STMicroelectronics STDES-EVT001V1 User Manual

STMicroelectronics STDES-EVT001V1 is a 1 kW BLDC traction controller designed for low voltage battery powered light electric vehicles, such as e-rickshaws or light electric vehicles running on 48VDC nominal voltage and 50 A peak current. The device is equipped with smart L6491 gate driver ICs that ensure real-time cycle-by-cycle overcurrent protection, and its motor control logic is based on six-step commutation in voltage mode, with Hall sensor feedback for position detection.

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UM2647

How to use the 1 kW traction controller reference design for 3-phase BLDC motors for light electric vehicles

Introduction

The 1 kW BLDC traction controller is a reference design for low voltage battery powered light electric vehicles running on nominal 48 V

and 50 A peak current. The wide input voltage range (42-65 V) and combination of hardware and design features deliver a highly responsive and efficient solution with fault diagnostic features that render this drive a highly viable solution across a variety of applications.

The inverter stage in full bridge 3-phase topology includes N-channel Power MOSFETs featuring STripFET F6 trench gate technology, driven by smart L6491 gate driver ICs with embedded comparators ensuringr real time cycle-by-cycle overcurrent protection.

The motor control logic is based on six step commutation in voltage mode, with Hall Sensor feedback for position detection.

Detailed instructions are provided for configuring the firmware with an easy-to-use GUI and compiling the binary files for download onto the STM8S microcontroller.

The microcontroller section on the board can accommodate I²C and UART communication protocols for enhanced interfacing and control such as LCD display.

Figure 1. 1 kW light electric vehicle BLDC motor controller

For further development, ST provides the ST Visual Development (STVD) environment and technical support for customizing and scaling the solution for Industrial and Automotive applications.

The system has been field tested on an e-Rickshaw, but it is designed for use with any low speed or light electric vehicles.

UM2647 - Rev 1 - November 2019

For further information contact your local STMicroelectronics sales office.

www.st.com

1

UM2647

BLDC motor control for light electric vehicles

BLDC motor control for light electric vehicles

This BLDC motor control application is based on a 6-step motor control algorithm with motor position feedback information from magnetic field Hall sensors on the motor. The MCU firmware generates PWM signals for the gate drivers to control the power delivered to the 3 phases of the motor and therefore determine motor speed and rotation.

The design includes the necessary mechanisms for the normal inputs expected in a light electric vehicle, including on and off, forward and reverse, a throttle or accelerator, and a brake.

Figure 2. BLDC traction control for light electric vehicles

VIPER115

Aux PSU bulk capacitors

STM8S105CT6

MCU

BLDC MC firmware

ON/OFF

FWD/REV

6-STEP algorithm

BRAKE

ACCEL

HALL

L6491

Gate Driver

L6491

Gate Driver

L6491

Gate Driver

The protection mechanisms included to prevent excess heating and current are also crucial aspects of the design, and the safest and most responsive solutions use hardware elements to monitor thresholds and trigger immediate reactions when limits are exceeded, instead of relying exclusively on MCU responses, which may not intervene quickly enough to avoid damage or injury.

UM2647 - Rev 1 page 2/36

2 Features and functions

•

48 V DC 1 kilowatt design

Six Step drive commutation topology

Input Voltage range: 42 V

to 65 V

Efficiency > 80%

Compatible with any 5 V throttle

Compatible with any start wound 48 V 3-phase BLDC motor with Hall sensor feedback

Protections:

– Overcurrent, overvoltage and undervoltage protection

– Option for two levels of ovecurrent protection with different thresholds

– Speed and position feedback fault detection and protection

VIPER115LS based auxiliary power supply

3 LEDs for fault indication

Drive ON/OFF switch

Drive Forward/Reverse switch

Drive disabled while mechanical brakes are applied

RoHS compliant

UM2647

Features and functions

UM2647 - Rev 1 page 3/36

UM2647

Auxiliary Power supply with high voltage converter and voltage regulator

Figure 3. Key components of the evaluation board

1. STPS1L60RL Schottky diode

2. STTH102A ultrafast recovery diode

3. STP100N8F6 MOSFETs

4. L6491D gate driver

5. M74HC4050 HEX Buffer

6. STM8S105C6T6 microcontroller

7. L7805 voltage regulator

8. VIPER115LS buck converter

9. Metallic shunt resistors

1 2 3 4

2.1

9 8 7 6

Auxiliary Power supply with high voltage converter and voltage regulator

The isolated Auxiliary power supply is based on the VIPER115LS high voltage converter operating in primary sensing mode, which generates a 12 V

voltage from an input battery or power supply voltage range of 35 to

68 V

. The downstream L7805 voltage regulator provides a further regulated 5 V to the digital controller and hall effect sensors.

UM2647 - Rev 1 page 4/36

UM2647

Power converter in 3-phase inverter topology

Figure 4. STDES-EVT001V1 auxiliary power supply schematic

BAT+VE

BAT-VE

VBUS

1N4007

+ C3

100uF/100V

VIPER115LS

C2 D20

1uF/25V/0805

10k

BAT46ZFILM

100k

220nF/50V/0805

R19

2k7

1nF/50V/0805

D18

STTH102A

1.2mH

D19

STTH102A

470uF/50V

+15V

D21

SMAJ18

TP13

TEST POINT

U17

VIN

GND

VOUT

L7805/TO220

100nF/100V/0805

3 +5V

+5V

C9 +

10uF/10V

C11

100nF/25V/0805

2.2

TSV631 Op-Amp

The TSV631 Operational Amplifier in this design provides current sensing with overcurrent protection. These devices feature a very low input bias current and a low offset voltage, making them ideal for applications that require precision.

Figure 7. Pin connections for TSV631

IN+ 1

VCC2

IN3

5 VCC+

4 OUT

The 880 kHz, 5 V CMOS operational amplifier supports rail-to-rail input and output, and is used here as a noninverting amplifier. The output of the inverter can be used to monitor for overcurrent events. The threshold current limit used here is different to the one used for cycle-by-cycle current limitation/shutdown used in the gate driver

IC.

UM2647 - Rev 1 page 7/36

UM2647

Control block with STM8S microcontroller

The output of the non-inverting amplifier is interfaced with the microcontroller pin, which can be configured as an analog input to enable continuous current monitoring or perhaps an adaptive algorithm.

Figure 8. Voltage gain and phase vs. frequency at V

= 5 V Figure 9. Phase margin vs. output current at V

= 5 V

-1.5

Vcc=5V, Vicm=2.5V

Rl =2kohms, T=25ºC

-1.0

-0.5

0.0

0 .5

Cl=100pF

Cl=330pF

1.0

1 .5

2.3.2

L6491D high voltage high and low-side gate driver

The L6491D half-bridge gate drivers that control the Power MOSFETs in the 3-phase bridge feature embedded comparators for fault (current) sensing functionality.

The comparator input is connected to an external shunt resistor for simple overcurrent detection function. The output signal of the comparator is fed to an integrated MOSFET with the open-drain output available on pin 2, shared with the SD input. When the comparator triggers, the device is set in shutdown state and both its outputs are set to low level, leaving the half bridge in 3-state.

The triggered gate driver also signals the other gate drivers to shut down, thereby providing comprehensive cycle by cycle overcurrent protection without the latencies introduced by equivalent microcontroller interventions.

UM2647 - Rev 1 page 8/36

UM2647 - Rev 1

Figure 10. L6491 block diagram

UM2647

Control block with STM8S microcontroller

3

3.1

UM2647

Motor control software

Motor control software

The BLDC traction control firmware is based on the STM8 BLDC Motor control library with additional user interface and other application-specific functions. The ST Visual Development (STVD) environment allows developers to further customize the firmware with additional behavior and functionality.

4

4.1

UM2647

STM8S motor control firmware library builder

STM8S motor control firmware library builder

The STM8 MC FW builder allows the development of specific motor control firmware configuration files through an interactive GUI. The files are then compiled in the ST Visual Development (STVD) environment with the

COSMIC C toolchains , ready for download onto the STM8S microcontroller.

Control inputs from user

The throttle input is detected via an A/D converter. Typically, the minimum maximum voltage is 5 V, which corresponds to maximum duty cycle, while the minimum voltage level can be calibrated to match the Throttle used. Brake and Direction are digital inputs to the MCU.

Figure 25. STEVAL-EVT001V1 reference design control and debug interfaces

4.5.2

4.5.3

Note:

Hall effect sensor signal conditioning

The signals from Hall sensors are processed in the firmware to eliminate false notches which might appear due to cogging/vibration under light load, especially in lab testing conditions.

Fault LED indications

Input voltage, power converter heatsink temperature and overcurrent events are monitored in firmware and signaled by three Fault status LEDs.

During startup, all LEDS blink to indicate normal operation.

Fault

Under Voltage

Over Voltage

Over Current

Over Temperature

Over Temperature with Over Voltage

Over Temperature with Under Voltage

Over Voltage with Over Current

Under Voltage with Over Current

Hall Signal Fault

(Not Valid State)

Table 1. Fault LED Indications

LED1

OFF

LED2

OFF

Toggle in sequence Toggle in sequence

LED3

Blink

OFF

Blink

Toggle in sequence

UM2647 - Rev 1 page 19/36

UM2647

How to set up and run the 1 kW traction control hardware

5 How to set up and run the 1 kW traction control hardware

Caution:

This procedure presumes that have already generated the BLDC motor control firmware with 6-step drive algorithm and loaded it onto the STM8S microcontroller.

The figure below shows a traction control setup with our 1 kW reference design, a BLDC motor with Hall sensors, an appropriate DC power supply and a potentiometer for throttle control.

A suitable heat sink along thermally conductive casing is also required for field testing and deployment, basing the overall thermal resistance of the heat sinking scheme on ambient conditions and duty cycle.

The system is designed for 48 V

input voltage; do not supply above 50 V.

Figure 26. 1 kW traction control hardware setup

1. Throttle (accelerator)

2. ST-LINK programmer/debugger

3. BLDC motor

4. DC power supply

5. Hall sensor signal from motor to drive

6. Motor terminals and bus voltage connector

7. BLC motor control reference design board

1 2 3

UM2647 - Rev 1

7 6 5 4

Step 1.

Connect the phase U, V and W motor terminals to the output connector of the board.

Step 2.

Connect the DC supply to the input connector.

Check the polarity (red is positive, black is ground).

Step 3.

Connect the Hall sensor signal from the motor to connector J9 of board (5-pin Connector).

page 20/36

UM2647 - Rev 1

UM2647

How to set up and run the 1 kW traction control hardware

Step 4.

Connect Throttle (accelerator) to connector J4 of board (3-pin connector)

Figure 27. Installation of the board

Step 5.

Set the DC power supply to 48 V and overcurrent rating to 22 A.

Step 6.

Check all the connections before switching on the supply.

Step 7.

Switch ON the power supply to the board.

Step 8.

Change the position of throttle to control the speed of the motor.

page 21/36

6

UM2647

Lab setup

Lab setup

The following figure shows the testing setup used to evaluate the performance of the 1 kW BLDC motor control reference design under different load conditions.

Figure 28. 1 kW BLDC motor control reference design

1. Hysteresis dynamometer to load the motor

2. BLDC motor

3. ST-LINK programmer/debugger

4. DC power supply

5. Throttle (accelerator)

6. BLDC motor control reference design

7. Dynamometer programmable controller

1 2 3

6.1

Load test at 0.5 Nm

7 6 5 4

Input

Current(A)

1.85

Input

Power(W)

88.8

Table 2. Test conditions for 0.5 Nm load test (V

= 48 V)

Dynamometer

Display Mechanical

Power(W)

47.7

Speed

(RPM)

912

Torque

(Nm)

0.5

Mechanical Power

Calculated(W)

Efficiency

(%)

Direction

47.75469169

53.78

Forward

UM2647 - Rev 1 page 22/36

UM2647

Load test at 3.0 Nm

Figure 29. Current waveform with Hall Sensor Signal at Phase A and B taken at 0.5 Nm torque load

(3) Phase current

(4) H1 - Phase A Hall Sensor Signal

(2) H2 - Phase B Hall Sensor Signal

6.2

Load test at 3.0 Nm

Input

Current(A)

13.22

Input

Power(W)

634.56

Table 3. Test conditions for 3.0 Nm load test (V

= 48 V)

Dynamometer

Display Mechanical

Power(W)

511.36

Speed

(RPM)

1628

Torque

(Nm)

Mechanical

Power

Calculated (W)

511.477882

Efficiency

(%)

Direction

80.60354924

Forward

UM2647 - Rev 1 page 23/36

UM2647

Test at no load

Figure 30. Current waveform with Hall Sensor Signal at Phase A and B taken at 3.0 Nm torque load

(3) Phase current

(4) H1 - Phase A Hall Sensor Signal

(2) H2 - Phase B Hall Sensor Signal

6.3

Test at no load

Input Current(A)

1.95

Table 4. Test conditions for no load (V

= 48 V)

Input Power(W)

93.6

Speed (RPM)

1222

UM2647 - Rev 1 page 24/36

UM2647

Performance graphs

Figure 31. Current waveform with Hall Sensor Signal at Phase A and B taken at No load

(3) Phase current

(4) H1 - Phase A Hall Sensor Signal

(2) H2 - Phase B Hall Sensor Signal

6.4

Performance graphs

The following performance graphs are derived from the measurements taken from performance testing of the traction control system at 0.5 Nm, 3.0 Nm and no load conditions from a nominal 48 V power supply voltage.

UM2647 - Rev 1 page 25/36

UM2647 - Rev 1

0.5

Figure 32. Speed vs torque

2000

1950

1900

1850

1800

1750

1700

1650

0.5

1 1.5

Load Torque (Nm)

Figure 33. Load torque vs efficiency

Load Torque vs Efficiency

2.5

1 1.5

Load Torque (Nm)

2.5

UM2647

Performance graphs

3 page 26/36

UM2647

Performance graphs

250

200

150

100

500

450

400

350

300

50 56

Figure 34. Input power vs efficiency

62 70

Efficiency (%)

78 85

UM2647 - Rev 1 page 27/36

7

UM2647

Bill of materials

Item

Bill of materials

Q.ty

Ref.

Table 5. STDES-EVT001V1 bill of materials

C1, C38, C61

C11, C49, C71

C12, C53, C55,

C57

C13, C62, C73

Part / Value Description

Manufacture r

22µF, 63V,

±20%

1µF, 25V, ±10%

100µF, 100V,

±20%

220nF, 50V,

±10%

(not mounted)

470µF, 25V,

±20%

Electrolytic capacitor, 5mm dia,

2mm pitch, Through

Hole

Ceramic Capacitor,

SMD0805

Electrolytic capacitor, 10mm dia, 5mm pitch

Through Hole

Ceramic Capacitor,

SMD0805

Electrolytic capacitor, 10mm dia, 5mm pitch

Through hole

1nF, 50V, ±10%

100nF, 100V,

±10%

Ceramic Capacitor,

SMD0805

Ceramic Capacitor,

SMD0805

10µF, 16v, ±20%

Electrolytic capacitor, 8mm dia,

3.5mm pitch,

Through Hole

100nF, 25V,

±10%

10nF, 50V,

±10%

100nF, 25V,

±10%

Ceramic Capacitor,

SMD0805

Ceramic Capacitor,

SMD0805

Ceramic Capacitor,

SMD0805

Panasonic

Electronics

Yageo

Nichicon

Yageo

Panasonic

Electronics

Yageo

Nichicon

Yageo

Order code

ECA-1JM220

AC0805KKX7R8BB105

UVR2A101MPD

AC0805KKX7R9BB224

ECA-1EM471

AC0805KRX7R9BB102

AC0805KKX7R0BB104

USH1C100MPD

AC0805KRX7R8BB104

AC0805KRX7R9BB103

AC0805KRX7R8BB104

C14, C15, C16,

C44, C46, C59,

C66, C67, C94,

C95, C96

C17, C18, C19,

C20, C21, C22,

C23, C24, C26,

C28, C31, C32

1nF, 25V, ±10%

Ceramic Capacitor,

SMD0805

Yageo AC0805KRX7R8BB102

ECA-2AHG471

C25, C27, C30

C34, C40, C47

C37, C72

C39, C43

470µF, 100V,

±20%

2.2nF, 760VAC,

500VAC, ±20%

220nF, 25V,

±10%

10nF, 25V,

±10%

20pF, 25V, ±5%

Electrolytic capacitor, 16mm dia, 7.5mm pitch,

Through hole

Panasonic

Electronics

Safety Ceramic Disc

Capacitors, Through

Hole

Ceramic Capacitor,

SMD0805

Vishay

Yageo

Ceramic Capacitor,

SMD0805

Ceramic Capacitor,

SMD0805

Yageo

AVX

VY1222M37Y5VQ63V0

AC0805KRX7R8BB224

AC0805KRX7R8BB103

08053A200JAT2A

UM2647 - Rev 1 page 28/36

UM2647 - Rev 1

UM2647

Bill of materials

Item

Q.ty

Ref.

Part / Value Description

Manufacture r

Order code

C41, C50, C51,

C60, C70, C98

C42, C56, C58,

C63, C64, C69,

C99

100nF, 25V,

±10%

100nF, 50V,

±10%

Ceramic Capacitor,

SMD0805

Ceramic Capacitor,

SMD0805

Yageo

C45

C48

C52, C100,

C101

C54

C65

C68

C90, C93

680nF, 25V,

±10%

1µF, 25V, ±10%

1µF, 50V, ±20%

100nF, 25V,

±10%

10nF, 25V,

±10%

10nF, 50V,

±10%

100nf, 25V,

±10%

D1, D3, D4, D8,

D10, D11, D13,

D15, D16

1.0 Amp, 60 V

Ceramic Capacitor,

SMD0805

Ceramic Capacitor,

SMD0805

Electrolytic capacitor, 5mm dia,

2mm pitch, Through hole

Ceramic Capacitor,

SMD0805

Ceramic Capacitor,

SMD0805

Ceramic Capacitor,

SMD1206

Ceramic Capacitor,

SMD0805

Yageo

Wurth

Electronics

Yageo

Wurth

Electronics

Wurth

Electronics

Schottky Diodes &

Rectifiers , SMA

D2, D5, D9,

D12, D14, D17

D18, D19

D20

D21

D22, D23, D24

D30

J1, J2, J10

J3, J13, J14,

J15, J16, J17,

J18

18V, 18V/

500MW, ±5%

1000V 1A

200V 1A

100 V, 150 mA

18V

200V 1A

30V, 300mA

CON2, connector

15V_+VE

CON3

BAT+VE

BAT-VE

AC0805KRX7R8BB104

AC0805KKX7R9BB104

AC0805KKX7R8BB684

AC0805KKX7R8BB105

860010672005

AC0805KRX7R8BB104

AC0805KRX7R8BB103

885012208081

885012207072

STPS1L60A

Zener Diode,

SOD-123

Rectifier , Through hole

Ultrafast Recovery

Diode, SMA

General Purpose

Signal Schottky

Diode, SOD-123

TVS Diodes, SMA ST

Ultrafast Diode,

SMA

Semiconduct or

General Purpose

Schottky Diodes,

SOD-523

Header and Wires,

2 Pins Through hole

Header and Wires,

1 Pin each Through hole

Header and Wires,

3 Pins Through hole

VBUS (marked on

Board)

GND (marked on board)

Molex

MMSZ5248BT1G

1N4007RLG

STTH102A

BAT46ZFILM

SMAJ18A-TR

STTH102AY

BAT30KFILM

22-28-4033

page 29/36

UM2647 - Rev 1

UM2647

Bill of materials

Item

Q.ty

J9, J11, J12

LD1, LD2, LD3,

LD4

Ref.

Q1, Q2, Q3, Q4,

Q5, Q6, Q7, Q8,

Q10, Q11, Q12,

Q13, Q14, Q15,

Q16, Q17, Q18,

Q19, Q20, Q21,

Q22, Q23, Q24,

Q25

RT1

R1, R47, R21,

R25, R28, R78

R2, R3, R31,

R32, R56, R57

R4, R17, R30,

R48, R55, R76

R5, R16, R33,

R46, R58, R73

R6, R53

STP100N8F6,

80 V, 100 A

10kΩ NTC

10K, 250mW,

±5%

100E, 250mW,

±5%

3R3, 250mW,

±5%

2R2, 250mW,

±5%

100k, 250mW,

±5%

R7, R8, R9,

R10, R11, R12,

R13, R14, R15,

R35, R36, R37,

R38, R40, R41,

R42, R43, R44,

R61, R62, R63,

R64, R66, R68,

R69, R70, R71

Part / Value

CON5, connector

LED_RED, 1.7V

BEAD, 150MA

360 MΩ, ±10%

1.2mH, 750mA,

±10%

Description

Manufacture r

Order code

Header and Wires,

5 Pins Through hole

LED Indicator,

SMD0805

Fixed inductor

1.2mh, 5 mm pitch

Through hole

Molex

Stanley

Electric

Wurth

Electronics

22-28-4033

BR1112H-TR

Fixed inductor 10µh,

SMD0805

Taiyo Yuden LBR2012T100K

7447480122

4R7, 250mW,

±1%

N-channel Power

MOSFET, TO-220

Through hole

NTC Thermistor

Thick Film,

SMD0805

Thick Film,

SMD0805

Thick Film,

SMD0805

Thick Film,

SMD0805

Thick Film,

SMD0805

Thick Film,

SMD0805

ST STP100N8F6

EPOCS/TDK B57703M103G40

Stackpole

Electronics

Stackpole

Electronics

Stackpole

Electronics

Stackpole

Electronics

Stackpole

Electronics

Stackpole

Electronics

RPC0805JT10K0

RPC0805JT100R

RPC0805JT3R30

RPC0805JT2R20

RPC0805JT100K

RNCP0805FTD4R70

R24, R80, R110 0R, 125mW

Thick Film,

SMD0805

Connectivity

CRG0805ZR

R18, R20, R79,

R88, R95, R100,

R102, R108,

R109, R114,

R115, R116,

R117, R118,

R119, R120,

R121, R122,

R123, R124,

R125, R126,

R127, R128

4K7, 250mW,

±5%

R19

2k7, 250mW,

±5%

Thick Film,

SMD0805

Thick Film,

SMD0805

Stackpole

Electronics

Stackpole

Electronics

RPC0805JT4K70

RPC0805JT2K70 page 30/36

UM2647 - Rev 1

UM2647

Bill of materials

Item

Q.ty

Ref.

Part / Value Description

Manufacture r

R22, R23, R105,

R106

0.015/SHUNT,

3W, ±1%

R27

1K8, 250mW,

±5%

R29, R72, R107,

R113

5K1, 250mW,

±5%

R26, R34, R50,

R59, R74, R75,

R81, R82, R83

R39, R60, R65,

R67

R45

R49

R51

R52

R77

1K, 250mW,

±5%

680, 250mW,

±0.5%

27K, 250mW,

±5%

330K, 250mW,

±5%

120E, 250mW,

±5%

82E, 250mW,

±5%

0E, 250mW

Metal Element

Current Sensing

Resistors, Through hole

Thick Film,

SMD0805

Thick Film,

SMD0805

Thick Film,

SMD0805

Thick Film,

SMD0805

Thick Film,

SMD0805

Thick Film,

SMD0805

Thick Film,

SMD0805

Thick Film,

SMD0805

Thick Film,

SMD1206

Thick Film,

SMD0805

Electronics

Stackpole

Electronics

Stackpole

Electronics

Stackpole

Electronics

Panasonic

Electronics

Panasonic

Electronics

Stackpole

Electronics

Panasonic

Electronics

Panasonic

Electronics

Yageo

R54

R111, R112

6K8, 250mW,

±0.5%

R84, R91, R92,

R93, R129,

R130

4.7K, 250mW,

±0.5%

1.5K, 250mW,

±5%

TP1, TP2, TP4,

TP5, TP12,

TP13

TEST POINT

U2, U4, U6

U12

U17

Thick Film,

SMD0805

Thick Film,

SMD0805

Panasonic

Electronics

Panasonic

Electronics

Panasonic

Electronics

VIPER115LS,

30V, 1.25mA

STM8S105C6T6

, 2.95-5.5V

8-bit MCU, LQFP 48

7x7x1.4

TSV631, 60 µA at 5 V

Operational

Amplifiers - Op

Amps 60uA ,

SOT23-5L

74HC4050D/

SO16, 15V

L7805/TO220,

1.5A

XTAL_16MHz

AC/DC Converters,

SSOP 10

Half-Bridge Gate

Driver, SO-14

Buffers & Line

Drivers, SO16

Linear Voltage

Regulators, TO-220

Crystal Oscillator,

HC-49/S Through

Hole

Nexperia

TXC

Corporation

L6491D

Order code

OAR3R015FLF

RPC0805JT1K80

RPC0805JT5K10

RPC0805JT1K00

ERJ-PB6D6800V

ERJ-T06J273V

RPC0805JT330K

ERJ-T06J121V

ERJ-T06J820V

RC1206FR-070RL

ERJ-PB6D6801V

ERJ-PB6D4701V

ERJ-T06J152V

VIPER115LS

STM8S105C6T6

TSV631ILT

74HC4050D

L7805

AS-16.000MAHK-B page 31/36

Revision history

Date

04-Nov-2019

Table 6. Document revision history

Version

Changes

Initial release.

UM2647

UM2647 - Rev 1 page 32/36

UM2647

Contents

1 BLDC motor control for light electric vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2 Features and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.1

Auxiliary Power supply with high voltage converter and voltage regulator. . . . . . . . . . . . . . . . 4

2.2

Power converter in 3-phase inverter topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3

Control block with STM8S microcontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.3.1

2.3.2

TSV631 Op-Amp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

L6491D high voltage high and low-side gate driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Motor control software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3.1

Application State machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4 STM8S motor control firmware library builder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4.1

How to configure the Motor section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.2

How to configure the Power Stage section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.3

How to configure the Drive Management section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.4

How to configure the Control Stage section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.5

Application-specific firmware functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.5.1

4.5.2

Control inputs from user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Hall effect sensor signal conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.5.3

Fault LED indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5 How to set up and run the 1 kW traction control hardware . . . . . . . . . . . . . . . . . . . . . . . . .20

6 Lab setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

6.1

Load test at 0.5 Nm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.2

Load test at 3.0 Nm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.3

Test at no load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.4

Performance graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7 Bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

UM2647 - Rev 1 page 33/36

UM2647

List of figures

List of figures

Figure 1. 1 kW light electric vehicle BLDC motor controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Figure 2. BLDC traction control for light electric vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Figure 3. Key components of the evaluation board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Figure 4. STDES-EVT001V1 auxiliary power supply schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Figure 5. STDES-EVT001V1 power converter schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 6. STDES-EVT001V1 control unit schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 7. Pin connections for TSV631 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 8. Voltage gain and phase vs. frequency at V

= 5 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Figure 9. Phase margin vs. output current at V

= 5 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Figure 10. L6491 block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 11. Motor control state machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Figure 12. MC FW builder GUI, Motor electrical parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 13. MC FW builder GUI, Motor sensor parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 14. MC FW builder GUI, power stage voltage parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 15. MC FW builder GUI, power stage voltage sensing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Figure 16. MC FW builder GUI, power stage temperature sensing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Figure 17. MC FW builder GUI, power stage driver parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 18. MC FW builder GUI, drive management speed/position parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 19. MC FW builder GUI, drive management drive parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Figure 20. MC FW builder GUI, drive management start-up parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Figure 21. MC FW builder GUI, control stage analog input parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Figure 22. MC FW builder GUI, control stage user interface parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Figure 23. MC FW builder GUI, control stage driving signal timer re-mapping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Figure 24. MC FW builder GUI, code generation success confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Figure 25. STEVAL-EVT001V1 reference design control and debug interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Figure 26. 1 kW traction control hardware setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Figure 27. Installation of the board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Figure 28. 1 kW BLDC motor control reference design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Figure 29. Current waveform with Hall Sensor Signal at Phase A and B taken at 0.5 Nm torque load . . . . . . . . . . . . . . . 23

Figure 30. Current waveform with Hall Sensor Signal at Phase A and B taken at 3.0 Nm torque load . . . . . . . . . . . . . . . 24

Figure 31. Current waveform with Hall Sensor Signal at Phase A and B taken at No load . . . . . . . . . . . . . . . . . . . . . . . 25

Figure 32. Speed vs torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Figure 33. Load torque vs efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Figure 34. Input power vs efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

UM2647 - Rev 1 page 34/36

UM2647

List of tables

List of tables

Table 1. Fault LED Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Table 2. Test conditions for 0.5 Nm load test (V

= 48 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Table 3. Test conditions for 3.0 Nm load test (V

= 48 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Table 4. Test conditions for no load (V

= 48 V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Table 5. STDES-EVT001V1 bill of materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Table 6. Document revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

UM2647 - Rev 1 page 35/36

UM2647

IMPORTANT NOTICE – PLEASE READ CAREFULLY

STMicroelectronics NV and its subsidiaries (“ST”) reserve the right to make changes, corrections, enhancements, modifications, and improvements to ST products and/or to this document at any time without notice. Purchasers should obtain the latest relevant information on ST products before placing orders. ST products are sold pursuant to ST’s terms and conditions of sale in place at the time of order acknowledgement.

Purchasers are solely responsible for the choice, selection, and use of ST products and ST assumes no liability for application assistance or the design of

Purchasers’ products.

No license, express or implied, to any intellectual property right is granted by ST herein.

Resale of ST products with provisions different from the information set forth herein shall void any warranty granted by ST for such product.

ST and the ST logo are trademarks of ST. For additional information about ST trademarks, please refer to www.st.com/trademarks . All other product or service names are the property of their respective owners.

Information in this document supersedes and replaces information previously supplied in any prior versions of this document.

UM2647 - Rev 1 page 36/36

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STMicroelectronics STDES-EVT001V1 User Manual

How to use the 1 kW traction controller reference design for 3-phase BLDC motors for light electric vehicles

Introduction

1

BLDC motor control for light electric vehicles

2 Features and functions

RELATED LINKS

RELATED LINKS

RELATED LINKS

TSV631 Op-Amp

RELATED LINKS

L6491D high voltage high and low-side gate driver

RELATED LINKS

3

Motor control software

RELATED LINKS

4

STM8S motor control firmware library builder

RELATED LINKS

Control inputs from user

Hall effect sensor signal conditioning

Fault LED indications

5 How to set up and run the 1 kW traction control hardware

6

Lab setup

Load Torque (Nm)

Load Torque vs Efficiency

Load Torque (Nm)

Efficiency (%)

7

Bill of materials

Contents

List of figures

List of tables

How to use the 1 kW traction controller reference design for 3-phase BLDC motors for light electric vehicles

Introduction

1

BLDC motor control for light electric vehicles

2 Features and functions

RELATED LINKS

RELATED LINKS

RELATED LINKS

TSV631 Op-Amp

RELATED LINKS

L6491D high voltage high and low-side gate driver

RELATED LINKS

3

Motor control software

RELATED LINKS

4

STM8S motor control firmware library builder

RELATED LINKS

Control inputs from user

Hall effect sensor signal conditioning

Fault LED indications

5 How to set up and run the 1 kW traction control hardware

6

Lab setup

Load Torque (Nm)

Load Torque vs Efficiency

Load Torque (Nm)

Efficiency (%)

7

Bill of materials

Contents

List of figures

List of tables

Свързани

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