Adi Motor Control Systems
Adi Motor Control Systems
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2 Motor Control Systems and Design
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Processors
Typical Motor Control Systems with Functional Mixed-Signal Control Processors. . . . . . . . . . . . . . . . . . . . . . . . . . 11
Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DSPs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Introduction
More Stringent Energy Regulations Drive Motor Control Innovations
In today’s expanding industrial marketplace, the demand for electrical power is growing at an unprecedented rate. More than 40% of that electrical
demand comes from industrial electric motors of all sizes. Because of that phenomenon, governments and certification agencies worldwide are
introducing new regulatory legislation and more stringent energy efficiency requirements on electric motor OEMs and end users. Like many great
technological innovations, there needs to be a pressing demand in the market for change.
Analog Devices recognized years ago that this new era of smarter and highly efficient motor control systems would be the new standard for the motor
control industry. As part of that recognition, ADI embarked on an integrated and comprehensive motor control design program in collaboration with our
strategic partners, who are experts in their respective fields (MathWorks,® ARM,® Boston Engineering,® IAR Systems,® and Xilinx®), aimed at addressing
the entire system architecture to achieve the greatest level of efficiency while improving system accuracy and reliability.
By taking a system-level view (see Figure 1) of these new challenges, ADI was able to develop products that not only exceeded the individual
performance specifications but also represented the optimal interface between other functional blocks of the circuit. This system solution approach
enables ADI to offer industrial-based customers a completely integrated solution that fits their specific needs while helping them meet the new, more
stringent energy regulations.
ADC
ADM708 Reset
CAN ADSP-CM408F
CAN QEP SPI
ADM3053
ADSP-CM408F motor drive control board (EZ-KIT®). Motor drive power board.
Inverter
VDC
U
+ V
AC AC
Line Motor
W I V, I W
𝛉, 𝛚
I DC TD
Gate
Drive
Motor Feedback
PWM Control Interface
Command I/F
System and
Communications
Voltage
Monitoring
Current
Demand Monitoring
Interface
ADI’s Power Management
Network Products Are Broadly
Interface Applicable Within Motor
Control Systems
Large Portfolio of Power
Rotor/Load Power and Management Products
Our Interface Position Feedback Support
Products Include:
CAN, RS-232, and
RS-485 DSP EZ-KIT Lite® Evaluation Boards
Simulink® Tools Integration
High Resolution Feedback Sensors Provide Accurate Motor Control Development
Shaft Position Information Platform for Model-Based Control
ADI Offers RDCs, ADCs, and Amps Suitable For
Motor Control
Visit analog.com 5
Insulation Rating Max Operating Isolated Output (V) Isolated Output (V)
Part Number (kV rms) Temperature (°C) Max Min
ADuM41351 5 125 30 12
ADuM42232 5 125 18 4.5
ADuM3223 3 125 18 4.5
ADuM3221 2.5 125 18 4.5
ADuM3220 2.5 125 18 4.5
ADuM7223 2.5 125 18 4.5
ADuM7234 1 105 18 12
1
ISOINV-EP Evaluate ADI’s new, fully featured isolated gate drivers (ADuM4135) technology in a system-level application at realistic dc bus voltages
(EV-MCS-ISOINVEP-Z).
2
ISOINV Evaluate ADI simple dual isolate gate driver (ADuM4223) technology in a system-level application at realistic dc bus voltages
(EV-MCS-ISOINV-Z).
R5
R2 HCPL-0631
C1 C2
D2
R6
ADuM1401
D4
10 mm
R7
C1
HCPL-0601
16 mm C3
R4
D3 R8
17 mm
isolation products.
Y
TxD
Encode Decode D
Z
Encode Decode
ADM2682E 5 15 16 Mbps 3.3, 5
ADM2687E 5 15 500 kbps 3.3, 5
ADM2582E 2.5 15 16 Mbps 3.3, 5
A
RxD
Decode Encode R
ADM2587E 2.5 15 500 kbps 3.3, 5
B
RE
GND1 GND2
Isolation
Barrier
Insulation Rating Max Data Rate Propagation Delay Isolated Output Supply Isolated Output
Part Number (kV rms) (Mbps) (ns) (mA) (V) Min
ADM3260 2.5 1 95 30 4.5
ADuM5000 2.5 — — 100 3.3
ADuM5200 2.5 25 60 100 3.3
ADuM5400 2.5 25 60 100 3.3
ADuM6000 5 — — 100 3.3
ADuM6200 5 25 60 100 3.3
ADuM6400 5 25 60 100 3.3
NEW
Power Management
Digital Power Factor Correction (PFC) Controller
The ADP1047 and ADP1048 are PFC controllers with accurate
input power metering capabilities built in. They provide accurate
measurement, such as input and output voltage, input current,
and power. The information can be reported to the microcontroller
of the power supply via the PMBus interface.
Interleaved PFC
controller with accurate Inrush control, real-time efficiency
PSON, inrush Programmable
power metering; capable optimization, enhanced dynamic 24-lead
ADP1048 3.3 I2C/PMBus Yes 2 control, ACOK, ac fault detection,
of supporting high response, synchronization, spread QSOP
PGOOD OCP, OVP, OTP
efficiency bridgeless spectrum, and light load shedding
topology
Integrated Regulators Devices Delivering Best-in-Class Efficiency, System Performance, and Size
ADI regulator products for motor control offer a selection of power integrated point of load (POL) devices supporting a wide range of power distribution
options. This includes standalone switch regulators with 5 V, 12 V, and 24 V process to multirail solutions that support load requirements from the
milliamperes to multiple ampere loads while maintaining effective efficiency and performance; to linear regulators offering low noise solutions that help
increase precision in fine position sensing applications.
Switching/Multirail Regulators
VIN Range VIN Range
Part Number Product Description IOUT Max (A) Part Number Product Description IOUT Max (A)
(V) (V)
1.2 MHz synchronous step- Synchronous step-down
ADP2119 2.3 to 5.5 2
down dc-to-dc regulator dc-to-dc regulator with
ADP2386 4.5 to 20 6
1.2 MHz synchronous step- programmable switching
ADP2120 2.3 to 5.5 1.25 frequency
down dc-to-dc regulator
High efficiency synchronous Synchronous step-down
step-down dc-to-dc regulator dc-to-dc regulator with
ADP2441 4.5 to 36 1
ADP2164 with selectable switching 2.7 to 6.5 4 adjustable switching frequency
frequency 300 kHz to 1 MHz
(600 kHz or 1.2 MHz) Switches:
3-channel regulator with dual Switches:
ADP2300/ 2.3 to 5.5,
ADP5024 3 MHz switching regulator and 1.2 each,
Nonsynchronous step-down ADP2301: 1.2, LDO:
ADP230x 3.0 to 20 one LDO LDO: 0.300
switching regulator ADP2302: 2, 1.7 to 5.5
ADP2303: 3 Switches:
4-channel regulator with dual Switches:
1.2 MHz/600 kHz low 2.3 to 5.5,
ADP5134 3 MHz switching regulator and 1.2 each,
ADP2370 quiescent current step-down 3.2 to 15 0.8 LDOs:
dual LDO LDOs: 0.300
dc-to-dc regulator 1.7 to 5.5
Synchronous step-down 5-channel integrated power Switches:
Switches:
dc-to-dc regulator with solution with quad step-down 4.5 to 15,
ADP2384 4.5 to 20 4 ADP5052 4, 4/1.2, 1.2,
programmable switching synchronous switching LDOs:
LDO: 0.200
frequency regulators and one LDO 1.7 to 5.5
0402 Chip
0402 Chip
Resistor
Resistor
0402 Chip
0402 Chip
0402 Chip
0402 Chip
0402 Chip
0402 Chip
Capacitor
Capacitor
Capacitor
Capacitor
0603 Chip
0603 Chip
Capacitor
Resistor
Resistor
Capacitor
0402 Chip
Resistor
0402 Chip
Resistor
6.8 mm
0603 Chip
Capacitor
0402 Chip
Capacitor
Inductor Inductor
0402 Chip
Capacitor
0402 Chip
Resistor
0402 Chip
Resistor 0603 Chip 0603 Chip
Capacitor Capacitor
0402 Chip
Capacitor
0402 Chip
Capacitor
0402 Chip
Capacitor
0402 Chip
Resistor
9.3 mm
Linear Regulators
VIN Range VIN Range
Part Number Product Description IOUT Max (A) Part Number Product Description IOUT Max (A)
(V) (V)
Ultralow noise CMOS ADM7170/ADM7171/
ADP151 2.2 to 5.5 0.2 Low noise, high PSRR LDO 2.3 to 6.5 0.5/1.0/2.0
linear regulator ADM7172
ADP7102: 0.300,
ADP7102/ADP7104 Low noise CMOS LDO 3.3 to 20 Low quiescent current CMOS
ADP7104: 0.500 ADP124/ADP125 2.3 to 5.5 0.5
linear regulator
Low noise CMOS LDO
ADP7105 3.3 to 20 0.5
with soft start ADP222/ADP223/ Dual, low noise, high PSRR
2.5 to 5.5 0.300 each
ADP7118 Low noise CMOS LDO 2.7 to 20 0.2 ADP224/ADP225 linear regulators
Low noise, high PSRR Triple, low noise, high PSRR
ADP7142 2.7 to 40 0.2 ADP322/ADP323 2.5 to 5.5 0.200 each
CMOS LDO linear regulators
No. Total
Sample Rate/ Resolution
Part Number Simultaneous Channel
Sim Channel (Bits)
Channels Count
AD7265/AD7266 2 12 1 MSPS/2 MSPS 12
AD7262/AD7264 2 2 1 MSPS 12/14
3 MSPS/
AD7352/AD7356/
2 2 5 MSPS/ 10 to 16
AD7357
4.75 MSPS
AD7656-1/
AD7657-1/ 6 6 250 kSPS 16/14/12
AD7658-1
AD7606/
AD7606-6/ 8/6/4 8/6/4 200 kSPS 16
AD7606-4
AD7607/AD7608/
8 8 200 kSPS 14/18/18
AD7609
AD7366/AD7367 2 4 1 MSPS 12/14
500 kSPS to
ADAS3023 8–8 8 16
125 kSPS
AD7902/AD7903 2 2 1 MSPS 16
Resolver-to-Digital Converters
Many motor control systems operate at variable shaft rotation speeds.
To provide the most accurate position information, a system with flex-
ible resolution is required. The resolver-to-digital converter that provides
resolution change on-the-fly is the AD2S1210. This converter delivers an
integrated solution including an excitation oscillator with programmable
frequency, programmable threshold levels, very wide analog input range,
and information indicating the exact nature of detected faults. The
AD2S1210 provides a high level of functionality required to interface to
resolvers with a reduced number of external components.
Processors
Processor Value System Value Out of Box Experience
XX ARM and DSP cores XX Embedded sinc filters for isolated Σ-Δ XX Support of MATLAB® and model-based design
XX Strong DMA capability XX High amount of local RAM and flash XX 230 VAC and 48 VDC development platforms
XX Real-time Ethernet (1588) XX Fast embedded 16-bit ADCs XX Strong local support team
XX High performance/cost ratio
industrial motor drives and servos. Based on the ARM Cortex-M4, the ADSP-CM40x combines AFE
Timer
industry-leading 240 MHz core clock speed, large 384 kB SRAM, and 2 MB flash memories
Σ
with industry-leading dual 16-bit ADCs. In addition to its raw digital and analog performance Sinc3
capabilities, the ADSP-CM40x offers a number of features including sinc filters for glueless
connection to AD740x Σ-Δ modulators and a harmonic analysis engine for power spectrum Trip
analysis.
Model Package Speed (MHz) SRAM/Flash Dual ADC Accuracy (ENOB) Comms
ADSP-CM409CBCZ-AF 19 mm × 19 mm, 212-ball CSP_BGA 240 384 kB/2 MB 13 USB, Ethernet
ADSP-CM408CSWZ-AF 24 mm × 24 mm, 176-lead LQFP 240 384 kB/2 MB 13 USB, Ethernet
ADSP-CM408CSWZ-BF 24 mm × 24 mm, 176-lead LQFP 240 384 kB/2 MB 13 USB
ADSP-CM407CSWZ-AF 24 mm × 24 mm, 176-lead LQFP 240 384 kB/2 MB 11 USB, Ethernet
ADSP-CM407CSWZ-BF 24 mm × 24 mm, 176-lead LQFP 240 384 kB/2 MB 11 USB
ADSP-CM403CSWZ-CF 14 mm × 14 mm, 120-lead LQFP 240 384 kB/2 MB 13 None
ADSP-CM403CSWZ-EF 14 mm × 14 mm, 120-lead LQFP 150 128 kB/512 kB 13 None
ADSP-CM403CSWZ-FF 14 mm × 14 mm, 120-lead LQFP 100 128 kB/256 kB 13 None
ADSP-CM402CSWZ-EF 14 mm × 14 mm, 120-lead LQFP 150 128 kB/512 kB 11 None
ADSP-CM402CSWZ-FF 14 mm × 14 mm, 120-lead LQFP 100 128 kB/256 kB 11 None
Peripherals
System Control Blocks
4× Quadrature
Enclosure
L1 Cache
Microcontroller L1 Memory 8× Timer
16 kB
L1 Instruction Up To 384 kB 2× CAN
Cache Parity-Eenabled
Zero-Wait-State SRAM
3× UART
GPIO (40 OR 91)
Cortex-M4
2× SPI
1× EMAC
with IEEE 1588
(Optional)
L3 Memory Analog Front End
Harmonic Analysis Engine
(HAE) Static Memory
Up to 2 MB Flash ADCC DACC Controller
(Executable) ASYNC
Hardware Functions
Interface
USB FS OTG
(Optional)
ADSP-214xx SHARC Floating-Point DSPs for Motion Controllers and High End Drive and Servo Control
The SHARC® processor family dominates the floating-point DSP market with exceptional core performance, memory size, memory performance, and cost
per MFLOP. As the fourth generation of SHARC 32-bit floating-point DSPs, the ADSP-214xx continues the legacy with unparalleled performance and
features. The ADSP-214xx processors incorporate up to 800 MMACs of performance, 5 MB of on chip memory, FFT/FIR/IIR accelerators, and a host of
external memory interfaces and peripherals that make these processors well suited for motion controllers and high end motor drive and servo systems.
Model Package Speed (MHz) On-Chip SRAM (MB) GPIOs Parallel Interfaces Accelerators
ADSP-21469BBCZ-3 24 mm × 24 mm, 176-lead LQFP 450 5 34 DDR2, AMI, link ports FFT/FIR/IIR
ADSP-21489BSWZ-3A 14 mm × 14 mm, 100-lead LQFP 350 5 32 — FFT/FIR/IIR
ADSP-21489BSWZ-3B 24 mm × 24 mm, 176-lead LQFP 350 5 34 SDRAM FFT/FIR/IIR
ADSP-21489BSWZ-4A 14 mm × 14 mm, 100-lead LQFP 400 5 32 — FFT/FIR/IIR
ADSP-21489BSWZ-4B 24 mm × 24 mm, 176-lead LQFP 400 5 34 SDRAM FFT/FIR/IIR
ADSP-21488BSWZ-3A 14 mm × 14 mm, 100-lead LQFP 350 3 32 — FFT/FIR/IIR
ADSP-21488BSWZ-3B 24 mm × 24 mm, 176-lead LQFP 350 3 34 SDRAM FFT/FIR/IIR
ADSP-21488BSWZ-4A 14 mm × 14 mm, 100-lead LQFP 400 3 32 — FFT/FIR/IIR
ADSP-21488BSWZ-4B 24 mm × 24 mm, 176-lead LQFP 400 3 34 SDRAM FFT/FIR/IIR
EP
SPEP BUS
Core PCG TIMER S/PDIF PCG ASRC PDAP/ SPORT DDR2
TWI SPI/B UART Link AMI
Flags C–D 1–0 Tx/Dx A–D 3–0 IDP 7–0 7–0 Core PWM
MLB Port CTL
Flags 3–0
1–0
External
DPI Routing/Pins DAI Routing/Pins Port
External Port Pin Mux
V+
IU
3-Phase
PWM IV
Generator
M
IW
GND
REF2
AD8210 V+ REF2
AD8210 V+
NC
AD8418 OUT NC
AD8418 OUT
ADC
Microcontroller
Part Number Input CMV (V) Gain (V/V) Bandwidth (kHz) Max TCVOS (μV/°C) Comments
AD8205/AD8206 –2 to +65 50/20 50/100 15
AD8207 –4 to +65 20 100 1 Zero drift
AD8216 0 to 65 3 3000 20 Fast output response
AD8218 4 to 80 20 500 0.5 Zero drift, low cost
AD8417/AD8418 –2 to +70 60/20 250 0.5 Zero drift, low cost
AD8210 –2 to +65 20 500 8 High precision
Propagation delay
AD8214 5 to 65 Comparator — Current output
90 ns typ
High common-mode
AD8212 +500 (ext pnp) Adjustable gain 1 MHz (G = 10) 10
voltage
AD8210 AD8214
Difference Amplifiers
Difference amplifiers can be used for voltage and current sensing in motor control systems because
they can reject very high common-mode voltage. They will enable the low voltage converters to
interface with the high voltage industrial environment. This is especially true when functional
isolation is needed. Excellent drift and CMRR are the advantages of ADI’s difference amplifiers.
Part Number CMV (±V) CMRR (dB) Min Gain Gain Drift (ppm/°C) Max VOS Drift (μV/°C) Max
AD8479 600 90 1 5 10
AD629 270 86 1 10 10
AD628 120 75 0.1 to 100 adj 5 no external 8 no external
There are other cases that will need attenuation and/or level shifting in the signal conditioning.
In industrial sites, anything higher than the power supply common-mode voltage will be seen by
these difference amplifiers.
Part Number CMV (±V) CMRR (dB) Min Gain Gain Drift (ppm/°C) Max IQ/Amp (mA) Comment
AD8275 –12.3 to +12 86 0.2 1 2.3 With level shifter
AD8276/AD8277 −2 (VS + 0.1) to +2 (VS − 1.5) 86 1 1 0.2 AD8277 is dual
AD8278/AD8279 −3 (VS + 0.1) to +3 (VS − 1.5) 80 0.5 or 2 1 0.2 AD8279 is dual
AD8273/AD8274 3 (–VS) + 4.5 to 3 (+VS) – 4.5 77 0.5 or 2 2 2.6 AD8273 is dual
Precision Op Amps
Precision op amps are used as signal conditioning in the motor control systems. They will be used
as the sensor to ADC interface, thus the rail-to-rail input and output in high linearity will be needed.
They can also be used between the resolver-to-digital converter (RDC) and the resolver to provide
high current in high slew rate and accuracy. Wider bandwidth amplifiers will be used to detect the
fast changing current in the system.
Part Number Power Supply (V) Output Voltage (V) Max Drift (ppm/°C) Load Current (mA) Comment
ADR43x Up to 18 2.048, 2.5, 3, 4.5, 4.096, 5 3 +30/–20 Low noise
ADR34xx Up to 5.5 1.2, 2.048, 2.5, 3, 4.096, 5 8 +10/–3 Low power, small size of 6-lead SOT-23, low cost
ADR1581 5 1.25 50 N/A Low cost, small size of 3-lead SOT-23
Hardware
XX Isolated inverter board, 24 V to 800 V dc, 2 kVA (2 versions)
XX Adapter board for connection to EZ-KIT
XX USB to serial adapter for using GUI
XX ADSP-CM408 EZ-KIT (sold separately)
Software
XX IAR Embedded Workbench C project
XX Executable demo application
XX .NET-based graphical user interface (GUI)
Additional resource: Analog Devices EngineerZone Motor Control Hardware Platforms Community at
ez.analog.com/community/motor-control-hardware-platforms2
Software:
XX MATLAB/Simulink libraries
XX C libraries
XX Demo application
Software:
XX MATLAB/Simulink libraries
XX C libraries
XX Demo application
Additional information for motor control development platform can be found: wiki.analog.com; search for motor control hardware
ADC
AXI
Linux
AXI Interconnect
Field
Isolation
Oriented
AXI
DMA Inverters
Controller
User Application
HDMI/S/P-DIF
DMA
C Code
HDL Code
18 Motor Control Systems and Design
Reference Designs
Analog Devices reference designs enable design engineers to apply ADI’s vast applications expertise quickly and with
a high level of confidence toward their own design using circuits that are built and tested by the experts to ensure
both performance and function. Low cost hardware allows for evaluation and rapid prototyping with several
development platforms. Thorough documentation and design files ease application understanding and minimize
system integration issues.
model-based design provides a structure for software reuse that permits Motor/
PC
Test Controller
established designs to be effectively scaled up or down in complexity Signals Model
Inverter Verify
Model
depending upon the desired application and reliably upgraded in a more
simplistic and cost-effective manner.
CODE
GENERATION
Model-based design saves valuable design resources by cutting
design time and providing final designs that are more accurate and
Motor/
more closely approximate predesign expectations for performance, System
Inverter
Target
systems functionality, and features and schedule. Embedded Controller HW
B6
PMSMCTRL
[ABC_ADC]
CNT_A [CNT_A] [CNT_A] [IABC_ADC] IABC_ADC IABC_SNS IABC_SNS IABC [IABC]
[THETA_QEP]
Current Sensor
[DUTY_ABC] DUTY_ABC CNT_B [CNT_B] [CNT_B]
[VDC_ADC]
CNT_C [CNT_C] [CNT_C] [VDC_ADC] VDC_ADC VDC_SNS VDC_SNS VDC [VDC]
[PD]
ePWM ADC Voltage Sensor
ADSP-CM40x
[RPM] K– MC Algorithm
(Simulink) [THETA_QEP] QEP_cnt
QEP_CNT THETA_SNS THETA_SNS
T
THETA [THETA]
[IABC] Embedded QEP
Decoder
SLATERPMSM HALL_ABC
[PD] PD HALL_ABC
HALL [HALL_ABC]
MC ‘C’ Code
MC Application
CC and Link Device Drivers Device Drivers PD
Firmware Position Sensor
Application Code
Sensors, Interfaces, and Device Drivers
20 Motor Control Systems and Design
AC AC
Motor Motor
>25A
Control
Control
1 4
Power Power
AC
Motor AC
Motor
+– +–
Σ-Δ Σ-Δ
<25A
Control
Control
It is easy to become overwhelmed with the endless number of variations in motor control configurations. To help simplify
things, Analog Devices has consolidated the number of possible motor control architectures into four fundamental categories
that most systems would fall into. Depending on your selection, ADI can quickly identify and recommend the proper products
and solutions for your specific design.
ARM Holdings plc is the world’s leading semiconductor intellectual property (IP) supplier. The
technology ARM designs are at the heart of many of the digital electronic products sold. ARM has
an innovative business model. Instead of bearing the costs associated with manufacturing, ARM
licenses its technology to a network of partners, mainly leading semiconductor manufacturers and
OEMs. These partners utilize ARM’s designs to create smart, low energy chips suitable for modern
electronic devices.
Visit www.arm.com
Boston Engineering delivers innovative and timely solutions by utilizing its Total System Responsibility™
(TSR) philosophy to meet demanding market needs. Through interdisciplinary teams, best practice
strategies, and seamless integration with client processes, Boston Engineering offers a complete
BOSTON solution that is both flexible and focused.
ENGINEERING™ Boston Engineering fulfills an increasing demand for outsourced engineering services. From
product development to information systems to engineering consulting.
Visit www.boston-engineering.com
IAR Systems is the world’s leading independent provider of software for programming of
processors in embedded systems. The software is used by approximately 20,000 large and
small corporations to develop products based on 8-, 16-, and 32-bit processors, mainly in
the areas of industrial automation, medical devices, consumer electronics, and the automotive
industry.
Visit www.IAR.com
Xilinx is the world’s leading provider of all programmable FPGAs, SoCs, and 3D ICs. These
industry-leading devices are coupled with a next-generation design environment and IP to
serve a broad range of customer needs, from programmable logic to programmable systems
integration.
Visit www.xilinx.com
ADIsimPower Selector
ADIsimPower Selector uses your specific application requirements
and compares solutions from over 300 power management parts
Circuits from the Lab Reference Designs
and over 10 different topologies. Each solution takes into consid-
eration the IC, external components, and operating condition to be For a complete list of Analog Devices
able to compare expected performance. Circuits from the Lab® Reference
Designs for motor control designs,
visit www.analog.com/circuits.