably the single most important decision made in this project. Two different stylesof motors exist that meet the requirements, and are discussed in detail below.

Switched-Reluctance motors (SRM) were some of the first electric motors to be used. They have very

low manufacturing costs and produce a high starting torque. Coupled with modern power electronics andsensor-less designs, they exhibit an astonishing efficiency that can easily go over ninety percent. Alsoimportant is the fact that it is a brushless motor. There are no contact points between the stator and rotor,except for the bearings, leading to high mean-time-to-failure operation. The lack of permanent magnetson its rotor also allows ultra high speed operation (>100,000 RPM), and high temperature applications.However, no design is without drawbacks. SRMs exhibit a high torque ripple during each revolution.This ripple is coupled with moderate to high vibrations and noise caused by the excitation of each pair ofpoles on the stator. Newer designs have tacked these two drawbacks by adding more poles and stiffeningthe stator structure, but this comes at higher manufacturing costs. SRMs also require an expensive andcomplex control scheme. Sensors are often used to determine the rotor position, which is requiredknowledge in order to turn on the proper switches. Sensors add higher costs to control systems along with

reliability issues. Even though SRMs were one of the first electric motors, they are still very uncommon.Most applications, until recent, were cost prohibitive.

The Permanent-Magnet Brush-Less Direct Current motor (PMBLDC) is a more common motor that hasproven itself over the last twenty years. It is much quieter than the SRMs and has a relatively easycontrol algorithm. It is suitable for many applications where moderate torque ripple is acceptable andefficiency is not the primary concern. High speed and high temperature operations also pose a problemfor this style of motor due to the permanent magnets on the rotors. However, the slightly elevatedmanufacturing cost of the PMBLDC, when compared to the SRM, poses only a small obstacle. Often thedevelopment of an algorithm for a SRM poses a more significant engineering cost than the relativelysimple PMBLDC. As more engineers are educated on the workings and control of SRMs, this cost will

decrease.

Either motor would be suitable for this application. Only minor changes need to be made to switchingand power supply topologies to swap between the two. Both are low cost enough to use, but SRMs dohave the cost advantage if their complex algorithms can be dealt with. Unfortunately, the group wasunable to find a commercially available SRM motor that would fit the bill. This pretty much determinedthe motor selection.

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3.2 Switching Topographies:

There are two categories for the switching schemes. One for a SRM motor and one for a PMBLDCmotor. The choice of motor ultimately decides with category of switching methods will be used.However, each motor has different switching methods based on the application and needs. Once themotor is determined, the cost vs. performance of each method will be analyzed to determine the

appropriate switching method.

For a SRM motor, a 4-switch and a 6-switch topography could be used for this application. With the 4-switch method, higher efficiency is achieved along with lower cost and simpler control methods.However, it also only utilizes 2 quadrant operation and hard switching. The 6-switch method is a bettersolution as far as operation, as it utilizes 4 quadrant operation and soft switching. However, with theadditional switches comes a decrease in efficiency and an increase in cost.

The possible topographies for a PMBLDC motor are 6-switch, 8-switch, and C-dump. The C-dump is ahighly efficient option, but is not as fault tolerant as other options.The 6- and 8-switch topographies are very similar to the 4- and 6-switch topographies used for SRM

motors as far as pros and cons. The 6-switch is more efficient and cost effective, but only offers 2quadrant operation and hard switching. The 8-switch method offers 4 quadrant operation and softswitching while sacrificing efficiency, cost, and simplicity.

This project will be using a 6-switch topography to control the PMBLDC motor. The motor is onlyrequired to rotate in one direction, eliminating the need for 4-quadrant operation.

3.3 Control System:

In looking at alternative designs for the control system, there are basically four different ways to control aBrushless Direct Current (BLDC) motor. The four different control schemes to consider are Digital

Signal Processor (DSP), Microprocessor, Field Programmable Gate Array (FPGA), and ApplicationSpecific Integrated Circuit (ASIC).

A DSP is a very good solution for using to control a BLDC motor. DSPs are designed to process data inreal-time, which is good since a motor control cannot tolerate any delay between calculating the currentposition of the motor and when the next phase should be energized and current phase de-energized.DSPs are also designed for intensive mathematical calculations. This is needed for calculating bothposition and actual speed. The disadvantages are DSPs usually have less peripherals available and thecost. DSPs average cost ranges from $10 to $50 US dollars.

A cheaper alternative to a DSP is the microcontroller approach. A microcontroller is a type of

microprocessor, but specifically designed for control applications. The average cost ranges from less thana $1 to $15 US Dollars. The disadvantage with a microcontroller is they are usually slower in processingdata, because they are designed to have more peripherals, which allows them to be used in many differenttypes of applications.

Field Programmable Gate Arrays (FPGA) should also be considered since they are able to process datafast, do to their dedicated logic circuits. The disadvantages are the can be extremely expensive and theylack an analog-to-digital converter (ADC). The cost of FPGA from Altera is from $20 to $455 US

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Dollars1. Since an ADC is not onboard, another IC would be needed which also adds to the cost for thissolution.

The final solution to consider is the ASIC approach. The biggest advantage to this solution is everythinghas already been designed and no algorithms need to be written, just drop in the IC and it works. The

disadvantages to this approach are the cost and the inability to change any aspects to how the controllerfunctions. The cost of ASICs range from just under $2 to $18 US. Of course, the $2 ASIC MC33035 hasvery few features, and the $18 MC73110 for example has all of the desired features built in, but the costtakes up almost half of the target budget of $40.

The controller of choice that appears to meet the necessary requirements is a combination of a DSP and amicrocontroller. It is the dsPIC manufactured by Microchip Inc. It gives us both the computationalpower of a DSP but also has the peripherals built in that are need, like a UART. The cost of a dsPICranges from $5 to $8 US depending on the size of memory and options needed.

3.4 Communication:For providing user feedback and the ability to change the operating parameters of the motor, we havedecided to add some type of communication between the control system and a user interface module. Theinterface module could be a laptop or possibly an LCD Display, but what ever the case may be thereneeds to be some sort of communication protocol between them. The 2 protocols being considered areRS-232 and USB.

The RS-232 has been the long running standard for serial type communication, and is very easy toimplement. The disadvantage is it is relatively slow when compared to todays speeds of serialcommunication. This shouldnt be a very big issue since only a small amount of data will be transmittedat any given time. The cost to implement is less than $2 US.

USB on the other hand, is both newer and faster than RS-232. It also has better noise immunity built intothe protocol than RS-232. The big advantage USB has over RS-232 is its a Plug-N-Play typearchitecture. Also, Manufactures of PCs and Laptops are starting to replace serial ports with USB ports.The disadvantages of using USB are the cost to implement and the complexity associated with thisprotocol. The cost of Silicon Laboratories CP2101 (a USB to UART IC) is $5.70 US.

1Arrow Electronics www.arrow.comStratix part is most expensive and Cyclone part is the least expensive

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http://www.arrow.com/http://www.arrow.com/

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4. Accepted Technical Design

4.1 Hardware Design

The hardware portion of the electric motor drive will function as shown in Figure 1 below:

Figure 1: Hardware block diagram

Inverterw/ Gate

Driver

The preceding block diagram, while very general, provides the basic overall design of the electric motordrive. Each block will be discussed in depth in the discussion to follow. The complete hardware designis shown in Figure 2,at the end of this section.

1 2 3 4

A

B

C

D

4321

D

C

B

A

J1PLUG ACMALE

AC 1

V+ 2

AC3

V-4

D2

GBPB2506WC13

0.1uF

T1

2

1 3

D120ETF06

VBUS

D3

KBPC801

+22V

+ C3

470uF

R1511k

R210k

R13

100

R10

.25 35W

R9

.25 35W

+

C4

1uF

R11

30k 5W+22V

R12

620k

R18

910k

R19

91kC140.1uF

VSENSE

Iac

R2020k C24

0.560uF

GND1

PKLMT2

C/AOUT3

I SENS4

MUL OUT5

I AC6

V/AOUT7

VRMS8

VREF 9

ENA 10

VSENS 11

R SET 12

SS 13

CT 14

VCC 15

GTDRV 16

U3

UC3854

Iac

R27150k

+ C5

1uF

R3

10k

PK_LIMIT

D101N5343

C1162pF

C9

620pFR2120k

PK_LIMIT

R251.91k

MUL_OUT

+22V

R148.2M

R153.9k

D41N5817

+22V

MUL_OUT

D51N5817

C27100pF

R291.82k

VRMS

R2684.5k

C250.164uF

VSENSE

VSENSE

C26 .0012uF

R2810k 1/4W

R22

10D91N5820

Q1IRF460

VBUS

Iac

POWER SUPPLYAND POWERFACTOR CORRECTION CIRCUIT

VRMS

IN3

OUT 2

ADJ1

U1

LM317T(3)

IN3

OUT 2

ADJ1

U2

LM317T(3)

R16392

R174.12k

R242.49k

R23

1k

+C11uF

+C710uF

+C21uF

+C810uF

D7

1N4002

D61N4002

+22V

+22V

+15V REGULATOR

+5V REGULATOR

D81N4748

C120.1uF

+C10100uF

+22V

Controller

Controller.Sch

PC INTERFACE

PC INTERFACE.Sch

+C45470uF

C60.51uF

SW120ASPST

Figure 2: Power Supply and Power Factor Correction Circuit

~AC/DC DC/DC

GateDriverSource

DSP

Source

DigitalSignal

Processor

PowerFactor

Prereg.

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4.1.1 AC/DC Converter

First and foremost, the AC/DC converter is a necessary component of the design and an obvious startingpoint. Direct current devices require a rectified voltage to operate, and that rectified voltage musteventually come from an AC source.

The AC/DC converter is a full wave rectifier that will provide approximately 108 VDC. This output isachieved by utilizing four diodes in a bridge configuration. This output is derived from the followingexpression which relates the output of a full wave rectifier to the peak voltage of a sinusoidal input:

MAXRMSDC

VVV

*222==

In order to achieve the AC/DC conversion, a single phase full wave rectifier IC, IR25XB04H,manufactured by International Rectifier, was utilized based upon the diode blocking voltage capabilities,cost, and current handling capabilities. The peak forward diode voltage is 0.975V, providing little powerloss. A 450F capacitor is placed across the output to filter the AC components in the output and improvethe DC quality of the output.

This rectified voltage supplies the remainder of the drive. It directly feeds to the DC/DC convertersupplying the motor, as well as a step down transformer that supplies the lower voltage level required bythe remaining components.

4.1.2 DC/DC converter

The DC/DC converter is necessary to boost the rectified voltage of 108 VDC to 400 VDC, the voltagerequired by the motor. This converter utilizes the inductance from the high side of a step-downtransformer, which will be discussed later, as the input inductance. The 400 VDCoutput of this DC/DCconverter supplies inverter the voltage it needs to run the motor.

In order to derive the duty ratio necessary to achieve a 400V output, the following relation, which appliesto boost converters, is used:

DVin

Vo

=

1

1

With Vin = 108 V and a desired Vo = 400 V, the required duty ratio is D = 0.73. The period (T) ofswitching will be controlled by the power factor preregulator, discussed later.

Immediately following the DC/DC converter is a simple voltage divider network parallel to the outputcapacitor. The network consists of two large resistors in series, 511 kon the high side and 9.76 Konthe low side. This results in a voltage of 7.497 V at the node between the two, which will provide therequired 7.5 V reference output voltage for the power factor preregulator.

Because of the high inrush current when the converter is first powered up, an additional divider network isplaced parallel with the output capacitor. This network will supply the required 5V signal to the enablepin of the power factor preregulator. However, this signal will only reach 5V when the capacitor voltagereaches 100V. This effectively turns on different stages at different times to minimize the inrush currentdue to charging capacitors. Figure 3 shows the inrush current resulting from a simulation run of thecircuit.

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Figure 3: Inrush current into the inductor of the boost converter.

4.1.3 Inverter

The inverter consists of six Insulated Gate Bipolar Transistors in a high/low configuration. The IGBTs

are arranged such that the phases of the motor can be turned on and off with the correct polarity basedupon inputs from the Digital Signal Processor. They utilize a three high/three low configuration, asshown below in Figure 4.

The DSP itself can not source sufficient current to control the IGBTs. This issue is resolved by utilizingsix gate drivers. These gate drivers provide the necessary voltage and current to drive the IGBTs.

An integrated power module, manufactured by International Rectifier, was selected as the inverter for thisapplication. It integrates six IGBTs with bootstrap diodes and a driver IC capable of utilizing the outputsignal from the DSP. It also has the capability for temperature monitoring and overcurrent protection.The IGBTs are rated for a maximum blocking voltage of 600 V and RMS phase current of 6 A at 25

oC.

The only drawback is that an additional power supply is required to provide the 15 V necessary for thegate driver IC. This will be provided via linear regulator, discussed later.

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Figure 4: IRAMX16UP60B - Integrated Current Shunt Configuration2

4.1.4 Motor

For the intended application, a Permanent Magnet BrushLess DC motor is ideal. It is a quiet motor basedon proven technology. It is also relatively easy to control when compared to other motors suitable for thisapplication. Furthermore, the fact that it is brushless decreases the required maintenance and increasesthe longevity of the motor.

The motor expected to be used is manufactured by Pacific Scientific, model PMA42N. It is a six pole PM

BLDC motor. It provides a rated power of 1441 watts and maximum speed of 5450 RPM at an operatingvoltage of 400 V. The maximum rated winding voltage is 480 V. The back EMF constant is 67 V-

RMS/kRPM. The DC line-to-line resistance is 5.1 and the line-to-line inductance is 14.5 mH. It meetsthe size requirements set forth for the FEC Electric Motor Drive competition.

4.1.5 Transformer

The transformer mentioned earlier is a linear transformer with a turns ratio of 55:13. This provides 22 Vto supply the remaining components of the circuit. The output of the low side of this transformer isrectified due to the switching current on the high side. This is achieved utilizing a full bridge rectifier IC.The IC chosen for this application is a KBPC3 series rectifier bridge manufactured by International

Rectifier. The output of this rectifier feeds the remaining components in the circuit. It directly powers thepower factor preregulator as well as two linear regulators.

4.1.6 Power Factor Preregulator

The power factor preregulator serves two purposes in this applicator. First, it controls the MOSFet usedin the DC/DC converter to provide the correct output voltage to the inverter. Second, it controls the

2Taken from International Rectifier product website.

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frequency of the switching to maximize the power factor. This is achieved by adjusting the switchingperiod so that the current drawn by the DC/DC converter resembles is a half-sinusoidal waveform. Thiswill minimize the current distortion and maximize the power factor. Figure 5 is a simulation output of thesteady-state ripple of the boost power factor correction output.

For this application, the UC3854 manufactured by Unitrode was chosen. It is supplied with a 22 V powersupply from the step down transformer and a 7.5 V reference, as discussed in the DC/DC converterportion of this report. It also provides the gate driver for the MOSFet used in the DC/DC converter.

4.1.7 Linear Regulator

Two linear regulators, both LM317K manufactured by National Semiconductor, provide the necessaryvoltage to both the gate driver IC portion of the inverter module and the DSP. The gate driver IC requires15 V. The DSP requires 5 V.

By adjusting R1 and R2, the appropriate output voltage can be achieved. The linear regulator forces a

voltage of 1.25 V across the terminals VOUT and ADJ. This voltage is thus forced upon R1. Since thevoltage across R1is constant, it forces a constant current through it, where IR1=1.25/R1. This also forcesthat current to flow through R2as it is in series with R1.

Figure 5: Steady-state ripple of the boost Power Factor Correction output

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The resulting voltage is determined by the following equation:

+=

1

2

R

R125.1OUTV

Note that there is an additional current coming from ADJ of approximately 50 to 100 A. However, this

has a minimal impact on the output (

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Position and speed feedback from the motor is being implemented using an encoder mounted on themotor. This will produce 1024 signal transitions per revolution. The dsPIC has a Quadrature EncoderInterface, or QEI, that will take care of much of the logic involved here. The encoder provides threesignals: phase A, phase B, and an index pulse. The index pulse is triggered once every revolution,providing absolute position information from which to reference the encoder count. The QEI will

determine the direction of the motor by analyzing the order in which the phase changes come in. A 16-bitcounter then contains the actual count of signal transitions on the phase lines. This counter can be set toreset every time an index pulse is received, and so transforming the counter into an absolute positionreference.

For monitoring fault conditions, the dsPIC provides an Input Change Notification Module. TheInternational Rectifier inverter chip being used has an overcurrent/ overtemperature signal. The processorcan be configured to generate an interrupt in response to a change on these pins. This removes the need toconstantly poll the fault input.

Also integrated on-chip is a 10-bit high speed analog-to-digital converter, with a maximum sampling rate

of 500ksps. The converter has 16 inputs multiplexed into 4 sample and hold registers. The current designcalls for two A/D conversions, which is well within the capacity of this processor.

The motor driver will be communicating with a PC for diagnostics and troubleshooting. To take care ofthis, the dsPIC30F is equipped with a Universal Asynchronous Receiver Transmitter (UART) module.This capability will be used to establish communication using the RS-232 protocol. Figure 7 shows acomplete block diagram for the dsPIC.

1 2 3 4

A

B

C

D

4321

D

C

B

A

V INPUT1

V REC 7

OUTPUT GND 8

V OUT 9

ENABLE 11

ERROR 12

INPUTGND17

SYNC18

U7

DCR01

C442.2uF

1234

J3

CON4 123456

J6

RJ11

R1 IN13

R2 IN8

T1IN11

T2IN10

GND

15

V+

2

V-

6

VCC

16

R1 OUT 12

R2 OUT 9

T1OUT 14

T2OUT 7

C1+1

C1 -3

C2+ 4

C2 - 5

U8

MAX232ACPE(16)

+5V

TXRX

+5V

R8

10k

R7

10k

C230.1uF

+C411uF

+C3410uF

162738495

J5

DB9

PC RX

PC TX

RXPC TX

TX PC RX

C220.1uF

+C421uF

+C431uF

+C391uF

+C401uF

+

C381uF

ISO+5V

ISO +5V

Vpp

EMUDEMUC

+5V

CONNECTION FROMCONTROLLER BOARD TO RS232 BOARD

TO PC COM PORT

ICD PROGRAMMER& DEBUGGER CONNECTION

ISOLATED +5VVOLTAGEREGULATOR

RS232 DRIVER

1234

J4

CON4

RXTX

+5V

Figure 7: RS-232 Circuit

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4.2 Software Design:

Figure 8 shows a block diagram of the software design. Each block in the diagram represents a separatemodule to be implemented. The hardware support described in the previous section makes this designmuch simpler. A discussion of each piece follows.

Figure 8: Software Functional Block Diagram

4.2.1 Speed/Position ModuleThe speed/position module takes in the signals from the encoder on the motor, and translates these intospeed (actual) and position information. The quadrature encoder interface on the dsPIC contains the logicto translate the encoder inputs into direction and position information.

The current speed of the motor is determined by the simple calculation t , where is distance

traveled between interrupts, and tis the time elapsed between interrupts. The distance, , is a measurable

constant determined by the physical placement of the sensors on the motor.

4.2.2 Speed Controller

The speed controller takes in the actualand compares it to the speed command (command) coming from theoutside world. command is a 0 10V analog signal referenced to the motor case that determines the speedat which the motor is running. The motor is required to stay within 5% of the command, or2V/1000RPM. The difference of the two signals (error) is run through a PID controller to determine thedesired current (idesired).

Speed

ControllerDC

Current

Controller

PWM

Generator

Speed / Position

Module

PWM Signals toPower Stage

DC

imeasured iactual

idesired ierror ioutputcommand error

Rotor

position

actual

Encoderinput

Temperature

Fault

monitoringOvercurrent

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4.2.3 Current Control ler

The current controller takes the desired current (idesired) calculated in the speed controller and compares itto the measured current in the return leg of the inverter. The difference of the two signals (ierror) is fed intoa second PID controller, to produce the output current (iout).

4.2.4 PWM Generator

The PWM Generator block, as the name implies, creates the PWM signals needed to control the circuit inthe power stage. The duty cycle of the signals will be directly related to the output current (iout) from thecurrent controller. Also feeding into this block is the position information from the speed/positioncontroller. This is used to determine which switches to turn in the power phase.

4.2.5 Fault Monitoring

The IR25XB04H inverter chip being used provides both overcurrent and overtemperature signals to theDSP. These signals will be monitored periodically to detect possible fault conditions. The actual speed of

the motor is also compared with the speed command input to determine if there is a stall occurring.

4.3 State Diagram

The controller is being implemented using a state diagram approach. Figure 9 contains the diagram. Theindividual states are discussed in detail in the following sections.

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Initialize

Stop

Figure 9: Motor Control State Diagram

4.3.1 Fault monitoring

The fault monitoring block in the system diagram will be executed during all of the states in our machine,and used to produce the FAULT_DETECTED signal. There are three possible faults: overcurrent,overtemperature, and a stall condition. Any one of these will set the FAULT_DETECTED bit. Regardlessof the current state when this occurs, control will be sent to the FAULT state.

4.3.2 Initialize

In the initialization state, all of the relevant registers and ports on the processor will be set to a known,stable state. Interrupts and timers will also get configured in this state. There is a RESET command (notshown on the diagram to avoid clutter) that will send the processor to this state from any other state.When the initialization code is done, the state will change to STOP.

Normal

Operation

Startup Fault

speedCmd > START_LIMIT

speedCmd > STOP_LIMIT

FAULT_CLEAREDFAULT_DETECTED

speedCmd

NORMAL_OP_LIMIT

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4.4 Software Implementation

Listing 1: Declarations

//value above which the motor is turned on

#def i ne START_LI MI T //TBD

//distance traveled between transitions

#def i ne ENCODER_DI STANCE //TBD#def i ne COUNTS_PER_SECOND //TBD

//value below which the motor is turned off

#def i ne STOP_LI MI T //TBD

//point where motor leaves startup mode and enters normal operation

#def i ne NORMAL_OP_LI MI T //TBD

//attempts processor will make to recover from a fault condition

#def i ne MAX_RECOVERY_ATTEMPTS //TBD

//enumeration containing fault values. Will be contained in a single

//int, all logically ORed together

//lower byte contains hard faults, upper byte contains possible fault

enum f aul t Condi t i on{ f Ok = 0x00;

f OverCurr ent = 0x01;f Over Temp = 0x02;f St al l Cond = 0x04;f Possi bl eSt al l = 0x10; }

f aul t Condi t i on f aul t Cond = f Ok; //contains any fault conditions

/ / possi bl e devi ce st at esenum devi ceSt ate

{ sI ni t i al i ze = 0x01;sSt op = 0x02;sSt ar t up = 0x04;sNor mal Op = 0x08;sFaul t = 0x80; }

devi ceSt at e dSt at e = sI ni t i al i ze;

//switch states

enum swi t chSt ate{ wAl l Of f = 0x00;

wPhase1Upper = 0x01;wPhase1Lower = 0x02;wPhase2Upper = 0x04;

wPhase2Lower = 0x08;wPhase3Upper = 0x10;wPhase3Lower = 0x20; }

swi t chSt ate swi t chesOn = wAl l Of f ; //start with all switches off

i nt speedCmd = 0; //result of ADC on external speed signali nt actual Speed = 0; //speed determined from encoder signalsi nt act ual Cur r ent = 0; //result of AD conversion on currenti nt r ecover yAt t empt s; //keeps track of attempted recovery from faulti nt desi r edCur r ent = 0; //output of speed controller loop

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Listing 2: State: Stop

whi l e (dSt ate == sSt op){

CheckFor Faul t s( &f aul t Cond) ; //verify everything is working properlyi f ( f aul t Cond ! = f Ok)

dSt at e = sFaul t ; //go to fault state

el se{

Get Cur r entSpeedCmd( speedCmd) ; //do AD conversion, get inputi f ( speedCmd > START_LI MI T)

dSt at e = sSt ar t ; //go to start state

/ / make sur e swi t ches are of fswi t chesOn = wAl l Of f ;

}}

Listing 3: State: Start

whi l e ( dSt ate == sStart ){

CheckFor Faul t s( &f aul t Cond) ; //verify everything is working properlyi f ( f aul t Cond ! = f Ok)

dSt at e = sFaul t ; //go to fault state

el se{

whi l e ( act ual Speed < NORMAL_OP_LI MI T){

//verify speed command is still above threshold

Get Cur r entSpeedCmd( speedCmd) ;

i f ( speedCmd < STOP_LI MI T)dSt ate = sSt op;

/*

Use open loop control to get the motor spinning. Control the switches based simply on

timing information stored in a lookup table. Meanwhile, monitor the actualSpeed to

make sure the motor is not stalled.

*/

}

/ / speed i s above t he t hr eshol d t o swi t ch overdSt at e = sNormal Oper at i onenabl eCur r ent Ti mer ( ) ; / / st ar t moni t or i ng cur r ent

}}

Listing 4: State: Normal Operation

whi l e (dSt at e == sNormal Op){//Processing here is done by interrupts

//Current loop is processed on a timer interrupt,

//and speed loop is processed on encoder interrupts

}

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Listing 5: State: Fault

/ / onl y l eave state i f al l f aul t s ar e cl ear ed/ / onl y go t o STOP st ate

whi l e ( dSt ate == sFaul t )

{CheckFor Faul t s( &f aul t Cond) ; / / updat e f aul t st at usi f ( f aul t Cond == f Ok){

dState = sSt op;}

}

Listing 6: Low Priority Interrupts

i f ( i nt er r upt == cur r ent Ti mer ){

/ / Faul t checkCheckFor Faul t s( &f aul t Cond) ; //verify everything is working properly

i f ( ( f aul t Cond & 0x0f ) ! = f Ok)dSt at e = sFaul t ; //go to fault state

Enabl eI nt er r upt s( ) ; / / al l ow ot her i nt er r upt sDoCur r ent ADC( act ual Cur r ent ) ; //Get measured current

//run current controller loop

out Cur r ent = Cur r ent Cont r ol l er ( act ual Cur r ent , desi r edCur r ent ) ;PWMCont r ol l er ( out Cur r ent ) ; //update PWM signal

}

el se i f ( i nt er r upt == Encoder Tr ansi t i on){

i nt el apsedTi me = t i mer val ue;

r eset t i mer ;

/ / get val ue of up/ down count er i n QEI , i ndi cat i ng di st ance f r om/ / i ndex pul seGet EncoderCount ( present EncoderCount ) ;

/ / conver t posi t i on i nto speed and swi t ches commandSpeedPosi t i on( pr esent EncoderCount , &actual Speed, &swi t chesOn, el apsedTi me) ;

/ / r un speed cont r ol l er wi t h ext ernal speed command and measur ed speedGet SpeedCmd( speedCmd)i f ( speedCmd < STOP_LI MI T)

dSt ate = sSt op; / / go t o st opped st ate

el sedesi r edCur r ent = SpeedCont r ol l er ( act ual Speed, speedCmd) ;

/ / Di agnost i c message to PCSendMessage( act ual Speed, actual Cur r ent , f aul t Cond) ;

}

Listing 7: High Priority Interrupts

i f ( i nt er r upt == RESET)

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{St opMot or ( ) ; / / st op mot or bef or e r eset t i ngdSt at e = sI ni t ;

}

Listing 8: Functions

CheckFor Faul t s( f aul t Condi t i on* f aul t Cond){

f aul t Cond = f Ok;

i f ( t emper at ur e)f aul t Cond | = f OverTemp;

i f ( over Cur r ent )f aul t Cond | = f Over Cur r ent ;

/ / St al l condi t i oni f ( act ual speed i s much smal l er t han speedCmd){

i f ( f aul t Cond & f Possi bl eSt al l )

f aul t Cond | = f St al l Cond;el sef aul t Cond | = f Possi bl eSt al l ;

}};

SpeedPosi t i on ( short i nt pr esent Encoder Count , i nt * act ual Speed, i nt *swi t chesOn, i ntel apsedCount )

{//set switchesOn parameter to match the encoder count range

swi t chesOn = encoder CountRange( presentEncoder Count ) ; //lookup table

el apsedTi me = el apsedCount / COUNTS_PER_SECOND;act ual Speed = ( ENCODER_DI STANCE/ el apsedTi me) ;

};

4.5 PC Diagnost ics

A PC application is being written to provide user feedback of how the motor is performing. Theapplication is developed in National Instruments LabWindows to provide an easy to use windows basedapplication. The information that will be displayed to the user is speed, temperature, and a graphicalrepresentation of phase current over time. The user will also be able to change the desired speed of themotor. The motor will still be able to run independently, by providing a DC voltage from 0 to 10 volts.Figure 10 shows the main panel with temperature and current speed, and the dial to change the desired

speed. Figure 11 shows what the graphical representation of the phase current over time will look like.

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Figure 10: PC Application Main Panel

Figure 11: PC Application Graphing Panel

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5. Testing Procedures

5.1 Initial System Checks/No Load Testing

Since the motor drive and motor system involves moving parts at high speeds, it is critical for safety to

inspect key sections of the drive individually before implementing them in the designed system. This willinvolve several steps which will verify the successful operation of:

5.1.1 Input Power Phase-Rectifier/DC-DC converterThe input power phase will be connected to the 120Vac/1Phase/60Hz supply. Expected results will be anoutput of 400Vdc from the DC-DC converter, 5Vdc, for the DSP, 15Vdc for the switching inverter chip,and 7.5Vdc for the power factor preregulator.

5.1.2 PWM signals f rom the DSP

Once the input power phase is verified, power will be applied to the DSP. Using an oscilloscope thePWM outputs of the DSP will be tested to verify that the calculated PWM scheme is created by the DSP.

5.1.3 Inverter switching outputs

After the DSP PWM scheme is operational, the inverter chip will be connected to the outputs of the DSP.The outputs of the inverter will be connected to the oscilloscope and tested to verify that the proper outputsignals are produced to effectively drive the PM BLDC motor.

5.1.4 No load testing

After the critical sections of the drive system are successfully tested individually, the motor will beconnected to the outputs of the inverter chip and run without a load. A 0-10V analog input will be appliedto the system and the speed of the shaft with no load measured. If the speed is in the ballpark of the 5V =

2500 RPM, and 10V = 5000RPM (values are from the FEC competition specifications), then the system isessentially working and ready to be assembled as a unit.

5.2 FEC Motor Drive Specifications

Once the initial system checks and no-load testing is successfully completed, the system will be tested toverify it meets the FEC competition specifications. The FEC competition provides a detailed list ofspecifications that the prototype motor and motor drive developed by the team must adhere to. Testing ofthese system requirements will be accomplished through several steps outlined below. The specificationsinclude:

500W continuous shaft output power from 1500-5000 RPM. Continuous output torque of 3.18 N-m from 150-1500 RPM. 70% efficiency for 50W-500W shaft loads from 150-5000 RPM. 80% power factor for 500W shaft load at 1500 RPM. Speed controlled by a 0-10V analog input for 0-5000 RPM range. Actual speed must be within 50

RPM or 5% of commanded input voltage (2V/RPM).

Less than 50 dBA sound measured 0.5m from unit in operation. Meet FCC class A requirements for radiated EMI. (Average EMI = 60 dBV for f> 1MHz).

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5.3 Drive System Testing Procedures

All of the requirements listed above will be discussed individually, providing explanation of the methodchosen to verify that the system meets the respective specification. The specifications for the FECcompetition are well defined. The nature of the specifications such as output power, torque, and efficiencyare quantified and straightforward to measure. As a result our prototype can be efficiently tested and its

performance to the specs verified.

5.3.1 Output Power

Testing that the system provides continuous output power of 500W from the speed range of 1500-5000RPM will be accomplished by attaching a load of 500W to the shaft. This will be accomplished by settingup a testing stand in the energy conversions lab. This will consist of an external motor present in the lab,coupled to the shaft of the PM BLDC motor with whatever brackets are necessary. The external motorwill provide the load. The PM BLDC motor will then be operated at speeds varying from the minimum tothe maximum of the specified range. If the motor achieves the desired speeds at 500W shaft load, then thesystem meets the spec.

5.3.2 Torque

Torque will be determined from the test stand and external motor load. Using this system the outputtorque of the motor will be measured. The speed of the motor will be varied from 150-1500 RPM asspecified in the FEC requirements, and if the system provides a continuous output torque of 3.18N-m thenthe specification is met.

5.3.3 Efficiency

Efficiency of the system can be measured by the following relation= Pout / PinTherefore, by measuring input power from the 120Vrms/60Hz/ 1-phase supply,i.e. the current and voltage and comparing with the power used by the motor, efficiency can bedetermined. The system will meet the specifications if its efficiency is measured to be at least 70% overthe specified range of shaft loads and speeds.

5.3.4 Power Factor

Power factor will be measured with a Fluke 41B multimeter found in the in the energy conversions lab.This meter will be connected to the input of the system and will display the power factor. If the value isgreater or equal to 0.8 the specification is met.

5.3.5 Speed Control

The speed control signal will be tested by varying the command signal from 0-10V, then measuring theresulting speed in RPM of the motor. If the speed is within 5% of the commanded voltage (2V/1000rpm)or 50 RPM then the specification is met

5.3.6 Acoustic Noise

Acoustic noise of the motor will be measured with some kind of sound detection device (i.e. microphone).If the motor emits a sound level less than 50dBA 0.5m from the unit over the motor speed range 150-5000RPM, then the specification is met.

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5.3.7 EMI

EMI emitted by the motor over the required speed range will be measured with a spectrum analyzer probeand measurement equipment. If the average of the radiated EMI is less than 60dBV over the distancespecified in the FCC class A industrial standard, then the specification is met.

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6. Financial Budget

The budget for this project is made up of labor and parts costs. Labor costs, as shown in Table 1,werecalculated at $10.00 per hour for each team member.

Table 1: Labor costs

Team Member Hours/Wk Weeks Hourly Rate Estimated Cost

Johnson, Brad 10 30 10.00$ 3,000.00$

Kerstetter, Karl 10 30 10.00$ 3,000.00$

Nikkel, David 10 30 10.00$ 3,000.00$

Stone, Stone 10 30 10.00$ 3,000.00$

Walsh, Michael 10 30 10.00$ 3,000.00$

Total: 15,000.00$

Looking at the projected parts cost, per Table 3 in Appendix A, yields a project cost of $2,939.02. This isnot including the team labor costs, which are being donated. This is well above the standard $75.00available per team member provided by for the Senior Design. The remaining funds are being provided bythe College of Engineering. Table 2 shows the total funds available to the FEC Motor Drive group. Thisshows that the project is within its operating budget.

Table 2: Funding Sources

Source Amount

Senior Design Budget $375.00

Department of Electrical and Computer Engineering $1500.00

College of Engineering $1500.00$3375.00

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7. Project Schedule

The Gantt chart below in Figure 12 shows the project schedule for the spring semester. The scheduleextends beyond the end of the semester to fulfill the FEC requirements.

Figure 12: Project Gantt Chart

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8. Design Team Information

The FEC Motor Driver team is made up of five engineering undergraduate students.

Brad Johnson, Electrical Engineer

Karl Kerstetter, Electrical Engineer, Team Leader

David Nikkel, Computer Engineer

Steve Stone, Computer Engineer

Michael Walsh, Electrical Engineer

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9. Conclusions and Recommendations

The team is confident that the design set forth here will meet all the requirements listed in the openingsections of this report. The component choices and control topology will fulfill all the needs of the FEC

competition.

It is possible to create an even more cost effective solution by completely removing any position sensorson the motor. This is possible by measuring the back emf on the different phases of the motor, andrelating this to the position. This raises the level of complexity of the project greatly, however. Aftercompleting all the objectives and requirements listed in the opening sections of this report, the group willattempt a sensorless solution.

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10. References

dsPIC30F Datasheet, Motor Control and Power Conversion Family. (2004). Microchip Technology, Inc.

Shiyoung Lee, Effects of Input Power Factor Correction on Variable Speed Drive Systems, Dissertationsubmitted to the Faculty of the Virginia Polytechnic Institute, Feb. 17th

, 1999.

John Bottrill, AC Requirement for Power Factor Correction Circuits, Texas Instruments, SLUA263,Copyright 2002.

Philip C. Todd, UC3854 Controlled Power Factor Correction Circuit Design, Texas Instruments,Unitrode U-134, Copyright 1999.

Unitrode, High Power Factor Preregulator, Texas Instruments, UC3854 Properties Page, Copyright1999.

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Appendix A Parts List

Table 3: Complete Parts list

Qty. Refdes Part Num. Descript ion CostTotalCost

1 ?? ?? CONNECTOR FOR PMBLDC MOTOR$-

$-

10 C? 08052R471K9B20D CAP 470PF 50V CERAMIC X7R 0805$0.06

$0.64

10C1, C2, C5,C38 - C43

ECE-A1HKA010 1.0UF 50V MINI ALUM ELECT (KA)$0.14

$1.40

3 C10 ECA-1HM101 CAP 100UF 50V ALUM LYTIC RADIAL$0.29

$0.87

10 C11 GRM1885C2A620JA01D CAP CER 62PF 100V 5% C0G 0603$0.06

$0.59

20C12, C15 -C23, C30 -C32

08052R104K9B20D CAP .10UF 50V CERAMIC X7R 0805$0.09

$1.82

1 C13 B81141C1104M CAP 0.1UF 440VAC EMI SUPPRESSN $1.77

$1.77

1 C14 2222 418 41204 CAP FILM MKP .12UF 250VDC 2%$0.65

$0.65


$1.13


$0.61


$0.30

10 C27 GRM2165C1H101JA01D CAP CER 100PF 50V 5% C0G 0805$0.07

$0.74

10 C28, C29 GRM1885C1H160JA01D CAP CER 16PF 50V 5% C0G 0603$0.07

$0.72

2 C3, C45 EET-ED2W471EA CAP 470UF 450V ELECT TS-ED $9.34 $18.68

3 C35 - C37 ECE-A1VKA220 22UF 35V MINI ALUM ELECT (KA)$0.15

$0.45

1 C4 UVR2W010MPD CAP 1UF 450V ELECT VR RADIAL$0.31

$0.31

10 C44 GRM219R61E225KA12D CAP CER 2.2UF 25V 10% X5R 0805$0.50

$4.99


$8.00

3C7, C8, C33,C34

ECA-1EM100 CAP 10UF 25V ALUM LYTIC RADIAL$0.15

$0.45

10 C9 GRM2165C1H621JA01D CAP CER 620PF 50V 5% C0G 0805$0.17

$1.73

1 D1 20ETF06FP DIODE FAST REC 600V 20A TO-220AC$1.69

$1.69

1 D10 1N5343B ZENER DIODE 7.5V 5% 5.0W T-18$1.20

$1.20

1 D2 GBPB2506W BRIDGE SGL PHASE 600V 25A D-34$4.50

$4.50

1 D3 8GBU01 BRIDGE SGL PHASE 100V 8A GBU$1.79

$1.79

2 D4, D5 1N5817-T DIODE SCHOTTKY 20V 1A DO-41$0.68

$1.36

2 D6, D7 1N4002-T RECTIFIER GPP 100V 1A DO-41$0.26

$0.52

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3 D8 1N4748ADO41 ZENER DIODE 22V 5% 1.0W DO-41$0.25

$0.75

1 D9 1N5820-T DIODE SCHOTTKY 20V 3A DO-201AD$0.68

$0.68

1DevelopmentBoard

DM300020BOARD DEV DSPICDEM MC1MOTORCTRL

$300.00

$300.00

1DevelopmentBoard IRADK10 KIT DESIGN 3-PH 115-230ACV MOTOR

$349.00

$349.00

1 J1 719W-00/02 CONN RCPT 5X20 FUSEHOLDER SCREW$2.42

$2.42

1 J2 226978-3 CONN JACK BNC RT/ANG 50OHM AU$7.10

$7.10

2 J3, J4 TM2REA-0604 JACK-PC MOUNT 6-4$3.12

$6.24

1 J5 747844-5AMP HD-20 PCB Right Angle ConnectorsRECP FRNT MTL SHL 9P

$1.40

$1.40

1 J6 RJ11-6N-B CONN MOD RJ11 W/FERRITE BLOCK$2.87

$2.87

1 M1 PMA42N-00112-00 PM BLDC motor (Price: TBD)$1,200.00 $1,200.00

1 M1 38720-6205 CONN BARRIER STRIP 5POS .375" $3.48 $3.48

1 M1 38660-7803 CONN TRI-BARRIER STRIP 3POS.500"$7.55

$7.55

1 Q1 IRF460500V Single N-Channel Hi-Rel MOSFET(DC/DC converter transistor)

$13.80

$13.80

5 R? 5063JD9K760F12AF5BC RES 9.76K OHM METALFILM .40W 1%$0.39

$1.95

5 R? B0207C20K00F5TBC RES 24K OHM 1/2W 5% CARBON FILM$0.33

$1.66

2 R?, R? 15FR025 RES CURRENT SENSE .025 OHM 5W$1.79

$3.58

5 R1 5063JD511K0F12AF5BC RES 511K OHM METAL FILM .40W 1%$0.39

$1.95

3 R11 286-30K Xicon 5W Small Metal Oxide Resistors $0.49 $1.47

10 R12 ERO-S2PHF6203 RES METAL FILM 620K OHM 1/4W 1%$0.17

$1.71

5 R13 CFR-50JB-100R RES 100 OHM 1/2W 5% CARBON FILM$0.05

$0.27

5 R14 CFR-50JB-8M2 RES 8.2M OHM 1/2W 5% CARBON FILM$0.05

$0.27

5 R15 5073NW3K900J12AFXBC RES 3.9K OHM METAL FILM 1W 5%$0.16

$0.80

5 R16 MFR-25FBF-392R RES 392 OHM 1/4W 1% METAL FILM$0.11

$0.54

5 R17 MFR-25FBF-4K12 RES 4.12K OHM 1/4W 1% METAL FILM$0.11

$0.54

5 R18 5043ED910K0F12AF5BC RES 910K OHM METAL FILM .40W 1%$0.19

$0.95

5 R19 5063JD91K00F12AF5BC RES 91.0K OHM METAL FILM .40W 1%$0.39

$1.95

10 R2 - R8 CFR-50JB-10K RES 10K OHM 1/2W 5% CARBON FILM$0.05

$0.54

5 R20, R21 5043ED20K00F12AF5BC RES 20.00K OHM METALFILM .40W 1%$0.19

$0.95

5 R22 CFR-50JB-10R RES 10 OHM 1/2W 5% CARBON FILM$0.05

$0.27


$0.54

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$0.54

5 R25 B0207C1K910F5TBC RES 1.91K OHM METL FILM .60W 1%$0.33

$1.66

5 R26 B0207C84K50F5TBC RES 84.5K OHM METAL FILM .6W 1%$0.33

$1.66

5 R27 B0207C150K0F5TBC RES 150K OHM METAL FILM .6W 1%$

0.33

$

1.665 R28 MFR-25FBF-10K0 RES 10.0K OHM 1/4W 1% METAL FILM

$0.05

$0.27

5 R29 B0207C1K820F5TBC RES 1.82K OHM METAL FILM .6W 1%$0.11

$0.54

5R30 - R32,R36, R37

CFR-50JB-470R RES 470 OHM 1/2W 5% CARBON FILM$0.05

$0.27

5 R33 - R35 CFR-50JB-33K RES 33K OHM 1/2W 5% CARBON FILM$0.05

$0.27

2 R9, R10 TDH35PR250J RESISTOR .25 OHM 35W SMD TO220$8.17

$16.34

1 SW1 CRE22F2FBRNE SWITCH ROCKER SPST RED 20A QC TE$0.95

$0.95

1 T11 mH primary side transformer, secondary

size windings to be adjusted.

$

-

$

-

2 U1, U2 LM317KCS IC VOLT REG POS ADJ 3TERM TO-220$1.36

$2.72

1 U3 UC3854N IC ENH HIGH P-F PREREG 16-DIP$2.45

$2.45

1 U4 MCP100-450HI/TO IC SUPERVISOR ACTIVE LOW TO-92$0.33

$0.33

1 U5 DSPIC30F2010-30I/SPG IC DSPIC MCU/DSP 12K 28DIP$11.35

$11.35

1 U6 IRAMS10UP60B Plug n Drive Integrated Power Module$19.30

$19.30

1 U7 DCR010505P IC ISO DC/DC CONV 5V TO 5V 18DIP$9.91

$9.91

1 U8 MAX232N IC DUAL EIA-232 DRVR/RCVR 16-DIP$

0.78

$

0.781 Y1 HC49US14.7456MABJ CRYSTAL 14.7456 MHZ HC49/US

$0.88

$0.88

1 Software SW006012 C COMPILER FOR DSPIC30F FAMILY$895.00

$895.00

Total$2,939.02

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Appendix B Relevant Data Sheet Portions

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Figure 13: dsPIC overview

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Figure 14: dsPIC block diagram

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Figure 15: Power Module Data Sheet

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Figure 16: Development Board for Power Module

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Figure 17: LM317 Voltage Regulator (U1, U2)

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Figure 18: Power Factor Correction IC (U3)

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Figure 19: Reset IC (U3)

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Figure 20: DRC01 Input isolated, output-regulated DC/DC converter (U7)

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Figure 21: RS232 Driver IC

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Figure 22: Rectifier Bridge Data Sheet

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Figure 23: Bridge Rectifier Data Sheet

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Figure 24: Transistor (Q1)

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Figure 25: Capacitors (C1, C2, C5, C35-C43)

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Figure 26: Diode (D6, D7 use 1N4002-T)

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Figure 27: Resistors (R2-R8, R13, R14, R22, R30-R39 USE THIS TYPE OF RESISTOR - 1/2W)

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Figure 28: Power Switch

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Figure 29: AC input plug with built-in fuse holder

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Figure 30: BNC speed input connector

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Figure 31: Used to connect controller board to RS232 board

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Figure 32: DB9 connector to interface with PC

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Figure 34: Terminal strip to connect motor to controller board

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Documents

Dt 2 Design Fall 2004