NXP Semiconductors BLDC

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Summary

Introduction

Document Overview

Provides instructions for running and controlling BLDC sensorless application with development boards.

Motor Control vs. SDK Peripheral Drivers

Hardware Setup

Linix 45 ZWN24-40 Motor

Details the Linix 45ZWN24-40 motor used with the application.

MIGE 60 CST-MO1330 Motor

Describes the MIGE 60CST-MO1330 motor for PMSM and BLDC applications.

Tower System Module Configurations

Details jumper settings for various Tower System MCU modules.

Tower System Assembly

Instructions for assembling the Tower System hardware.

Freedom Platform Module Configurations

Details jumper settings for various Freedom development boards.

Freedom Platform Assembly

Instructions for assembling the Freedom development platform.

High-Voltage Platform Components

Components needed for the High-Voltage Platform.

Project File Structure

IAR Folder Configuration

Configuration files for IAR Embedded Workbench IDE.

Project Files Description

Details device-specific files, initialization routines, and motor definitions.

Middleware Folders

Description of middleware folders like mc_algorithms and mc_drivers.

User Interface

Control Button Assignment

Maps development boards to control buttons and LED states for application control.

FreeMASTER Remote Control Setup

Steps to establish communication and control the BLDC motor using FreeMASTER.

FreeMASTER TSA and Variable Monitoring

Adding custom variables and using TSA for FreeMASTER monitoring.

FreeMASTER Control Page Operation

Details the FreeMASTER control page for adjusting speed, current, and state.

Instructions

Running the Motor

Steps to assemble hardware, download project, and start the motor.

Stopping the Motor

Procedures for stopping the motor and handling emergencies.

Clearing a Fault

Procedure to clear faults using the control page button.

Turning on Demonstration Mode

How to enable or disable the demonstration mode via FreeMASTER or board buttons.

Summary

Introduction

Document Overview

Provides instructions for running and controlling BLDC sensorless application with development boards.

Motor Control vs. SDK Peripheral Drivers

Hardware Setup

Linix 45 ZWN24-40 Motor

Details the Linix 45ZWN24-40 motor used with the application.

MIGE 60 CST-MO1330 Motor

Describes the MIGE 60CST-MO1330 motor for PMSM and BLDC applications.

Tower System Module Configurations

Details jumper settings for various Tower System MCU modules.

Tower System Assembly

Instructions for assembling the Tower System hardware.

Freedom Platform Module Configurations

Details jumper settings for various Freedom development boards.

Freedom Platform Assembly

Instructions for assembling the Freedom development platform.

High-Voltage Platform Components

Components needed for the High-Voltage Platform.

Project File Structure

IAR Folder Configuration

Configuration files for IAR Embedded Workbench IDE.

Project Files Description

Details device-specific files, initialization routines, and motor definitions.

Middleware Folders

Description of middleware folders like mc_algorithms and mc_drivers.

User Interface

Control Button Assignment

Maps development boards to control buttons and LED states for application control.

FreeMASTER Remote Control Setup

Steps to establish communication and control the BLDC motor using FreeMASTER.

FreeMASTER TSA and Variable Monitoring

Adding custom variables and using TSA for FreeMASTER monitoring.

FreeMASTER Control Page Operation

Details the FreeMASTER control page for adjusting speed, current, and state.

Instructions

Running the Motor

Steps to assemble hardware, download project, and start the motor.

Stopping the Motor

Procedures for stopping the motor and handling emergencies.

Clearing a Fault

Procedure to clear faults using the control page button.

Turning on Demonstration Mode

How to enable or disable the demonstration mode via FreeMASTER or board buttons.

This document describes the BLDC Control Demo User's Guide, which provides instructions for running and controlling a Brushless DC (BLDC) sensorless application using NXP's Freedom and Tower System development boards. The guide details the necessary software, hardware setup, jumper settings, project arrangement, and user interface for this application.

Function Description

The BLDC Control Demo is designed to demonstrate the rotation of a motor using a BLDC sensorless application. It leverages Kinetis KV series motor-control MCUs for motor-control applications, supporting both low-voltage/low-power applications (with BLDC control) and high-voltage applications (up to 1 kW of power) depending on the platform used. The core functionality involves controlling a BLDC motor without the need for Hall sensors, relying instead on sensorless algorithms.

The application utilizes SDK peripheral drivers for general peripheral configuration (clocks, SPI, SIM, ports) but employs specialized motor-control drivers for critical timing-sensitive features like PWM signal generation, analog signal sampling, and synchronization between PWM and ADC units. This optimization is crucial for the control algorithms, which typically run in a 50-µs loop. The motor-control drivers are specifically designed to configure critical MC peripherals such as eFlexPWM, FTM, ADC, and PDB, which are not fully supported by standard SDK peripheral drivers for the required timing and features.

The project file structure includes several key components:

main.c: Contains basic application initialization (enabling interrupts), subroutines for accessing MCU peripherals, and interrupt service routines.
mcdrv.h and mcdrv_<board&MCU>.h/c: These files include and implement motor-control driver peripheral initialization functions specific to the board and MCU, defining macros for PWM period, ADC channels for back-EMF voltages, and board voltage/current.
pin_mux.c/h: Handle board initialization and pin routing configuration.
board.c/h: Common MCUXpresso SDK files for debug console initialization and board-specific pinout macros.
clock_config.c/h: Manage MCU clock configuration.
m1_bldc_appconfig.h: Defines constants for application control processes, including motor parameters, regulator settings, and BLDC sensorless control algorithms.
mc_algorithms: Contains the control algorithms for the BLDC motor.
mc_drivers: Includes source and header files for initializing and running motor-control applications.
mc_state_machine and state_machine: Implement software routines executed during different application states (Fault, Initialization, Stop, Run) and state transitions.

The motor-control projects are built upon the Real-Time Control Embedded Software Library (RTCESL), which provides mathematical functions and is fully compatible with the official RTCESL release 4.5.

Usage Features

The BLDC Control Demo offers both direct control via a user button on the development board and remote control through the FreeMASTER software.

Direct Control (User Button):

Demo Mode Activation: Pressing the SW2 button (or corresponding button on the development board) switches the demo mode on or off.
Motor Start/Stop: When demo mode is activated, the motor starts rotation. Pressing the button again stops the motor and transitions the application back to the STOP state.
LED Indications:
- Green continuous LED: Indicates the application is in the RUN state.
- Flashing LED: Indicates a FAULT state.
- LED off (or red LED): Indicates the STOP state.
HVP Platform: For the High-Voltage Platform, the demo mode runs automatically after the board is switched on, as it lacks push-buttons for direct control.

Remote Control (FreeMASTER Software):

FreeMASTER 3.0 is required for optimal remote operation via the USB interface.

Project Loading: Open the bldc.pmp project file located in the <sdk_package_folder>\middleware\motor_control\freemaster directory.
Communication Establishment: Click the green "GO!" button to establish communication between the MCU and the PC. Successful communication is indicated by "RS232 UART Communication; COMxx; speed=115200" in the status bar.
Troubleshooting Communication: If communication fails, verify "COM_ALL" is set in the "Port" option and the speed is 115200 bps in the "Project->Options->Comm" tab. Unplug and replug the USB cable if "OpenSDA-CDC Serial Port" is not displayed. Ensure the development board has sufficient power.
Control Page: The FreeMASTER control page provides a comprehensive interface:
- Speed Slider: Sets the required motor speed.
- Speed Gauge: Displays the actual and required speeds.
- DC-Bus Voltage Gauge: Shows the actual DC-bus voltage.
- DC-Bus Current Gauge: Shows the actual DC-bus current.
- DC-Bus Current Limitation Slider: Sets the DC-bus current limit.
- Demo Mode Button: Toggles the demonstration mode on/off.
- STOP Button: Stops the entire application.
- Application State Notification: Displays the current application state and any faults.
MCAT Tuning Tool: The FreeMASTER GUI includes an MCAT tuning tool plug-in module, allowing users to change motor-control parameters, adjust start-up, and control parameters via various tabs representing submodules of the embedded-side control.
Starting the Motor: Set the required speed using the speed slider on the FreeMASTER control page.
Stopping the Motor: Click the "Stop" button on the FreeMASTER control page, set the speed slider to zero, or turn off the power supply in emergencies.
Clearing a Fault: Click the "CLEAR FAULT" button on the control page if a fault occurs.
Turning on Demonstration Mode: Click the "Demo" button on the FreeMASTER control page.

Maintenance Features

The user guide emphasizes the importance of proper hardware setup and jumper configurations for each supported development board (Tower System and Freedom platforms). It provides detailed tables for jumper settings for various MCU modules (TWR-KV46F150M, TWR-KV58F220M, TWR-KE18F, FRDM-KV11Z, FRDM-KE15Z, FRDM-KE16Z) and the TWR-MC-LV3PH module.

Hardware Assembly: Instructions are provided for assembling the Tower System (inserting MCU and motor control modules into elevator card slots, connecting power and USB cables) and the Freedom development platform (connecting the FRDM-MC-LVBLDC shield, motor wires, USB cable, and DC power supply).
Software Configuration: The guide outlines the project file structure and the role of various source and header files, which is crucial for understanding and potentially modifying the application.
Troubleshooting: Specific steps are given for troubleshooting communication issues with FreeMASTER, including checking port settings, speed, and power supply.
No Modification Recommendation: It is highly recommended not to modify the default configuration of allocated MC peripherals due to potential application-timing conflicts, as this could impact the stability and performance of the motor control. The mcdrv_<board&MCU>.c file contains these critical configuration functions.
Symbol Files for Debugging: For advanced users wanting to monitor their own variables, the guide explains how symbol files (generated during the build process) can be used with FreeMASTER to provide addresses of all variables. The TSA (Target Side Addressing) feature, enabled by the BOARD_FMSTR_USE_TSA macro, stores variable addresses and sizes in MCU flash memory for FreeMASTER visibility.