An Overview of the Resolver

Interface for Motor Control

Applications
FTF-AUT-F0234

Leos CHALUPA | Automotive MCU Product Group

APR.2014

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Session Introduction

• This session will explain cost-effective solutions to interface the

resolver position sensor directly to Freescale's automotive MCU.
• We will discuss basic operation, benefits of saving an external IC,
run time diagnostics and flexible selection of the “limp” mode.

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Session Objectives

• By the end of this session you will:

− Be more familiar with resolver-based position sensing
− Understand the run-time diagnostic principles
− Describe how to use Freescale microcontrollers to save an external
IC for Resolver interfacing
− Name the advantages of the presented solution
− Know where to look for support, documentation and examples

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Agenda
• Resolver basics
− Brief
history
− Resolver types, constructions and operation principles

• Angle position sensing

− Principle
of resolver position extraction
− Sources of position sensing errors

• Direct MCU-resolver interface

• Freescale support, examples, documentation and

more

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Resolver Basics

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Brief Resolver History
• Developed in 1940s at MIT (Supported by the U.S. military)
• Resolvers have been part of electromechanical servo and shaft angle
positioning systems for over 50 years
• Resolver position sensor constructions evolved over time
− 1970s: Brushless resolver
− 1980s: Hollow shaft brushless resolver
− 1990s: Variable reluctance resolver
• Resolver position conversion methods evolved from phase analog techniques
to tracking observer-based digital techniques with run-time diagnostic
• Since 2000, the Freescale Motor Control team has investigated different
approaches of the resolver-to-digital conversion using available MCUs/DSCs.
The first application was the SMT pick and place machine where fast
dynamics and high precision is a key for overall cost effectiveness.
Until today, the method was continuously improved and ported to practically
all el. motor control MCUs, including special CPU autonomous version based
on the eTPU to target ramping EV and HEV markets

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Resolvers: Electro-magnetic Induction Angle Sensors

Rotor is put directly on the drive’s shaft

Usin

Stator is fixed on drive’s shield

Simple assembly and maintenance


No bearings – “unlimited” durability
Resist well against distortion, vibration, deviation of operating
Uref
temperature and dust
Ucos
Rotor shaft
Worldwide consumption is millions of pieces at present time
Widely used in precise positioning applications
The number of generated sine and cosine cycles per one
mechanical revolution depends on the number of resolver pole-
pairs (usually 1-3 cycles)
Basic parameters:
− Electrical Error – +/-10’, Transformation Ratio – 0.5,
Phase Shift – +/-10°
− Input Voltage – 4-30V, Input Current – 20-100 mA,
Input Frequency – 400 Hz – 40 kHz

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 Resolver Types
Traditional Brushless Brushless Variable Reluctance
Primary side With variable air-gap With solid rotor
Rotary coupling
transformers

Primary side Primary side

stator stator
θ [°] θ [°] θ [°]
rotor rotor
cos cos cos

HF HF HF
excitation excitation excitation
sin sin sin
Secondary side Secondary Side Secondary side
Rotating magnetic coupling transfers HF The VR variable air-gap resolver has The VR solid rotor resolver has primary
energy from the stator (primary) to the rotor primary and secondary windings in the and secondary windings in the stator,
(secondary), connected directly to the resolver stator, therefore it does not need a therefore it does not need a rotating
primary. This generates an AC magnetic field rotating magnetic coupling. The contour magnetic coupling. The rotor contains a
with a sinusoidal distribution, hence causing HF of rotor is made as the permeance diagonal section of highly permeable
voltages in the stator windings (secondary side) of air-gap between the stator and rotor material that varies the magnetic field
with amplitudes dependent (sine/cosine) on the is varied in sinusoid oscillation. Thus, across the stator as the rotor turns.
rotational angle of the rotor. the induced voltage amplitudes Thus, the induced voltage amplitudes
correspond to the sine and cosine of correspond to the sine and cosine of
the rotor angle. the rotor angle.
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Traditional Brushless Resolver

Source: Tamagawa Seiki co., www.tamagawa-seiki.com Source: Artus, www.psartus.com

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Brushless VR Resolver

Source: Tamagawa Seiki co., www.tamagawa-seiki.com Source: Admotec Inc., machinedesign.com

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Basic Resolver Terms

• Excitation – The winding powered by high frequency (e.g. 10 kHz) sine

wave
• Number of multiples/poles – The multiplied speed ratio of the output
angle signal is indicated. The number of poles is twice that of shaft angle
multiplication
• Transformation ratio – Ratio of output voltage amplitude to the excitation
voltage amplitude
• Phase shift – Phase difference between the excitation voltage and output
voltage
• Electrical error – The difference between electrical angle (presented by
the ratio of resolver outputs) and theoretical angle value
• Input impedance – The impedance of the excitation side
• Output impedance – The impedance of the output windings

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Resolver Angle Position Sensing

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Resolver Based Angular Sensing Methods

• Phase Analog Technique

− The two stator windings are excited by signals that are in phase quadrature to each
other. This induces a voltage in the rotor winding with an amplitude and frequency that
are fixed and a time-phase that varies with shaft angle. This has been the most widely
used technique because it can easily be converted to produce a digital signal by
measuring the change in phase shift with respect to the reference signal.
• Angle Tracking Resolver to Digital Conversion (RDC)
− A tracking converter contains a phase demodulator. Therefore, frequency variation and
incoherent noise do not affect accuracy. Tracking converters can operate with any
reference excitation, sine or square wave, with only minor accuracy variations.
− This technique is implemented by most of the RDC ICs.
− More will be discussed further in this presentation.

Ext. circuitry RDC IC

Δ sin
Angle RC Analogue demodulation,
Sensor VCO Counter
Network PLL
Δ cos
Resolver Sine
Amplifier Cosine
excitation
Run Time Diagnostic

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Angle Tracking Observer Principle

LP est
Filter

Angle Tracking

 est
Envelope Pos. Error e() 
Regulator
Extractor Comparator

Sine
Cosine
Generator

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 Angle Tracking Observer Basics

Implementation Basics: Angular error evaluation:

( ) () () ( )
sin( )
e Θ - Θ̂  sin (Θ)  cos Θ̂  cos(Θ )  sin Θ̂  sin Θ - Θ̂
+ 1 +
e(Θ - Θ̂ )  sin (Θ - Θ̂ )  Θ - Θ̂ for (Θ - Θ̂ )  7
1 (s)
K1 s s +
-
cos( ) e( -)

K2
sin ( )
Transfer function:
cos( )
Θ̂(s) K (1  K 2s )
F(s)   2 1
Θ(s) s  K1K 2s  K1

Features:
• Non-sensitivity to disturbance and harmonic distortion of the carrier
• Non-sensitivity to voltage and frequency changes
• High accuracy of the angle extraction

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 BASICS OF ANGLE EXTRACTION 5/6
TUNNING THE ANGLE TRACKING OBSERVER
Tuning the Angle Tracking Observer
35
Transfer function of the General

Peak overshoot [%]

Second Order System: 30

25

20

15

10

Transient responses: 0
0.5 400
600

Overshoot
1 800
Dampin 1.5 1000 d/s]
g factor [- 1200 ncy [ra
] 2 1400
l freque
Natura

±2%
0.050

0.045

Settling time [s]

0.040

0.035

0.030

0.025

0.020

Settling time 0.015

0.010

0.005

0
0.5 400
1 600
800
Dampin 1000 ]
g facto 1.5 1200 ncy [ra
d/s
r [-] 2 1400
l freque
Natura
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Direct MCU R-D Conversion

There are two basic approaches to performing resolver-to-digital

conversion using on-chip resources
• Case 1) – Based on the synchronous “rectification” of the high
frequency carrier of the feedback signals:
− This requires synchronized triggering of the ADC S&H circuit with respect to
the resolver excitation signal
− This is mostly approached by using RSD ADC + triggering timer channels +
angle tracking software algorithm
• Case 2) – “Demodulation” of the oversampled feedback signals:
− This does not require synchronized triggering, however it requires fast ADC
capable to over-sample two high-frequency feedback signals
− This is mostly approached by using Sigma-Delta ADC + high-frequency
digital demodulation + angle tracking software algorithm (with phase-delay
compensation)
− Improves dynamics

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Case 1: Sin/Cos Envelope Extractor

Detail view

Resolver excitation
signal at 10 kHz

“sin” envelope
Timer OC
ADC Trigger
Resolver feedback
“sin” signal

“cos” envelope

Resolver feedback
“cos” signal

ADC ADC
sampling sampling

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Case 2: Over-sampling of Resolver Signals

Detail view

Resolver excitation
signal at 10 kHz

“sin” envelope
Timer OC
Resolver feedback
“sin” signal

“cos” envelope

Resolver feedback
“cos” signal

SDADC sampling

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Direct MCU-Resolver Interface

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Direct MCU R-D Conversion vs. RDC IC

MPCxxxxX
Ext. circuitry Peripherals CPU
Δ sin
SW RDC Angle RC
∑∆A/D Demodulation PD ATO
Application
Sensor Network s/w

Sync.
Δ cos
Run Time Diagnostic
Output
eTIMER
H/W layer

Ext. circuitry RDC IC MCU

Δ sin
Angle RC Analogue demodulation, Application
RDC IC Sensor Network PLL
VCO Counter
s/w
Δ cos
SWG - Sine
Amplifier Resolver Cosine
excitation Run Time Diagnostic Run Time Diagnostic

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Direct MCU R-D Conversion: Application Example
12 V
2nd order PWM MPCxxxxX
LP Filter (eTPU)
Excitation CPU
Amplifier
SDADC 4+5
2xch s. ended mode;
optional excitation
monitoring INIT values
R1 R2
LP Filter, Cosine Angle Tracking
SDADC 2+3
S4 Observer Angular position
2xch. s. ended mode
S2
DC ATO
Common Sine Angular speed

Tracking err.
S1 S3 Mode SDADC 0+1

sin, cos
2xch. s. ended mode
Shift
Detection
Resolver
Diagnostic Fault diagnostic

Angular speed

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Resolver Differential Excitation Stage

MPCxxxxX

PWM
(eTPU)

Low-pass filter

Excitation Amplifier ≈ existing solution

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Resolver Input Stage (Phy. Layer)

MPCxxxxX
SDADC 4+5
2xch s. ended mode;
optional excitation
monitoring

SDADC 0+1
2xch. s. ended mode

SDADC 2+3
2xch. s. ended mode

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Evaluation Results

MPC5746M SW RDC RDC IC

• Position accuracy ±0.09 deg. 12bit ±1LSB • Position accuracy ±0.13 deg. 12bit ±2LSB
• External hardware • External hardware
‒ Excitation amplifier ‒ Excitation amplifier
‒ Hardware tuned for given resolver ‒ LP Filter, DC Common Mode Shift Detection
‒ Differential measurement
‒ Phase difference, offset, gain error uncompensated • True 12-bit resolution without noise
‒ LP Filter, DC Common Mode Shift Detection
• Repeatability ±0.07 deg.
• Noise, repeatability ±0.033 deg.
‒ Higher CPU* & ADC load
0,15 angleErr
Position accuracy

0,1
resolver error [mech. deg[

Noise

0,05

0
-180 -135 -90 -45 0 45 90 135 180

-0,05

-0,1
reference position [mech. deg]

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Diagnostics: Calibratable Fault Thresholds

• Fault diagnostic thresholds are implemented in software, therefore

can be easily calibrated.

SIN_AMPLS
COS_AMPL

SIN_POS
COS_POS

SIN_ZERO
COS_ZERO

SIN_NEG
COS_POS

SIN_AMPLS
COS_AMPL

UNIT_CIRCLE_MAX
OBSERVER
_ERROR

UNIT_CIRCLE_MIN

OBSERVER
_ERROR

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 Fault Example: SIN Short to GND

Sin Cos Means Unit Circle ATO

SIN_Z SIN_P SIN_N SIN_A COS_Z COS_P COS_ COS_ SIN_MEAN SIN_MEAN COS_MEA COS_MEA UNIT_CIRCL UNIT_CIRCL OBSERVE Calculated
ERO OS EG MPL ERO OS NEG AMPL _POS _NEG N_POS N_NEG E_MIN E_MAX R_ERROR Angle

1.2b SIN Wire(or pin) short to GND ? ? ? 1 ? ? ? ? 1 0 ? ? 1 1 ? +/- 35deg

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 Fault Example: REFSIN Open

Sin Cos Means Unit Circle ATO

SIN_Z SIN_P SIN_N SIN_A COS_Z COS_P COS_ COS_ SIN_MEAN SIN_MEAN COS_MEA COS_MEA UNIT_CIRCL UNIT_CIRCL OBSERVE Calculated
ERO OS EG MPL ERO OS NEG AMPL _POS _NEG N_POS N_NEG E_MIN E_MAX R_ERROR Angle
1.3a REFSIN Wire(or pin) open ? 0 1 0 ? ? ? ? 0 1 ? ? 1 1 ? wrong

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 Fault Example: Shortcut REZ_GEN and REFSIN

Sin Cos Means Unit Circle ATO

SIN_Z SIN_P SIN_N SIN_A COS_Z COS_P COS_ COS_ SIN_MEAN SIN_MEAN COS_MEA COS_MEA UNIT_CIRCL UNIT_CIRCL OBSERVE Calculated
ERO OS EG MPL ERO OS NEG AMPL _POS _NEG N_POS N_NEG E_MIN E_MAX R_ERROR Angle
Short between REZ_GEN and
2.2 REFSIN ? 1 0 1 ? ? ? ? 1 0 ? ? 1 1 ? wrong

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Resolver + R/D IC Comments

• Advantages
− Positioninformation during MCU initialization stage
− High resolution: 12-bit
− Simple SPI interface between MCU and RDC IC

• Disadvantages
− Only simple diagnostic possible (raw signal data not accessible)
− No limp operation modes
− RDC IC may require up to 30 pins
− Larger board area
− Higher system cost

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Resolver + SW Observer Comments

• Advantages
− High resolution: 10-12 bit (dependent on the resolution of A/D converter)
− Simple hardware
− Lower cost than resolver + ASIC
− Intelligent diagnostics possible with complex conditioning for fault source
detection
− Limp mode operation modes possible

• Disadvantages
− Intensive
calculation needs, higher CPU load easily managed by
Freescale 32-bit Qorivva microcontrollers

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Freescale Support, Examples,
Documentation

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Motor Control Development Kit: Composition
PMSM with
3-phase Current FET 3-phase Resolver/Encoder
Shunts Power Stage or
FET DRIVER
MC33937A
BLDC with
Hall/No Sensor
Incremental
Encoder Interface

MC33937A
3-phase
Low Voltage
Power Stage
Qorivva Resolver/Sin-Cos
MPC5643L MCU SBC Interface
MC33905

Switches and Pushbuttons

MCU ON/OFF, Up/Down, Reset

Controller Board
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Sensor: Position and Speed Measurement
Resolver
Usin




Uref

Ucos
Rotor shaft

ADC measurement

Encoder

Incremental Encoder Pulses

Functional properties: Source: Heidenhain

• Sine-wave excitation signal generation Key features:

• Position measurement • Adjustable magnitude of excitation signal
• Speed measurement • Adjustable frequency of excitation signal
• Revolution measurement • Sensor fault state detection

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Motor Control Development Kit Series: Content
• Out-of-the-box experience offers:
− Complete schematics of the development kit hardware
− Complete source code of the development kit software application
− Math and Motor Control libraries (MCLib) in object code
− FreeMASTER & MCAT interface to easy application visualization / control
− Extensive documentation including User Guide, Quick Start Guide and Fact
Sheet

FreeMASTER Scope FreeMASTER HTML-based Control Page

www.freescale.com/AutoMCDevKits

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Auto Math and Motor Control Library Set
Target Platform GreenHills Multi WindRiver Diab Cosmic
Qorivva MCU RTM Rev 1.0 RTM Rev 1.0
S12ZVM RTM Rev 1.0

MLIB GFLIB GDFLIB GMCLIB ACLIB/AMCLIB

• Trigonometric Functions
• Absolute Value, Negative • GFLIB_Sin, GFLIB_Cos, • Finite Impulse Filter • Clark Transformation • Angle Tracking Observer
Value GFLIB_Tan • GDFLIB_FilterFIR • GMCLIB_Clark • Tracking Observer
• MLIB_Abs, MLIB_AbsSat • GFLIB_Asin, GFLIB_Acos, • Moving Average Filter • GMCLIB_ClarkInv
• PMSM BEMF Observer in
• MLIB_Neg, MLIB_NegSat GFLIB_Atan, GFLIB_AtanYX • GDFLIB_FilterMA • Park Transformation
• Limitation Functions • GMCLIB_Park Alpha/Beta
• Add/Subtract Functions • 1st Order Infinite Impulse
• MLIB_Add, MLIB_AddSat • GFLIB_Limit, Filter • GMCLIB_ParkInv • PMSM BEMF Observer in
• MLIB_Sub, MLIB_SubSat GFLIB_VectorLimit
• GDFLIB_FilterIIR1init • Duty Cycle Calculation D/Q
• GFLIB_LowerLimit, • GMCLIB_SvmStd
• Multiply/Divide/Add- • GDFLIB_FilterIIR1 • Content To Be Defined
GFLIB_UpperLimit • Elimination of DC Ripples
multiply Functions • 2nd Order Infinite Impulse
• PI Controller Functions • GMCLIB_ElimDcBusRip
• MLIB_Mul, MLIB_MulSat
• GFLIB_ControllerPIr, Filter
• MLIB_Div, MLIB_DivSat • GDFLIB_FilterIIR2init • Decoupling of PMSM
GFLIB_ControllerPIrAW
• MLIB_Mac, MLIB_MacSat
• GFLIB_ControllerPIp, • GDFLIB_FilterIIR2 Motors
• MLIB_VMac • GMCLIB_DecouplingPMSM
GFLIB_ControllerPIpAW
• Shifting • Interpolation
• MLIB_ShL, MLIB_ShLSat
• GFLIB_Lut1D, GFLIB_Lut2D
• MLIB_ShR
• MLIB_ShBi, MLIB_ShBiSat • Hysteresis Function
• GFLIB_Hyst
• Normalisation, Round
• Signal Integration ω ωfbck wRotElRes
Functions GDFLIB_FilterMA
• MLIB_Norm, MLIB_Round Function
• GFLIB_IntegratorTR GetSpeedElRes()
• Conversion Functions
• Sign Function
• MLIB_ConvertPU,
• GFLIB_Sign
MLIB_Convert si
• Signal Ramp Function
• GFLIB_Ramp n θerr GFLIB_ControllerPIrA θfbck thRotElRes
GFLIB_IntegratorTr
• Square Root Function W
• GFLIB_Sqrt
cos -
GFLIB_Sin

GFLIB_Cos

GetPositionElRes()
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MC Development Kits: Web Page Summary

Motor Control Development Kits

www.freescale.com/AutoMCDevKits
See short promotional video on Freescale’s YouTube channel

Math & Motor Control Library Set

www.freescale.com/automclib

Motor Control Application Tuning Tool (MCAT)

www.freescale.com/MCAT
See short promotional video on Freescale’s YouTube channel

FreeMASTER
www.freescale.com/freemaster

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 TM

www.Freescale.com

© 2014 Freescale Semiconductor, Inc. | External Use