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Texas Instruments TIDA-060040 Manual

Texas Instruments TIDA-060040 Manual

Absolute angle encoder reference design with halleffect sensors for precise motor position control

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Design Guide: TIDA-060040
Absolute Angle Encoder Reference Design With Hall­
Effect Sensors for Precise Motor Position Control
Description
This reference design demonstrates a method for
absolute angle encoding typical in precision motor
control applications such as robotic arm control.
Angle encoding can be achieved using various
magnetic sensing technologies. This is done by
detecting two magnetic flux density, B-field, vector
components which are naturally 90° out of phase. As
the magnet spins, the sensor inputs are sinusoidal
which allows for calculations using trigonometric
properties. However, due to electrical and mechanical
characteristics of the system, it is often necessary
to correct the final result to achieve the greatest
accuracy. Typically in most precision motor control
applications, the final target error is less than
0.1°. This design explores the process for selecting
a magnet, determining placement, and correcting
for system-level imperfections to achieve a highly-
accurate angle measurement.
Resources
TIDA-060040
TMAG5170
DRV5055
Ask our TI E2E
3.3 V
SPI Bus
C2000
Motor Driver
LaunchPad™
Interface
Motor Supply
Voltage
TIDUC07 – MARCH 2022
Submit Document Feedback
Design Folder
Product Folder
Product Folder
support experts
Hall-Effect
Sensor
BLDC
TIDA-060040
Motor
Copyright © 2022 Texas Instruments Incorporated
Features
Measure angle in on-axis, in-plane, and off-axis
alignments for flexible alignment and sensor
placement
Calibration process for accuracy of 0.1°
Selectable digital SPI communication or analog
output
Design files with sensor placement guidance
Applications
Mobile robot motor control
Mobile robot sensing module
Robotic lawn mower
Robot servo drive
Servo drive position sensor
Position sensors
Self-balancing personal transporter
Absolute Angle Encoder Reference Design With Hall-Effect Sensors for
Description
Precise Motor Position Control
1

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Summary of Contents for Texas Instruments TIDA-060040

  • Page 1 SPI Bus C2000 Hall-Effect Motor Driver LaunchPad™ Sensor Interface BLDC TIDA-060040 Motor Motor Supply Voltage TIDUC07 – MARCH 2022 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for Submit Document Feedback Precise Motor Position Control Copyright © 2022 Texas Instruments Incorporated...
  • Page 2: System Description

    For inductive and linear Hall-effect based solutions, the premise of the angle calculation uses sinusoidal outputs which are 90° out of phase from each other. Absolute Angle Encoder Reference Design With Hall-Effect Sensors for TIDUC07 – MARCH 2022 Precise Motor Position Control Submit Document Feedback Copyright © 2022 Texas Instruments Incorporated...
  • Page 3 1D In-Plane • 1D Off-Axis • 3D In-Plane • 3D Off-Axis • 3D On-Axis TIDUC07 – MARCH 2022 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for Submit Document Feedback Precise Motor Position Control Copyright © 2022 Texas Instruments Incorporated...
  • Page 4: System Overview

    BLDC TIDA-060040 Motor Motor Supply Voltage Figure 2-1. TIDA-060040 Block Diagram 2.2 Highlighted Products 2.2.1 TMAG5170 TMAG5170 is a high-precision linear 3D Hall-effect sensor designed for a wide range of industrial applications. The high level of integration offers flexibility and accuracy in a variety of position sensing systems.
  • Page 5: Design Considerations

    XYZZYX conversion pattern, the total integration time is 4.825 ms. At a motor speed of about 35 RPM, the TIDUC07 – MARCH 2022 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for Submit Document Feedback Precise Motor Position Control Copyright © 2022 Texas Instruments Incorporated...
  • Page 6 Figure 2-4. Absolute Angle Encoder Reference Design With Hall-Effect Sensors for TIDUC07 – MARCH 2022 Precise Motor Position Control Submit Document Feedback Copyright © 2022 Texas Instruments Incorporated...
  • Page 7 With such a small input signal, the output noise could cause significant errors in angle calculations. TIDUC07 – MARCH 2022 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for Submit Document Feedback Precise Motor Position Control Copyright © 2022 Texas Instruments Incorporated...
  • Page 8 5.9-mm Airgap Magnetic Field Inputs. Angle (deg) Figure 2-8. 5.9-mm Airgap Magnetic Field Inputs Absolute Angle Encoder Reference Design With Hall-Effect Sensors for TIDUC07 – MARCH 2022 Precise Motor Position Control Submit Document Feedback Copyright © 2022 Texas Instruments Incorporated...
  • Page 9 Z-component of the field vector which in this alignment is 0 mT for all angles. Instead, it is more ideal to use the LPG through-hole package in this location. TIDA-060040 includes an optional component footprint for this package variant adjacent to the target location for the SOT-23 package. Make sure the sensors have the same vertical spacing from the PCB to ensure each observes an equivalent input from the rotating magnet, and that the sensor is installed orthogonal to the surface of the PCB.
  • Page 10 As a result, there is a wide range of locations suitable for the SOT-23 package option. Absolute Angle Encoder Reference Design With Hall-Effect Sensors for TIDUC07 – MARCH 2022 Precise Motor Position Control Submit Document Feedback Copyright © 2022 Texas Instruments Incorporated...
  • Page 11 This condition is ideal for 3D sensors, such as TMAG5170. Since the vector is entirely within the XY plane, a single sensor should experience perfectly sinusoidal inputs when monitoring these axes. TIDUC07 – MARCH 2022 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for Submit Document Feedback Precise Motor Position Control Copyright © 2022 Texas Instruments Incorporated...
  • Page 12 • TMAG5170 Error Figure 2-15. Expected TMAG5170 In-Plane Angle Error Absolute Angle Encoder Reference Design With Hall-Effect Sensors for TIDUC07 – MARCH 2022 Precise Motor Position Control Submit Document Feedback Copyright © 2022 Texas Instruments Incorporated...
  • Page 13 However, each of these cases has assumed ideal mechanical tolerances. Test Results details the actual observed error from each of these device configurations. TIDUC07 – MARCH 2022 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for Submit Document Feedback Precise Motor Position Control Copyright © 2022 Texas Instruments Incorporated...
  • Page 14 One important factor when designing an angle encoder using these devices is the actual sensor location on the PCB. The sensor placement in the package may result with unintentional placement errors in any of the 3 axes. Figure 2-20. TIDA-060040 Sensor Placement Absolute Angle Encoder Reference Design With Hall-Effect Sensors for TIDUC07 –...
  • Page 15 LPG through-hole package depending on the sensor location. Figure 2-22. TMAG5170 Sensor Location For TMAG5170, the layout files TIDA-060040 contain an alignment layer which indicates the actual sensor location. Additionally, a via has been placed at the target sensor location to assist with alignment.
  • Page 16 System Overview www.ti.com 2.3.7 45° Alignment The TIDA-060040 also shows an additional alignment option for TMAG5170. Figure 2-23. TMAG5170 45° Alignment This second sensor location option has the device physically rotated 45°. Instead of the normal orthogonal alignment, the X and Y axes of the sensor each observe the same input magnitude. The effective input for each axis is the average of the two axes.
  • Page 17 Hardware, Software, Testing Requirements, and Test Results 3 Hardware, Software, Testing Requirements, and Test Results 3.1 Hardware Requirements Figure 3-1 illustrates the schematic and board connections of TIDA-060040. TMAG5170 45 Degree Alignment Encoder DRV5055 Encoder DRV5055 OUT1 OUT2 VCC_1...
  • Page 18 Hardware, Software, Testing Requirements, and Test Results www.ti.com Figure 3-2 shows the layout of TIDA-060040. Figure 3-2. TIDA-060040 Layout This layout may be used or adjusted as needed to suit any magnet and motor geometry. While this design includes options for...
  • Page 19: Test Setup

    3D printed mounting plate Figure 3-4. Mounting Plate • TI-SCB (SENS077) • Micro USB cable TIDUC07 – MARCH 2022 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for Submit Document Feedback Precise Motor Position Control Copyright © 2022 Texas Instruments Incorporated...
  • Page 20 3. Insert magnet into recess in magnet holder 4. Connect TIDA-060040 to the 3D printed mounting plate 5. Connect TIDA-060040 to the TI-SCB (TI sensor control board) 6. Connect TI-SCB to PC via USB cable 3.2.3 Test Software Configuration and Initial Data Capture 1.
  • Page 21: Test Results

    • Motor Shaft tilt – results in an orthogonality error between TIDA-060040 and the rotating magnet. This produces a fixed shift to the expected field alignment. •...
  • Page 22 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for TIDUC07 – MARCH 2022 Precise Motor Position Control Submit Document Feedback Copyright © 2022 Texas Instruments Incorporated...
  • Page 23 TIDUC07 – MARCH 2022 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for Submit Document Feedback Precise Motor Position Control Copyright © 2022 Texas Instruments Incorporated...
  • Page 24 -1.2 -1.5 -1.8 -2.1 -2.4 -2.7 Angle (deg) Figure 3-11. On-Axis Mechanical Angle Error Absolute Angle Encoder Reference Design With Hall-Effect Sensors for TIDUC07 – MARCH 2022 Precise Motor Position Control Submit Document Feedback Copyright © 2022 Texas Instruments Incorporated...
  • Page 25 As a result tilt and alignment errors will result in phase error and changing input amplitudes. TIDUC07 – MARCH 2022 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for Submit Document Feedback Precise Motor Position Control Copyright © 2022 Texas Instruments Incorporated...
  • Page 26 Table 3-3. In-Plane Harmonic Correction Factors HARMONIC α β 5.33 2.68 –0.5 –1.22 –0.26 0.51 0.17 0.05 –0.04 –0.02 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for TIDUC07 – MARCH 2022 Precise Motor Position Control Submit Document Feedback Copyright © 2022 Texas Instruments Incorporated...
  • Page 27 The observed error for this alignment were similar to what was observed with the In-Plane Configuration. Figure 3-16. Off-Axis Configuration TIDUC07 – MARCH 2022 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for Submit Document Feedback Precise Motor Position Control Copyright © 2022 Texas Instruments Incorporated...
  • Page 28 -0.4 -0.5 -0.6 -0.7 -0.8 -0.9 Angle (deg) Figure 3-18. Off-Axis Calibrated Angle Error Absolute Angle Encoder Reference Design With Hall-Effect Sensors for TIDUC07 – MARCH 2022 Precise Motor Position Control Submit Document Feedback Copyright © 2022 Texas Instruments Incorporated...
  • Page 29 -0.1 -0.2 -0.3 -0.4 -0.5 Angle (deg) Figure 3-20. 45° Calibrated Angle Error TIDUC07 – MARCH 2022 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for Submit Document Feedback Precise Motor Position Control Copyright © 2022 Texas Instruments Incorporated...
  • Page 30 Mechanical Error Angle (deg) Figure 3-22. DRV5055 Off-Axis Mechanical Angle Error Absolute Angle Encoder Reference Design With Hall-Effect Sensors for TIDUC07 – MARCH 2022 Precise Motor Position Control Submit Document Feedback Copyright © 2022 Texas Instruments Incorporated...
  • Page 31 Figure 3-23. DRV5055 Off-Axis Calibrated Angle Error TIDUC07 – MARCH 2022 Absolute Angle Encoder Reference Design With Hall-Effect Sensors for Submit Document Feedback Precise Motor Position Control Copyright © 2022 Texas Instruments Incorporated...
  • Page 32: Design Files

    4.1 Design Files 4.1.1 Schematics To download the schematics and layout, see the design files at TIDA-060040. 4.1.2 BOM To download the bill of materials (BOM), see the design files at TIDA-060040. 4.2 Tools and Software Tools TMAG5170UEVM GUI The TMAG5170UEVM GUI offers a simple platform to configure device registers and monitor and record outputs of both TMAG5170A1 and TMAG5170A2.
  • Page 33 TI products. TI’s provision of these resources does not expand or otherwise alter TI’s applicable warranties or warranty disclaimers for TI products. TI objects to and rejects any additional or different terms you may have proposed. IMPORTANT NOTICE Mailing Address: Texas Instruments, Post Office Box 655303, Dallas, Texas 75265 Copyright © 2022, Texas Instruments Incorporated...