Renesas YROTATE-IT-RX62T User Manual
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Renesas YROTATE-IT-RX62T User Manual

Renesas YROTATE-IT-RX62T User Manual

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USER MANUAL
YROTATE-IT-RX62T
UM-YROTATE-IT-RX62T
Rev.1.00
Jan 15, 2014
Low Cost Motor Control Kit based on RX62T
Introduction
The Renesas Motor Control Kit, YROTATE-IT-RX62T, is based on the RX62T device from the powerful 32-bit
RX microcontroller family.
The kit enables engineers to easily test and evaluate the performance of the RX62T in a laboratory
environment when driving any 3-phase Permanent Magnet Synchronous Motor (e.g. AC Brushless Motor)
using an advanced sensorless Field Oriented Control algorithm. Typical applications for this type of solution
are compressors, air conditioning, fans, air extractors, pumps and industrial drives.
The phase current measurement is done via three shunts which offers a low cost solution, avoiding the
need for an expensive current sensor. A single shunt current reading method is also available.
The powerful user-friendly PC Graphical User Interface (GUI) gives real time access to key motor
performance parameters and provides a unique motor auto-tuning facility.
The hardware is designed for easy access to key system test points and for the ability to hook up to an
RX62T debugger. Although the board is normally powered directly from the USB port of a Host PC,
connectors are provided to utilise external power supplies where required.
The YROTATE-IT-RX62T is an ideal tool to check out all the key performance parameters of your selected
motor, before embarking on a final end application system design.
Target Device:
RX62T/63T Microcontroller Series
UM-YROTATE-IT-RX62T Rev.1.00
Page 1 of 51
Jan 15, 2014

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  • Page 1 RX62T debugger. Although the board is normally powered directly from the USB port of a Host PC, connectors are provided to utilise external power supplies where required. The YROTATE-IT-RX62T is an ideal tool to check out all the key performance parameters of your selected motor, before embarking on a final end application system design.

  • Page 2: Table Of Contents

    RX62T YROTATE-IT-RX62T Motor Control Kit Contents 1. Key features .................................. 3 2. Hardware overview ............................... 4 3. Power supply selection ..............................6 .............................. 7 4. Test points for debugging 5. LEDs function description ............................. 8 6. Internal power stage brief description ......................... 9 7.

  • Page 3: Key Features

    RX62T YROTATE-IT-RX62T Motor Control Kit 1. Key features UM-YROTATE-IT-RX62T Rev.1.00 Page 3 of 51 Jan 15, 2014...

  • Page 4: Hardware Overview

    The Motor Control kit is a single board inverter, based on the new RX series microcontroller RX62T. The hardware includes a low-voltage MOSFETs power stage, and a communication stage. The ordering part name of the kit is: YROTATE-IT-RX62T. The latest updates of the kit material are available on the webpage: http://tinyurl.com/YROTATE-IT-RX62T...
  • Page 5 RX62T YROTATE-IT-RX62T Motor Control Kit This stage uses the PC USB power lines as power supply. Furthermore, the possibility to supply all the board using the PC USB port was added, realizing a step-up converter to obtain the inverter V necessary for the motor;...

  • Page 6: Power Supply Selection

    RX62T YROTATE-IT-RX62T Motor Control Kit 3. Power supply selection As stated before, there are two ways to supply power to the board. One possibility is to use directly the PC USB supply, and in this case the current you can give to the motor is limited by the USB possibilities.

  • Page 7: Test Points For Debugging

    RX62T YROTATE-IT-RX62T Motor Control Kit 4. Test points for debugging Several specific test points are available on the board to visualize with the oscilloscope the behavior of some internal analog signals. it is very useful during the tuning process for adapting the software to a new motor to use the test points.

  • Page 8: Leds Function Description

    RX62T YROTATE-IT-RX62T Motor Control Kit 5. LEDs function description Three LEDs available on the board are directly connected to the hardware and allows the user to understand the status of the supply of the board. Please refer to the LED map for the following indications: •...

  • Page 9: Internal Power Stage Brief Description

    The power stage is a complete 3-phase bridge composed with discrete low voltage power MOSFETs, mounted on the bottom side of the board. The MOSFETs are the Renesas RJK0654DPB n-channel power MOSFETs (please refer to the data-sheet for the characteristics).

  • Page 10: Interface With An External Power Stage

    RX62T YROTATE-IT-RX62T Motor Control Kit 7. Interface with an external power stage Since internal power stage allows only the management of small motors, an interface with an external power stage was added to the PCB. This was made easy due to the presence in the microcontroller of several timer sections that make it possible to manage up to two 3-phase Brushless AC motors at the same time.
  • Page 11 RX62T YROTATE-IT-RX62T Motor Control Kit AN103 (UP84) VBUS VOLTAGE SIGNAL AN101 (UP86) V PHASE CURRENT SIGNAL AN102 (UP85) U PHASE CURRENT SIGNAL 100R 100R 100R MTIC5U (UP96) U PHASE COMM. SIGNAL MTIC5V (UP97) V PHASE COMM. SIGNAL MTIC5W (UP98) W PHASE COMM. SIGNAL...
  • Page 12 RX62T YROTATE-IT-RX62T Motor Control Kit clamped with a diode directly connected with the microcontroller power supply, so a suitable series resistance is needed in the power stage to avoid damages to the board. c) A further connector (J12) can be used to supply the board from the power stage or vice-versa (making a short circuit between the pins 1 and 2 of the jumper JP5);...
  • Page 13 RX62T YROTATE-IT-RX62T Motor Control Kit UM-YROTATE-IT-RX62T Rev.1.00 Page 13 of 51 Jan 15, 2014...

  • Page 14: Connection With A 1.5Kw External Power Stage

    RX62T YROTATE-IT-RX62T Motor Control Kit 8. Connection with a 1.5KW external power stage The interface for an external power supply was designed to be compatible with the power stages of previous Renesas motor control platforms MCRP05/06. So it becomes possible to use the same power stage and connect any Motor Control board using RX62T, RL78/G14 or RX220 microcontroller families.

  • Page 15: Control Microcontroller Overview

    RX62T YROTATE-IT-RX62T Motor Control Kit 9. Control microcontroller overview The RX62T/63T Group is a set of microcontrollers featuring the high-speed, high-performance RX CPU as the 100MHz processor core. Each basic instruction of the processor is executable in one cycle of the system clock. Calculation functionality is enhanced by the inclusion of a single-precision floating-point calculation unit as well as a 32-bit multiplier and divider.
  • Page 16 RX62T YROTATE-IT-RX62T Motor Control Kit Large-capacity flash memory units capable of high-speed operation are included as on-chip memory, significantly reducing the cost of configuring systems. The main application fields of this microcontroller are: industrial equipment, household electrical appliances, machines requiring motor control, and inverter-powered machines.

  • Page 17: Permanent Magnets Ac Brushless Motor Model

    RX62T YROTATE-IT-RX62T Motor Control Kit 10. Permanent magnets AC Brushless motor model The synchronous permanent magnets motor (e.g. sinusoidal Brushless motor) is widely used in the industry. More and more home appliance makers are now using such AC Brushless motor, mainly because of the intrinsic motor efficiency.
  • Page 18 RX62T YROTATE-IT-RX62T Motor Control Kit λ λ λ - λ is the magnetic flux linkage with the i-th stator winding is the stator phase resistance (the resistance of one of the stator windings) The magnetic flux linkages λ are composed by two items, one due to the stator currents, one to the permanent magnets.
  • Page 19 RX62T YROTATE-IT-RX62T Motor Control Kit Supposing that the rotor is rotating at constant speed ω (that is: ϑ(t) = ωt) the flux linkages derivatives can be calculated, and we obtain: ω ϑ − Λ sin( π ω ϑ − Λ...
  • Page 20 RX62T YROTATE-IT-RX62T Motor Control Kit The reference frame transformations from the (α,β) system to the (d, q) system depends on the instantaneous position angle ϑ ϑ ϑ ϑ So we obtain two inter-dependant equations in the (d, q) system: ω...
  • Page 21 RX62T YROTATE-IT-RX62T Motor Control Kit λ α α α λ β β β These equations show that magnetic flux can be obtained from applied voltages and measured currents simply by integration: λ λ ∫ − α α α α λ...

  • Page 22: Sensorless Field Oriented Control Algorithm

    RX62T YROTATE-IT-RX62T Motor Control Kit 11. Sensorless Field Oriented Control Algorithm Please, find below the sensorless FOC algorithm block diagram. Vα α α α (α, β) → Id PI (d, q) → 0 [Id Motor (α, β) Vβ β β β...

  • Page 23: Flux Feedback Gain

    RX62T YROTATE-IT-RX62T Motor Control Kit 12. Flux Feedback Gain The block scheme of the exact BEMF integration method for flux position estimation is the following: λ λ λ λ ϑ λ λ λ λ ϑ ϑ ϑ ϑ λ λ λ λ...

  • Page 24: Software Description

    YROTATE-IT-RX62T Motor Control Kit 13. Software description The software of the YROTATE-IT-RX62T kit is working on the RX62T microcontroller clocked at 100MHz. It is a fast and powerful device for this class of algorithm. This allows the user to realize virtually what he wants in addition.
  • Page 25 RX62T YROTATE-IT-RX62T Motor Control Kit Main Program EEPROM parameters upload A/D channels offset reading Peripherals initialization Variables initialization Interrupt enabling Main loop synchronization cnt_int == 0 ? cnt_int = NUM_INT Main loop body Speed ramp management Communication management General board management Parameters modification management UM-YROTATE-IT-RX62T Rev.1.00...
  • Page 26 RX62T YROTATE-IT-RX62T Motor Control Kit Control interrupt Phase currents (iu , iv ) reading Transformations (using the phase angle ϑ): , iv ) → (ia , ib ) → (id , iq Read DC Link voltage v Phase angle update: ϑ = ϑ...
  • Page 27 RX62T YROTATE-IT-RX62T Motor Control Kit The CD-ROM of the motor control kit YROTATE-IT-RX62T contains two projects available in zipped files called: 1) File name: “MCRP07_RX62T_intPS_v7.zip” loaded by default on the kit PCB to manage low voltage motor using the internal power stage made of MOSFETs and available on the board.

  • Page 28: Application Customization Using "Customize.h" File

    RX62T YROTATE-IT-RX62T Motor Control Kit 14. Application customization using “customize.h” file Please find below snapshot of the file “customize.h” which contents many interesting options and details about the RX62T embedded software. Feel free to modify it and recompile the source code in order to use the new values. The “customize.h”...
  • Page 29 RX62T YROTATE-IT-RX62T Motor Control Kit UM-YROTATE-IT-RX62T Rev.1.00 Page 29 of 51 Jan 15, 2014...

  • Page 30: Start-Up Procedure

    RX62T YROTATE-IT-RX62T Motor Control Kit 15. Start-up procedure When the motor is in stand-still, the phase of the permanent magnet flux vector cannot be detected with the used algorithm. So an appropriate start-up procedure has to be applied. The idea is to move the motor in feed-forward (with higher current than that required to win the load), till a speed at which the estimation algorithm can work.
  • Page 31 RX62T YROTATE-IT-RX62T Motor Control Kit Furthermore id and iq begin to be similar to the real flux and torque components of the current. The real components are supposed to be id and iq (those values are obtained applying a low-pass filter to id...

  • Page 32: Reference System Transformations In Details

    RX62T YROTATE-IT-RX62T Motor Control Kit 16. Reference system transformations in details Find below the detailed equations used for the coordinates transformations. − − α − − β (u, v, w) → (α, β) α − − α β α β...

  • Page 33: Pwm Modulation Technique

    RX62T YROTATE-IT-RX62T Motor Control Kit 17. PWM modulation technique Among the various possibilities, a particular form of PWM modulation was chosen. In this modulation technique, the voltages to be imposed are shifted in order to have in every moment one of the three phases of the motor connected to the system ground.

  • Page 34: Pc Graphical User Interface

    RX62T YROTATE-IT-RX62T Motor Control Kit 18. PC Graphical User Interface The User Interface is easily installed via the CD-ROM installer. The PC Interface is using the optically isolated USB connection to powered the board and communicate with it. Once the Motor Control PC GUI is installed based on the explanations of the Quick Start Guide, please click on the “Speed Control”...
  • Page 35 RX62T YROTATE-IT-RX62T Motor Control Kit Alarm 2: The alarm 2 is called “hardware overcurrent” and described in the software by “FAULT_ALL”. This alarm is produced by the microcontroller peripheral called Port Output Enable (POE) in case of external overcurrent signal. The hardware overcurrent is producing a falling edge input on the POE pin.

  • Page 36: Motor Auto-Calibration Using The Pc Gui

    RX62T YROTATE-IT-RX62T Motor Control Kit 19. Motor Auto-calibration using the PC GUI The full calibration of any 3-phase AC Brushless motor can be performed automatically using the PC Graphical User Interface. Three specific buttons are now available for and shown below:...
  • Page 37 RX62T YROTATE-IT-RX62T Motor Control Kit b) Let’s setup the Motor control kit for 24V external power supply: the jumper JP2 needs to be set to 2-3 position. c) Let’s connect the 24V Power supply to the RX62T motor control reference kit: d) Now, connect the USB cable to the PC and the Kit and connect the 24V to the kit and the motor to the kit: UM-YROTATE-IT-RX62T Rev.1.00...
  • Page 38 RX62T YROTATE-IT-RX62T Motor Control Kit e) Launch the PC GU from the folder: “C:\Program Files\MCDEMO” launch: “MotorController.exe” Click on the “setup” button and select “RX62T Kit” and select “Autodetect” and click on “Connect” to ensure the PC GUI is connected to the RX62T kit.
  • Page 39 RX62T YROTATE-IT-RX62T Motor Control Kit h) Now click on the button “Cu. PI tuning” to open the manual current PI tuning window and check the step answer by clicking on “Apply current step” button. Depending on the motor, the parameters found by the automatic procedure can be too fast or too slow.
  • Page 40 RX62T YROTATE-IT-RX62T Motor Control Kit You can adjust manually the parameters to obtain an even better step response and also increase the step current level by increasing the percentage of “Cur. [%] to 90%. The default value is 50%. Once it’s done, the window can be closed as the proportional and integral coefficients of the PI current are tuned.
  • Page 41 RX62T YROTATE-IT-RX62T Motor Control Kit k) Set a start-up current equal to 25% of the maximum current. In our case 25% of 3.5A is 0.875A. Please enter the value 875 into the parameter n°6 and click on the “write” button on the left.
  • Page 42 RX62T YROTATE-IT-RX62T Motor Control Kit Please click on the “Oscilloscope” button to see the motor waveforms with the current in Y-axis and the time in x- axis. You can also display the phase by clicking on “Phase” selector: For the oscilloscope window, use an opportune time scale: “1 sample every 1” should be used for extremely fast phenomena when running at very high speed.
  • Page 43 RX62T YROTATE-IT-RX62T Motor Control Kit The setting “1 sample every 128” should be used for extremely low phenomena when running at very low speed. Let’s start with an intermediate value and adjust it in order to see some periods of the current or the phase.
  • Page 44 RX62T YROTATE-IT-RX62T Motor Control Kit In our case, at 350 it started to be very unstable, but the motor is still running. Set the speed to “0”. Then use half of the found value: 175 in our case, click on “write” and set the speed to 2000 RPM.
  • Page 45 RX62T YROTATE-IT-RX62T Motor Control Kit Troubleshooting: At the stage i) if the motor doesn’t start or generate an alarm n°3, please set the speed to “0” to clear the alarm which indicates that the software lost the phase. One first test is to increase or decrease the start-up current and the...

  • Page 46: List Of Motors Tuned Automatically Using The Pc Gui

    RX62T YROTATE-IT-RX62T Motor Control Kit 20. List of motors tuned automatically using the PC GUI Please find below a short list of AC Brushless motors tuned automatically using the auto-tuning procedure described above. For each motor a specific text file is available to be loaded onto the PC GUI.

  • Page 47: List Of Variables Used In The File Name: "Motorcontrol.c

    RX62T YROTATE-IT-RX62T Motor Control Kit 21. List of variables used in the file name: “motorcontrol.c” The file called “motorcontrol.c” includes the motor control algorithm routines. Please find below the description of the variables used in this file. Label(s) Type Description...
  • Page 48 RX62T YROTATE-IT-RX62T Motor Control Kit Label(s) Type Description Unit omegae_s float Electrical speed during startup (instant value) rad/s delta_om float Speed quantity added at every step during startup ramp. rad/s om_chg float Speed to reach during the startup; when this speed is reached, rad/s the startup ramp ends.
  • Page 49 RX62T YROTATE-IT-RX62T Motor Control Kit Label(s) Type Description Unit errint float Speed PI integral memory ampere kp_cur, ki_cur float Proportional and integral constant in current PI controllers. volt/ampere kp_vel, ki_vel float Proportional and integral constant in speed PI controller. ampere/(rad/s)
  • Page 50 RX62T YROTATE-IT-RX62T Motor Control Kit Label(s) Type Description Unit vbus_ad signed A/D conversion result of the DC link voltage reading. short iss_off signed A/D conversion offsets of measured single shunt current; the short value is around 2048, that corresponds to one half of the A/D converter supply voltage (5Vdc) (12bit A/D).
  • Page 51 RX62T YROTATE-IT-RX62T Motor Control Kit Label(s) Type Description Unit tele_ang float Corrected electrical position. om_mec float Mechanical angular speed. rad/s om_eme float Electro-mechanical angular speed. rad/s enc_buf[] float Encoder filter buffer. UM-YROTATE-IT-RX62T Rev.1.00 Page 51 of 51 Jan 15, 2014...
  • Page 52 Revision History Description Rev. Date Page Summary 1.00 15, 2014 First Edition...
  • Page 53 General Precautions in the Handling of MPU/MCU Products The following usage notes are applicable to all MPU/MCU products from Renesas. For detailed usage notes on the products covered by this document, refer to the relevant sections of the document as well as any technical updates that have been issued for the products.
  • Page 54 10. It is the responsibility of the buyer or distributor of Renesas Electronics products, who distributes, disposes of, or otherwise places the product with a third party, to notify such third party in advance of the contents and conditions set forth in this document, Renesas Electronics assumes no responsibility for any losses incurred by you or third parties as a result of unauthorized use of Renesas Electronics products.

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