Renesas YROTATE-IT-RX220 User Manual
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Renesas YROTATE-IT-RX220 User Manual

Renesas YROTATE-IT-RX220 User Manual

Low cost motor control kit based on rx220
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USER MANUAL
YROTATE-IT-RX220
UM-YROTATE-IT-RX220
Rev.1.00
Jan 15, 2014
Low Cost Motor Control Kit based on RX220
Introduction
The Renesas Motor Control Kit, YROTATE-IT-RX220, is based on the RX220 device from the powerful 32-bit RX
microcontroller family.
The kit enables engineers to easily test and evaluate the performance of the RX220 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 RX220
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-RX220 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:
RX220
UM-YROTATE-IT-RX220 Rev.1.00
Page 1 of 50
Jan 15, 2014

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Summary of Contents for Renesas YROTATE-IT-RX220

  • Page 1 Low Cost Motor Control Kit based on RX220 Introduction The Renesas Motor Control Kit, YROTATE-IT-RX220, is based on the RX220 device from the powerful 32-bit RX microcontroller family. The kit enables engineers to easily test and evaluate the performance of the RX220 in a laboratory environment when driving any 3-phase Permanent Magnet Synchronous Motor (e.g.

  • Page 2: Table Of Contents

    RX220 YROTATE-IT-RX220 Motor Control Kit Contents 1. Hardware overview ............................... 3 2. Connectors description ..............................4 3. Power supply selection ..............................5 4. LEDs function description ............................. 6 5. Test points for debugging ............................. 7 6. Internal power stage brief description ......................... 9 7.

  • Page 3: Hardware Overview

    YROTATE-IT-RX220 Motor Control Kit 1. Hardware overview The inverter kit YROTATE-IT-RX220 is a single board inverter, based on the RX series microcontroller RX220 and includes a low-voltage MOSFETs power stage and a communication stage. To obtain the maximum flexibility, the reference kit includes: •...

  • Page 4: Connectors Description

    The E1 connector is used for the programming and the debugging of the software running on the RX220. The external power stage connector is compatible with the power stages, designed for Renesas inverter kits, which are able to drive 230V motor up to 1.5KW.

  • Page 5: Power Supply Selection

    RX220 YROTATE-IT-RX220 Motor Control Kit 3. Power supply selection As stated before, there are two ways to supply power to the board. 1. The first possibility is to use directly the PC USB supply. In this case the current you can give to the motor is limited by the USB current capabilities.

  • Page 6: Leds Function Description

    RX220 YROTATE-IT-RX220 Motor Control Kit 4. LEDs function description Some of the LEDs available on the board are directly connected to the hardware and allow the user to understand the status of the board. Please refer to the LED map for the following indications: •...

  • Page 7: Test Points For Debugging

    RX220 YROTATE-IT-RX220 Motor Control Kit 5. 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. Furthermore, it is possible to visualize internal variables as analog waveforms using filtered PWM outputs.
  • Page 8 RX220 YROTATE-IT-RX220 Motor Control Kit • TP1, TP2, TP3 are three filtered PWM outputs which can be used to visualize the behavior of internal variables. o In the standard software TP1 is the output for the system phase, e.g. estimated rotor...

  • Page 9: Internal Power Stage Brief Description

    The power stage is a complete 3-phase bridge composed with discrete low voltage power MOSFETs. The MOSFETs are the Renesas RJK0654DPB n-channel power MOSFETs. Please refer to the data-sheet for the switches characteristics and to the board schematics for the details on the driving circuit.

  • Page 10: Interface With An External Power Stage

    RX220 YROTATE-IT-RX220 Motor Control Kit 7. Interface with an external power stage Since internal power stage allows only the management of low voltage motors, an interface with an external power stage has been developed. The selection between the internal power stage and the external power stages is ensured by jumpers. It is a safe way to ensure that the right voltage and current signals are active.
  • Page 11 RX220 YROTATE-IT-RX220 Motor Control Kit o if pins 1 and 2 are shorted, then the external power stage low voltage supply (between 15V to 24V) is connected to the internal DC Bus Voltage; in this case both the step-down converters of the board will work;...
  • Page 12 RX220 YROTATE-IT-RX220 Motor Control Kit a) The PWM drive signals are directly connected to the microcontroller output pins, and there is no pull-up or pull-down resistor connected, so the polarization has to be done in the power stage. In case of alarm, the microcontroller output pins can be placed in high impedance state, so the external polarization is necessary.
  • Page 13 RX220 YROTATE-IT-RX220 Motor Control Kit +VBUS THERMAL SENSOR +15V VBUS Current Sensor OUT U Intelligent Power OUT V Current Module Sensor OUT W MOTOR ALRM +15V Current PWGND Sensor UM-YROTATE-IT-RX220 Rev.1.00 Page 13 of 50 Jan 15, 2014...

  • Page 14: Single Shunt Current Reading

    RX220 YROTATE-IT-RX220 Motor Control Kit 8. Single shunt current reading While the normal configuration of the board and the standard software are based on three shunts current reading, we also offer the possibility to configure the board for single shunt current reading. Some hardware modifications are required, and a different software version has to be loaded.

  • Page 15: Current Reading Timing In Three Shunts And Single Shunt Configurations

    RX220 YROTATE-IT-RX220 Motor Control Kit 9. Current reading timing in three shunts and single shunt configurations The figures below show the different situations related to the two configurations. The first figure is related to three shunts current reading, the other are related to the single shunt current reading.

  • Page 16: Control Mcu Overview

    RX220 YROTATE-IT-RX220 Motor Control Kit 10. Control MCU overview The RX220 Group is a low power entry-level 32-bit microcontroller. The RX220 Group of products is the slimmed-down version of the higher model RX210 Group, and has very high compatibility in terms of pin arrangement and on the software level.

  • Page 17: Permanent Magnets Brushless Motor Model

    RX220 YROTATE-IT-RX220 Motor Control Kit 11. Permanent magnets brushless motor model The synchronous permanent magnets motor (sinusoidal brushless motor) is widely used in the industry. More and more home appliance makers are now using such brushless motor, mainly because of the intrinsic motor efficiency.
  • Page 18 RX220 YROTATE-IT-RX220 Motor Control Kit Let’s analyse the motor from a mathematic point of view. If we apply three voltages v (t), v (t), v (t) to the stator windings, the relations between phase voltages and currents are: λ λ...
  • Page 19 RX220 YROTATE-IT-RX220 Motor Control Kit It is, in every axis, the projection of the constant flux vector Λ in the direction of the axis: λ ϑ Λ cos( π λ ϑ Λ − cos( π λ ϑ Λ − cos( Supposing that the rotor is rotating at constant speed ω...
  • Page 20 RX220 YROTATE-IT-RX220 Motor Control Kit ωλ α − α α β β ωλ β β α A second reference frame is used to represent the equations as the frame is turning at the rotor speed. So the “d” axis is chosen in the direction of the magnetic vector Λ...
  • Page 21 RX220 YROTATE-IT-RX220 Motor Control Kit In the block scheme the mechanic part is included, where “p” is the number of pole pairs, while “B” represents friction, “J” the inertia, “τ “ the load torque and “τ” the motor torque. load τ...
  • Page 22 RX220 YROTATE-IT-RX220 Motor Control Kit The system speed ω can be obtained as the derivative of the angle ϑ. ω ϑ ) (t Based on this, a sensorless control algorithm was developed to give the imposed phase voltages, to measure phase currents, to estimate the angular position ϑ and finally the system speed.

  • Page 23: Sensorless Field Oriented Control Algorithm

    RX220 YROTATE-IT-RX220 Motor Control Kit 12. Sensorless Field Oriented Control algorithm Please, find below the sensorless vector control algorithm block diagram. Vα α α α (α, β) → Id PI (d, q) → 0 [Id Motor (α, β) Vβ β β β...

  • Page 24: Software Description

    YROTATE-IT-RX220 Motor Control Kit 13. Software description On YROTATE-IT-RX220 the software previously described is working on RX220 clocked at 32MHz. Using the interrupt skipping function it is possible to regulate separately the PWM frequency and the sampling frequency, allowing the user to add additional tasks to the motor control.
  • Page 25 RX220 YROTATE-IT-RX220 Motor Control Kit The following flowcharts show the software implementation of the motor control part of the software. Please fin below the flowchart for the main loop: Software organization Hardware and software initialization Interrupt enabling PWM Interrupt 10ms Main loop UM-YROTATE-IT-RX220 Rev.1.00...
  • Page 26 RX220 YROTATE-IT-RX220 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-RX220 Rev.1.00...
  • Page 27 RX220 YROTATE-IT-RX220 Motor Control Kit Control Interrupt Phase currents (iu , iv ) reading (three shunts current reading) Transformations (using the phase angle ϑ): , iv ) → (ia , ib ) → (id , iq Read DC Link voltage v Phase angle update: ϑ...

  • Page 28: Start-Up Procedure

    RX220 YROTATE-IT-RX220 Motor Control Kit 14. 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 29 RX220 YROTATE-IT-RX220 Motor Control Kit c) At t = t , while iq is maintained to zero and id is maintained to its value i , speed is increased start . The system phase ϑ with a ramp till the value s...

  • Page 30: Reference System Transformations In Details

    RX220 YROTATE-IT-RX220 Motor Control Kit 15. Reference system transformations in details Find below the detailed equations used for the coordinates transformations in the embedded software for the RX220 microcontroller. − − α − − β (u, v, w) → (α, β) α...

  • Page 31: Rotor Position Estimation

    RX220 YROTATE-IT-RX220 Motor Control Kit 16. Rotor position estimation The rotor position estimation method which has been chosen is the direct integration of the back EMF. Please find below the fundamental equations: ϑ λ λ Λ − ∫ − −...
  • Page 32 RX220 YROTATE-IT-RX220 Motor Control Kit In the second case, to prevent the integral to diverge, and the errors related to wrong initial conditions are rejected, by the correcting action of the feedback. The block scheme of the exact BEMF integration method for flux position estimation is the following: The inputs of the system are the imposed voltage vector V and the measured current vector I.

  • Page 33: Internal Representation Of Physical Quantities

    RX220 YROTATE-IT-RX220 Motor Control Kit 17. Internal representation of physical quantities The idea which lies under the internal representation of physical variables is to maximize the resolution, keeping as simple as possible the calculations and keeping reasonably low the memory occupation. So whenever it had been possible, the physical variables have been represented under a “per unit”...
  • Page 34 RX220 YROTATE-IT-RX220 Motor Control Kit ( → Omega[internal_angular_velocity_unit1] = NORMVAL * (Angle(n) - Angle(n - k)) / k) We obtain: KO1 = NORMVAL * KA / KT = NORMVAL * 65536 / (2 * pi * Fs) The entire speed range cannot, in general, be represented in a 16bit word, but a long is needed. This high resolution can be useful for some particular calculations, while when, for example, the speed is used to calculate voltages, lesser resolution is enough.
  • Page 35 RX220 YROTATE-IT-RX220 Motor Control Kit Current The maximum current readable by the A/D converter is chosen as the base value: BASE_CURRENT_AMP = MAX_CURRENT_AMP It is represented with NORMVAL = 16384: Current[internal_current_unit] = KI * Current[Amp] KI = NORMVAL / BASE_CURRENT_AMP Impedance The base impedance value can be deduced by the base voltage and current values;...
  • Page 36 RX220 YROTATE-IT-RX220 Motor Control Kit KL = NORMVAL / BASE_INDUCTANCE_HEN = = NORMVAL * BASE_SPEED_R_S * BASE_CURRENT_AMP / BASE_VOLTAGE_VOLT Flux In a similar way, the "base" flux can be chosen equal to: BASE_FLUX_WEB = BASE_VOLTAGE_VOL / BASE_SPEED_R_S Then we can express the flux as:...

  • Page 37: Eeprom Parameters List

    RX220 YROTATE-IT-RX220 Motor Control Kit 18. EEPROM parameters list Please find below the software parameters list including their full description. Each parameters located in the “customize.h” header file can be tuned by the user directly by the Graphic User Interface, without re- compiling the program.

  • Page 38: Pc Graphical User Interface

    RX220 YROTATE-IT-RX220 Motor Control Kit 19. PC Graphical User Interface Once the Motor Control PC GUI is installed based on the explanations of the Quick Start Guide, please click on the “Speed Control” button to display the following window: Please find below the description of the Alarm codes coming from the PC GUI: Alarm 1: The alarm 1 is called “EEPROM alarm”...
  • Page 39 RX220 YROTATE-IT-RX220 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 MCU 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 40: Motor Auto-Calibration Using The Pc Gui

    RX220 YROTATE-IT-RX220 Motor Control Kit 20. 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 41 RX220 YROTATE-IT-RX220 Motor Control Kit b) Let’s setup the Motor control kit for 24V external power supply: the jumper JP1 and JP2 needs to be set to 1-3 position as explained in the “Chapter 3 Power Supply selection”. c) Let’s connect the 24V...
  • Page 42 RX220 YROTATE-IT-RX220 Motor Control Kit Click on the “setup” button and select “RX220 Kit” and select “Autodetect” and click on “Connect” to ensure the PC GUI is connected to the RX220 kit. On the left hand side, the new buttons appears: “Cu. PI tuning”, “Cu. PI tuning (AUTO)”, “Motor Identification”...
  • Page 43 RX220 YROTATE-IT-RX220 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 44 RX220 YROTATE-IT-RX220 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 45 RX220 YROTATE-IT-RX220 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 46 RX220 YROTATE-IT-RX220 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 47 RX220 YROTATE-IT-RX220 Motor Control Kit Let’s start with an intermediate value and adjust it in order to see some periods of the current or the phase. When the motor is running, you can adjust the speed PI parameters. Please follow the procedure: while running at a medium speed range: 2 times the minimum speed.
  • Page 48 RX220 YROTATE-IT-RX220 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 49 RX220 YROTATE-IT-RX220 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 50: List Of Motors Tuned Automatically Using The Pc Gui

    RX220 YROTATE-IT-RX220 Motor Control Kit 21. 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 51 Revision History Description Rev. Date Page Summary 1.00 n 15, 2014 First Edition...
  • Page 52 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 53 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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